ACMV

CADANGAN UNIVERSITI TEKNOLOGI MARA (UiTM) KAMPUS MUKAH DI ATAS
SEBAHAGIAN LOT 35, BLOK 99, MUKAH LAND DISTRICT, MUKAH DIVISION,
SARAWAK.
AS-BUILT DRAWINGS AND OPERATION AND MAINTENANCE MANUAL FOR

AIR-CONDITIONING & MECHANICAL VENTILATION SYSTEM
OPERATION AND MAINTENANCE MANUAL (VOL 1 OF 2)
CONCESSIONAIRE
KP Mukah Development Sdn. Bhd.

Level 3A, Wisma Bukit Mata Kuching,
Jalan Tunku Abdul Rahman,
93100 Kuching, Sarawak
Arkitek: Jurutera Sivil & Struktur:

Jurubina Unireka Jurutera Perunding Wahba Sdn Bhd
Suite 19.11 Kueh Hock Kui Commercial Centre, S/L No. 4, Lot 12155,
Lot 3007 Jalan Tun Ahmad Zaidi Adruce, Ground Floor, Song Plaza,
93150 Kuching, Jalan Tun Jugah / Jalan Song,
Sarawak 93350 Kuching,
Sarawak
Jurutera Mekanikal & Elektrikal: Jurukur Bahan:

Perunding CHL Sdn. Bhd. PUBM Quantity Surveyors Sdn Bhd
No. 15A, 1st & 2nd Floor, Lot 248, 1st Floor,
Lot 511, Section 6, KTLD, Lorong 3, Jalan Ang Cheng Ho,
Jalan Kulas, 93100 Kuching,
PO Box 1114, Sarawak
93722 Kuching,
Sarawak
CADANGAN UNIVERSITI TEKNOLOGI MARA (UITM), KAMPUS MUKAH, DI ATAS
SARAWAK (O&M)
TABLES OF CONTENT
SECTION DESCRIPTION
1.0 INTRODUCTION
2.0 DESCRIPTION OF THE INSTALLATIONS
3.0 SYSTEM OPERATING PROCEDURE/INSTRUCTION
3.1 Chiller Plant

3.2 AHU
3.3 FCU
3.4 Air-Cool Split Unit
3.5 Cooling Tower
3.6 Pump
3.7 Exhaust Fan
4.0 LIST OF EQUIPMENT INSTALLATION & SPARES
4.1 List of Equipment Installed

4.2 Spare Parts
5.0 SERVICE & MAINTENANCE
5.1 Maintenance Schedule

5.2 Service Report and Records
5.3 Breakdown & Maintenance Call
6.0 MANUFACTURER LITERATURE & CATALOGUES
6.1 Chiller Plant

6.2 AHU
6.3 FCU
6.4 Air-Cool Split Unit
6.5 Cooling Tower
6.6 Pump
6.7 Exhaust Fan
7.0 TEST CERTIFICATES
8.0 AS BUILT DRAWING

SARAWAK (O&M)
1.0
INTRODUCTION
Introduction
The entire Air-Conditioning and Mechanical Ventilation system consist of the following:-
1. Carrier – 5 nos. of Air Handling Unit located at Bangunan Pentadbiran Level 1 and Level 2.
2. Carrier – 2 nos. of Air Handling Unit located at Bangunan Perpustakaan Level 1 and Level 2.
3. Carrier – 2 nos. of Air Handling Unit located at Dewan Peperiksaan Level 1.
4. Carrier – 12 nos. of Air Handling Unit located at Fakulti Perladangan dan Agroteknologi Level 1, Level
2 and Level 3.
5. Carrier – 12 nos. of Air Handling Unit located at Fakulti Sains Gunaan Level 1, Level 2 and Level 3.
6. Carrier – 2 nos. of Air Handling Unit located at Dewan Kuliah Level 1.
7. Carrier – 2 nos. of Air Handling Unit located at Unit Penyelenggaraan, Keselamatan, Kesihatan
Level 1.
8. Carrier – 2 nos. of Fan Coil Unit located at Bangunan Pentadbiran Level 1 and Level 2.
9. Carrier – 2 nos. of Fan Coil Unit located at Bangunan Perpustakaan Level 1 and Level 2.
10. Carrier – 2 nos. of Fan Coil Unit located at Dewan Peperiksaan Level 1.
11. Carrier – 48 nos. of Fan Coil Unit located at Fakulti Perladangan dan Agroteknologi Level 1, Level 2
and Level 3.
12. Carrier – 34 nos. of Fan Coil Unit located at Fakulti Sains Gunaan Level 1, Level 2 and Level 3.
13. Carrier – 59 nos. of Fan Coil Unit located at Fakulti Perniagaan Level 1 and Level 2.
14. Carrier – 7 nos. of Fan Coil Unit located at Unit Penyelenggaraan, Keselamatan, Kesihatan Level 1
and Level 2.
15. Carrier Split Unit – 8 nos. of Wall Mounted located at Fakulti Perladangan dan Agroteknologi Level 1,
Level 2 and Level 3.
16. Carrier Split Unit – 8 nos. of Ceiling Hanged located at Fakulti Sains Gunaan Level 1.
17. Carrier Split Unit – 1 no. of Wall Mounted located at Fakulti Sains Gunaan Level 1.
18. Carrier Split Unit – 1 no. of Ceiling Hanged located at Unit Penyelenggaraan, Keselamatan, Kesihatan
Level 1.
19. Carrier Split Unit – 1 no. of Wall Mounted located at Unit Penyelenggaraan, Keselamatan, Kesihatan
Level 1.
20. Carrier Split Unit – 1 no. of Wall Mounted located at Medan Selera dan Pusat Pelajar Level 1.
21. Carrier Split Unit – 6 nos. of Ceiling Hanged located at Medan Selera dan Pusat Pelajar Level 2.
22. Carrier Split Unit – 2 nos. of Wall Mounted located at Surau Level 1.
23. Carrier Split Unit – 13 nos. of Wall Mounted located at Citu Level 1 and Level 2.
24. Carrier Split Unit – 1 no. of Ceiling Cassette located at Citu Level 1.
25. Carrier Split Unit – 1 no. of Ceiling Hanged located at Citu Level 1.
26. Carrier Split Unit – 15 nos. of Wall Mounted located at Rumah Tetamu Level 1 and Level 2.
27. Carrier Split Unit – 2 nos. of Wall Mounted located at Pejabat Pengurusan Kolej Level 1.
28. Carrier Split Unit – 2 nos. of Ceiling Hanged located at Pejabat Pengurusan Kolej Level 1.
29. Carrier Split Unit – 1 no. of Ceiling Cassette located at Pejabat Pengurusan Kolej Level 1.
30. Carrier Split Unit – 1 no. of Wall Mounted located at Bengkel Kejuruteraan Akuatik dan Depo Ground
Floor.
31. Carrier Split Unit – 5 nos. of Wall Mounted located at Makmal Diagnostic Ground Floor.
32. Carrier Split Unit – 6 nos. of Ceiling Hanged located at Makmal Diagnostic Ground Floor.
33. Carrier Split Unit – 7 nos. of Wall Mounted located at Pejabat Pusat Akuakultur & Unit Perladangan
Ground Floor and First Floor.
34. Carrier Split Unit – 3 nos. of Ceiling Hanged located at Pejabat Pusat Akuakultur & Unit Perladangan
35. Carrier Split Unit – 1 no. of Ceiling Cassette located at Pejabat Pusat Akuakultur & Unit Perladangan
36. Carrier Split Unit – 1 no. of Wall Mounted located at Pusat Pemprosesan Ground Floor.
37. Carrier Split Unit – 4 nos. of Ceiling Hanged located at Pusat Pemprosesan Ground Floor.
38. Carrier Split Unit – 11 nos. of Wall Mounted located at Kemudahan Sokongan Akademik /
Penyelidikan - Pusat Jual Hasil & Stor Ground Floor.
39. Carrier Split Unit – 2 nos. of Ceiling Hanged located at Kemudahan Sokongan Akademik /
40. Carrier Split Unit – 1 no. of Wall Mounted located at Pondok Pengawal Keselamatan Ground Floor.
41. KDK Exhaust Fan – 8 nos. of Ceiling Mounted located at Bangunan Pentadbiran Level 1 and Level 2.
42. KDK Exhaust Fan – 1 no. of Wall Mounted located at Bangunan Perpustakaan Level 1.
43. Nicotra Exhaust Fan – 4 nos. of Cabinet Fan located at Bangunan Perpustakaan Level 1 and Level
2.
44. KDK Exhaust Fan – 4 nos. of Wall Mounted located at Dewan Peperiksaan Level 1.
45. KDK Exhaust Fan – 1 no. of Ceiling Mounted located at Dewan Peperiksaan Level 1.
46. Nicotra Exhaust Fan – 1 no. of In Line Duct Fan located at Fakulti Perladangan dan Agroteknologi
Level 1.
47. KDK Exhaust Fan – 15 nos. of Ceiling Mounted located at Fakulti Perladangan dan Agroteknologi
Level 1, Level 2 and Level 3.
48. KDK Exhaust Fan – 30 nos. of Wall Mounted located at Fakulti Perladangan dan Agroteknologi Level
1, Level 2 and Level 3.
49. KDK Exhaust Fan – 26 nos. of Wall Mounted located at Fakulti Sains Gunaan Level 1, Level 2 and
Level 3.
50. KDK Exhaust Fan – 21 nos. of Ceiling Mounted located at Fakulti Sains Gunaan Level 1, Level 2 and
Level 3.
51. Nicotra Exhaust Fan – 1 no. of In Line Duct Fan located at Fakulti Sains Gunaan Level 1.
52. KDK Exhaust Fan – 13 nos. of Ceiling Mounted located at Fakulti Perniagaan Level 1 and Level 2.
53. KDK Exhaust Fan – 2 nos. of Ceiling Mounted located at Dewan Kuliah Level 1.
54. KDK Exhaust Fan – 2 nos. of Ceiling Mounted located at Unit Penyelenggaraan, Keselamatan,
Kesihatan Level 2.
55. KDK Exhaust Fan – 6 nos. of Wall Mounted located at Unit Penyelenggaraan, Keselamatan, Kesihatan
Level 1.
56. Nicotra Exhaust Fan – 1 no. of In Line Duct Fan located at Unit Penyelenggaraan, Keselamatan,
Kesihatan Level 1.
57. KDK Exhaust Fan – 2 nos. of Wall Mounted located at MSB Room Substation 2 and 3.
58. KDK Exhaust Fan – 6 nos. of Wall Mounted located at Medan Selera dan Pusat Pelajar Level 1 and
Level 2.
59. Nicotra Exhaust Fan – 9 nos. of Centrifugal located at Medan Selera dan Pusat Pelajar Level 1.
60. KDK Exhaust Fan – 3 nos. of Wall Mounted located at Surau Level 1.
61. KDK Exhaust Fan – 2 nos. of Wall Mounted located at Citu Level 1 and Level 2.
62. KDK Exhaust Fan – 14 nos. of Wall Mounted located at Rumah Tetamu Level 1, Level 3, Level 4 and
Level 5.
63. KDK Exhaust Fan – 13 nos. of Ceiling Mounted located at Rumah Tetamu Level 1 and Level 2.
64. KDK Exhaust Fan – 2 nos. of Wall Mounted located at Pejabat Pengurusan Kolej Level 1.
65. KDK Exhaust Fan – 5 nos. of Wall Mounted located at Bengkel Kejuruteraan Akuatik dan Depo
Ground Floor.
66. KDK Exhaust Fan – 5 nos. of Wall Mounted located at Makmal Diagnostic Ground Floor.
67. KDK Exhaust Fan – 6 nos. of Wall Mounted located at Pejabat Pusat Akuakultur & Unit Perladangan
68. KDK Exhaust Fan – 1 no. of Wall Mounted located at Pusat Hatcheri.
69. KDK Exhaust Fan – 7 nos. of Wall Mounted located at Kemudahan Sokongan Akademik /
70. Nicotra Exhaust Fan – 2 nos. of Axial Fan located at Central Utility Plant Level 1.
71. KDK Exhaust Fan – 5 nos. of Wall Mounted located at Central Utility Plant Level 1.
72. KDK Exhaust Fan – 1 no. of Wall Mounted located at Pondok Pengawal Keselamatan Ground Floor.
73. Carrier – 3 nos. of Centrifugal Chiller located at Central Utility Plant Level 1.
74. Carrier – 1 no. of Multiple Screw Compressor Chiller at Central Utility Plant Level 1.
75. Regent – 4 nos. of Horizontal Split Casing Pump at Central Utility Plant Level 1.
76. Regent – 4 nos. of End Suction Pump at Central Utility Plant Level 1.
77. Truwater – 2 nos. of Low Noise Type Cooling Tower at Central Utility Plant Roof
SARAWAK (O&M)
2.0
DESCRIPTION OF THE INSTALLATIONS
BANGUNAN PENTADBIRAN
SCHEDULE OF AIR HANDLING UNIT
Fan Total
Total Fan Fluid
Airflow Static Water Water Drain Length Width Height Weight
AHU Marking Model Brand Cooling Motor Flow
(l/s) (Inch Inlet Outlet Pipe (mm) (mm) (mm) (Kg)
Cap (kW) (kW) Rate, L/s
w.g)
B1-L1-AHU-1 39G0912 Carrier 30 1767 2.3 3 2 1/2" 2 1/2" 1" 1.28 1450 1250 1050 258
B1-L1-AHU-2 39G1621 Carrier 86 5590 2.5 7.5 3" 3" 1" 3.69 1950 2150 1750 813
B1-L2-AHU-1 39G1621 Carrier 96 5910 2.6 11 3" 3" 1" 4.14 1950 2150 1750 873
B1-L2-AHU-2 39G1621 Carrier 114 6717 3.1 11 3" 3" 1" 4.89 1950 2150 1750 883
B1-L2-AHU-3 39G1621 Carrier 115 6669 2.8 11 3" 3" 1" 4.94 1950 2150 1750 900
SCHEDULE OF FAN COIL UNIT
Fan Total
Total Fan Fluid
FCU Marking Model Brand Cooling Motor Flow
w.g)
B1-L1-FCU-1 42CET003 Carrier 3.07 140 0.015 32W 3/4”FPT 3/4”FPT 3/4”MPT 0.13 770 557 242 21.5
B1-L2-FCU-1 42CET006 Carrier 4.79 282 0.015 72W 3/4”FPT 3/4”FPT 3/4”MPT 0.2 1170 557 242 30
SCHEDULE OF EXHAUST FAN
Speed
Exhaust Fan Marking Type Airflow (l/s) Static (Pa) Wattage (w) V/PH/Hz Fan Dia. Brand Model
(RPM)
B1-L1-EF-1 CEILING MOUNTED 150 1207 60 25.7 240/1/50 200mm KDK 20 CQT1

BANGUNAN PERPUSTAKAAN
Fan Total
Total Fan Fluid
w.g)
B2-L1-AHU-1 39G1822 Carrier 174 7942 2.4 11 3" 3" 1" 7.47 2100 2250 1950 1080
B2-L2-AHU-1 39G2230 Carrier 286 13686 2.9 30 3" 3" 1" 12.28 2400 3050 2350 1831
Total Fan Total Fan Fluid

Airflow Water Water Drain Length Width Height Weight
FCU Marking Model Brand Cooling Static Motor Flow
(l/s) Inlet Outlet Pipe (mm) (mm) (mm) (Kg)
Cap (kW) (Inch w.g) (kW) Rate, L/s
B2-L1-FCU-1 40LM070 Carrier 21.6 900 0.6 0.9 1” 1” 3/4” 0.86 680 1200 480 95
B2-L2-FCU-1 42CET003 Carrier 3.1 137 0.015 32W 3/4”FPT 3/4”FPT 3/4”MPT 0.13 770 557 242 21.5
Speed
(RPM)
DEWAN PEPERIKSAAN
Fan Total
Total Fan Fluid
w.g)
B3-L1-AHU-1 39G1825 Carrier 237 8870 2.7 15 3" 3" 1" 10.17 2100 2550 1950 1213
B3-L1-AHU-2 39G1825 Carrier 237 8870 2.7 15 3" 3" 1" 10.17 2100 2550 1950 1213

B3-L1-FCU-1 42CET010 Carrier 7.9 472 0.015 70wx2 3/4"FPT 3/4"FPT 3/4"MPT 0.34 1530 557 242 45
B3-L1-FCU-2 42CET003 Carrier 3.1 111 0.015 32w 3/4"FPT 3/4"FPT 3/4"MPT 0.13 770 557 242 21.5
Speed
(RPM)
B3-L1-EF-1 WALL MOUNTED 200 1109-1301 FREE 25.7 240/1/50 200mm KDK 20 AQM8

FAKULTI PERLADANGAN DAN AGROTEKNOLOGI
Fan Total
Total Fan Fluid
w.g)
B4a-L1-AHU-1 39G0914 Carrier 237 2150 2.3 4 2 1/2” 2 1/2” 1" 2.33 1450 1450 1050 288
B4a-L1-AHU-2 39G0914 Carrier 237 2150 2.2 4 2 1/2” 2 1/2” 1" 2.33 1450 1450 1050 288
B4a-L1-AHU-3 39G1015 Carrier 54 2297 2.1 3 2 1/2” 2 1/2” 1" 2.72 1550 1550 1150 412
B4a-L1-AHU-4 39G1015 Carrier 54 2297 2.0 3 2 1/2” 2 1/2” 1" 2.72 1550 1550 1150 412
B4a-L2-AHU-1 39G0914 Carrier 63 2150 2.3 4 2 1/2” 2 1/2” 1" 2.33 1450 1450 1050 288
B4a-L2-AHU-2 39G0914 Carrier 63 2150 2.2 4 2 1/2” 2 1/2” 1" 2.33 1450 1450 1050 288
B4a-L2-AHU-3 39G1015 Carrier 54 2297 2.1 3 2 1/2” 2 1/2” 1" 2.72 1550 1550 1150 412
B4a-L2-AHU-4 39G1015 Carrier 54 2297 2.0 3 2 1/2” 2 1/2” 1" 2.72 1550 1550 1150 412
B4a-L3-AHU-1 39G0914 Carrier 63 2150 2.2 4 2 1/2” 2 1/2” 1" 2.33 1450 1450 1050 288
B4a-L3-AHU-2 39G0914 Carrier 63 2150 2.3 4 2 1/2” 2 1/2” 1" 2.33 1450 1450 1050 288
B4a-L3-AHU-3 39G1015 Carrier 54 2297 2.0 3 2 1/2” 2 1/2” 1" 2.81 1550 1550 1150 406
B4a-L3-AHU-4 39G1015 Carrier 54 2297 2.0 3 2 1/2” 2 1/2” 1" 2.81 1550 1550 1150 406

B4a-L1-FCU-1 42CET003 Carrier 3.1 79 0.015 32w 3/4"FPT 3/4"FPT 3/4"MPT 0.13 770 557 242 21.5
B4a-L1-FCU-2 40LM060 Carrier 18.4 737 0.5 0.82 1" 1" 3/4" 1.1 680 1000 480 72
B4a-L1-FCU-7 42CET004 Carrier 4.0 152 0.015 45w 3/4"FPT 3/4"FPT 3/4"MPT 0.17 890 557 242 25
B4a-L2-FCU-6 42CET010 Carrier 7.9 371 0.015 70wx2 3/4"FPT 3/4"FPT 3/4"MPT 0.34 1530 557 242 45
SCHEDULE OF A/C SPLIT UNIT
Pipe Size
Cooling Capacity
A/C Split Tag No. Type Brand Model CFM
(kW)
Liquid Gas Drain Pipe
B4a-A/C-1 WALL MOUNT Carrier 38KCV212/42KCV212 3.5 360 *1/4 *1/2 15.7mm
Speed
(RPM)
B4a-L1-EF-1 IN LINE DUCT FAN 359 1120 (H) 80 147 240/1/50 200mm NICOTRA CD 200
B4a-L1-EF-2 CEILING MOUNTED 172 1207 70 25.7 240/1/50 200mm KDK 20 CQT1
B4a-L1-EF-4 WALL MOUNTED 288 1109-1301 FREE 18.3 240/1/50 200mm KDK 20 AQM8
Speed
(RPM)

PEJABAT PUSAT AKUAKULTUR & UNIT PERLADANGAN
Pipe Size
Cooling Capacity
(kW)
B4a-a-A/C-1 WALL MOUNT Carrier 38KCV209/42KCV209 2.6 295 *1/4 *3/8 15.7mm
B4a-a-A/C-3 CEILING Carrier 38VTA040/42XQ040 11.7 980 *3/8 *3/4 21mm
B4a-a-A/C-4 CEILING Carrier 38VTA040/42XQ040 11.7 980 *3/8 *3/4 21mm
B4a-a-A/C-10 CEILING Carrier 38CSR024/42XQ025 7.3 780 *3/8 *5/8 21mm
B4a-a-A/C-11 CASSETTE Carrier 38FN024/42TNC024 7 718 *3/8 *5/8 32mm
Speed
(RPM)
B4a-a-EF-1 WALL MOUNTED 80 1109-1301 FREE 18.3 240/1/50 200mm KDK 20 AQM8
PUSAT PEMPROSESAN
Pipe Size
Cooling Capacity
(kW)
B4a-c-A/C-1 WALL MOUNT Carrier 38KCV209/42KCV209 2.6 295 *1/4 *3/8 15.7mm
B4a-c-A/C-2 CEILING EXPOSED Carrier 38VTA060/42XQ060 17.6 1300 *3/8 *3/4 21mm
BENGKEL KEJURUTERAAN AKUATIK & DEPO
Pipe Size
Cooling Capacity
(kW)
B4a-d-A/C-1 WALL MOUNT Carrier 38KCV209/42KCV209 2.6 295 *1/4 *3/8 15.7mm
Speed
(RPM)
B4a-d-EF-1 WALL MOUNTED 108 1109-1301 FREE 18.3 240/1/50 200mm KDK 20 AQM8
MAKMAL DIAGNOSTIC
Pipe Size
Cooling Capacity
(kW)
B4a-e-A/C-1 WALL MOUNT Carrier 38KCV209/42KCV209 2.6 295 *1/4 *3/8 15.7mm
B4a-e-A/C-4 CEILING Carrier 38VTA040/42XQ040 11.7 980 *3/8 *3/4 21mm
Speed
(RPM)
B4e-d-EF-1 WALL MOUNTED 157 1109-1301 FREE 18.3 240/1/50 200mm KDK 20 AQM8
UNIT LADANG – KEMUDAHAN SOKONGAN AKADEMIK/ PENYELIDIKAN – PUSAT JUAL HASIL & STOR
Pipe Size
Cooling Capacity
(kW)
B4a-g-A/C-1 WALL MOUNT Carrier 38KCV209/42KCV209 2.6 295 *1/4 *3/8 15.7mm
B4a-g-A/C-9 CEILING Carrier 38VTA040/42XQ040 11.7 980 *3/8 *3/4 21mm
B4a-g-A/C-11 CEILING Carrier 38VTA040/42XQ040 11.7 980 *3/8 *3/4 21mm
Speed
(RPM)
B4a-g-EF-1 WALL MOUNTED 96 1109-1301 FREE 18.3 240/1/50 200mm KDK 20 AQM8
FAKULTI SAINS GUNAAN
Fan Total
Total Fan Fluid
w.g)
B4b-L1-AHU-1 39G1015 Carrier 59 2,441 1.6 3 2 1/2” 2 1/2” 1" 2.56 1550 1550 1150 401
B4b-L1-AHU-2 39G0912 Carrier 40 1,779 1.9 3 2 1/2” 2 1/2” 1" 1.72 1450 1250 1050 273
B4b-L1-AHU-3 39G0914 Carrier 48 2,168 1.8 3 2 1/2” 2 1/2” 1" 2.06 1450 1450 1050 308
B4b-L1-AHU-4 39G0914 Carrier 48 2,168 1.8 2.2 2 1/2” 2 1/2” 1" 2.06 1450 1450 1050 308
B4b-L2-AHU-1 39G0914 Carrier 97 2,098 1.7 3 2 1/2” 2 1/2” 1" 4.17 1450 1450 1050 281
B4b-L2-AHU-2 3951015 Carrier 58 2,266 1.5 2.2 2 1/2” 2 1/2” 1" 2.5 1550 1550 1150 401
B4b-L2-AHU-3 39G1015 Carrier 67 2,450 1.8 3 2 1/2” 2 1/2” 1" 2.89 1550 1550 1150 417
B4b-L2-AHU-4 39G1015 Carrier 65 2,282 1.7 3 2 1/2” 2 1/2” 1" 2.81 1550 1550 1150 417
B4b-L3-AHU-1 39G0914 Carrier 55 2,139 2.0 4 2 1/2” 2 1/2” 1" 2.36 1450 1450 1050 288
B4b-L3-AHU-2 39G1015 Carrier 55 2,421 1.8 3 2 1/2” 2 1/2” 1" 2.39 1550 1550 1150 406
B4b-L3-AHU-3 39G1015 Carrier 68 2,519 2.1 4 2 1/2” 2 1/2” 1" 2.92 1550 1550 1150 424
B4b-L3-AHU-4 39G1015 Carrier 61 2,207 1.8 3 2 1/2” 2 1/2” 1" 2.64 1550 1550 1150 412

B4b-L1-FCU-1 40LM090 Carrier 29.1 978 0.6 1.43 1" 1" 3/4" 0.43 680 1200 480 100
B4b-L1-FCU-3 40LM090 Carrier 29.1 1,140 0.6 1.43 1" 1" 3/4" 0.43 680 1200 480 100
B4b-L2-FCU-1 42CET008 Carrier 7.3 377 0.015 55wx2 3/4"FPT 3/4"FPT 3/4"MPT 0.31 1410 557 242 41
B4b-L2-FCU-2 42CET005 Carrier 4.3 212 0.015 70w 3/4"FPT 3/4"FPT 3/4"MPT 0.19 970 557 242 25.6
Pipe Size
Cooling Capacity
(kW)
B4b-A/C-1 CEILING Carrier 38VTA040/42XQ040 11.7 980 *3/8 *3/4 21mm

B4b-A/C-7 WALL MOUNT Carrier 38KCV212/42KCV212 3.5 360 *1/4 *1/2 15.7mm
Speed
(RPM)
B4b-L1-EF-1 WALL MOUNTED 308 1109-1301 FREE 18.3 240/1/50 200mm KDK 20 AQM8
B4b-L1-EF-3 CEILING MOUNTED 121 1207 70 25.7 240/1/50 200mm KDK 20 CQT1
B4b-L1-EF-6 IN-LINE DUCT FAN 210 700 (H) 80 147 240/1/50 200mm NICOTRA CD 200
Speed
(RPM)

Speed
(RPM)
FAKULTI PENGURUSAN PERNIAGAAN

B4c-L1-FCU-1 42CET008 Carrier 7.3 800 0.015 55wx2 3/4"FPT 3/4"FPT 3/4"MPT 0.31 1410 557 242 41
B4c-L1-FCU-5 42CET003 Carrier 3.1 300 0.015 32w 3/4"FPT 3/4"FPT 3/4"MPT 0.13 770 557 242 21.5
B4c-L1-FCU-19 40LM060 Carrier 18.4 1,758 0.5 0.82 1" 1" 3/4" 1.1 680 1000 480 72
18.05NP
B4c-L2-FCU-19 40LM120 Carrier 35.2 3,475 0.7 1.83 25.4 0.43 0.43 680 1600 480 120
T (MPT)
Speed
(RPM)
B4c-L1-EF-1 CEILING MOUNTED 111 1207 70 25.7 240/1/50 200mm KDK 20 CQT1
Speed
(RPM)
DEWAN KULIAH
Fan Total
Total Fan Fluid
w.g)
B5-L1-AHU-1 39G1418 Carrier 108 4,607 2.5 7.5 3" 3" 1" 4.67 1750 1850 1550 710
B5-L1-AHU-2 39G1621 Carrier 139 5,627 2.4 7.5 3" 3" 1" 5.97 1950 2150 1750 862
Speed
(RPM)
UNIT PENYELENGGARAAN, KESELAMATAN, KESIHATAN
Fan Total
Total Fan Fluid
w.g)
B8-L1-AHU-1 39G1418 Carrier 76 4,526 2.1 5.5 3" 3" 1" 3.25 1750 1850 1550 671
B9-L1-AHU-1 39G1317 Carrier 68 3,856 2.2 5.5 3" 3" 1" 2.92 1750 1750 1450 615

B7-L2-FCU-1 40LM070 Carrier 21.6 923 0.6 0.9 1" 1" 3/4" 0.86 680 1200 480 95
B7-L2-FCU-3 42CET004 Carrier 4.0 179 0.015 45w 3/4"FPT 3/4"FPT 3/4"MPT 0.17 890 557 242 25
B7-L2-FCU-4 40LM040 Carrier 11.6 603 0.4 0.57 1" 1" 3/4" 0.65 680 1000 480 68
Pipe Size
Cooling Capacity
(kW)
B8-A/C-1 CEILING Carrier 38VTA040/42XQ040 11.7 980 *3/8 *3/4 21mm

B9-A/C-1 WALL MOUNT Carrier 38KCV209/42KCV209 2.6 295 *1/4 *3/8 15.7mm
Speed
(RPM)
B7-L2-EF-1 CEILING MOUNTED 58 1109-1301 70 25.7 240/1/50 200mm KDK 20 CQT1
B9-L1-EF-1 IN LINE DUCT FAN 218 700 (L) 70 147 240/1/50 200mm NICOTRA CD 200
UTILITI - MSB ROOM SUBSTATION 2 & SUBSTATION 3
Speed
(RPM)
MSB2-EF-1 WALL MOUNTED 333 1109-1301 FREE 18.3 240/1/50 200mm KDK 20 AQM8
MEDAN SELERA & PUSAT PELAJAR
Cooling Capacity Pipe Size

(kW) Liquid Gas Drain Pipe
B13-L1-A/C-1 WALL MOUNT Carrier 38KCV209/42KCV209 2.6 295 *1/4 *3/8 15.7mm
B13-L2-A/C-1 CEILING Carrier 38VTA040/42XQ040 11.7 980 *3/8 *3/4 21mm
B13-L2-A/C-5 CEILING Carrier 38CSR018/42XQ025 6.4 780 *1/4 *1/2 21mm
Speed
(RPM)
B13-L1-KEF-1 CENTRIFUGAL 744 2138 380 750 415/3/50 315mm NICOTRA RSH 315R c/w Drivepak
SURAU
Pipe Size
Cooling Capacity
(kW)
Speed
(RPM)
CITU
Pipe Size
Cooling Capacity
(kW)
B16-L1-A/C-4 CASSETTE Carrier 38FN033/42TNC033 9.7 971 *3/8 *3/4 32mm
Speed
(RPM)
RUMAH TETAMU
Pipe Size
Cooling Capacity
(kW)
Speed
(RPM)

Speed
(RPM)
PEJABAT PENGURUSAN KOLEJ
Pipe Size
Cooling Capacity
(kW)
B18-L1-A/C-5 CASSETTE Carrier 38FN045/42TNC045 13.2 971 *3/8 *3/4 32mm
Speed
(RPM)
KAFETERIA

50.8 50.8 3/4"

B20-FCU-1 40LM200 Carrier 58.3 7,203 0.8 3 2.25 784 1651 1541 230
MPT MPT MPT
50.8 50.8 3/4"
B20-FCU-2 40LM200 Carrier 58.3 7,203 0.8 3 2.25 784 1651 1541 230
MPT MPT MPT
Speed
(RPM)
B20-GF-EF-1 WALL MOUNTED 165 1109-1301 FREE 18.3 240/1/50 200mm KDK 20 AQM8
B20-GF-KEF-1 CENTRIFUGAL 4000 1183 400 4000 240/1/50 630mm NICOTRA RSH 630R c/w Drivepak
PONDOK PENGAWAL KESELAMATAN
Pipe Size
Cooling Capacity
(kW)
GH-A/C-1 WALL MOUNT Carrier 38KCV212/42KCV212 3.5 360 *1/4 *1/2 15.7mm
Speed
(RPM)
GH-EF-1 WALL MOUNTED 63 1109-1301 FREE 18.3 240/1/50 200mm KDK 20 AQM8
CENTRAL UTILITY PLANT
SCHEDULE OF CHILLER
Description Brand Model Type Total Cooling Capacity (Tons) Refrigerant
Chiller No. 1 Carrier 19XR4647385KG52 Water Cooled Centrifugal Liquid Chiller (Duty) 550 R134a
Chiller No. 3 Carrier 19XR4647385KG52 Water Cooled Centrifugal Liquid Chiller (Standby) 550 R134a
Chiller No. 4 Carrier 30HXC260 Water Cooled Multiple Screw Compressor Liquid Chiller 250 R134a
SCHEDULE OF COOLING TOWER
Description Brand Model Type Total Cooling Capacity
Cooling Tower 1 Truwater TXS 800 – 4L Low Noise Type 800 TRS
SCHEDULE OF PUMP
Description Brand Model Type Capacity
Chilled Water Pump No. 1 Regent D150/38 Horizontal Split Casing Pump 98 L/s VS 38 meter head
Condenser Water Pump No. 1 Regent 200-320 End Suction Pump 158.9 L/s VS 20 meter head
Speed
(RPM)
ADT
CUP-EF-1 AXIAL FAN 3300 1440 130 1500 415/3/50 560mm NICOTRA
560/160/10B/35/ALU
ADT
CUP-EF-2 AXIAL FAN 3300 1440 130 1500 415/3/50 560mm NICOTRA
560/160/10B/35/ALU
CUP-EF-3 WALL MOUNTED 796 1109-1301 FREE 18.3 240/1/50 200mm KDK 20 AQM8
SARAWAK (O&M)
3.0
SYSTEM OPERATING PROCEDURE/INSTRUCTION
SARAWAK (O&M)
3.1
SYSTEM OPERATING PROCEDURE/INSTRUCTION:
CHILLER PLANT
19XR
Hermetic Centrifugal Liquid Chillers
50/60 Hz
With PIC II Controls and HFC-134a
Start-Up, Operation, and Maintenance Instructions

SAFETY CONSIDERATIONS
Centrifugal liquid chillers are designed to provide safe with soap and water. If liquid refrigerant enters the eyes, IMME-
and reliable service when operated within design speci- DIATELY FLUSH EYES with water and consult a physician.
fications. When operating this equipment, use good judg- NEVER APPLY an open flame or live steam to a refrigerant
ment and safety precautions to avoid damage to equip- cylinder. Dangerous over pressure can result. When it is necessary
ment and property or injury to personnel. to heat refrigerant, use only warm (110 F [43 C]) water.
Be sure you understand and follow the procedures and DO NOT REUSE disposable (nonreturnable) cylinders or attempt
safety precautions contained in the chiller instructions to refill them. It is DANGEROUS AND ILLEGAL. When cylinder
as well as those listed in this guide. is emptied, evacuate remaining gas pressure, loosen the collar and
unscrew and discard the valve stem. DO NOT INCINERATE.
CHECK THE REFRIGERANT TYPE before adding refrigerant to
the chiller. The introduction of the wrong refrigerant can cause dam-
DO NOT VENT refrigerant relief valves within a building. Outlet age or malfunction to this chiller.
from rupture disc or relief valve must be vented outdoors in ac-
cordance with the latest edition of ANSI/ASHRAE 15 (American Operation of this equipment with refrigerants other than those
National Standards Institute/American Society of Heating, Refrig- cited herein should comply with ANSI/ASHRAE15 (latest edi-
eration, and Air Conditioning Engineers). The accumulation of tion). Contact Carrier for further information on use of this chiller
refrigerant in an enclosed space can displace oxygen and cause with other refrigerants.
asphyxiation. DO NOT ATTEMPT TO REMOVE fittings, covers, etc., while chiller
PROVIDE adequate ventilation in accordance with ANSI/ASHRAE is under pressure or while chiller is running. Be sure pressure is at
15, especially for enclosed and low overhead spaces. Inhalation of 0 psig (0 kPa) before breaking any refrigerant connection.
high concentrations of vapor is harmful and may cause heart ir- CAREFULLY INSPECT all relief devices, rupture discs, and other
regularities, unconsciousness, or death. Misuse can be fatal. Vapor relief devices AT LEAST ONCE A YEAR. If chiller operates in a
is heavier than air and reduces the amount of oxygen available for corrosive atmosphere, inspect the devices at more frequent
breathing. Product causes eye and skin irritation. Decomposition intervals.
products are hazardous. DO NOT ATTEMPT TO REPAIR OR RECONDITION any relief
DO NOT USE OXYGEN to purge lines or to pressurize a chiller device when corrosion or build-up of foreign material (rust, dirt,
for any purpose. Oxygen gas reacts violently with oil, grease, and scale, etc.) is found within the valve body or mechanism. Replace
other common substances. the device.
NEVER EXCEED specified test pressures, VERIFY the allowable DO NOT install relief devices in series or backwards.
test pressure by checking the instruction literature and the design USE CARE when working near or in line with a compressed spring.
pressures on the equipment nameplate. Sudden release of the spring can cause it and objects in its path to
DO NOT USE air for leak testing. Use only refrigerant or dry act as projectiles.
nitrogen.
DO NOT VALVE OFF any safety device.
BE SURE that all pressure relief devices are properly installed and DO NOT STEP on refrigerant lines. Broken lines can whip about
functioning before operating any chiller. and release refrigerant, causing personal injury.
RISK OF INJURY OR DEATH by electrocution. High voltage is DO NOT climb over a chiller. Use platform, catwalk, or staging.
present on motor leads even though the motor is not running when Follow safe practices when using ladders.
a solid-state or inside-delta mechanical starter is used. Open the USE MECHANICAL EQUIPMENT (crane, hoist, etc.) to lift or
power supply disconnect before touching motor leads or terminals. move inspection covers or other heavy components. Even if com-
ponents are light, use mechanical equipment when there is a risk of
slipping or losing your balance.
DO NOT WELD OR FLAMECUT any refrigerant line or vessel BE AWARE that certain automatic start arrangements CAN
until all refrigerant (liquid and vapor) has been removed from chiller. ENGAGE THE STARTER, TOWER FAN, OR PUMPS. Open the
Traces of vapor should be displaced with dry air or nitrogen and disconnect ahead of the starter, tower fans, or pumps.
the work area should be well ventilated. Refrigerant in contact with USE only repair or replacement parts that meet the code require-
an open flame produces toxic gases. ments of the original equipment.
DO NOT USE eyebolts or eyebolt holes to rig chiller sections or DO NOT VENT OR DRAIN waterboxes containing industrial brines,
the entire assembly. liquid, gases, or semisolids without the permission of your process
DO NOT work on high-voltage equipment unless you are a quali- control group.
fied electrician. DO NOT LOOSEN waterbox cover bolts until the waterbox has
DO NOT WORK ON electrical components, including control pan- been completely drained.
els, switches, starters, or oil heater until you are sure ALL POWER DOUBLE-CHECK that coupling nut wrenches, dial indicators, or
IS OFF and no residual voltage can leak from capacitors or solid- other items have been removed before rotating any shafts.
state components. DO NOT LOOSEN a packing gland nut before checking that the
LOCK OPEN AND TAG electrical circuits during servicing. IF WORK nut has a positive thread engagement.
IS INTERRUPTED, confirm that all circuits are deenergized be- PERIODICALLY INSPECT all valves, fittings, and piping for cor-
fore resuming work. rosion, rust, leaks, or damage.
AVOID SPILLING liquid refrigerant on skin or getting it into PROVIDE A DRAIN connection in the vent line near each pres-
the eyes. USE SAFETY GOGGLES. Wash any spills from the skin sure relief device to prevent a build-up of condensate or rain water.
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Book 2 PC 211 Catalog No. 531-974 Printed in U.S.A. Form 19XR-3SS Pg 1 6-98 Replaces: New
Tab 5a
CONTENTS
Page Page
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . 1 Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Remote Start/Stop Controls . . . . . . . . . . . . . . . . 36
Spare Safety Inputs . . . . . . . . . . . . . . . . . . . . . . . . 36
ABBREVIATIONS AND EXPLANATIONS . . . . . . 4 Spare Safety Alarm Contacts . . . . . . . . . . . . . . 36
CHILLER FAMILIARIZATION . . . . . . . . . . . . . . . . 5-7 Refrigerant Leak Detector . . . . . . . . . . . . . . . . . . . 36
Chiller Information Plate . . . . . . . . . . . . . . . . . . . . 5 Condenser Pump Control . . . . . . . . . . . . . . . . . . 36
System Components . . . . . . . . . . . . . . . . . . . . . . . . 5 Condenser Freeze Prevention . . . . . . . . . . . . . . 37
Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Tower Fan Relay Low and High . . . . . . . . . . . . . 37
Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Auto. Restart After Power Failure . . . . . . . . . . . 37
Motor-Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Water/Brine Reset . . . . . . . . . . . . . . . . . . . . . . . . . 37
Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 • RESET TYPE 1
Factory-Mounted Starter (Optional) . . . . . . . . . . 7 • RESET TYPE 2
Storage Vessel (Optional) . . . . . . . . . . . . . . . . . . . 7 • RESET TYPE 3
REFRIGERATION CYCLE . . . . . . . . . . . . . . . . . . . . 7 Demand Limit Control Option . . . . . . . . . . . . . . . . 38
Surge Prevention Algorithm . . . . . . . . . . . . . . . . 38
MOTOR AND LUBRICATING OIL Surge Protection . . . . . . . . . . . . . . . . . . . . . . . . . . 39
COOLING CYCLE . . . . . . . . . . . . . . . . . . . . . . . . 7,8 Lead/Lag Control . . . . . . . . . . . . . . . . . . . . . . . . . . 39
LUBRICATION CYCLE . . . . . . . . . . . . . . . . . . . . . . 8 • COMMON POINT SENSOR INSTALLATION
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 • CHILLER COMMUNICATION WIRING
Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 • LEAD/LAG OPERATION
Oil Reclaim System . . . . . . . . . . . . . . . . . . . . . . . . . 8 • FAULTED CHILLER OPERATION
• PRIMARY OIL RECOVERY MODE • LOAD BALANCING
• SECONDARY OIL RECOVERY METHOD • AUTO. RESTART AFTER POWER FAILURE
Ice Build Control . . . . . . . . . . . . . . . . . . . . . . . . . . 41
STARTING EQUIPMENT . . . . . . . . . . . . . . . . . . . . . 8-10 • ICE BUILD INITIATION
Unit-Mounted Solid-State Starter • START-UP/RECYCLE OPERATION
(Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 • TEMPERATURE CONTROL DURING
Unit-Mounted Wye-Delta Starter ICE BUILD
(Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 • TERMINATION OF ICE BUILD
CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-43 • RETURN TO NON-ICE BUILD OPERATIONS
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Attach to Network Device Control . . . . . . . . . . 42
• ANALOG SIGNAL • ATTACHING TO OTHER CCN MODULES
• DISCRETE SIGNAL Service Operation . . . . . . . . . . . . . . . . . . . . . . . . . 43
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 • TO ACCESS THE SERVICE SCREENS
PIC II System Components . . . . . . . . . . . . . . . . . 10 • TO LOG OUT OF NETWORK DEVICE
• CHILLER VISUAL CONTROLLER (CVC) • HOLIDAY SCHEDULING
• INTEGRATED STARTER MODULE (ISM) START-UP/SHUTDOWN/RECYCLE
• CHILLER CONTROL MODULE (CCM) SEQUENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44,45
• OIL HEATER CONTACTOR (1C) Local Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
• OIL PUMP CONTACTOR (2C) Shutdown Sequence . . . . . . . . . . . . . . . . . . . . . . . 45
• HOT GAS BYPASS CONTACTOR RELAY (3C) Automatic Soft Stop Amps Threshold . . . . . . . 45
(Optional) Chilled Water Recycle Mode . . . . . . . . . . . . . . . . 45
• CONTROL TRANSFORMERS (T1, T2) Safety Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . 45
CVC Operation and Menus . . . . . . . . . . . . . . . . . 14
• GENERAL BEFORE INITIAL START-UP . . . . . . . . . . . . . . . . 46-58
• ALARMS AND ALERTS Job Data Required . . . . . . . . . . . . . . . . . . . . . . . . . 46
• CVC MENU ITEMS Equipment Required . . . . . . . . . . . . . . . . . . . . . . . 46
• BASIC CVC OPERATIONS (Using the Softkeys) Using the Optional Storage Tank
• TO VIEW STATUS and Pumpout System . . . . . . . . . . . . . . . . . . . . 46
• OVERRIDE OPERATIONS Remove Shipping Packaging . . . . . . . . . . . . . . . 46
• TIME SCHEDULE OPERATION Open Oil Circuit Valves . . . . . . . . . . . . . . . . . . . . 46
• TO VIEW AND CHANGE SET POINTS Tighten All Gasketed Joints and
• SERVICE OPERATION Guide Vane Shaft Packing . . . . . . . . . . . . . . . . 46
PIC II System Functions . . . . . . . . . . . . . . . . . . . 32 Check Chiller Tightness . . . . . . . . . . . . . . . . . . . . 46
• CAPACITY CONTROL Refrigerant Tracer . . . . . . . . . . . . . . . . . . . . . . . . . 46
• ECW CONTROL OPTION Leak Test Chiller . . . . . . . . . . . . . . . . . . . . . . . . . . 48
• CONTROL POINT DEADBAND Standing Vacuum Test . . . . . . . . . . . . . . . . . . . . . 48
• DIFFUSER CONTROL Chiller Dehydration . . . . . . . . . . . . . . . . . . . . . . . . 51
• PROPORTIONAL BANDS AND GAIN Inspect Water Piping . . . . . . . . . . . . . . . . . . . . . . . 51
• DEMAND LIMITING Check Optional Pumpout Compressor
• CHILLER TIMERS Water Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
• OCCUPANCY SCHEDULE Check Relief Valves . . . . . . . . . . . . . . . . . . . . . . . 51
Safety Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Inspect Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Shunt Trip (Option) . . . . . . . . . . . . . . . . . . . . . . . . 35 Carrier Comfort Network Interface . . . . . . . . . . 52
Default Screen Freeze . . . . . . . . . . . . . . . . . . . . . 35 Check Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Ramp Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 • MECHANICAL STARTER
Capacity Override . . . . . . . . . . . . . . . . . . . . . . . . . 35 • BENSHAW, INC. REDISTART MICRO
High Discharge Temperature Control . . . . . . . 35 SOLID-STATE STARTER
Oil Sump Temperature Control . . . . . . . . . . . . . 35 Oil Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
2
CONTENTS (cont)
Page Page
Power Up the Controls and After Extended Shutdown . . . . . . . . . . . . . . . . . . 60
Check the Oil Heater . . . . . . . . . . . . . . . . . . . . . 53 Cold Weather Operation . . . . . . . . . . . . . . . . . . . 60
• SOFTWARE VERSION Manual Guide Vane Operation . . . . . . . . . . . . . . 60
Software Configuration . . . . . . . . . . . . . . . . . . . . 53 Refrigeration Log . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Input the Design Set Points . . . . . . . . . . . . . . . . 53 PUMPOUT AND REFRIGERANT TRANSFER
Input the Local Occupied Schedule PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . 62-64
(OCCPC01S) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Input Service Configurations . . . . . . . . . . . . . . . 53 Operating the Optional Pumpout Unit . . . . . . 62
• PASSWORD • TO READ REFRIGERANT PRESSURES
• INPUT TIME AND DATE Chillers with Storage Tanks . . . . . . . . . . . . . . . . 63
• CHANGE CVC CONFIGURATION • TRANSFER REFRIGERANT FROM
IF NECESSARY PUMPOUT STORAGE TANK TO CHILLER
• TO CHANGE THE PASSWORD • TRANSFER THE REFRIGERANT FROM
• TO CHANGE THE CVC DISPLAY FROM CHILLER TO PUMPOUT STORAGE TANK
ENGLISH TO METRIC UNITS Chillers with Isolation Valves . . . . . . . . . . . . . . . 64
• MODIFY CONTROLLER IDENTIFICATION • TRANSFER ALL REFRIGERANT TO
IF NECESSARY CHILLER CONDENSER VESSEL
• INPUT EQUIPMENT SERVICE PARAMETERS • TRANSFER ALL REFRIGERANT TO
IF NECESSARY CHILLER COOLER VESSEL
• CONFIGURE DIFFUSER CONTROL IF • RETURN CHILLER TO NORMAL
NECESSARY OPERATING CONDITIONS
• MODIFY EQUIPMENT CONFIGURATION
IF NECESSARY GENERAL MAINTENANCE . . . . . . . . . . . . . . . . . 65,66
Perform a Control Test . . . . . . . . . . . . . . . . . . . . . . 56 Refrigerant Properties . . . . . . . . . . . . . . . . . . . . . 65
Check Optional Pumpout System Adding Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . 65
Controls and Compressor . . . . . . . . . . . . . . . . 56 Removing Refrigerant . . . . . . . . . . . . . . . . . . . . . . 65
High Altitude Locations . . . . . . . . . . . . . . . . . . . . 56 Adjusting the Refrigerant Charge . . . . . . . . . . . 65
Charge Refrigerant Into Chiller . . . . . . . . . . . . . 56 Refrigerant Leak Testing . . . . . . . . . . . . . . . . . . . 65
• CHILLER EQUALIZATION WITHOUT A Leak Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
PUMPOUT UNIT Test After Service, Repair, or Major Leak . . . . 65
• CHILLER EQUALIZATION WITH • REFRIGERANT TRACER
PUMPOUT UNIT • TO PRESSURIZE WITH DRY NITROGEN
• TRIMMING REFRIGERANT CHARGE Repair the Leak, Retest, and Apply
Standing Vacuum Test . . . . . . . . . . . . . . . . . . . 65
INITIAL START-UP . . . . . . . . . . . . . . . . . . . . . . . . . 58,59 Checking Guide Vane Linkage . . . . . . . . . . . . . . 65
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Trim Refrigerant Charge . . . . . . . . . . . . . . . . . . . 65
Dry Run to Test Start-Up Sequence . . . . . . . . . 58
Check Motor Rotation . . . . . . . . . . . . . . . . . . . . . . 58 WEEKLY MAINTENANCE . . . . . . . . . . . . . . . . . . . 66
• IF THE MOTOR ROTATION IS CLOCKWISE Check the Lubrication System . . . . . . . . . . . . . . 66
• IF THE MOTOR ROTATION IS NOT SCHEDULED MAINTENANCE . . . . . . . . . . . . . . 66-69
CLOCKWISE Service Ontime . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Check Oil Pressure and Compressor Inspect the Control Panel . . . . . . . . . . . . . . . . . . 66
Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Check Safety and Operating Controls
To Prevent Accidental Start-Up . . . . . . . . . . . . . 59 Monthly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Check Chiller Operating Condition . . . . . . . . . . 59 Changing Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . 66
Instruct the Customer Operator . . . . . . . . . . . . 59 Oil Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
• COOLER-CONDENSER Oil Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
• OPTIONAL PUMPOUT STORAGE TANK AND • TO CHANGE THE OIL
PUMPOUT SYSTEM Refrigerant Filter . . . . . . . . . . . . . . . . . . . . . . . . . . 67
• MOTOR COMPRESSOR ASSEMBLY Oil Reclaim Filter . . . . . . . . . . . . . . . . . . . . . . . . . . 67
• MOTOR COMPRESSOR LUBRICATION Inspect Refrigerant Float System . . . . . . . . . . . 67
SYSTEM Inspect Relief Valves and Piping . . . . . . . . . . . . 67
• CONTROL SYSTEM Compressor Bearing and Gear
• AUXILIARY EQUIPMENT Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
• DESCRIBE CHILLER CYCLES Inspect the Heat Exchanger Tubes
• REVIEW MAINTENANCE and Flow Devices . . . . . . . . . . . . . . . . . . . . . . . . 68
• SAFETY DEVICES AND PROCEDURES • COOLER AND FLOW DEVICES
• CHECK OPERATOR KNOWLEDGE • CONDENSER AND FLOW DEVICES
• REVIEW THE START-UP, OPERATION, AND Water Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
MAINTENANCE MANUAL Water Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . 59-61 Inspect the Starting Equipment . . . . . . . . . . . . . 68
Operator Duties . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Check Pressure Transducers . . . . . . . . . . . . . . . 68
Prepare the Chiller for Start-Up . . . . . . . . . . . . . 59 Optional Pumpout System Maintenance . . . . . 68
To Start the Chiller . . . . . . . . . . . . . . . . . . . . . . . . 59 • OPTIONAL PUMPOUT COMPRESSOR OIL
Check the Running System . . . . . . . . . . . . . . . . 59 CHARGE
To Stop the Chiller . . . . . . . . . . . . . . . . . . . . . . . . . 60 • OPTIONAL PUMPOUT SAFETY CONTROL
After Limited Shutdown . . . . . . . . . . . . . . . . . . . . 60 SETTINGS
Preparation for Extended Shutdown . . . . . . . . 60 Ordering Replacement Chiller Parts . . . . . . . . 69
3
CONTENTS (cont)
Page Page
Notes on Module Operation . . . . . . . . . . . . . . . . 80
TROUBLESHOOTING GUIDE . . . . . . . . . . . . . . . 69-99 Chiller Control Module (CCM) . . . . . . . . . . . . . . . . 81
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 • INPUTS
Checking the Display Messages . . . . . . . . . . . . 69 • OUTPUTS
Checking Temperature Sensors . . . . . . . . . . . . 69 ISM Integrated Starter Module . . . . . . . . . . . . . . 81
• RESISTANCE CHECK • INPUTS
• VOLTAGE DROP • OUTPUTS
• CHECK SENSOR ACCURACY Replacing Defective Processor Modules . . . . 81
• DUAL TEMPERATURE SENSORS • INSTALLATION
Checking Pressure Transducers . . . . . . . . . . . . 70 Solid-State Starters . . . . . . . . . . . . . . . . . . . . . . . . 81
• COOLER AND CONDENSER PRESSURE • TESTING SILICON CONTROL RECTIFIERS
TRANSDUCER AND WATERSIDE FLOW DEVICE IN BENSHAW, INC. SOLID-STATE STARTERS
CALIBRATION • SCR REMOVAL/INSTALLATION
• TRANSDUCER REPLACEMENT Physical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Control Algorithms Checkout Procedure . . . . 70
Control Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100,101
Control Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 INITIAL START-UP CHECKLIST FOR
• RED LED (Labeled as STAT) 19XR HERMETIC CENTRIFUGAL
• GREEN LED (Labeled as COM) LIQUID CHILLER . . . . . . . . . . . . . . . . . . CL-1 to CL-12
INTRODUCTION ABBREVIATIONS AND EXPLANATIONS

Frequently used abbreviations in this manual include:
Prior to initial start-up of the 19XR unit, those involved
in the start-up, operation, and maintenance should be thor- CCM — Chiller Control Module
oughly familiar with these instructions and other necessary CCN — Carrier Comfort Network
job data. This book is outlined to familiarize those involved CVC — Chiller Visual Control
CCW — Counterclockwise
in the start-up, operation and maintenance of the unit with CW — Clockwise
the control system before performing start-up procedures. Pro- ECDW — Entering Condenser Water
cedures in this manual are arranged in the sequence required ECW — Entering Chilled Water
for proper chiller start-up and operation. EMS — Energy Management System
HGBP — Hot Gas Bypass
I/O — Input/Output
ISM — Integrated Starter Module
LCD — Liquid Crystal Display
LCDW — Leaving Condenser Water
This unit uses a microprocessor control system. Do not LCW — Leaving Chilled Water
short or jumper between terminations on circuit boards LED — Light-Emitting Diode
or modules; control or board failure may result. OLTA — Overload Trip Amps
PIC II — Product Integrated Control II
Be aware of electrostatic discharge (static electricity) when RLA — Rated Load Amps
handling or making contact with circuit boards or mod- SCR — Silicon Controlled Rectifier
ule connections. Always touch a chassis (grounded) part SI — International System of Units
to dissipate body electrostatic charge before working in- TXV — Thermostatic Expansion Valve
side control center.
Words printed in all capital letters or in italics may be viewed
Use extreme care when handling tools near boards and on the Chiller Visual Control (CVC) (e.g., LOCAL, CCN,
when connecting or disconnecting terminal plugs. Cir- ALARM, etc.).
cuit boards can easily be damaged. Always hold boards
by the edges and avoid touching components and Words printed in both all capital letters and italics can also
connections. be viewed on the CVC and are parameters (e.g., CONTROL
MODE, COMPRESSOR START RELAY, ICE BUILD
This equipment uses, and can radiate, radio frequency OPTION, etc.) with associated values (e.g., modes, tempera-
energy. If not installed and used in accordance with the tures, percentages, pressures, on, off, etc.).
instruction manual, it may cause interference to radio
communications. It has been tested and found to com- Words printed in all capital letters and in a box represent
ply with the limits for a Class A computing device pur- softkeys on the CVC control panel (e.g., ENTER ,
suant to Subpart J of Part 15 of FCC Rules, which are EXIT , INCREASE , QUIT , etc.).
designed to provide reasonable protection against such
interference when operated in a commercial environ- Factory-installed additional components are referred to as
ment. Operation of this equipment in a residential area options in this manual; factory-supplied but field-installed
is likely to cause interference, in which case the user, at additional components are referred to as accessories.
his own expense, will be required to take whatever mea- The chiller software part number of the 19XR unit is lo-
sures may be required to correct the interference. cated on the back of the CVC.
Always store and transport replacement or defective boards
in anti-static shipping bag.
4
CHILLER FAMILIARIZATION Motor-Compressor — This component maintains sys-
(Fig. 1 and 2) tem temperature and pressure differences and moves the heat-
carrying refrigerant from the cooler to the condenser.
Chiller Information Plate — The information plate is
located on the right side of the chiller control panel. Control Panel — The control panel is the user interface
for controlling the chiller. It regulates the chiller’s capacity
System Components — The components include the as required to maintain proper leaving chilled water tem-
cooler and condenser heat exchangers in separate vessels, perature. The control panel:
motor-compressor, lubrication package, control panel, and • registers cooler, condenser, and lubricating system
motor starter. All connections from pressure vessels have ex- pressures
ternal threads to enable each component to be pressure tested • shows chiller operating condition and alarm shutdown
with a threaded pipe cap during factory assembly. conditions
Cooler — This vessel (also known as the evaporator) is • records the total chiller operating hours
located underneath the compressor. The cooler is main- • sequences chiller start, stop, and recycle under micro-
tained at lower temperature/pressure so evaporating refrig- processor control
erant can remove heat from water flowing through its inter- • displays status of motor starter
nal tubes. • provides access to other CCN (Carrier Comfort Network)
devices
Condenser — The condenser operates at a higher
temperature/pressure than the cooler and has water flowing
through its internal tubes in order to remove heat from the
refrigerant.
MODEL NUMBER NOMENCLATURE
Fig. 1 — 19XR Identification

5
1 LEGEND
2 1 — Guide Vane Actuator
3 2 — Suction Elbow
3 — Chiller Visual Control (CVC)
4 4 — Chiller Identification Nameplate
5 5 — Cooler, Auto Reset Relief Valves
17 6 6 — Cooler Pressure Transducer
7 — Condenser In/Out Temperature
Thermistors
8 — Condenser Waterflow Device
9 — Cooler In/Out Temperature Thermistors
10 — Cooler Waterflow Device
16 11 — Refrigerant Charging Valve
12 — Typical Flange Connection
13 — Oil Drain Charging Valve
14 — Oil Level Sight Glasses
7 15 — Refrigerant Oil Cooler (Hidden)
16 — Auxiliary Power Panel
17 — Motor Housing
15 14
13
12
9
11 10
FRONT VIEW
18 19 20 21 22 LEGEND
18 — Condenser Auto. Reset Relief Valves
19 — Motor Circuit Breaker
20 — Solid-State Starter Control Display
21 — Unit-Mounted Starter (Optional),
34 Solid-State Starter Shown
22 — Motor Sight Glass
23
23 — Cooler Return-End Waterbox Cover
24 — ASME Nameplate (One Hidden)
25 — Typical Waterbox Drain Port
26 — Condenser Return-End Waterbox Cover
27 — Refrigerant Moisture/Flow Indicator
28 — Refrigerant Filter/Drier
29 — Liquid Line Isolation Valve (Optional)
30 — Linear Float Valve Chamber
31 — Vessel Take-Apart Connector
32 — Discharge Isolation Valve (Optional)
33 — Pumpout Valve
34 — Condenser Pressure Transducer
33 24
32
31 30 29 28 27 26 25 24
REAR VIEW
Fig. 2 — Typical 19XR Components
6
Factory-Mounted Starter (Optional) — The starter [37 to 40 C]) when it is discharged from the compressor into
allows for the proper start and disconnect of electrical en- the condenser.
ergy for the compressor-motor, oil pump, oil heater, and con- Relatively cool (typically 65 to 90 F [18 to 32 C]) water
trol panel. flowing into the condenser tubes removes heat from the re-
frigerant and the vapor condenses to liquid.
Storage Vessel (Optional) — There are 2 sizes of
storage vessels available. The vessels have double relief valves, The liquid refrigerant passes through orifices into the FLASC
a magnetically-coupled dial-type refrigerant level gage, a (Flash Subcooler) chamber (Fig. 3). Since the FLASC cham-
one-inch FPT drain valve, and a 1⁄2-in. male flare vapor ber is at a lower pressure, part of the liquid refrigerant flashes
connection for the pumpout unit. to vapor, thereby cooling the remaining liquid. The FLASC
vapor is recondensed on the tubes which are cooled by en-
NOTE: If a storage vessel is not used at the jobsite, factory- tering condenser water. The liquid drains into a float cham-
installed isolation valves on the chiller may be used to iso- ber between the FLASC chamber and cooler. Here a float
late the chiller charge in either the cooler or condenser. valve forms a liquid seal to keep FLASC chamber vapor from
An optional pumpout system is used to transfer refrigerant entering the cooler. When liquid refrigerant passes through
from vessel to vessel. the valve, some of it flashes to vapor in the reduced pressure
on the cooler side. In flashing, it removes heat from the re-
REFRIGERATION CYCLE maining liquid. The refrigerant is now at a temperature and
The compressor continuously draws refrigerant vapor from pressure at which the cycle began.
the cooler at a rate set by the amount of guide vane opening.
As the compressor suction reduces the pressure in the cooler, MOTOR AND LUBRICATING OIL
the remaining refrigerant boils at a fairly low temperature COOLING CYCLE
(typically 38 to 42 F [3 to 6 C]). The energy required for The motor and the lubricating oil are cooled by liquid re-
boiling is obtained from the water flowing through the cooler frigerant taken from the bottom of the condenser vessel
tubes. With heat energy removed, the water becomes cold (Fig. 3). Refrigerant flow is maintained by the pressure dif-
enough to use in an air conditioning circuit or for process ferential that exists due to compressor operation. After the
liquid cooling. refrigerant flows past an isolation valve, an in-line
After taking heat from the water, the refrigerant vapor is filter, and a sight glass/moisture indicator, the flow is split
compressed. Compression adds still more heat energy, and between the motor cooling and oil cooling systems.
the refrigerant is quite warm (typically 98 to 102 F
Fig. 3 — Refrigerant Motor Cooling and Oil Cooling Cycles
7
Flow to the motor cooling system passes through an ori- During shutdown, the oil pump will run for 60 seconds to
fice and into the motor. Once past the orifice, the refrigerant post-lubricate after the compressor shuts down. The oil pump
is directed over the motor by a spray nozzle. The refrigerant can also be energized for testing purposes during a Control
collects in the bottom of the motor casing and is then drained Test.
back into the cooler through the motor refrigerant drain line. Ramp loading can slow the rate of guide vane opening to
A back pressure valve or an orifice in this line maintains a minimize oil foaming at start-up. If the guide vanes open
higher pressure in the motor shell than in the cooler/oil sump. quickly, the sudden drop in suction pressure can cause any
The motor is protected by a temperature sensor imbedded in refrigerant in the oil to flash. The resulting oil foam can-
the stator windings. An increase in motor winding tempera- not be pumped efficiently; therefore, oil pressure falls off
ture past the motor override set point overrides the tempera- and lubrication is poor. If oil pressure falls below 15 psid
ture capacity control to hold, and if the motor temperature (103 kPad) differential, the PIC II will shut down the
rises 10° F (5.5° C) above this set point, closes the inlet guide compressor.
vanes. If the temperature rises above the safety limit, the com- If the controls are subject to a power failure that lasts more
pressor shuts down. than 3 hours, the oil pump will be energized periodically when
Refrigerant that flows to the oil cooling system is regu- the power is restored. This helps to eliminate refrigerant that
lated by thermostatic expansion valves (TXVs). The TXVs has migrated to the oil sump during the power failure. The
regulate flow into the oil/refrigerant plate and frame-type heat controls energize the pump for 60 seconds every 30 minutes
exchanger (the oil cooler in Fig. 3). The expansion valve until the chiller is started.
bulbs control oil temperature to the bearings. The refrigerant
leaving the oil cooler heat exchanger then returns to the chiller Oil Reclaim System — The oil reclaim system re-
cooler. turns oil lost from the compressor housing back to the oil
reservoir by recovering the oil from 2 areas on the chiller.
LUBRICATION CYCLE The guide vane housing is the primary area of recovery. Oil
is also recovered by skimming it from the operating refrig-
Summary — The oil pump, oil filter, and oil cooler make erant level in the cooler vessel.
up a package located partially in the transmission casting of
the compressor-motor assembly. The oil is pumped into a PRIMARY OIL RECOVERY MODE — Oil is normally
filter assembly to remove foreign particles and is then forced recovered through the guide vane housing on the chiller. This
into an oil cooler heat exchanger where the oil is cooled to is possible because oil is normally entrained with refrigerant
proper operational temperatures. After the oil cooler, part of in the chiller. As the compressor pulls the refrigerant up from
the flow is directed to the gears and the high speed shaft the cooler into the guide vane housing to be compressed, the
bearings; the remaining flow is directed to the motor shaft oil normally drops out at this point and falls to the bottom
bearings. Oil drains into the transmission oil sump to com- of the guide vane housing where it accumulates. Using dis-
plete the cycle (Fig. 4). charge gas pressure to power an eductor, the oil is drawn
from the housing and is discharged into the oil reservoir.
Details — Oil is charged into the lubrication system through SECONDARY OIL RECOVERY METHOD — The sec-
a hand valve. Two sight glasses in the oil reservoir permit oil ondary method of oil recovery is significant under light load
level observation. Normal oil level is between the middle of conditions, when the refrigerant going up to the compressor
the upper sight glass and the top of the lower sight glass suction does not have enough velocity in which to bring oil
when the compressor is shut down. The oil level should be along. Under these conditions, oil collects in a greater con-
visible in at least one of the 2 sight glasses during operation. centration at the top level of the refrigerant in the cooler.
Oil sump temperature is displayed on the CVC (Chiller This oil and refrigerant mixture is skimmed from the side of
Visual Control) default screen. During compressor opera- the cooler and is then drawn up to the guide vane housing.
tion, the oil sump temperature ranges between 125 to 150 F There is a filter in this line. Because the guide vane housing
(52 to 66 C). pressure is much lower than the cooler pressure, the refrig-
The oil pump suction is fed from the oil reservoir. An erant boils off, leaving the oil behind to be collected by the
oil pressure relief valve maintains 18 to 25 psid (124 to primary oil recovery method.
172 kPad) differential pressure in the system at the pump
discharge. This differential pressure can be read directly from STARTING EQUIPMENT
the CVC default screen. The oil pump discharges oil to the The 19XR requires a motor starter to operate the centrifu-
oil filter assembly. This filter can be closed to permit gal hermetic compressor motor, the oil pump, and various
removal of the filter without draining the entire oil system auxiliary equipment. The starter is the main field wiring in-
(see Maintenance sections, pages 65 to 69, for details). The terface for the contractor.
oil is then piped to the oil cooler heat exchanger. The oil See Carrier Specification Z-415 for specific starter re-
cooler uses refrigerant from the condenser as the coolant. quirements. All starters must meet these specifications in
The refrigerant cools the oil to a temperature between 120 order to properly start and satisfy mechanical safety require-
and 140 F (49 to 60 C). ments. Starters may be supplied as separate, free-standing
As the oil leaves the oil cooler, it passes the oil pressure units or may be mounted directly on the chiller (unit mounted)
transducer and the thermal bulb for the refrigerant expan- for low-voltage units only.
sion valve on the oil cooler. The oil is then divided. Part of Three separate circuit breakers are inside the starter. Cir-
the oil flows to the thrust bearing, forward pinion bearing, cuit breaker CB1 is the compressor motor circuit breaker.
and gear spray. The rest of the oil lubricates the motor shaft The disconnect switch on the starter front cover is connected
bearings and the rear pinion bearing. The oil temperature is to this breaker. Circuit breaker CB1 supplies power to the
measured in the bearing housing as it leaves the thrust and compressor motor.
forward journal bearings. The oil then drains into the oil res-
ervoir at the base of the compressor. The PIC II (Product
Integrated Control II) measures the temperature of the oil in
the sump and maintains the temperature during shutdown The main circuit breaker (CB1) on the front of the starter
(see Oil Sump Temperature Control section, page 35). This disconnects the main motor current only. Power is still
temperature is read on the CVC default screen. energized for the other circuits. Two more circuit break-
During the chiller start-up, the PIC II energizes the oil pump ers inside the starter must be turned off to disconnect
and provides 45 seconds of prelubrication to the bearings power to the oil pump, PIC II controls, and oil heater.
after pressure is verified before starting the compressor.
8
REAR MOTOR FWD MOTOR OIL SUPPLY TO
BEARING BEARING FORWARD HIGH
SPEED BEARING
LABYRINTH
GAS LINE
MOTOR
COOLING LINE
ISOLATION
VALVE
OIL FILTER
TXV BULB PRESSURE ISOLATION PUMP
TRANSDUCER VALVE
OIL SIGHT
OIL HEATER GLASS
COOLER OIL PUMP EDUCTOR FILTER
MOTOR ISOLATION
SIGHT GLASS VALVE
Fig. 4 — Lubrication System
Circuit breaker CB2 supplies power to the control panel, torque required to get the motor moving. The voltage is re-
oil heater, and portions of the starter controls. duced by silicon controlled rectifiers (SCRs). The voltage
Circuit breaker CB3 supplies power to the oil pump. Both and current are then ramped up in a desired period of time.
CB2 and CB3 are wired in parallel with CB1 so that power Once full voltage is reached, a bypass contactor is energized
is supplied to them if the CB1 disconnect is open. to bypass the SCRs.
All starters must include a Carrier control module called
the Integrated Starter Module (ISM), excluding the
Benshaw solid-state starters. This module controls and moni- When voltage is supplied to the solid-state circuitry, the
tors all aspects of the starter. See the Controls section on heat sinks in the starter as well as the wires leading to
page 10 for additional ISM information. All starter replace- the motor and the motor terminal are at line voltage.
ment parts are supplied by the starter manufacturer exclud- Do not touch the heat sinks, power wiring, or motor
ing the ISM (contact Carrier’s Replacement Component terminals while voltage is present or serious injury will
Division [RCD]). result.
Unit-Mounted Solid-State Starter (Optional) There is a display on the front of the Benshaw, Inc., solid-
— The 19XR chiller may be equipped with a solid-state, state starters that is useful for troubleshooting and starter check-
reduced-voltage starter (Fig. 5 and 6). This starter’s primary out. The display indicates:
function is to provide on-off control of the compressor mo- • voltage to the SCRs
tor. This type of starter reduces the peak starting torque, • SCR control voltage
reduces the motor inrush current, and decreases mechanical • power indication
shock. This capability is summed up by the phrase ‘‘soft start- • proper phasing for rotation
ing.’’ The solid-state starter is available as a 19XR option • start circuit energized
(factory supplied and installed). The solid-state starters manu- • over-temperature
facturer name is located inside the starter access door. • ground fault
A solid-state, reduced-voltage starter operates by reduc- • current unbalance
ing the starting voltage. The starting torque of a motor at full • run state
voltage is typically 125% to 175% of the running torque. • software configuration
When the voltage and the current are reduced at start-up, the The starter is further explained in the Check Starter and
starting torque is reduced as well. The object is to reduce the Troubleshooting Guide sections, pages 52 and 66.
starting voltage to just the voltage necessary to develop the
9
Unit-Mounted Wye-Delta Starter (Optional)
— The 19XR chiller may be equipped with a wye-delta starter
mounted on the unit. This starter is intended for use with
low-voltage motors (under 600 v). It reduces the starting
6 current inrush by connecting each phase of the motor
windings into a wye configuration. This occurs during the
starting period when the motor is accelerating up to speed.
1 Once the motor is up to speed, the starter automatically con-
nects the phase windings into a delta configuration. Starter
control, monitoring, and motor protection is provided by
Carrier’s Integrated Starter Module (ISM).
2 CONTROLS
Definitions
3
5 ANALOG SIGNAL — An analog signal varies in propor-
tion to the monitored source. It quantifies values between
operating limits. (Example: A temperature sensor is an ana-
log device because its resistance changes in proportion to
the temperature, generating many values.)
DISCRETE SIGNAL — A discrete signal is a 2-position rep-
4
resentation of the value of a monitored source. (Example: A
switch produces a discrete signal indicating whether a value
is above or below a set point or boundary by generating an
on/off, high/low, or open/closed signal.)
LEGEND
General — The 19XR hermetic centrifugal liquid chiller
contains a microprocessor-based control center that moni-
1 — Ready-Start Micro Input/Output Card tors and controls all operations of the chiller (see Fig. 7).
2 — Circuit Breaker 2 (CB2):
Machine Control and Heater Power The microprocessor control system matches the cooling
3 — Circuit Breaker 3 (CB3): Oil Pump Power capacity of the chiller to the cooling load while providing
4 — Ready-Start Micro Central Processing Unit Card (CPU) state-of-the-art chiller protection. The system controls cool-
5 — Restart Micro Power Card (hidden, not depicted) ing load within the set point plus the deadband by sensing
6 — Restart Micro Bypass Card (hidden, not depicted)
the leaving chilled water or brine temperature and regula-
Fig. 5 — Solid-State Starter Box, ting the inlet guide vane via a mechanically-linked actuator
Internal View motor. The guide vane is a variable flow pre-whirl assem-
bly that controls the refrigeration effect in the cooler by
regulating the amount of refrigerant vapor flow into the com-
pressor. An increase in guide vane opening increases capac-
ity. A decrease in guide vane opening decreases capacity. The
microprocessor-based control center protects the chiller by
monitoring the digital and analog inputs and executing
capacity overrides or safety shutdowns, if required.
PIC II System Components — The chiller control
system is called the PIC II (Product Integrated Control II).
See Table 1. The PIC II controls the operation of the chiller
by monitoring all operating conditions. The PIC II can di-
agnose a problem and let the operator know what the prob-
lem is and what to check. It promptly positions the guide
vanes to maintain leaving chilled water temperature. It can
interface with auxiliary equipment such as pumps and cool-
ing tower fans to turn them on when required. It continually
checks all safeties to prevent any unsafe operating condi-
tion. It also regulates the oil heater while the compressor is
off and regulates the hot gas bypass valve, if installed. The
PIC II controls provide critical protection for the compres-
sor motor and controls the motor starter.
Fig. 6 — Typical Starter External View

(Solid-State Starter Shown)
10
COOLER SCHRADER CONTROL GUIDE VANE POWER COMMUNICATION
FITTING (HIDDEN) PANEL ACTUATOR CABLE PANEL CABLE
WATER
SENSOR
CABLES WATER
SENSOR
CABLES
COOLER
PRESSURE
CONNECTION
CONDENSER CONDENSER CONDENSER COMPRESSOR MOTOR WINDING

PRESSURE SCHRADER PRESSURE DISCHARGE TEMPERATURE
CABLE FITTING (HIDDEN) CONNECTION ELBOW JOINTS CABLE
TRANSDUCER
TOP VIEW
VIEW A — A (COMPRESSOR DETAIL)

Fig. 7 — 19XR Controls and Sensor Locations
11
The PIC II can interface with the Carrier Comfort Net- tower fan, spare alarm contacts, and the shunt trip. The ISM
work (CCN) if desired. It can communicate with other monitors starter inputs such as line voltage, motor current,
PIC I or PIC II equipped chillers and other CCN devices. ground fault, remote start contact, spare safety, condenser
The PIC II consists of 3 modules housed inside 3 major high pressure, oil pump interlock, starter 1M, and run con-
components. The component names and corresponding contacts. The ISM contains logic capable of safety shutdown. It
trol voltages are listed below (also see Table 1): shuts down the chiller if communications with the CVC
are lost.
• control panel
— all extra low-voltage wiring (24 v or less) CHILLER CONTROL MODULE (CCM) — This module
• power panel is located in the control panel. The CCM provides the input
— 230 or 115 v control voltage (per job requirement) and outputs necessary to control the chiller. This module moni-
— up to 600 v for oil pump power tors refrigerant pressure, entering and leaving water tem-
peratures, and outputs control for the guide vane actuator,
• starter cabinet oil heaters, and oil pump. The CCM is the connection point
— chiller power wiring (per job requirement) for optional demand limit, chilled water reset, remote tem-
perature reset, and refrigerant leak sensor.
Table 1 — Major PIC Components and
Panel Locations* OIL HEATER CONTACTOR (1C) — This contactor is lo-
cated in the power panel (Fig. 11) and operates the heater at
PIC II COMPONENT PANEL LOCATION either 115 or 230 v. It is controlled by the PIC II to maintain
Chiller Visual Controller (CVC) and Display Control Panel oil temperature during chiller shutdown.
Integrated Starter Module (ISM) Starter Cabinet OIL PUMP CONTACTOR (2C) — This contactor is located
Chiller Control Module (CCM) Control Panel in the power panel. It operates all 200 to 575-v oil pumps.
Oil Heater Contactor (1C) Power Panel The PIC II energizes the contactor to turn on the oil pump
Oil Pump Contactor (2C) Power Panel as necessary.
Hot Gas Bypass Relay (3C) (Optional) Power Panel HOT GAS BYPASS CONTACTOR RELAY (3C) (Op-
Control Transformers (T1, T2) Power Panel tional) — This relay, located in the power panel, controls the
Temperature Sensors See Fig. 7. opening of the hot gas bypass valve. The PIC II energizes
Pressure Transducers See Fig. 7. the relay during low load, high lift conditions.
*See Fig. 5 and Fig. 7-11.
CONTROL TRANSFORMERS (T1, T2) — These trans-
formers convert incoming control voltage to 24 vac power
for the 3 power panel contactor relays, CCM, and CVC.
CHILLER VISUAL CONTROLLER (CVC) — The CVC is
the ‘‘brain’’ of the PIC II. This module contains all the op-
erating software needed to control the chiller. The CVC is
mounted to the control panel (Fig. 10) and is the input center
for all local chiller set points, schedules, configurable
functions, and options. The CVC has a stop button, an alarm
light, four buttons for logic inputs, and a backlight display.
The backlight will automatically turn off after 15 minutes of
non-use. The functions of the four buttons or ‘‘softkeys’’ are
menu driven and are shown on the display directly above Fig. 8 — Control Sensors (Temperature)
the softkeys.
The viewing angle of the CVC can be adjusted for opti-
mum viewing. Remove the 2 bolts connecting the control
panel to the brackets attached to the cooler. Place them in
one of the holes to pivot the control panel forward to back-
ward to change the viewing angle. See Fig. 10. To change
the contrast of the display, access the adjustment on the back
of the CVC. See Fig. 10.
INTEGRATED STARTER MODULE (ISM) — This mod-
ule is located in the starter cabinet. This module initiates com- Fig. 9 — Control Sensors
mands from the CVC for starter functions such as starting (Pressure Transducers, Typical)
and stopping the compressor, condenser, chilled water pumps,
12
Fig. 10 — Control Panel
Fig. 11 — Power Panel
13
CVC Operation and Menus (Fig. 12-18) PRIMARY STATUS
MESSAGE
COMPRESSOR
ONTIME
DATE TIME
GENERAL SECONDARY
STATUS RUNNING TEMP CONTROL 01-01-95 11:48
• The CVC display automatically reverts to the default screen MESSAGE LEAVING CHILLED WATER 28.8 HOURS
CHW IN CHW OUT EVAP REF
after 15 minutes if no softkey activity takes place and if ALARM LIGHT
55.1 44.1 40.7
the chiller is not in the pumpdown mode (Fig. 12). (ILLUMINATED CDW IN CDW OUT COND REF
WHEN POWER ON) 85.0 95.0 98.1
• If a screen other than the default screen is displayed on the • BLINKS CONTINUOUSLY
ON FOR AN ALARM
OIL PRESS OIL TEMP AMPS %
CVC, the name of that screen is in the upper right corner 21.8 132.9 93
• CONFIRMONCE
BLINKS TO
A STOP CCN LOCAL RESET MENU
(Fig. 13).
• The CVC may be set to display either English or SI units.
Use the CVC configuration screen (accessed from the Serv-
ice menu) to change the units. See the Service Operation STOP BUTTON
• HOLD FOR ONE
section, page 43. SECOND TO STOP
• Local Operation — The PIC II can be placed in local SOFT KEYS

EACH KEY'S FUNCTION IS MENU
operating mode by pressing the LOCAL softkey. The DEFINED BY THE MENU DESCRIPTION LINE
ON MENU LINE ABOVE
PIC II then accepts commands from the CVC only and
uses the Local Time Schedule to determine chiller start Fig. 12 — CVC Default Screen
and stop times.
• CCN Operation — The PIC II can be placed in the CCN
operating mode by pressing the CCN softkey. The
PIC II then accepts modifications from any CCN interface 19XR_II SERVICE
or module (with the proper authority), as well as from the ALARM HISTORY
CVC. The PIC II uses the CCN time schedule to deter- CONTROL TEST
CONTROL ALGORITHM STATUS
mine start and stop times. EQUIPMENT CONFIGURATION
ISM (STARTER) CONFIGURATION DATA
EQUIPMENT SERVICE
TIME AND DATE
ALARMS AND ALERTS — An alarm shuts down the com- ATTACH TO NETWORK DEVICE
LOG OUT OF DEVICE
pressor. An alert does not shut down the compressor, but it CVC CONFIGURATION
notifies the operator that an unusual condition has occurred.

An alarm (*) or alert (!) is indicated on the STATUS screens
on the far right field of the CVC display screen.
Alarms are indicated when the control center alarm light
(!) flashes. The primary alarm message is displayed on the
default screen. An additional, secondary message and
troubleshooting information are sent to the ALARM HIS-
TORY table. Fig. 13 — CVC Service Screen
When an alarm is detected, the CVC default screen will
freeze (stop updating) at the time of alarm. The freeze en-
ables the operator to view the chiller conditions at the time
of alarm. The STATUS tables will show the updated infor- • The SERVICE menu can be used to view or modify
mation. Once all alarms have been cleared (by pressing the information on the Alarm History, Control Test, Control
RESET softkey), the default CVC screen will return to nor- Algorithm Status, Equipment Configuration, ISM Starter
mal operation. Configuration data, Equipment Service, Time and Date, At-
tach to Network Device, Log Out of Network Device, and
CVC MENU ITEMS — To perform any of the operations CVC Configuration screens.
described below, the PIC II must be powered up and have
successfully completed its self test. The self test takes place For more information on the menu structures, refer to
automatically, after power-up. Fig. 15.
Press the MENU softkey to view the list of menu struc- Press the softkey that corresponds to the menu structure
tures: STATUS , SCHEDULE , SETPOINT , and to be viewed : STATUS , SCHEDULE , SETPOINT , or
SERVICE . SERVICE . To view or change parameters within any of
• The STATUS menu allows viewing and limited calibra- these menu structures, use the NEXT and PREVIOUS soft-
tion or modification of control points and sensors, relays keys to scroll down to the desired item or table. Use the
and contacts, and the options board.
SELECT softkey to select that item. The softkey choices
• The SCHEDULE menu allows viewing and modification
of the local and CCN time schedules and Ice Build time that then appear depend on the selected table or menu. The
schedules. softkey choices and their functions are described below.
• The SETPOINT menu allows set point adjustments, such BASIC CVC OPERATIONS (Using the Softkeys) — To per-
as the entering chilled water and leaving chilled water set form any of the operations described below, the PIC II must
points. be powered up and have successfully completed its self test.
14
• Press QUIT to leave the selected decision or field with- 2. Press NEXT or PREVIOUS to highlight the desired
out saving any changes. status table. The list of tables is:
• MAINSTAT — Overall chiller status
• STARTUP — Status required to perform startup of chiller
• COMPRESS — Status of sensors related to the
compressor
• HEAT_EX — Status of sensors related to the heat
• Press ENTER to leave the selected decision or field and exchangers
save changes. • POWER — Status of motor input power
• ISM_STAT — Status of motor starter
• CVC_PSWD — Service menu password forcing ac-
cess screen
• Press NEXT to scroll the cursor bar down in order to

highlight a point or to view more points below the current
screen. 3. Press SELECT to view the desired point status table.
• Press PREVIOUS to scroll the cursor bar up in order to

highlight a point or to view points above the current screen. 4. On the point status table, press NEXT or
PREVIOUS until the desired point is displayed on the
screen.
• Press SELECT to view the next screen level (high-

lighted with the cursor bar), or to override (if allowable)
the highlighted point value.
19XR_II MAINSTAT POINT STATUS
Control Mode OFF
Run Status Ready
Start Inhibit Timer 0.0 Min
Occupied? NO
System Alert/Alarm NORMAL
Chiller Start/Stop STOP
Remote Start Contact Open
Temperature Reset 0.0 F
Control Point 44.0 F
• Press EXIT to return to the previous screen level. Chilled Water Temp
Active Demand Limit
44.6 F
100%
Average Line Current 0.0%
• Press INCREASE or DECREASE to change the high-

lighted point value.
Fig. 14 — Example of Status Screen
OVERRIDE OPERATIONS
To Override a Value or Status
1. From any point status screen, press NEXT or
PREVIOUS to highlight the desired value.
TO VIEW STATUS (Fig. 14) — The status table shows the
actual value of overall chiller status such as CONTROL MODE,
RUN STATUS, AUTO CHILLED WATER, RESET, and RE-
MOTE RESET SENSOR.
1. On the menu screen, press STATUS to view the list of
point status tables. 2. Press SELECT to select the highlighted value. Then:
15
DEFAULT SCREEN
CCN LOCAL RESET MENU (SOFTKEYS)
Start Chiller In CCN Control
Start Chiller in Local Control
Clear Alarms Access Main Menu
STATUS SCHEDULE SETPOINT SERVICE
1 1 1 1 (ENTER A 4-DIGIT PASSWORD)

List the
Status Tables List the Service Tables
Display The Setpoint Table

• MAINSTAT
• STARTUP
• COMPRESS List the Schedules
• HEAT_EX • Base Demand Limit
• POWER • LCW Setpoint
• ISM_STAT • ECW Setpoint
• CVC_PSWD • Ice Build Setpoint
• Tower Fan High Setpoint
Select a Status Table Select the Setpoint
NEXT PREVIOUS SELECT EXIT NEXT PREVIOUS SELECT EXIT
Modify the Setpoint
Select a Modification Point
INCREASE DECREASE QUIT ENTER
NEXT PREVIOUS SELECT EXIT
Modify a Discrete Point

STOP START RELEASE ENTER
ON OFF
Modify an Analog Point

INCREASE DECREASE RELEASE ENTER • OCCPC01S – LOCAL TIME SCHEDULE
• OCCPC02S – ICE BUILD TIME SCHEDULE
Modify Control Options • OCCPC03S – CCN TIME SCHEDULE
ENABLE DISABLE RELEASE ENTER Select a Schedule
1
2
3
4
5
6
7
8
Override
Select a Time Period/Override
Modify a Schedule Time
INCREASE DECREASE ENTER EXIT (ANALOG VALUES)
Add/Eliminate a Day
ENABLE DISABLE ENTER EXIT (DISCRETE VALUES)
ALARM HISTORY
CONTROL TEST
CONTROL ALGORITHM STATUS
EQUIPMENT CONFIGURATION
ISM (STARTER) CONFIG DATA
EQUIPMENT SERVICE
TIME AND DATE
ATTACH TO NETWORK DEVICE
LOG OUT OF DEVICE
CVC CONFIGURATION
SEE FIGURE 16
Fig. 15 — 19XR CVC Menu Structure
16
SERVICE TABLE
ALARM HISTORY
Display Alarm History

(The table holds up to 25 alarms and
alerts with the most recent alarm
at the top of the screen.)
CONTROL TEST List the Control Tests
• CCM Thermistors
CONTROL ALGORITHM STATUS • CCM Pressure Transducers
• Pumps
• Discrete Outputs
List the Control Algorithm Status Tables • Guide Vane Actuator
• CAPACITY (Capacity Control) • Diffuser Actuator
• OVERRIDE (Override Status) • Pumpdown/Lockout
• LL_MAINT (Lead Lag Status) • Terminate Lockout
• ISM_HIST (ISM Alarm History) • Guide Vane Calibration
• LOADSHED Select a Test
• WSMDEFME (Water System Manager Control Status) NEXT PREVIOUS SELECT EXIT
• OCCDEFCM (Time Schedule Status)
Select a Table
OCCDEFM (Time Schedule Status)

• CAPACITY (Capacity Control Algorithm)
Data Select Table • OVERRIDE (Override Status)
NEXT PREVIOUS SELECT EXIT • LL_MAINT (LEADLAG Status)
• WSMDEFM2 (Water System Manager Control Status)
OCCPC01S (Local Status)

OCCPC02S (CCN, ICE BUILD Status) Maintenance Table Data
OCCPC03S (CCN Status)
EQUIPMENT CONFIGURATION List the Equipment Configuration Tables
• NET_OPT
• BRODEF
• OCCEFCS
• HOLIDAYS
• CONSUME
• RUNTIME
Select a Table
Select a Parameter
Modify a Parameter
INCREASE DECREASE QUIT ENTER (ANALOG VALUES)
ENABLE DISABLE QUIT ENTER (DISCRETE VALUES)
CONTINUED YES NO QUIT ENTER (DISCRETE VALUES)

ON NEXT PAGE
Fig. 16 — 19XR Service Menu Structure
17
SERVICE MENU CONTINUED
FROM PREVIOUS PAGE
ISM (STARTER CONFIG DATA)
EQUIPMENT SERVICE
4 4 4 4 (ENTER A 4-DIGIT PASSWORD)
Service Tables:
• OPTIONS Service Tables:
• SETUP1 • ISM (STARTER) CONFIG PASSWORD
• SETUP2 • ISM_CONFIG
• LEADLAG
• RAMP_DEM
• TEMP_CTL
Select a Service Table
Select a Service Table Parameter
Modify a Service Table Parameter

INCREASE DECREASE QUIT ENTER (ANALOG VALUES)
ENABLE DISABLE QUIT ENTER (DISCRETE VALUES)

NO YES QUIT ENTER (DISCRETE VALUES)
TIME AND DATE
Display Time and Date Table:

• To Modify — Current Time — Day of Week
ATTACH TO NETWORK DEVICE — Current Date — Holiday Today
INCREASE DECREASE ENTER EXIT
List Network Devices
• Local • Device 6
• Device 1 • Device 7
• Device 4
• Device 5
Select a Device
NEXT PREVIOUS SELECT ATTACH
Modify Device Address

• Use to attach CVC to another CCN network or device
• Attach to "LOCAL" to enter this machine
• To upload new tables
LOG OUT OF DEVICE
Default Screen
CCN LOCAL RESET MENU
CVC CONFIGURATION
CVC Configuration Table
• To Modify — CVC CCN Address • To View — CVC Software Version
— English or S.I. Metric Units (last 2 digits of part number
— Password indicate software version)
LEGEND
CCN — Carrier Comfort Network
CVC — Chiller Visual Control
PIC II — Product Integrated Control II
Fig. 16 — 19XR Service Menu Structure (cont)
18
For Discrete Points — Press START or STOP to se- 2. Press NEXT or PREVIOUS to highlight the de-
lect the desired state. sired schedule.
OCCPC01S — LOCAL Time Schedule
OCCPC02S — ICE BUILD Time Schedule
OCCPC03 — CCN Time Schedule
For Analog Points — Press INCREASE or

DECREASE to select the desired value.
3. Press SELECT to view the desired time schedule.
3. Press ENTER to register the new value.
4. Press NEXT or PREVIOUS to highlight the de-

sired period or override to change.
NOTE: When overriding or changing metric values, it is nec-

essary to hold down the softkey for a few seconds in order
to see a value change, especially on kilopascal values.
To Remove an Override 5. Press SELECT to access the highlighted period or
1. On the point status table press NEXT or override.
PREVIOUS to highlight the desired value.
6. a. Press INCREASE or DECREASE to change the

2. Press SELECT to access the highlighted value. time values. Override values are in one-hour incre-
ments, up to 4 hours.
3. Press RELEASE to remove the override and return the

point to the PIC II’s automatic control.
Override Indication — An override value is indicated by

‘‘SUPVSR,’’ ‘‘SERVC,’’ or ‘‘BEST’’ flashing next to the point
value on the STATUS table.
TIME SCHEDULE OPERATION (Fig. 17)

1. On the Menu screen, press SCHEDULE .
Fig. 17 — Example of Time Schedule

Operation Screen
19
2. There are 5 set points on this screen: BASE DEMAND
b. Press ENABLE to select days in the day-of-week LIMIT, LCW SETPOINT (leaving chilled water set point),
fields. Press DISABLE to eliminate days from the ECW SETPOINT (entering chilled water set point), ICE
period. BUILD SETPOINT, and TOWER FAN HIGH SET-
POINT. Only one of the chilled water set points can be
active at one time. The set point that is active is deter-
mined from the SERVICE menu. See the Service Opera-
tion section, page 43. The ice build (ICE BUILD) func-
tion is also activated and configured from the SERVICE
menu.
7. Press ENTER to register the values and to move
horizontally (left to right) within a period. 3. Press NEXT or PREVIOUS to highlight the desired
set point entry.
8. Press EXIT to leave the period or override.

4. Press SELECT to modify the highlighted set point.
9. Either return to Step 4 to select another period or

override, or press EXIT again to leave the current time
schedule screen and save the changes. 5. Press INCREASE or DECREASE to change the se-
lected set point value.
10. The Holiday Designation (HOLIDEF table) may be found

in the Service Operation section, page 43. The month,
day, and duration for the holiday must be assigned. The 6. Press ENTER to save the changes and return to the
Broadcast function in the BRODEF table also must be previous screen.
enabled for holiday periods to function.
TO VIEW AND CHANGE SET POINTS (Fig. 18)
1. To view the SETPOINT table, from the MENU screen
press SETPOINT .
SERVICE OPERATION — To view the menu-driven pro-

grams available for Service Operation, see Service Opera-
tion section, page 43. For examples of CVC display screens,
see Table 2.
19XR_II SETPOINT SETPOINT SELECT

Base Demand Limit 100%
Control Point
LCW Setpoint 50.0 F
ECW Setpoint 60.0 F
ICE BUILD Setpoint 40.0 F
Tower Fan High Setpoint 85.0 F
Fig. 18 — Example of Set Point Screen
20
Table 2 — CVC Display Data
6. Reference Point Names shown in these tables in all capital letters
IMPORTANT: The following notes apply to all Table 2 can be read by CCN and BS software. Of these capitalized names,
examples.
those preceded by a dagger can also be changed (that is, written
1. Only 12 lines of information appear on the CVC screen at any one to) by the CCN, BS, and the CVC. Capitalized Reference Point
Names preceded by two asterisks can be changed only from the
time. Press the NEXT or PREVIOUS softkey to highlight a
CVC. Reference Point Names in lower case type can be viewed
point or to view items below or above the current screen. Press by CCN or BS only by viewing the whole table.
the NEXT softkey twice to page forward; press the 7. Alarms and Alerts: An asterisk in the far right field of a CVC status
screen indicates that the chiller is in an alarm state; an exclama-
PREVIOUS softkey twice to page back. tion point in the far right field of the CVC screen indicates an alert
2. To access the information shown in Examples 9 through 21, enter state. The asterisk (or exclamation point) indicates that the value
your 4-digit password after pressing the SERVICE softkey. If on that line has exceeded (or is approaching) a limit. For more
information on alarms and alerts, see the Alarms and Alerts
no softkeys are pressed for 15 minutes, the CVC automatically section, page 14.
logs off (to prevent unrestricted access to PIC II controls) and re-
LEGEND
verts to the default screen. If this happens, you must reenter your
password to access the tables shown in Examples 9 through 21. CCN — Carrier Comfort Network
3. Terms in the Description column of these tables are listed as they CHW — Chilled Water
appear on the CVC screen. CHWR — Chilled Water Return
CHWS — Chilled Water Supply
4. The CVC may be configured in English or Metric (SI) units using CVC — Chiller Visual Control
the CVC CONFIGURATION screen. See the Service Operation CT — Current Transformer
section, page 43, for instructions on making this change. ECW — Entering Chilled Water
5. The items in the Reference Point Name column do not appear on HGBP — Hot Gas Bypass
the CVC screen. They are data or variable names used in CCN or ISM — Integrated Starter Module
Building Supervisor (BS) software. They are listed in these tables LCW — Leaving Chilled Water
as a convenience to the operator if it is necessary to cross ref- LRA — Locked Rotor Amps
erence CCN/BS documentation or use CCN/BS programs. For more mA — Milliamps
P — Pressure
information, see the 19XR CCN literature. SS — Solid State
T — Temperature
VFD — Variable Frequency Drive
WSM — Water System Manager
EXAMPLE 1 — CVC DEFAULT SCREEN

The following data is displayed in the CVC Default screen.
DESCRIPTION RANGE UNITS REFERENCE POINT NAME DISPLAY

(ALARM HISTORY)
(PRIMARY MESSAGE)
(SECONDARY MESSAGE)
(DATE AND TIME)
Compressor Ontime 0-500000.0 HOURS C HRS
Entering Chilled Water −40-245 DEG F ECW CHW IN
Leaving Chilled Water −40-245 DEG F LCW CHW OUT
Evaporator Temperature −40-245 DEG F ERT EVAP REF
Entering Condenser Water −40-245 DEG F ECDW CDW IN
Leaving Condenser Water −40-245 DEG F LCDW CDW OUT
Condenser Temperature −40-245 DEG F CRT COND REF
Oil Pressure 0-420 PSI OILPD OILPRESS
Oil Sump Temp −40-245 DEG F OILT OIL TEMP
Average Line Current 0-999 % AMPS % AMPS %
0-1 CCN
0-1 LOCAL
0-1 RESET
NOTE: The last three entries are used to indicate operating mode to the PIC II. These values may be forced by the CVC only.
21
Table 2 — CVC Display Data (cont)
EXAMPLE 2 — MAINTSTAT DISPLAY SCREEN
To access this display from the CVC default screen:
1. Press MENU .
2. Press STATUS ( MAINSTAT will be highlighted).
3. Press SELECT .
DESCRIPTION STATUS UNITS POINT

Control Mode NOTE 1 NOTE 1 MODE
Run Status NOTE 2 NOTE 2 STATUS
Start Inhibit Timer 0-15 min T START
Occupied ? 0/1 NO/YES OCC
System Alert/Alarm 0-2 NOTE 3 SYS ALM
*Chiller Start/Stop 0/1 STOP/START CHIL S S
*Remote Start Contact 0/1 OFF/ON REMCON
Temperature Reset −30-30 DEG F T RESET
*Control Point 10-120 DEG F LCW STPT
Chilled Water Temp −40-245 DEG F CHW TMP
*Active Demand Limit 40-100 % DEM LIM
Average Line Current 0-999 % % AMPS
Motor Percent Kilowatts 0-999 % KW P
Auto Demand Limit Input 4-20 mA AUTODEM
Auto Chilled Water Reset 4-20 mA AUTORES
Remote Reset Sensor −40-245 DEG F R RESET
Total Compressor Starts 0-99999 c starts
Starts in 12 Hours 0-8 STARTS
Compressor Ontime 0-500000.0 HOURS c hrs
*Service Ontime 0-32767 HOURS S HRS
Ice Build Contact 0-1 OPEN/CLOSE ICE CON
Refrigerant Leak Sensor 0-20 mA REF LEAK
NOTES:
1. Reset, Off, Local, CCN
2. Timeout, Ready, Recycle, Prestart, Start-up, Ramping, Running, Demand, Override, Shutdown, Trippout, Pumpdown, Lockout
3. Normal, Alert, Alarm
4. All variables with capital letter point names are available for CCN read operation. Those shown with (*) support write operations for all CCN
devices.
EXAMPLE 3 — STARTUP DISPLAY SCREEN

1. Press MENU .
2. Press STATUS .
3. Scroll down to highlight STARTUP .
4. Press SELECT .

Actual Guide Vane Pos 0-100 % GV ACT
**Chilled Water Pump 0-1 OFF/ON CHWP
Chilled Water Flow 0-1 NO/YES CHW FLOW
**Condenser Water Pump 0-1 OFF/ON CDP
Condenser Water Flow 0-1 NO/YES CDW FLOW
Oil Pump Relay 0-1 OFF/ON OILR
**Oil Pump Delta P −6.7-200 ^PSI OILPD
Compressor Start Relay 0-1 OFF/ON CMPR
Compressor Start Contact 0-1 OPEN/CLOSED ICR AUX
Starter Trans Relay 0-1 OFF/ON CMPTRANS
Compressor Run Contact 0-1 OPEN/CLOSED RUN AUX
**Tower Fan Relay Low 0-1 OFF/ON TFR LOW
**Tower Fan Relay High 0-1 OFF/ON TFR HIGH
Starter Fault 0-1 ALARM/NORMAL STR FLT
Spare Safety Input 0-1 ALARM/NORMAL SAFETY
Shunt Trip Relay 0-1 OFF/ON TRIPR
Starter Fault Status 0-255 STRSTAT
NOTE: All variables with CAPITAL LETTER point names are available for CCN read operation. Those shown with (**) shall support write operations
for the CVC only.
22
EXAMPLE 4 — COMPRESS DISPLAY SCREEN
1. Press MENU .
2. Press STATUS .
3. Scroll down to highlight COMPRESS .
4. Press SELECT .

Guide Vane Delta 0-100 % GV DELTA
**Target Guide Vane Pos 0-100 % GV TRG
Oil Sump Temp −40-245 DEG F OILT
**Oil Pump Delta P −6.7-200 DEG F OILPD
Comp Discharge Temp −40-245 DEG F CMPD
Comp Thrust Brg Temp −40-245 DEG F MTRB
Comp Motor Winding Temp −40-245 DEG F MTRW
Spare Temperature 1 −40-245 DEG F SPARE1
Oil Heater Relay 0/1 OFF/ON OILH
Diffuser Actuator 0-100 % DIFF ACT
**Target VFD Speed 0-110 % VFD OUT
**Actual VFD Speed 0-100 % VFD ACT
Surge Protection Counts 0-5 spc
for the CVC only.
EXAMPLE 5 — HEAT EX DISPLAY SCREEN

1. Press MENU .
2. Press STATUS .
3. Scroll down to highlight HEAT EX .
4. Press SELECT .

**Chilled Water Delta P −6.7-420 PSI CHW PD
Entering Chilled Water −40-245 DEG F ECW
Leaving Chilled Water −40-245 DEG F LCW
Chilled Water Delta T −6.7-420 ^F CHW DT
Chill Water Pulldown/Min −20-20 ^F CHW PULL
Evaporator Refrig Temp −40-245 DEG F ERT
**Evaporator Pressure −6.7-420 PSI ERP
Evaporator Approach 0-99 ^F EVAP APP
**Condenser Water Delta P −6.7-420 PSI COND PD
Entering Condenser Water −40-245 DEG F ECDW
Leaving Condenser Water −40-245 DEG F LCDW
Condenser Refrig Temp −40-245 DEG F CRT
**Condenser Pressure −6.7-420 PSI CRP
Condenser Approach 0-99 ^F COND APP
Hot Gas Bypass Relay 0/1 OFF/ON HGBR
Surge/HGBP Active ? 0/1 NO/YES SHG ACT
Active Delta P 0-200 PSI dp a
Active Delta T 0-200 DEG F dt a
Surge/HGBP Delta T 0-200 DEG F dt c
for the CVC only.
23
EXAMPLE 6 — POWER DISPLAY SCREEN
1. Press MENU .
2. Press STATUS .
3. Scroll down to highlight POWER .
4. Press SELECT .

Average Line Current 0-999 % % AMPS
Actual Line Current 0-99999 AMPS AMP A
Average Line Voltage 0-999 % VOLT P
Actual Line Voltage 0-99999 VOLTS VOLT A
Power Factor 0.0-1.0 PF
Motor Kilowatts 0-99999 kW KW A
Motor Kilowatt-Hours 0-99999 kWH KWH
Demand Kilowatts 0-99999 kWH DEM KWH
Line Current Phase 1 0-99999 AMPS AMPS 1
Line Voltage Phase 1 0-99999 VOLTS VOLTS 1
Ground Fault Phase 1 0-999 AMPS GF 1
Frequency 0-99 Hz FREQ
I2T Sum Heat-Phase 1 0-200 % HEAT1SUM
NOTE: All variables with CAPITAL LETTER point names are available for CCN read operation.
EXAMPLE 7 — ISM STAT SCREEN

1. Press MENU .
2. Press STATUS .
3. Scroll down to highlight ISM STAT .
4. Press SELECT .

ISM Fault Status 0-223 ISMFLT
Single Cycle Dropout 0-1 NORMAL/ALARM CYCLE 1
Phase Loss 0-1 NORMAL/ALARM PH LOSS
Overvoltage 0-1 NORMAL/ALARM OV VOLT
Undervoltage 0-1 NORMAL/ALARM UN VOLT
Current Imbalance 0-1 NORMAL/ALARM AMP UNB
Voltage Imbalance 0-1 NORMAL/ALARM VOLT UNB
Overload Trip 0-1 NORMAL/ALARM OVERLOAD
Locked Rotor Trip 0-1 NORMAL/ALARM LRATRIP
Starter LRA Trip 0-1 NORMAL/ALARM SLRATRIP
Ground Fault 0-1 NORMAL/ALARM GRND FLT
Phase Reversal 0-1 NORMAL/ALARM PH REV
Frequency Out of Range 0-1 NORMAL/ALARM FREQFLT
ISM Power on Reset 0-1 NORMAL/ALARM ISM POR
Phase 1 Fault 0-1 NORMAL/ALARM PHASE 1
ICR Start Complete 0-1 FALSE/TRUE START OK
IM Start/Run Fault 0-1 NORMAL/ALARM 1M FLT
2M Start/Run Fault 0-1 NORMAL/ALARM 2M FLT
Pressure Trip Contact 0-1 NORMAL/ALARM PRS TRIP
Starter Fault 0-1 NORMAL/ALARM STRT FLT
Motor Amps Not Sensed 0-1 NORMAL/ALARM NO AMPS
Starter Acceleration Fault 0-1 NORMAL/ALARM ACCELFLT
High Motor Amps 0-1 NORMAL/ALARM HIGHAMPS
ICR Stop Complete 0-1 FALSET/TRUE STOP OK
1M/2M Stop Fault 0-1 NORMAL/ALARM 1M2MSTOP
Motor Amps When Stopped 0-1 NORMAL/ALARM AMPSTOP
Hardware Failure 0-1 NORMAL/ALARM HARDWARE
NOTE: All variables with CAPITAL LETTER point names are available for CCN read operation.
24
EXAMPLE 8 — SET POINT DISPLAY SCREEN
1. Press MENU .
2. Press SETPOINT (Base Demand Limit will be highlighted).
3. Press SELECT .
DESCRIPTION STATUS UNITS POINT DEFAULT

Base Demand Limit 40-100 % DLM 100
Control Point
LCW Set Point 10-120 DEG F lcw sp 50.0
ECW Set Point 15-120 DEG F ecw sp 60.0
Ice Build Set Point 15-60 DEG F ice sp 40.0
Tower Fan High Set Point 55-105 DEG F tf2 sp 75
NOTE: All variables are available for CCN read operation; forcing shall not be supported on set point screens.
EXAMPLE 9 — CAPACITY DISPLAY SCREEN

1. Press MENU .
2. Press SERVICE .
3. Scroll down to highlight CONTROL ALGORITHM STATUS .
4. Press SELECT .
5. Scroll down to highlight CAPACITY .

Entering Chilled Water −40-245 DEG F ECW
Leaving Chilled Water −40-245 DEG F LCW
Capacity Control
Control Point 10-120 DEG F ctrlpt
Control Point Error −99-99 DEG F cperr
ECW Delta T −99-99 DEG F ecwdt
ECW Reset −99-99 DEG F ecwres
LCW Reset −99-99 DEG F lcwres
Total Error + Resets −99-99 DEG F error
Guide Vane Delta −2-2 % gvd
Target Guide Vane Pos 0-100 % GV TRG
Target VFD Speed 0-100 % VFD IN
ACTUAL VFD Speed 0-100 % VFD ACT
VFD Gain 0.1-1.5 vfd gain
Demand Inhibit Active 0-1 NO/YES DEM INH
Amps/kW Ramp 0-100 % DMD RAMP
NOTE: All variables with CAPITAL LETTER point names are available for CCN read operation; forcing shall not be supported on maintenance
screen.
25
EXAMPLE 10 — OVERRIDE DISPLAY SCREEN
1. Press MENU .
2. Press SERVICE .
4. Press SELECT .
5. Scroll down to highlight OVERRIDE .

Comp Motor Winding Temp −40-245 DEG F MTRW
Comp Motor Temp Override 150-200 DEG F mt over
Condenser Pressure 0-420 PSI CRP
Cond Press Override 90-180 PSI cp over
Evaporator Refrig Temp −40-245 DEG F ERT
Evap Ref Override Temp 2-45 DEG F rt over
Comp Discharge Temp −40-245 DEG F CMPD
Comp Discharge Alert 125-200 DEG F cd alert
Comp Thrust Brg Temp −40-245 DEG F MTRB
Comp Thrust Brg Alert 165-185 DEG F tb alert
Actual Superheat −20-99 DEG F SUPRHEAT
Superheat Required 6-99 ^F SUPR REQ
Condenser Refrig Temp −40-245 ^F CRT
screens.
EXAMPLE 11 — LL MAINT DISPLAY SCREEN

1. Press MENU .
2. Press SERVICE .
4. Press SELECT .
5. Scroll down to highlight LL MAINT. .

Lead Lag Control
LEAD/LAG: Configuration NOTE 1 leadlag
Current Mode NOTE 2 llmode
Load Balance Option 0/1 DSABLE/ENABLE loadbal
LAG Start Time 2-60 MIN lagstart
LAG Stop Time 2-60 MIN lagstop
PRESTART FAULT Time 2-30 MIN preflt
Pulldown: Delta T/Min x.xx ^ DEG pull dt
Satisfied? 0/1 NO/YES pull sat
LEAD CHILLER in Control 0/1 NO/YES leadctrl
LAG CHILLER: Mode NOTE 3 lagmode
Run Status NOTE 4 lagstat
Start/Stop NOTE 5 lag s s
Recovery Start Request 0/1 NO/YES lag rec
STANDBY CHILLER: Mode NOTE 3 stdmode
Run Status NOTE 4 stdstat
Start/Stop NOTE 5 Std s s
Recovery Start Request 0/1 NO/YES std rec
NOTES:
1. DISABLE, LEAD, LAG, STANDBY, INVALID
2. DISABLE, LEAD, LAG, STANDBY, RECOVERY, CONFIG
3. Reset, Off, Local, CCN
4. Timeout, Ready, Recycle, Prestart, Startup Ramping, Running, Demand, Override, Shutdown, Trippout, Pumpdown, Lockout
5. Stop, Start, Retain
6. All variables with CAPITAL LETTER point names are available for CCN read operation; forcing shall not be supported on maintenance screens.
26
EXAMPLE 12 — ISM HIST DISPLAY SCREEN
1. Press MENU .
2. Press SERVICE .
4. Press SELECT .
5. Scroll down to highlight ISM HIST .

ISM FAULT HISTORY
Values At Last Fault:
Line Current Phase 1 0-99999 AMPS AMPS 1F
Line Voltage Phase 1 0-99999 VOLTS VOLTS 1F
Ground Fault Phase 1 0-999 AMPS GF 1F
I2T Sum Heat-Phase 1 0-200 % HEAT1SUMF
Phase 1 Faulted? 0/1 NO/YES PH1 FLT
Line Frequency 0-99 Hz FREQ F
ISM Fault Status 0-9999 ISM STAT
screens.
EXAMPLE 13 — WSMDEFME DISPLAY SCREEN

1. Press MENU .
2. Press SERVICE .
4. Press SELECT .
5. Scroll down to highlight WSMDEFME .

WSM Active? 0/1 NO/YES WSMSTAT
Chilled Water Temp 0.0-99.9 DEG F CHWTEMP
Equipment Status 0/1 OFF/ON CHLRST
Commanded State XXXXXXXX TEXT CHLRENA
CHW setpt Reset Value 0.0-25.0 DEG F CHWRVAL
Current CHW Set Point 0.0-99.9 DEG F CHWSTPT
screens.
27
EXAMPLE 14 — NET OPT DISPLAY SCREEN
1. Press MENU .
2. Press SERVICE .
3. Scroll down to highlight EQUIPMENT CONFIGURATION .
4. Press SELECT .
5. Scroll down to highlight NET OPT .

Loadshed Function
Group Number 0-99 ldsgrp 0
Demand Limit Decrease 0-60 % ldsdelta 20
Maximum Loadshed Time 0-120 MIN maxldstm 60
CCN Occupancy Config:
Schedule Number 3-99 occpcxxe 3
Broadcast Option 0-1 DSABLE/ENABLE occbrcst DSABLE
Alarm Configuration
Re-alarm Time 0-1440 MIN 30
Alarm Routing 0-1 10000000
NOTE: No variables are available for CCN read or write operation.
EXAMPLE 15 — ISM CONF DISPLAY SCREEN

1. Press MENU .
2. Press SERVICE .
3. Scroll down to highlight ISM (STARTER) CONFIG DATA .
4. Press SELECT .
5. Scroll down to highlight ISM CONF .

Starter Type 0-2 starter 1
(0 = Full, 1 = Red, 2 = SS/VFD)
Motor Rated Line Voltage 200-13200 VOLTS v fs 460
Volt Transformer Ratio:1 1-33 vt rat 1
Overvoltage Threshold 105-115 % overvolt 115
Undervoltage Threshold 85-95 % undvolt 85
Over/Under Volt Time 1-10 SEC uvuntime 5
Voltage % Imbalance 1-10 % v unbal 5
Voltage Imbalance Time 1-10 SEC v time 5
Motor Rated Load Amps 10-5000 AMPS a fs 200
Motor Locked Rotor Trip 100-60000 AMPS motor lr 1000
Locked Rotor Start Delay 1-10 cycles lrdelay 5
Starter LRA Rating 100-60000 AMPS start lr 2000
Motor Current CT Ratio:1 10-1000 ct turns 100
Current % Imbalance 5-40 % c unbal 15
Current Imbalance Time 1-10 SEC c time 5
3 Grnd Fault CT’s? (1 = No) 0-1 NO/YES gf phase YES
Ground Fault CT Ratio:1 150 gf ctr 150
Ground Fault Current 1-20 AMPS gf amps 15
Ground Fault Start Delay 1-20 cycles gf delay 10
Ground Fault Persistence 1-10 cycles gf pers 5
Single Cycle Dropout 0/1 DSABLE/ENABLE cycdrop DSABLE
Frequency = 60 Hz? (No = 50) 0/1 NO/YES freq YES
Line Frequency Faulting 0/1 DSABLE/ENABLE freq en DSABLE
28
EXAMPLE 16 — OPTIONS DISPLAY SCREEN
1. Press MENU .
2. Press SERVICE .
3. Scroll down to highlight EQUIPMENT SERVICE .
4. Press SELECT .
5. Scroll down to highlight OPTIONS .

Auto Restart Option 0/1 DSABLE/ENABLE astart DSABLE
Remote Contacts Option 0/1 DSABLE/ENABLE r contact DSABLE
Soft Stop Amps Threshold 40-100 % softstop 100
Surge/Hot Gas Bypass
Surge Limit/HGBP Option 0/1 srg hgbp 0
Select: Surge = 0, HGBP = 1
Min. Load Point (T1/P1)
Surge/HGBP Delta T1 0.5-15 ^F hgb dt1 1.5
Surge/HGBP Delta P1 30-170 PSI hgb dp1 50
Full Load Point (T2/P2)
Surge/HGBP Delta T2 0.5-15 ^F hgb dt2 10
Surge/HGBP Delta P2 50-170 PSI hgb dp2 85
Surge/HGBP Deadband 0.5-3 ^F hgb dp 1
Surge Protection
Surge Delta % Amps 5-15 % surge a 10
Surge Time Period 7-10 MIN surge t 8
Ice Build Control
Ice Build Option 0/1 DSABLE/ENABLE ibopt DSABLE
Ice Build Termination 0-2 ibterm 0
0 = Temp, 1 = Contacts, 2 = Both
Ice Build Recycle 0/1 DSABLE/ENABLE ibrecyc DSABLE
Refrigerant Leak Option 0/1 DSABLE/ENABLE DSABLE
Refrigerant Leak Alarm mA 4-20 mA REF LEAK 20
EXAMPLE 17 — SETUP1 DISPLAY SCREEN

1. Press MENU .
2. Press SERVICE .
4. Press SELECT .
5. Scroll down to highlight SETUP1 .

Comp Motor Temp Override 150-200 DEG F mt over 200
Cond Press Override 90-165 PSI cp over 125
Comp Discharge Alert 125-200 DEG F cd alert 200
Comp Thrust Brg Alert 165-185 DEG F tb alert 175
Chilled Medium 0/1 WATER/BRINE medium WATER
Chilled Water Deadband .5-2.0 ^F cw db 1.0
Evap Refrig Trippoint 0.0-40.0 DEG F ert trip 33
Refrig Override Delta T 2.0-5.0 ^F ref over 3
Condenser Freeze Point −20 - 35 DEG F cdfreeze 34
Evap Flow Delta P Cutout 0.5 - 50.0 PSI evap cut 5.0
Cond Flow Delta P Cutout 0.5 - 50.0 PSI cond cut 5.0
Water Flow Verify Time 0.5-5 MIN wflow t 5
Oil Press Verify Time 15-300 SEC oilpr t 40
Recycle control
Recycle Restart Delta T 2.0-10.0 DEG F rcycr dt 5
Recycle Shutdown Delta 0.5-4.0 DEG F rcycs dt 1
SPARE ALERT/ALARM ENABLE
Disable=0, Lo=1/3,Hi=2/4
Spare Temp #1 Enable 0.4 sp1 en 0
Spare Temp #1 Limit −40-245 DEG F sp1 lim 245
Spare Temp #2 Enable 0-4 sp2 en 0
Spare Temp #2 Limit -40-245 DEG F sp2 lim 245
NOTE: No variables are available for CCN read operation; forcing shall not be supported on service screens.
29
EXAMPLE 18 — SETUP2 DISPLAY SCREEN
1. Press MENU .
2. Press SERVICE .
4. Press SELECT .
5. Scroll down to highlight SETUP2 .

Capacity Control
Proportional Inc Band 2-10 gv inc 6.5
Proportional DEC Band 2-10 gv dec 6.0
Proportional ECW Gain 1-3 gv ecw 2.0
Guide Vane Travel Limit 30-100 % gv lim 80
Diffuser Control
Diffuser Option 0-1 DSABLE/ENABLE diff opt DSABLE
Guide Vane 25% Load Pt 0-78 % gv 25 25
Diffuser 25% Load 0-100 % df 25 0
Diffuser 50% Load Pt 0-100 % df 50 0
Diffuser 75% Load Pt 0-100 % df 75 0
Diffuser Full Span mA 15-22 mA diff ma 18
VFD Speed Control
VFD Option 0/1 DSABLE/ENABLE vfd opt DSABLE
VFD Gain 0.1-1.5 vfd gain 0.75
VFD Increase Step 1-5 % vfd step 2
VFD Minimum Speed 65-100 % vfd min 70
VFD Maximum speed 90-110 % vfd max 100
NOTE: No variables are available for CCN read operation; forcing shall be supported on service screens.
EXAMPLE 19 − LEADLAG DISPLAY SCREEN

1. Press MENU .
2. Press SERVICE .
4. Press SELECT .
5. Scroll down to highlight LEADLAG .

Lead Lag Control
LEAD/LAG Configuration 0-3 leadlag 0
DSABLE=0, LEAD=1,
LAG=2, STANDBY=3
Load Balance Option 0/1 DSABLE/ENABLE load/bal DSABLE
Common Sensor Option 0/1 DSABLE/ENABLE commsens DSABLE
LAG Percent Capacity 25-75 % lag per 50
LAG Address 1-236 lag add 92
LAG START Timer 2-60 MIN lagstart 10
LAG STOP Timer 2-60 MIN lagstop 10
PRESTART FAULT Timer 2-30 MIN preflt 5
STANDBY Chiller Option 0/1 DSABLE/ENABLE stndopt DSABLE
STANDBY Percent Capacity 25-57 % stnd per 50
STANDBY Address 1-236 stnd add 93
30
EXAMPLE 20 — RAMP_DEM DISPLAY SCREEN
1. Press MENU .
2. Press SERVICE .
4. Press SELECT .
5. Scroll down to highlight RAMP_DEM .

Pulldown Ramp Type: 0/1 ramp opt 1
Select: Temp=0, Load=1
Demand Limit + kW Ramp
Demand Limit Source 0/1 dem src 0
Select: Amps=0, kW=1
Motor Load Ramp %/Min 5-20 kw ramp 10
Demand Limit Prop Band 3-15 % dem prop 10
Demand Limit At 20 mA 40-100 % dem 20ma 40
20mA Demand Limit Opt 0/1 DS/ENABLE dem sel DSABLE
Motor Rated Kilowatts 50-9999 kW motor kw 145
Demand Watts Interval 5-60 MIN dw int 15
EXAMPLE 20 — TEMP_CTL DISPLAY SCREEN

1. Press MENU .
2. Press SERVICE .
4. Press SELECT .
5. Scroll down to highlight TEMP_CTL .

Control Point
EWB Control Option 0/1 DSABLE/ENABLE ecw opt DSABLE
Temp Pulldown Deg/Min 2-10 ^F tmp ramp 3
Temperature Reset
RESET TYPE 1
Degrees REset At 20 mA −30- 30 ^F deg 20ma 10
RESET TYPE 2
Remote Temp (No Reset) −40-245 DEG F res rt1 85
Remote Temp (Full Reset) _40-245 DEG F res rt2 65
Degrees Reset −30-30 ^F deg rt 10
RESET TYPE 3
CHW Delta T (No Reset) 0-15 ^F restd 1 10
CHW Delta T (Full Reset) 0-15 ^F restd 2 0
Degrees Reset −30-30 ^F deg chw 5
Select/Enable Reset Type 0-3 res sel 0
31
PIC II System Functions The Proportional Band — There are two response modes,
one for temperature response above the control point, the
NOTE: Words not part of paragraph headings and printed other for the response below the control point.
in all capital letters can be viewed on the CVC (e.g., LO-
CAL, CCN, RUNNING, ALARM, etc.). Words printed in The temperature response above the control point is called
both in all capital letters and italics can also be viewed on the PROPORTIONAL INC BAND, and it can slow or quicken
the CVC and are parameters (CONTROL MODE, COOL- guide vane response to chilled water/brine temperatures above
ING SET POINT, TARGET GUIDE VANE POS, etc.) with the DEADBAND. The PROPORTIONAL INC BAND can be
associated values (e.g., modes, temperatures, pressures, per- adjusted from a setting of 2 to 10; the default setting is 6.5.
centages, on, off, enable, disable, etc.). Works printed in all The response below the control point is called the
capital letters and in a box represent softkeys on the CVC PROPORTIONAL DEC BAND, and it can slow or quicken
(e.g., ENTER and EXIT ). See Table 2 for examples of the guide vane response to chilled water temperature below
the deadband plus the control point. The PROPORTIONAL
the type of information that can appear on the CVC screens. DEC BAND can be adjusted on the CVC from a setting of
Figures 12-18 give an overview of CVC operations and menus. 2 to 10. The default setting is 6.0.
CAPACITY CONTROL — The PIC II controls the chiller NOTE: Increasing either of these settings causes the guide
capacity by modulating the inlet guide vanes in response to vanes to respond more slowly than they would at a lower
chilled water temperature changes away from the CON- setting.
TROL POINT. The CONTROL POINT may be changed by
a CCN network device or is determined by the PIC II adding The PROPORTIONAL ECW GAIN can be adjusted on the
any active chilled water reset to the SET POINT. The PIC II CVC display for values of 1, 2, or 3; the default setting is 2.
uses the PROPORTIONAL INC (Increase) BAND, PRO- Increase this setting to increase guide vane response to a change
PORTIONAL DEC (Decrease) BAND, and the PROPOR- in entering chilled water temperature.
TIONAL ECW (Entering Chilled Water) GAIN to determine DEMAND LIMITING — The PIC II responds to the
how fast or slow to respond. CONTROL POINT may be viewed ACTIVE DEMAND LIMIT set point by limiting the opening
or overridden from the MAINSTAT screen. of the guide vanes. It compares the ACTIVE DEMAND LIMIT
ECW CONTROL OPTION — If this option is enabled, the set point to the DEMAND LIMIT SOURCE (either the
PIC II uses the ENTERING CHILLED WATER temperature AVERAGE LINE CURRENT or the MOTOR KW). Depend-
to modulate the vanes instead of the LEAVING CHILLED ing on how the control is configured. DEMAND LIMIT
WATER temperature. The ECW CONTROL OPTION may be SOURCE is on the RAMP_DEM screen. The default source
viewed on the TEMP_CTL screen, which is accessed from is the compressor motor current.
the EQUIPMENT SERVICE screen. CHILLER TIMERS — The PIC II maintains 2 runtime clocks,
CONTROL POINT DEADBAND — This is the tolerance known as COMPRESSOR ONTIME and SERVICE ON-
range on the chilled water/brine temperature control point. TIME. COMPRESSOR ONTIME indicates the total life-
If the water temperature goes outside the CHILLED WATER time compressor run hours. This timer can register up to
DEADBAND, the PIC II opens or closes the guide vanes un- 500,000 hours before the clock turns back to zero. The
til the temperature is within tolerance. The PIC II may be SERVICE ONTIME is a reset table timer that can be used to
configured with a 0.5 to 2 F (0.3 to 1.1 C) deadband. CHILLED indicate the hours since the last service visit or any other
WATER DEADBAND may be viewed or modified on the event. The time can be changed from the CVC to whatever
SETUP1 screen, which is accessed from the EQUIPMENT value is desired. This timer can register up to 32,767 hours
SERVICE table. before it rolls over to zero.
For example, a 1° F (0.6° C) deadband setting controls The chiller also maintains a start-to-start timer and a stop-
the water temperature within ±0.5° F (0.3° C) of the control to-start timer. These timers limit how soon the chiller can be
point. This may cause frequent guide vane movement if the started. START INHIBIT TIMER is displayed on the
chilled water load fluctuates frequently. A value of 1° F MAINSTAT screen. See the Start-Up/Shutdown/Recycle Se-
(0.6° C) is the default setting. quence section, page 44, for more information on this topic.
DIFFUSER CONTROL — On 19XR compressors equipped OCCUPANCY SCHEDULE — The chiller schedule, de-
with a variable discharge diffuser, the PIC II adjusts the dif- scribed in the Time Schedule Operation section (page 19),
fuser actuator position (DIFFUSER ACTUATOR on the COM- determines when the chiller can run. Each schedule consists
PRESS screen) to correspond to the actual guide vane po- of from 1 to 8 occupied or unoccupied time periods, set by
sition (ACTUAL GUIDE VANE POS on the COMPRESS the operator. The chiller can be started and run during an
screen). occupied time period (when OCCUPIED ? is set to YES on
the MAINSTAT display screen). It cannot be started or run
The diffuser control can be enabled or disabled from the during an unoccupied time period (when OCCUPIED ? is
SETUP2 screen. See Table 2, Example 18. In addition, the set to NO on the MAINSTAT display screen). These time
diffuser and guide vane load points may be viewed and modi- periods can be set for each day of the week and for holidays.
fied from this screen. These points must be correct for the The day begins with 0000 hours and ends with 2400 hours.
compressor size. The diffuser opening can be incremented The default setting for OCCUPIED ? is YES, unless an un-
from fully open to completely closed. A 0% setting is fully occupied time period is in effect.
open; a 100% setting is completely closed. To obtain the proper
settings for Diffuser Control, contact a Carrier Engineering These schedules can be set up to follow a building’s oc-
representative. cupancy schedule, or the chiller can be set so to run 100%
of the time, if the operator wishes. The schedules also can be
PROPORTIONAL BANDS AND GAIN — Proportional band bypassed by forcing the CHILLER START/STOP parameter
is the rate at which the guide vane position is corrected in on the MAINSTAT screen to START. For more information
proportion to how far the chilled water/brine temperature is on forced starts, see Local Start-Up, page 44.
from the control point. Proportional gain determines how The schedules also can be overridden to keep the chiller
quickly the guide vanes react to how quickly the tempera- in an occupied state for up to 4 hours, on a one time basis.
ture is moving from the CONTROL POINT. The propor- See the Time Schedule Operation section, page 19.
tional bands and gain may be viewed or modified from the
SETUP2 screen, which is accessed from the EQUIPMENT
SERVICE table.
32
Figure 17 shows a schedule for a typical office building • voltage imbalance
with a 3-hour, off-peak, cool-down period from midnight • current imbalance
to 3 a.m., following a weekend shutdown. Holiday periods
are in an unoccupied state 24 hours per day. The building • excessive motor acceleration time
operates Monday through Friday, 7:00 a.m. to 6:00 p.m., and • excessive starter transition time
Saturdays from 6:00 a.m. to 1:00 p.m. This schedule also • lack of motor current signal
includes the Monday midnight to 3:00 a.m. weekend cool- • excessive motor amps
down schedule.
• excessive compressor surge
NOTE: This schedule is for illustration only and is not in-
tended to be a recommended schedule for chiller operation. • temperature and transducer faults
Whenever the chiller is in the LOCAL mode, it uses *Superheat is the difference between saturation temperature
Occupancy Schedule 01 (OCCPC01S). When the chiller is and sensible temperature. The high discharge temperature
in the ICE BUILD mode, it uses Occupancy Schedule 02 safety measures only sensible temperature.
(OCCPC02S). When the chiller is in CCN mode, it uses Starter faults or optional protective devices within the starter
Occupancy Schedule 03 (OCCPC03S). can shut down the chiller. The protective devices you
The CCN SCHEDULE NUMBER is configured on the have for your application depend on what options were
NET_OPT display screen, accessed from the EQUIPMENT purchased.
CONFIGURATION table. See Table 2, Example 14.
SCHEDULE NUMBER can be changed to any value from
03 to 99. If this number is changed on the NET_OPT screen,
the operator must go to the ATTACH TO NETWORK DE- If compressor motor overload occurs, check the motor
VICE screen to upload the new number into the SCHED- for grounded or open phases before attempting a
ULE screen. See Fig. 16. restart.
Safety Controls — The PIC II monitors all safety con- If the PIC II control initiates a safety shutdown, it dis-
trol inputs and, if required, shuts down the chiller or limits plays the reason for the shutdown (the fault) on the CVC
the guide vanes to protect the chiller from possible damage display screen along with a primary and secondary message,
from any of the following conditions: energizes an alarm relay in the starter, and blinks the alarm
• high bearing temperature light on the control panel. The alarm is stored in memory
• high motor winding temperature and can be viewed on the ALARM HISTORY and
ISM_HIST screens on the CVC, along with a message for
• high discharge temperature troubleshooting. If the safety shutdown was also initiated by
• low discharge superheat* a fault detected in the motor starter, the conditions at the
• low oil pressure time of the fault will be stored in ISM_HIST.
• low cooler refrigerant temperature/pressure To give more precise information or warnings on the chill-
er’s operating condition, the operator can define alert limits
• condenser high pressure or low pressure on various monitored inputs. Safety contact and alert limits
• inadequate water/brine cooler and condenser flow are defined in Table 3. Alarm and alert messages are listed
• high, low, or loss of voltage in the Troubleshooting Guide section, page 69.
• ground fault
33
Table 3 — Protective Safety Limits and Control Settings
MONITORED PARAMETER LIMIT APPLICABLE COMMENTS
TEMPERATURE SENSORS OUT OF –40 to 245 F (–40 to 118.3 C) Must be outside range for 2 seconds
RANGE
PRESSURE TRANSDUCERS OUT OF 0.06 to 0.98 Voltage Ratio Must be outside range for 3 seconds.
RANGE Ratio = Input Voltage ÷ Voltage Reference
COMPRESSOR DISCHARGE .220 F (104.4 C) Preset, alert setting configurable
TEMPERATURE
MOTOR WINDING TEMPERATURE .220 F (104.4 C) Preset, alert setting configurable
BEARING TEMPERATURE .185 F (85 C) Preset, alert setting configurable
EVAPORATOR REFRIGERANT ,33 F (for water chilling) (0.6° C) Preset, configure chilled medium for water
TEMPERATURE (SETUP1 table)
,EVAP REFRIG TRIPPOINT (set point Configure chilled medium for brine (SETUP1
adjustable from 0 to 40 F [–18 to 4 C] for table). Adjust EVAP REFRIG TRIPPOINT for
brine chilling) proper cutout
TRANSDUCER VOLTAGE ,4.5 vdc . 5.5 vdc Preset
CONDENSER PRESSURE — SWITCH .263 ± 7 psig (1813 ± 48 kPa), reset at Preset
180 ± 10 (1241 ± 69 kPa)
— CONTROL 165 psig (1138 kPa) Preset
OIL PRESSURE Cutout ,15 psid (103 kPad) Preset
Alert ,18 psid (124 kPad)
LINE VOLTAGE — HIGH .110% for one minute Preset, based on transformed line voltage to
— LOW ,90% for one minute or <85% for 3 seconds ISM. Also monitored at CVC and CCM power
input.
— SINGLE-CYCLE ,50% for one cycle
COMPRESSOR MOTOR LOAD .110% for 30 seconds Preset
,15% with compressor running Preset
.15% with compressor off Preset
STARTER ACCELERATION TIME .45 seconds For chillers with reduced voltage mechanical
(Determined by inrush current and solid-state starters
going below 100% compressor .10 seconds For chillers with full voltage starters
motor load) (Configured on ISM_CONFIG table)
STARTER TRANSITION .75 seconds Reduced voltage starters only
CONDENSER FREEZE PROTECTION Energizes condenser pump relay if condenser CONDENSER FREEZE POINT configured in
refrigerant temperature or condenser entering SETUP1 table with a default setting of
water temperature is below the configured 34 F (1 C).
condenser freeze point temperature. Deener-
gizes when the temperature is 5 F (3 C)
above condenser freeze point temperature.
DISCHARGE SUPERHEAT Minimum value calculated based on Calculated minimum required superheat and
operating conditions and then compared actual superheat are shown on OVERRIDE
to actual superheat. screen.
VARIABLE DIFFUSER OPERATION Detects discharge pulses caused by incorrect Preset, no calibration needed.
diffuser position.
34
Shunt Trip (Option) — The function of the shunt trip If kilowatts is selected for the DEMAND LIMIT SOURCE,
option on the PIC II is to act as a safety trip. The shunt trip the MOTOR RATED KILOWATTS must be entered (infor-
is wired from an output on the ISM to a shunt trip equipped mation found on the chiller Requisition form).
motor circuit breaker. If the PIC II tries to shut down the The TEMP PULLDOWN DEG/MIN may be viewed or modi-
compressor using a normal shutdown procedure but is un- fied on the TEMP_CTL screen which is accessed from the
successful for 30 seconds, the shunt trip output is energized EQUIPMENT SERVICE screen. PULLDOWN RAMP TYPE,
and causes the circuit breaker to trip off. If ground fault pro- DEMAND LIMIT SOURCE, and MOTOR LOAD RAMP
tection has been applied to the starter, the ground fault trip %/MIN may be viewed or modified on the RAMP_DEM screen.
also energizes the shunt trip to trip the circuit breaker. Pro-
tective devices in the starter can also energize the shunt trip. Capacity Override (Table 4) — Capacity overrides
The shunt trip feature can be tested using the Control Test can prevent some safety shutdowns caused by exceeding the
feature. motor amperage limit, refrigerant low temperature safety limit,
motor high temperature safety limit, and condenser high pres-
Default Screen Freeze — When the chiller is in an sure limit. In all cases there are 2 stages of compressor vane
alarm state, the default CVC display ‘‘freezes,’’ that is, it control.
stops updating. The first line of the CVC default screen dis-
plays a primary alarm message; the second line displays a 1. The vanes are prevented from opening further, and
secondary alarm message. the status line on the CVC indicates the reason for the
override.
The CVC default screen freezes to enable the operator to
see the conditions of the chiller at the time of the alarm. If 2. The vanes are closed until the condition decreases to be-
the value in alarm is one normally displayed on the default low the first step set point. Then the vanes are released to
screen, it flashes between normal and reverse video. The CVC normal capacity control.
default screen remains frozen until the condition that caused Whenever the motor current demand limit set point
the alarm is remedied by the operator. (ACTIVE DEMAND LIMIT) is reached, it activates a capac-
Knowledge of the operating state of the chiller at the time ity override, again, with a 2-step process. Exceeding 110%
an alarm occurs is useful when troubleshooting. Additional of the rated load amps for more than 30 seconds will initiate
chiller information can be viewed on the status screens and a safety shutdown.
the ISM_HIST screen. Troubleshooting information is re- The compressor high lift (surge prevention) set point will
corded in the ALARM HISTORY table, which can be ac- cause a capacity override as well. When the surge preven-
cessed from the SERVICE menu. tion set point is reached, the controller normally will only
To determine what caused the alarm, the operator should prevent the guide vanes from opening. If so equipped, the
read both the primary and secondary default screen mes- hot gas bypass valve will open instead of holding the vanes.
sages, as well as the alarm history. The primary message See the Surge Prevention Algorithm section, page 38.
indicates the most recent alarm condition. The secondary mes-
sage gives more detail on the alarm condition. Since there High Discharge Temperature Control — If the dis-
may be more than one alarm condition, another alarm mes- charge temperature increases above 160 F (71.1 C), the guide
sage may appear after the first condition is cleared. Check vanes are proportionally opened to increase gas flow through
the ALARM HISTORY screen for additional help in deter- the compressor. If the leaving chilled water temperature is
mining the reasons for the alarms. Once all existing alarms then brought 5° F (2.8° C) below the control set point tem-
perature, the PIC II will bring the chiller into the recycle
are cleared (by pressing the RESET softkey), the default mode.
CVC display returns to normal operation.
Oil Sump Temperature Control — The oil sump tem-
Ramp Loading — The ramp loading control slows down perature control is regulated by the PIC II, which uses the
the rate at which the compressor loads up. This control can oil heater relay when the chiller is shut down.
prevent the compressor from loading up during the short pe-
riod of time when the chiller is started and the chilled water As part of the pre-start checks executed by the controls,
loop has to be brought down to CONTROL POINT. This helps the oil sump temperature (OIL SUMP TEMP) is compared
reduce electrical demand charges by slowly bringing the chilled to the cooler refrigerant temperature (EVAPORATOR
water to CONTROL POINT. The total power draw during REFRIG TEMP). If the difference between these 2 tempera-
this period remains almost unchanged. tures is 50 F (27.8 C) or less, the start-up will be delayed
until the oil temperature is 50 F (27.8 C) or more. Once this
There are two methods of ramp loading with the PIC II. temperature is confirmed, the start-up continues.
Ramp loading can be based on chilled water temperature or
on motor load. Either method is selected from the The oil heater relay is energized whenever the chiller com-
RAMP__DEM screen. pressor is off and the oil sump temperature is less than
140 F (60.0 C) or the oil sump temperature is less than
1. Temperature ramp loading (TEMP PULLDOWN DEG/ the cooler refrigerant temperature plus 53° F (11.7° C). The
MIN) limits the degrees per minute rate at which either oil heater is turned off when the oil sump temperature is
leaving chilled water or entering chilled water tempera- either
ture decreases. This rate is configured by the operator on
the TEMP_CTL screen. The lowest temperature ramp rate • more than 152 F (66.7 C), or
will also be used if chiller power has been off for 3 hours • more than 142 F (61.1 C) and more than the cooler
or more (even if the motor ramp load is selected as the refrigerant temperature plus 55° F (12.8° C).
ramp loading method. The oil heater is always off during start-up or when the
2. Motor load ramp loading (LOAD PULLDOWN) limits the compressor is running.
degrees per minute rate at which the compressor motor The oil pump is also energized during the time the oil
current or compressor motor load increases. The LOAD is being heated (for 60 seconds at the end of every
PULLDOWN rate is configured by the operator on the 30 minutes).
RAMP_DEM screen in amps or kilowatts.
35
Table 4 — Capacity Overrides
SECOND STAGE OVERRIDE
FIRST STAGE SET POINT SET POINT TERMINATION
OVERRIDE
CAPACITY CONTROL View/Modify Default Configurable Value Value
on CVC Screen Value Range
HIGH CONDENSER 125 psig 90 to 165 psig .Override ,Override
PRESSURE SETUP1 (862 kPa) (620 to 1138 kPa) Set Point Set Point
+ 2.4 psid (16.5 kPad)
HIGH MOTOR .200 F 150 to 200 F .Override ,Override
SETUP1 Set Point
TEMPERATURE (93.3 C) (66 to 93 C) +10° F (6° C) Set Point
LOW REFRIGERANT
TEMPERATURE <Trippoint .Trippoint
(Refrigerant SETUP1 3° F (1.6° C) 2° to 5° F + Override + Override
Override Delta (1° to 3° C) DT –1° F (0.56° C) DT +2° F (1.2° C)
Temperature)
Min: T1 — 1.5° F 0.5° to 15° F
(0.8° C) (0.3° to 8.3° C)
HIGH COMPRESSOR P1 — 50 psid 30 to 170 psid Within Lift Limits
(345 kPad) (207 to1172 kPad)
LIFT OPTIONS Max: T2 — 10° F 0.5° to 15° F None Plus Surge/HGBP
(Surge Prevention) (5.6° C) (0.3° to 8.3° C) Deadband Setting
P2 — 85 psid 50 to 170 psid
(586 kPad) (348 to 1172 kPad)
MANUAL GUIDE VANE CAPACITY Automatic 0 to 100% None Release of
TARGET Manual Control
MOTOR LOAD — MAINSTAT 100% 40 to 100% >5% of 2% Lower
ACTIVE DEMAND LIMIT Set Point Than Set Point
LOW DISCHARGE Calculated Minimum 2° F (1.1° C) 1° F (0.56° C)
SUPERHEAT OVERRIDE Superheat None Below Calculated Above Calculated
for Conditions Minimum Superheat Minimum Superheat
Oil Cooler — The oil must be cooled when the com- factory-installed jumper. (Wire multiple inputs in series.) The
pressor is running. This is accomplished through a small, opening of any contact will result in a safety shutdown and
plate-type heat exchanger (also called the oil cooler) located a display on the CVC. Refer to the certified drawings for
behind the oil pump. The heat exchanger uses liquid con- safety contact ratings.
denser refrigerant as the cooling liquid. Refrigerant thermo- Analog temperature sensors may also be added to the mod-
static expansion valves (TXVs) regulate refrigerant flow to ule (SPARE TEMP #1 and #2). The analog temperature sen-
control the oil temperature entering the bearings. The bulbs sors may be configured to cause an alert or alarm on the CCN
for the expansion valves are strapped to the oil supply line network. The alert will not shut the chiller down. Config-
leaving the heat exchanger, and the valves are set to main- uring for alarm state will cause the chiller to shut down.
tain 110 F (43 C).
NOTE: The TXVs are not adjustable. The oil sump temper- Spare Safety Alarm Contacts — One set of alarm
ature may be at a lower temperature during compressor contacts is provided in the starter. The contact ratings are
operations. provided in the certified drawings. The contacts are located
on terminal strip JP, terminals 15 and 16.
Remote Start/Stop Controls — A remote device, such
as a timeclock that uses a set of contacts, may be used to Refrigerant Leak Detector — An input is available
start and stop the chiller. However, the device should not be on the CCM module [terminal 15-5 (−) and J5-6 (+)] for a
programmed to start and stop the chiller in excess of 2 or refrigerant leak detector. Enabling REFRIGERANT LEAK
3 times every 12 hours. If more than 8 starts in 12 hours (the OPTION (OPTIONS screen) will allow the PIC II controls
STARTS IN 12 HOURS parameter on the MAINSTAT screen) to go into an alarm state at a user configured level
occur, an excessive starts alarm displays, preventing the chiller (REFRIGERANT LEAK ALARM mA). The input is con-
figured for 4 to 20 mA by setting the DIP switch 1 on SW2
from starting. The operator must press the RESET softkey at the ON position, or configured for 0 to 5 vdc by setting
on the CVC to override the starts counter and start the chiller. switch 1 at the OFF position. The output of the refrigerant
If the chiller records 12 starts (excluding recycle starts) in a leak detector is displayed as REFRIGERANT LEAK SEN-
sliding 12-hour period, it can be restarted only by pressing SOR on the MAINSTAT screen. For a 0 to 5 vcd input, 0 vdc
the RESET softkey followed by the LOCAL or CCN input represents 4 mA displayed and 5 vdc input represents
20 mA displayed.
softkey. This ensures that, if the automatic system is mal-
functioning, the chiller will not repeatedly cycle on and off. Condenser Pump Control — The chiller will moni-
If the automatic restart after a power failure option (AUTO tor the condenser pressure (CONDENSER PRESSURE) and
RESTART OPTION on the OPTIONS screen) is not acti- may turn on the condenser pump if the condenser pressure
vated when a power failure occurs, and if the remote contact becomes too high while the compressor is shut down. The
is closed, the chiller will indicate an alarm because of the condenser pressure override (COND PRESS OVERRIDE)
loss of voltage. parameter is used to determine this pressure point. COND
The contacts for remote start are wired into the starter at PRESS OVERRIDE is found in the SETUP1 display screen,
terminal strip J2, terminals 5 and 6 on the ISM. See the cer- which is accessed from the EQUIPMENT SERVICE table.
tified drawings for further details on contact ratings. The con- The default value is 125 psig (862 kPa).
tacts must have 24 vac rating. If the CONDENSER PRESSURE is greater than or equal
to the COND PRESS OVERRIDE, and the entering con-
Spare Safety Inputs — Normally closed (NC) dis- denser water temperature (ENTERING CONDENSER
crete inputs for additional field-supplied safeties may be wired WATER) is less than 115 F (46 C), the condenser pump will
to the spare protective limits input channel in place of the
36
energize to try to decrease the pressure. The pump will
turn off when the condenser pressure is 3.5 psi (24.1 kPa)
less than the pressure override or when the condenser re-
frigerant temperature (CONDENSER REFRIG TEMP) is within The tower fan relay control is not a substitute for a
3° F (1.7° C) of the entering condenser water temperature condenser water temperature control. When used with
(ENTERING CONDENSER WATER). a water temperature control system, the tower fan relay
control can be used to help prevent low condenser
Condenser Freeze Prevention — This control water temperatures.
algorithm helps prevent condenser tube freeze-up by ener-
gizing the condenser pump relay. The PIC II controls the Auto. Restart After Power Failure — This option
pump and, by starting it, helps to prevent the water in the may be enabled or disabled and may be viewed or modified
condenser from freezing. The PIC II can perform this func- on the OPTIONS screen, which is accessed from the EQUIP-
tion whenever the chiller is not running except when it is MENT CONFIGURATION table. If the AUTO. RESTART
either actively in pumpdown or in pumpdown/lockout with option is enabled, the chiller will start up automatically after
the freeze prevention disabled. a power failure has occurred (after a single cycle dropout;
When the CONDENSER REFRIG TEMP is less than low, high, or loss of voltage; and the power is within ± 10%
or equal to the CONDENSER FREEZE POINT, the of normal). The 15- and 3-minute inhibit timers are ignored
CONDENSER WATER PUMP is energized until the during this type of start-up.
CONDENSER REFRIG TEMP is greater than the CON- When power is restored after the power failure and if the
DENSER FREEZE POINT plus 5° F (2.7° C) and the compressor had been running, the oil pump will energize for
ENTERING CONDENSER WATER TEMPERATURE is less one minute before energizing the cooler pump. AUTO.
than or equal to the CONDENSER FREEZE POINT. An alarm RESTART will then continue like a normal start-up.
is generated if the chiller is in PUMPDOWN mode and the
pump is energized. An alert is generated if the chiller is not If power to the CVC module has been off for more than
in PUMPDOWN mode and the pump is energized. If the 3 hours or the timeclock has been set for the first time, start
chiller is in RECYCLE SHUTDOWN mode, the mode will the compressor with the slowest temperature-based ramp load
transition to a non-recycle shutdown. rate possible in order to minimize oil foaming.
The oil pump is energized occasionally during the time
Tower Fan Relay Low and High — Low condenser the oil is being brought up to proper temperature in order to
water temperature can cause the chiller to shut down when eliminate refrigerant that has migrated to the oil sump dur-
refrigerant temperature is low. The tower fan relays, located ing the power failure. The pump turns on for 60 seconds at
in the starter, are controlled by the PIC II to energize and the end of every 30-minute period until the chiller is started.
deenergize as the pressure differential between cooler and
condenser vessels changes. This prevents low condenser wa- Water/Brine Reset — Three types of chilled water or
ter temperature and maximizes chiller efficiency. The tower brine reset are available and can be viewed or modified on
fan relay can only accomplish this if the relay has been added the TEMP_CTL screen, which is accessed from the EQUIP-
to the cooling tower temperature controller. MENT SERVICE table.
The tower fan relay low is turned on whenever the con- The CVC default screen indicates when the chilled water
denser water pump is running, flow is verified, and the dif- reset is active. RESET TEMPERATURE on the MAIN-
ference between cooler and condenser pressure is more than STAT screen indicates the amount of reset. The CONTROL
30 psid (207 kPad) for entering condenser water tempera- POINT will be determined by adding the RESET
ture greater than 65 F (18.3 C). TEMPERATURE to the SETPOINT.
The tower fan relay low is turned off when the condenser To activate a reset type, access the TEMP_CTL screen and
pump is off, flow is stopped, or the cooler refrigerant tem- input all configuration information for that reset type. Then,
perature is less than the override temperature for ENTER- input the reset type number (1, 2, or 3) in the SELECT/
ING CONDENSER WATER temperature less than 62 F ENABLE RESET TYPE input line.
(16.7 C), or the differential pressure is less than 25 psid
(172.4 kPad) for entering condenser water less than RESET TYPE 1: 4 to 20 mA (0 to 5 vdc) TEMPERATURE
80 F (27 C). RESET — Reset Type 1 is an automatic chilled water tem-
perature reset based on a remote temperature sensor input
The tower fan relay high is turned on whenever the con- configured for either an externally powered 4 to 20 mA or a
denser water pump is running, flow is verified and the dif- 0 to 5 vcd signal. Reset Type 1 permits up to ±30 F (±16 C)
ference between cooler and condenser pressure is more than of automatic reset to the chilled water set point.
35 psid (241.3 kPa) for entering condenser water tempera-
ture greater than the TOWER FAN HIGH SETPOINT (SET- The auto, chilled water reset is hardwired to terminals
POINT menu, default 75 F [23.9 C]). J5-3 (−) and J5-4 (+) on the CCM. Switch setting number 2
on SW2 will determine the type of input signal. With the
The tower fan relay high is turned off when the condenser switch set at the ON position the input is configured for an
pump is off, flow is stopped, or the cooler refrigerant tem- externally powered 4 to 20 mA signal. With the switch in the
perature is less than the override temperature and ENTER- OFF position the input is configured for an external
ING CONDENSER WATER is less than 70 F (21.1 C), or the 0 to 5 vdc signal.
difference between cooler and condenser pressure is less than
28 Psid (193 kPa), or ENTERING CONDENSER WATER tem- RESET TYPE 2: REMOTE TEMPERATURE RESET — Re-
perature is less than TOWER FAN HIGH SETPOINT minus set Type 2 is an automatic chilled water temperature reset
3 F (−16.1 C). based on a remote temperature sensor input signal. Reset Type
2 permits ± 30° F (± 16° C) of automatic reset to the set
The TOWER FAN RELAY LOW and HIGH parameter is point based on a temperature sensor wired to the CCM mod-
accessed from the STARTUP screen. ule (see wiring diagrams or certified drawings). The tem-
IMPORTANT: A field-supplied water temperature con- perature sensor must be wired to terminal J4-13 and J4-14.
trol system for condenser water should be installed. To configure Reset Type 2, enter the temperature of
The system should maintain the leaving condenser the remote sensor at the point where no temperature reset
water temperature at a temperature that is 20° F will occur (REMOTE TEMP [NO RESET]). Next, enter the
(11° C) above the leaving chilled water temperature. temperature at which the full amount of reset will occur
37
(REMOTE TEMP [FULL RESET]). Then, enter the maxi- PREVENTION is on, the point must pass through the dead-
mum amount of reset required to operate the chiller band region before the HOT GAS BYPASS/SURGE PRE-
(DEGREES RESET). Reset Type 2 can now be activated. VENTION is turned off. Information on modifying the de-
fault set points of the minimum and full load points may be
RESET TYPE 3 — Reset Type 3 is an automatic chilled wa- found in the Input Service Configurations section, page 53.
ter temperature reset based on cooler temperature differ-
ence. Reset Type 3 adds ± 30° F (± 16° C) based on the Corrective action can be taken by making one of 2 choices.
temperature difference between the entering and leaving chilled If a hot gas bypass line is present and the hot gas option
water temperature. is selected on the OPTIONS table (SURGE LIMIT/HGBP
To configure Reset Type 3, enter the chilled water tem- OPTION is set to 1), the hot gas bypass valve can be ener-
perature difference (the difference between entering and gized. If the hot gas bypass option is not selected (SURGE
leaving chilled water) at which no temperature reset occurs LIMIT/HGBP OPTION is set to 0), hold the guide vanes.
(CHW DELTA T [NO RESET]). This chilled water temper- See Table 4, Capacity Overrides. Both of these corrective
ature difference is usually the full design load temper- actions try to reduce the lift experienced by the compressor
ature difference. Next, enter the difference in chilled water and help prevent a surge condition.
temperature at which the full amount of reset occurs (CHW
DELTA T [FULL RESET]). Finally, enter the amount of re-
set (DEGREES RESET). Reset Type 3 can now be activated.
Demand Limit Control Option — The demand limit
control option (20 mA DEMAND LIMIT OPT) is externally
controlled by a 4 to 20 mA or 0 to 5 vdc signal from an
energy management system (EMS). The option is set up on
the RAMP_DEM screen. When enabled, 4 mA is the 100%
demand set point with an operator-configured minimum de-
mand at a 20 mA set point (DEMAND LIMIT AT 20 mA).
The auto. demand limit is hardwired to terminals J5-5 (−)
and J5-6 (+) on the CCM. Switch setting number 1 on SW2
will determine the type of input signal. With the switch set
at the ON position the input is configured for an externally
powered 4 to 20 mA signal. With the switch in the OFF
position the input is configured for an external 0 to 5 vdc
signal.
LEGEND
Surge Prevention Algorithm — This is an operator-
ECW — Entering Chilled Water
configurable feature that can determine if lift conditions are HGBP — Hot Gas Bypass
too high for the compressor and then take corrective action. LCW — Leaving Chilled Water
Lift is defined as the difference between the pressure at the DP = (Condenser Psi) − (Cooler Psi)
impeller eye and at the impeller discharge. The maximum DT = (ECW) − (LCW)
lift a particular impeller wheel can perform varies with the Fig. 19 — 19XR Hot Gas Bypass/Surge
gas flow across the impeller and the size of the wheel. Prevention with Default English Settings
A surge condition occurs when the lift becomes so
high the gas flow across the impeller reverses. This condi-
tion can eventually cause chiller damage. The surge preven-
tion algorithm notifies the operator that chiller operating
conditions are marginal and to take action to help prevent
chiller damage such as lowering entering condenser water
temperature.
The surge prevention algorithm first determines if cor-
rective action is necessary. The algorithm checks 2 sets of
operator-configured data points, the minimum load points (MIN.
LOAD POINT [T1/P1]) and the full load points (FULL
LOAD POINT [T2/P2]). These points have default settings
as defined on the OPTIONS screen or on Table 4.
The surge prevention algorithm function and settings are
graphically displayed in Fig. 19 and 20. The two sets of load
points on the graph (default settings are shown) describe a
line the algorithm uses to determine the maximum lift of the
compressor. When the actual differential pressure between
the cooler and condenser and the temperature difference be-
tween the entering and leaving chilled water are above the
line on the graph (as defined by the minimum and full load
points), the algorithm goes into a corrective action mode. If
the actual values are below the line and outside of the dead-
band region, the algorithm takes no action. When the point LEGEND
defined by the ACTIVE DELTA P and ACTIVE DELTA T, ECW — Entering Chilled Water
moves from the region where the HOT GAS BYPASS/ HGBP — Hot Gas Bypass
SURGE PREVENTION is off, the point must pass through LCW — Leaving Chilled Water
the deadband region to the line determined by the config- DP = (Condenser kPa) − (Cooler kPa)
ured valves before the HOT GAS BYPASS/SURGE DT = (ECW) − (LCW)
PREVENTION will be turned on. As the point moves from Fig. 20 — 19XR Hot Gas Bypass/Surge
the region where the HOT GAS BYPASS/SURGE Prevention with Default Metric Settings
38
Surge Protection — The PIC II monitors surge, which If the entering chilled water control option (ECW CON-
is a fluctuation in compressor motor amperage. Each time TROL OPTION) is enabled (configured in TEMP_CTL screen)
the fluctuation exceeds an operator-specified limit (SURGE and a common point sensor is desired (COMMON SENSOR
DELTA % AMPS), the PIC II counts the surge. If more than OPTION in LEADLAG screen selected as 1) then the sensor
5 surges occur within an operator-specified time (SURGE is wired in Spare Temp #2 position on the CCM.
TIME PERIOD), the PIC II initiates a surge protection shut- When installing chillers in series, a common point sensor
down of the chiller. should be used. If a common point sensor is not used, the
The surge limit can be adjusted from the OPTIONS screen. leaving chilled water sensor of the upstream chiller must be
moved into the leaving chilled water pipe of the downstream
Scroll down to the SURGE DELTA % AMPS parameter, and chiller.
use the INCREASE or DECREASE softkey to adjust the
If return chilled water control is required on chillers piped
percent of surge. The default setting is 10% amps. in series, the common point return chilled water sensor should
The surge time period can also be adjusted from the be installed. If this sensor is not installed, the return chilled
OPTIONS screen. Scroll to the SURGE TIME PERIOD water sensor of the downstream chiller must be relocated to
parameter, and use the INCREASE or DECREASE soft- the return chilled water pipe of the upstream chiller.
key to adjust the amount of time. The default setting is To properly control the common supply point temperature
8 minutes. sensor when chillers are piped in parallel, the water flow through
the shutdown chillers must be isolated so no water bypass
Access the display screen (COMPRESS) to monitor the around the operating chiller occurs. The common point sen-
surge count (SURGE PROTECTION COUNTS). sor option must not be used if water bypass around the
Lead/Lag Control — The lead/lag control system operating chiller is occurring.
automatically starts and stops a lag or second chiller in a CHILLER COMMUNICATION WIRING — Refer to the
2-chiller water system. A third chiller can be added to the chiller’s Installation Instructions, Carrier Comfort Network
lead/lag system as a standby chiller to start up in case Interface section for information on chiller communication
the lead or lag chiller in the system has shut down during wiring.
an alarm condition and additional cooling is required. LEAD/LAG OPERATION — The PIC II not only has the
Refer to Fig. 15 and 16 for menu, table, and screen selection ability to operate 2 chillers in lead/lag, but it can also start
information. a designated standby chiller when either the lead or lag chiller
NOTE: The lead/lag function can be configured on the LEAD- is faulted and capacity requirements are not met. The lead/
LAG screen, which is accessed from the SERVICE menu lag option only operates when the chillers are in CCN mode.
and EQUIPMENT SERVICE table. See Table 2, If any other chiller configured for lead/lag is set to the
Example 19. Lead/lag status during chiller operation can be LOCAL or OFF modes, it will be unavailable for lead/lag
viewed on the LL_MAINT display screen, which is ac- operation.
cessed from the SERVICE menu and CONTROL ALGO-
RITHM STATUS table. See Table 2, Example 11. Lead/Lag Chiller Configuration and Operation
• A chiller is designated the lead chiller when its LEAD/
Lead/Lag System Requirements: LAG CONFIGURATION value on the LEADLAG screen
• all chillers in the system must have software capable of is set to ‘‘1.’’
performing the lead/lag function • A chiller is designated the lag chiller when its LEAD/LAG
• water pumps MUST be energized from the PIC II controls CONFIGURATION value is set to ‘‘2.’’
• water flows should be constant
• the CCN time schedules for all chillers must be identical • A chiller is designated as a standby chiller when its LEAD/
LAG CONFIGURATION value is set to ‘‘3.’’
Operation Features: • A value of ‘‘0’’ disables the lead/lag designation of a chiller.
• 2 chiller lead/lag
• addition of a third chiller for backup To configure the LAG ADDRESS value on the LEAD-
• manual rotation of lead chiller LAG screen, always enter the address of the other chiller on
• load balancing if configured the system. For example, if you are configuring chiller A,
• staggered restart of the chillers after a power failure enter the address for chiller B as the lag address. If you are
• chillers may be piped in parallel or in series chilled water configuring chiller B, enter the address for chiller A as the
flow lag address. This makes it easier to rotate the lead and lag
chillers.
COMMON POINT SENSOR INSTALLATION — Lead/ If the address assignments in the LAG ADDRESS and
lag operation does not require a common chilled water point STANDBY ADDRESS parameters conflict, the lead/lag func-
sensor. Common point sensors (Spare Temp #1 and #2) can tion is disabled and an alert (!) message displays. For
be added to the CCM module, if desired. Spare Temp #1 and example, if the LAG ADDRESS matches the lead chiller’s
#2 are wired to plug J4 terminals 25-26 and 27-28 (J4 lower, address, the lead/lag will be disabled and an alert (!)
respectively). message displayed. The lead/lag maintenance screen
NOTE: If the common point sensor option is chosen on a (LL_MAINT) displays the message ‘INVALID CONFIG’ in
chilled water system, each chiller should have its own com- the LEAD/LAG CONFIGURATION and CURRENT MODE
mon point sensor installed. Each chiller uses its own com- fields.
mon point sensor for control when that chiller is designated The lead chiller responds to normal start/stop controls such
as the lead chiller. The PIC II cannot read the value of com- as the occupancy schedule, a forced start or stop, and remote
mon point sensors installed on the other chillers in the chilled start contact inputs. After completing start-up and ramp load-
water system. ing, the PIC II evaluates the need for additional capacity. If
If leaving chilled water control (ECW CONTROL OP- additional capacity is needed, the PIC II initiates the start-up
TION is set to 0 [DSABLE] TEMP_CTL screen) and a com- of the chiller configured at the LAG ADDRESS. If the lag
mon point sensor is desired (COMMON SENSOR OPTION chiller is faulted (in alarm) or is in the OFF or LOCAL modes,
in LEADLAG screen selected as 1) then the sensor is wired the chiller at the STANDBY ADDRESS (if configured) is
in Spare Temp #1 position on the CCM. requested to start. After the second chiller is started and is
39
running, the lead chiller monitors conditions and eval- start. If the lag chiller fails to start, the standby chiller, if
uates whether the capacity has been reduced enough for the configured is started.
lead chiller to sustain the system alone. If the capacity is Lag Chiller Shutdown Requirements — The following con-
reduced enough for the lead chiller to sustain the CONTROL ditions must be met in order for the lag chiller to be stopped.
POINT temperatures alone, then the operating lag chiller is
stopped. 1. Lead chiller compressor motor average line current or load
value (MOTOR PERCENT KILOWATTS on the MAIN-
If the lead chiller is stopped in CCN mode for any reason STAT screen) is less than the lead chiller percent
other than an alarm (*) condition, the lag and standby chill- capacity.
ers are also stopped. If the configured lead chiller stops for
an alarm condition, the configured lag chiller takes the lead NOTE: Lead chiller percent capacity = 115 – LAG PER-
chiller’s place as the lead chiller, and the standby chiller serves CENT CAPACITY. The LAG PERCENT CAPACITY
as the lag chiller. parameter is on the LEADLAG screen, which is accessed
from the EQUIPMENT SERVICE table on the SERV-
If the configured lead chiller does not complete the start-up ICE menu.
before the PRESTART FAULT TIMER (a user-configured
value) elapses, then the lag chiller starts and the lead chiller 2. The lead chiller chilled water temperature is less than
shuts down. The lead chiller then monitors the start request the CONTROL POINT temperature (see the MAINSTAT
from the acting lead chiller. The PRESTART FAULT TIMER screen) plus 1⁄2 the CHILLED WATER DEADBAND tem-
is initiated at the time of a start request. The PRESTART FAULT perature (see the SETUP1 screen).
TIMER provides a timeout if there is a prestart alert condi- 3. The configured LAG STOP TIME entry has elapsed. The
tion that prevents the chiller from starting in a timely man- LAG STOP TIMER starts when the lead chiller chilled
ner. The PRESTART FAULT TIMER parameter is on the LEAD- water temperature is less than the chilled water
LAG screen, which is accessed from the EQUIPMENT SERV- CONTROL POINT plus 1/2 of the CHILLED WATER
ICE table of the SERVICE menu. DEADBAND and the lead chiller compressor motor load
If the lag chiller does not achieve start-up before the (MOTOR PERCENT KILOWATT or AVERAGE LINE CUR-
PRESTART FAULT TIMER elapses, the lag chiller stops, and RENT on the MAINSTAT screen) is less than the lead
the standby chiller is requested to start, if configured and chiller percent capacity.
ready. NOTE: Lead chiller percent capacity = 115 – LAG PER-
Standby Chiller Configuration and Operation — A chiller is CENT CAPACITY. The LAG PERCENT CAPACITY param-
designated as a standby chiller when its LEAD/LAG eter is on the LEADLAG screen, which is accessed from the
CONFIGURATION value on the LEADLAG screen is set to EQUIPMENT SERVICE table on the SERVICE menu.
‘‘3.’’ The standby chiller can operate as a replacement for FAULTED CHILLER OPERATION — If the lead chiller
the lag chiller only if one of the other two chillers is in an shuts down because of an alarm (*) condition, it stops com-
alarm (*) condition (as shown on the CVC panel). If both municating to the lag and standby chillers. After 30 seconds,
lead and lag chillers are in an alarm (*) condition, the standby the lag chiller becomes the acting lead chiller and starts and
chiller defaults to operate in CCN mode, based on its con- stops the standby chiller, if necessary.
figured occupancy schedule and remote contacts input. If the lag chiller goes into alarm when the lead chiller is
Lag Chiller Start-Up Requirements — Before the lag chiller also in alarm, the standby chiller reverts to a stand-alone CCN
can be started, the following conditions must be met: mode of operation.
1. Lead chiller ramp loading must be complete. If the lead chiller is in an alarm (*) condition (as shown
2. Lead chilled water temperature must be greater than the on the CVC panel), press the RESET softkey to clear the
CONTROL POINT temperature (see the MAINSTAT screen) alarm. The chiller is placed in CCN mode. The lead chiller
plus 1/2 the CHILLED WATER DEADBAND tempera- communicates and monitors the RUN STATUS of the lag
ture (see the SETUP1 screen). and standby chillers. If both the lag and standby chillers are
NOTE: The chilled water temperature sensor may be the running, the lead chiller does not attempt to start and does
leaving chilled water sensor, the return water sensor, the not assume the role of lead chiller until either the lag or standby
common supply water sensor, or the common return wa- chiller shuts down. If only one chiller is running, the lead
ter sensor, depending on which options are configured and chiller waits for a start request from the operating chiller.
enabled. When the configured lead chiller starts, it assumes its role as
3. Lead chiller ACTIVE DEMAND LIMIT (see the lead chiller.
MAINSTAT screen) value must be greater than 95% of If the lag chiller is the only chiller running when the lead
full load amps. chiller assumes its role as a lead chiller then the lag chiller
4. Lead chiller temperature pulldown rate (TEMP PULL- will perform a RECOVERY START REQUEST (LL_MAINT
DOWN DEG/MIN on the TEMP_CTL screen) of the chilled screen). The lead chiller will start up when the following
water temperature is less than 0.5° F (0.27° C) per minute. conditions are met.
5. The lag chiller status indicates it is in CCN mode and is 1. Lag chiller ramp loading must be complete.
not in an alarm condition. If the current lag chiller is in 2. Lag CHILLED WATER TEMP (MAINSTAT screen) is
an alarm condition, the standby chiller becomes the ac- greater than CONTROL POINT plus 1/2 the CHILLED
tive lag chiller, if it is configured and available. WATER DEADBAND temperature.
6. The configured LAG START TIMER entry has elapsed. 3. Lag chiller ACTIVE DEMAND LIMIT value must be greater
The LAG START TIMER starts when the lead chiller than 95% of full load amps.
ramp loading is completed. The LAG START TIMER 4. Lag chiller temperature pulldown rate (TEMP PULL-
entry is on the LEADLAG screen, which is accessed DOWN DEG/MIN) of the chilled water temperature is less
from the EQUIPMENT SERVICE table of the than 0.5 F (0.27 C) per minute.
SERVICE menu.
5. The standby chiller is not running as a lag chiller.
When all the above requirements have been met, the lag
chiller is commanded to a STARTUP mode (SUPVSR flash- 6. The configured LAG START TIMER has elapsed. The LAG
ing next to the point value on the STATUS table). The START TIMER is started when ramp loading is
PIC II control then monitors the lag chiller for a successful completed.
40
LOAD BALANCING — When the LOAD BALANCE • the chilled water temperature is less than the ice build set
OPTION (see LEADLAG screen) is enabled, the lead chiller point and the remote contact inputs from an ice level in-
sets the ACTIVE DEMAND LIMIT in the lag chiller to the dicator are open. In this case, the operator sets the ICE
lead chiller’s compressor motor load value MOTOR PER- BUILD TERMINATION parameter to 2 on the OPTIONS
CENT KILOWATTS or AVERAGE LINE CURRENT on the screen.
MAINSTAT screen). This value has limits of 40% to 100%. • the end of the ice build time schedule has been reached.
When the lag chiller ACTIVE DEMAND LIMIT is set, the
CONTROL POINT must be modified to a value of 3° F ICE BUILD INITIATION — The ice build time schedule
(1.67° C) less than the lead chiller’s CONTROL POINT value. (OCCPC02S) is the means for activating the ice build
If the LOAD BALANCE OPTION is disabled, the ACTIVE option. The ice build option is enabled if:
DEMAND LIMIT and the CONTROL POINT are forced to • a day of the week and a time period on the ice build time
the same value as the lead chiller. schedule are enabled. The SCHEDULE screen shows an
AUTO. RESTART AFTER POWER FAILURE — When an X in the day field and ON/OFF times are designated for
auto. restart condition occurs, each chiller may have a delay the day(s),
added to the start-up sequence, depending on its lead/lag • and the ICE BUILD OPTION is enabled.
configuration. The lead chiller does not have a delay. The The following events take place (unless overridden by a
lag chiller has a 45-second delay. The standby chiller has a higher authority CCN device).
90-second delay. The delay time is added after the chiller 1. CHILLER START/STOP is forced to START.
water flow is verified. The PIC II ensures the guide vanes 2. The CONTROL POINT is forced to the ICE BUILD
are closed. After the guide vane position is confirmed, the SETPOINT.
delay for lag and standby chillers occurs prior to energizing
the oil pump. The normal start-up sequence then continues. 3. Any force (Auto) is removed from the ACTIVE
The auto. restart delay sequence occurs whether the chiller DEMAND LIMIT.
is in CCN or LOCAL mode and is intended to stagger the NOTE: A parameter’s value can be forced, that is, the value
compressor motor starts. Preventing the motors from start- can be manually changed at the CVC by an operator, changed
ing simultaneously helps reduce the inrush demands on the from another CCN device, or changed by other algorithms
building power system. in the PIC II control system.
Ice Build Control — The ice build control option NOTE: Items 1-3 (shown above) do not occur if the chiller
automatically sets the CONTROL POINT of the chiller to a is configured and operating as a lag or standby chiller for
temperature that allows ice building for thermal storage. lead/lag operation and is actively being controlled by a lead
chiller. The lead chiller communicates the ICE BUILD SET
NOTE: For ice build control to operate properly, the PIC II POINT, the desired CHILLER START/STOP state, and the
must be in CCN mode. ACTIVE DEMAND LIMIT to the lag or standby chiller as
NOTE: See Fig. 15 and 16 for more information on ice build- required for ice build, if configured to do so.
related menus.
START-UP/RECYCLE OPERATION — If the chiller is not
The PIC II can be configured for ice build operation. running when ice build activates, the PIC II checks the fol-
• From the SERVICE menu, access the EQUIPMENT SERV- lowing conditions, based on the ICE BUILD TERMINA-
ICE table. From there, select the OPTIONS screen to en- TION value, to avoid starting the compressor unnecessarily:
able or disable the ICE BUILD OPTION. See • if ICE BUILD TERMINATION is set to the TEMP option
Table 2, Example 16. and the ENTERING CHILLED WATER temperature is less
• The ICE BUILD SETPOINT can be configured from the than or equal to the ICE BUILD SETPOINT;
SETPOINT display, which is accessed from the PIC II main • if ICE BUILD TERMINATION is set to the CONTACTS
menu. See Table 2, Example 8. option and the remote contacts are open;
• The ice build schedule can be viewed or modified from • if the ICE BUILD TERMINATION is set to the BOTH (tem-
the SCHEDULE table. From this table, select the ice build perature and contacts) option and the ENTERING CHILLED
schedule (OCCPC02S) screen. See Fig. 17 and the section WATER temperature is less than or equal to the ICE BUILD
on Time Schedule Operation, page 19, for more informa- SETPOINT and the remote contacts are open.
tion on modifying chiller schedules.
The ICE BUILD RECYCLE on the OPTIONS screen de-
The ice build time schedule defines the period(s) during termines whether or not the chiller will go into an ice build
which ice build is active if the ice build option is RECYCLE mode.
enabled. If the ice build time schedule overlaps other sched-
• If the ICE BUILD RECYCLE is set to DSABLE (disable),
ules, the ice build time schedule takes priority. During the
the PIC II reverts to normal temperature control when the
ice build period, the CONTROL POINT is set to the ICE ice build function terminates.
BUILD SETPOINT for temperature control. The ICE BUILD
RECYCLE and ICE BUILD TERMINATION parameters, ac- • If the ICE BUILD RECYCLE is set to ENABLE, the
cessed from the OPTIONS screen, allow the chiller operator PIC II goes into an ICE BUILD RECYCLE mode and the
to recycle or terminate the ice build cycle. The ice build cycle chilled water pump relay remains energized to keep the
can be configured to terminate if: chilled water flowing when the ice build function termi-
• the ENTERING CHILLED WATER temperature is less than nates. If the temperature of the ENTERING CHILLED
the ICE BUILD SETPOINT. In this case, the operator sets WATER increases above the ICE BUILD SETPOINT plus
the ICE BUILD TERMINATION parameter to 0 on the the RECYCLE RESTART DELTA T value, the compressor
restarts and controls the chilled water/brine temperature to
OPTIONS screen.
the ICE BUILD SETPOINT.
• the REMOTE CONTACT inputs from an ice level indi-
cator are opened. In this case, the operator sets the ICE TEMPERATURE CONTROL DURING ICE BUILD — Dur-
BUILD TERMINATION parameter to 1 on the OPTIONS ing ice build, the capacity control algorithm shall use the
screen. CONTROL POINT minus 5 F (−2.8 C) for control of the
LEAVING CHILLED WATER temperature. See Table 2, ex-
ample 9, the CAPACITY CONTROL parameter on the CA-
PACITY screen.) The ECW CONTROL OPTION and any
41
temperature reset option shall be ignored, if enabled, dur- address of the chiller on which it is mounted. Whenever the
ing ice build. The AUTO DEMAND LIMIT INPUT shall controller identification of the CVC changes, the change is
also be ignored if enabled during ice build. reflected automatically in the BUS and ADDRESS columns
• ECW CONTROL OPTION and any temperature reset for the local device. See Fig. 16. Default address for local
options (configured on TEMP_CTL screen). device is BUS 0 ELEMENT 1.
• 20 mA DEMAND LIMIT OPT (configured on
RAMP_DEM screen).
TERMINATION OF ICE BUILD — The ice build function
terminates under the following conditions:
1. Time Schedule — When the current time on the ice build
time schedule (OCCPC02S) is not set as an ice build time
period.
2. Entering Chilled Water Temperature — Compressor
operation terminates, based on temperature, if the ICE
BUILD TERMINATION parameter is set to 0 (TEMP),
the ENTERING CHILLED WATER temperature is less than
the ICE BUILD SETPOINT, and the ICE BUILD Fig. 21 — Example of Attach to Network
RECYCLE is set to DSABLE. If the ICE BUILD RE- Device Screen
CYCLE OPTION is set to ENABLE, a recycle shutdown
occurs and recycle start-up depends on the LEAVING
CHILLED WATER temperature being greater than the
WATER/BRINE CONTROL POINT plus the RECYCLE When the ATTACH TO NETWORK DEVICE screen is
RESTART DELTA T temperature. accessed, information can not be read from the CVC on any
3. Remote Contacts/Ice Level Input — Compressor opera- device until one of the devices listed on that screen is
tion terminates when the ICE BUILD TERMINATION attached. The CVC erases information about the module to
parameter is set to 1 CONTACTS) and the remote con- which it was attached to make room for information on
tacts are open and the ICE BUILD RECYCLE is set to another device. Therefore, a CCN module must be attached
DSABLE (0). In this case, the contacts provide ice level when this screen is entered.
termination control. The contacts are used to stop the To attach any CCN device, highlight it using the
ice build function when a time period on the ice build SELECT softkey and press the ATTACH softkey. The mes-
schedule (OCCPC02S) is set for ice build operation. The sage ‘‘UPLOADING TABLES, PLEASE WAIT’’ displays.
remote contacts can still be opened and closed to start The CVC then uploads the highlighted device or module. If
and stop the chiller when a specific time period on the ice the module address cannot be found, the message ‘‘COM-
build schedule is not set for ice build. MUNICATION FAILURE’’ appears. The CVC then reverts
4. Entering Chilled Water Temperature and ICE BUILD Con- back to the ATTACH TO DEVICE screen. Try another de-
tacts — Compressor operation terminates when the ICE vice or check the address of the device that would not at-
BUILD TERMINATION parameter is set to 2 (BOTH) tach. The upload process time for each CCN module is dif-
and the conditions described above in items 2 and 3 for ferent. In general, the uploading process takes 1 to 2 minutes.
entering chilled water temperature and remote contacts Before leaving the ATTACH TO NETWORK DEVICE screen,
have occurred. select the local device. Otherwise, the CVC will be unable
NOTE: It is not possible to override the CHILLER START/ to display information on the local chiller.
STOP, CONTROL POINT, and ACTIVE DEMAND LIMIT ATTACHING TO OTHER CCN MODULES — If the chiller
variables from CCN devices (with a priority 4 or greater) CVC has been connected to a CCN Network or other PIC
during the ice build period. However, a CCN device can over- controlled chillers through CCN wiring, the CVC can be used
ride these settings during 2-chiller lead/lag operation. to view or change parameters on the other controllers. Other
RETURN TO NON-ICE BUILD OPERATIONS — The ice PIC II chillers can be viewed and set points changed (if the
build function forces the chiller to start, even if all other sched- other unit is in CCN control), if desired, from this particular
ules indicate that the chiller should stop. When the ice build CVC module.
function terminates, the chiller returns to normal tempera- If the module number is not valid, the ‘‘COMMUNICA-
ture control and start/stop schedule operation. The CHILLER TION FAILURE’’ message will show and a new address num-
START/STOP and CONTROL POINT return to normal op- ber must be entered or the wiring checked. If the module is
eration. If the CHILLER START/STOP or CONTROL POINT communicating properly, the ‘‘UPLOAD IN PROGRESS’’
has been forced (with a device of less than 4 priority) before message will flash and the new module can now be viewed.
the ice build function started, when the ice build function Whenever there is a question regarding which module on
ends, the previous forces (of less than 4 priority) are not au- the CVC is currently being shown, check the device name
tomatically restored. descriptor on the upper left hand corner of the CVC screen.
See Fig. 21.
Attach to Network Device Control — The Service
menu includes the ATTACH TO NETWORK DEVICE screen. When the CCN device has been viewed, the ATTACH TO
From this screen, the operator can: NETWORK DEVICE table should be used to attach to the
PIC that is on the chiller. Move to the ATTACH TO NET-
• enter the time schedule number (if changed) for OCCPC03S, WORK DEVICE table (LOCAL should be highlighted) and
as defined in the NET_OPT screen
• attach the CVC to any CCN device, if the chiller has been press the ATTACH softkey to upload the LOCAL device.
connected to a CCN network. This may include other PIC- The CVC for the 19XR will be uploaded and default screen
controlled chillers. will display.
• upgrade software NOTE: The CVC will not automatically reattach to the local
Figure 21 shows the ATTACH TO NETWORK DEVICE module on the chiller. Press the ATTACH softkey to attach
screen. The LOCAL parameter is always the CVC module to the LOCAL device and view the chiller operation.
42
Service Operation — An overview of the tables and HOLIDAY SCHEDULING (Fig. 22) — The time schedules
screens available for the SERVICE function is shown in may be configured for special operation during a holiday
Fig. 16. period. When modifying a time period, the ‘‘H’’ at the end
of the days of the week field signifies that the period is
TO ACCESS THE SERVICE SCREENS — When the applicable to a holiday. (See Fig. 17.)
SERVICE screens are accessed, a password must be
entered. The broadcast function must be activated for the holidays
configured on the HOLIDEF screen to work properly.
1. From the main MENU screen, press the SERVICE soft- Access the BRODEF screen from the EQUIPMENT CON-
key. The softkeys now correspond to the numerals 1, 2, FIGURATION table and select ENABLE to the activated
3, 4. function. Note that when the chiller is connected to a CCN
2. Press the four digits of the password, one at a time. An Network, only one chiller or CCN device can be configured
asterisk (*) appears as each digit is entered. as the broadcast device. The controller that is configured
as the broadcaster is the device responsible for transmitting
holiday, time, and daylight-savings dates throughout the
network.
To access the BRODEF screen, see the SERVICE menu
structure, Fig. 16.
NOTE: The initial factory-set password is 1 - 1- 1 - 1. If To view or change the holiday periods for up to 18 dif-
the password is incorrect, an error message is displayed. ferent holidays, perform the following operation:
1. At the Menu screen, press SERVICE to access the Serv-
ice menu.
2. If not logged on, follow the instructions for To Log On
or To Log Off. Once logged on, press NEXT until Equip-
ment Configuration is highlighted.
If this occurs, return to Step 1 and try to access the SERV-
ICE screens again. If the password is correct, the softkey 3. Once Equipment Configuration is highlighted, press
labels change to: SELECT to access.
4. Press NEXT until HOLIDAYS is highlighted. This is
the Holiday Definition table.
5. Press SELECT to enter the Data Table Select screen.
This screen lists 18 holiday tables.
NOTE: The SERVICE screen password can be changed 6. Press NEXT to highlight the holiday table that is to be
by entering the CVC CONFIGURATION screen under
SERVICE menu. The password is located at the bottom viewed or changed. Each table is one holiday period,
of the menu. starting on a specific date, and lasting up to 99 days.
The CVC screen displays the following list of available 7. Press SELECT to access the holiday table. The Con-
SERVICE screens: figuration Select table now shows the holiday start month
• Alarm History and day, and how many days the holiday period will last.
• Control Test 8. Press NEXT or PREVIOUS to highlight the
• Control Algorithm Status month, day, or duration.
• Equipment Configuration
• ISM (STARTER) Config Data 9. Press SELECT to modify the month, day, or
• Equipment Service duration.
• Time and Date 10. Press INCREASE or DECREASE to change the
• Attach to Network Device selected value.
• Log Out of Device
• CVC Configuration 11. Press ENTER to save the changes.
See Fig. 16 for additional screens and tables available from 12. Press EXIT to return to the previous menu.
the SERVICE screens listed above. Use the EXIT softkey
to return to the main MENU screen.
NOTE: To prevent unauthorized persons from accessing the
CVC service screens, the CVC automatically signs off and
password-protects itself if a key has not been pressed for
15 minutes. The sequence is as follows. Fifteen minutes
after the last key is pressed, the default screen displays, the
CVC screen light goes out (analogous to a screen saver),
and the CVC logs out of the password-protected SERVICE
menu. Other screen and menus, such as the STATUS screen
can be accessed without the password by pressing the ap-
propriate softkey.
TO LOG OUT OF NETWORK DEVICE — To access this
screen and log out of a network device, from the default CVC
screen, press the MENU and SERVICE softkeys. Enter
the password and, from the SERVICE menu, highlight LOG
OUT OF NETWORK DEVICE and press the SELECT Fig. 22 — Example of Holiday Period Screen
softkey. The CVC default screen will now be displayed.
43
START-UP/SHUTDOWN/RECYCLE WATER FLOW VERIFY TIME (operator-configured, default
SEQUENCE (Fig. 23) 5 minutes) expires to confirm flow. After flow is verified, the
chilled water temperature is compared to CONTROL POINT
Local Start-Up — Local start-up (or a manual start-up) plus 1/2 CHILLED WATER DEADBAND. If the temperature
is initiated by pressing the LOCAL menu softkey on the is less than or equal to this value, the PIC II turns off the
condenser pump relay and goes into a RECYCLE mode.
default CVC screen. Local start-up can proceed when the
chiller schedule indicates that the current time and date have If the water/brine temperature is high enough, the start-up
been established as a run time and date, and after the inter- sequence continues and checks the guide vane position. If
nal 15-minute start-to-start and the 1-minute stop-to-start the guide vanes are more than 4% open, the start-up waits
inhibit timers have expired. These timers are represented in until the PIC II closes the vanes. If the vanes are closed and
the START INHIBIT TIMER and can be viewed on the MAIN- the oil pump pressure is less than 4 psi (28 kPa), the oil
STAT screen and DEFAULT screen. The timer must expire pump relay energizes. The PIC II then waits until the oil pres-
before the chiller will start. If the timers have not expired sure (OIL PRESS VERIFY TIME, operator-configured,
the RUN STATUS parameter on the MAINSTAT screen now default of 40 seconds) reaches a maximum of 18 psi
reads TIMEOUT. (124 kPa). After oil pressure is verified, the PIC II waits
40 seconds, and the compressor start relay (1CR) energizes
NOTE: The time schedule is said to be ‘‘occupied’’ if the to start the compressor.
OCCUPIED ? parameter on the MAINSTAT screen is set to Compressor ontime and service ontime timers start, and
YES. For more information on occupancy schedules, see the the compressor starts in 12 hours counter and the number of
sections on Time Schedule Operation (page 19), Occupancy starts over a 12-hour period counter advance by one.
Schedule (page 32), and To Prevent Accidental Start-Up
(page 59), and Fig. 17. Failure to verify any of the requirements up to this point
will result in the PIC II aborting the start and displaying the
If the OCCUPIED ? parameter on the MAINSTAT screen applicable pre-start mode of failure on the CVC default screen.
is set to NO, the chiller can be forced to start as follows. A pre-start failure does not advance the starts in 12 hours
From the default CVC screen, press the MENU and counter. Any failure after the 1CR relay has energized
STATUS softkeys. Scroll to highlight MAINSTAT. Press results in a safety shutdown, advances the starts in the
12 hours counter by one, and displays the applicable shut-
the SELECT softkey. Scroll to highlight CHILLER START/ down status on the CVC display.
STOP. Press the START softkey to override the schedule
and start the chiller.
NOTE: The chiller will continue to run until this forced start
is released, regardless of the programmed schedule. To
release the forced start, highlight CHILLER START/STOP from
the MAINSTAT screen and press the RELEASE softkey.
This action returns the chiller to the start and stop times
established by the schedule.
The chiller may also be started by overriding the time sched-
ule. From the default screen, press the MENU and
SCHEDULE softkeys. Scroll down and select the current
schedule. Select OVERRIDE, and set the desired override
time.
Another condition for start-up must be met for chillers that
have the REMOTE CONTACTS OPTION on the EQUIP-
MENT SERVICE screen set to ENABLE. For these chillers,
the REMOTE CONTACTS INPUT parameter on the MAIN- A — START INITIATED — Prestart checks made; evaporator
STAT screen must be CLOSED. From the CVC default screen, pump started.
B — Condenser water pump started (5 seconds after A).
press the MENU and STATUS softkeys. Scroll to high- C — Water flows verified (30 seconds to 5 minutes maximum
after B). Chilled water temperatures checked against con-
light MAINSTAT and press the SELECT softkey. Scroll trol point. Guide vanes checked for closure. Oil pump started;
down the STATUS01 screen to highlight REMOTE CON- tower fan control enabled.
D — Oil pressure verified (15 seconds minimum, 300 seconds
TACTS INPUT and press the SELECT softkey. Then, press maximum after C).
E — Compressor motor starts, compressor ontime and service
the CLOSE softkey. To end the override, select REMOTE ontime start, 15-minute inhibit timer starts (10 seconds
CONTACTS INPUT and press the RELEASE softkey. after D), total compressor starts advances by one, and the
number of starts over a 12-hour period advances by one.
Once local start-up begins, the PIC II performs a series of F — SHUTDOWN INITIATED — Compressor motor stops, com-
pre-start tests to verify that all pre-start alerts and safeties pressor ontime and service ontime stops, and 1-minute
are within the limits shown in Table 3. The RUN STATUS inhibit timer starts.
G — Oil pump and evaporator pumps deenergized (60 seconds
parameter on the MAINSTAT screen line now reads after F). Condenser pump and tower fan control may con-
PRESTART. If a test is not successful, the start-up is de- tinue to operate if condenser pressure is high. Evaporator
layed or aborted. If the tests are successful, the chilled water/ pump may continue if in RECYCLE mode.
brine pump relay energizes, and the MAINSTAT screen line O/A — Restart permitted (both inhibit timers expired: minimum of
15 minutes after E; minimum of 1 minute after F).
now reads STARTUP.
Five seconds later, the condenser pump relay energizes. Fig. 23 — Control Sequence
Thirty seconds later the PIC II monitors the chilled water
and condenser water flow devices and waits until the
44
Shutdown Sequence — Chiller shutdown begins if Chilled Water Recycle Mode — The chiller may cycle
any of the following occurs: off and wait until the load increases to restart when
• the STOP button is pressed for at least one second (the the compressor is running in a lightly loaded condition. This
alarm light blinks once to confirm the stop command) cycling is normal and is known as 9recycle.9 A recycle shut-
• a recycle condition is present (see Chilled Water Recycle down is initiated when any of the following conditions
Mode section) are true:
• the time schedule has gone into unoccupied mode • the chiller is in LCW control, the difference between the
• the chiller protective limit has been reached and chiller is LEAVING CHILLED WATER temperature and ENTER-
in alarm ING CHILLED WATER temperature is less than the
• the start/stop status is overridden to stop from the CCN RECYCLE SHUTDOWN DELTA T (found in the
network or the CVC SETUP1 table) and the LEAVING CHILLED WATER tem-
When a stop signal occurs, the shutdown sequence first perature is below the CONTROL POINT, −5 F (−15.0 C)
stops the compressor by deactivating the start relay (1CR). the CONTROL POINT has not increased in the last 5 min-
A status message of ‘‘SHUTDOWN IN PROGRESS, COM- utes and ICE BUILD is not active.
PRESSOR DEENERGIZED’’ is displayed, and the com- • the ECW CONTROL OPTION is enabled, the difference
pressor ontime and service ontime stop. The guide vanes are between the ENTERING CHILLED WATER temperature
then brought to the closed position. The oil pump relay and and the LEAVING CHILLED WATER temperature is less
the chilled water/brine pump relay shut down 60 seconds than the RECYCLE SHUTDOWN DELTA T (found in the
after the compressor stops. The condenser water pump shuts SETUP1 table), and the ENTERING CHILLED WATER
down at the same time if the ENTERING CONDENSER temperature is below the CONTROL POINT −5 F
WATER temperature is greater than or equal to 115 F (−15.0 C) and the CONTROL POINT has not increased in
(46.1 C) and the CONDENSER REFRIG TEMP is greater the last 5 minutes.
than the CONDENSER FREEZE POINT plus 5 F (−15.0 C). • the LEAVING CHILLED WATER temperature is within
The stop-to-start timer now begins to count down. If the start- 3° F (2° C) of the EVAP REFRIG TRIPPOINT.
to-start timer value is still greater than the value of the start- When the chiller is in RECYCLE mode, the chilled water
to-stop timer, then this time displays on the CVC. pump relay remains energized so the chilled water temper-
Certain conditions that occur during shutdown can change ature can be monitored for increasing load. The recycle
this sequence. control uses RECYCLE RESTART DELTA T to check when
• If the AVERAGE LINE CURRENT is greater than 15% af- the compressor should be restarted. This is an operator-
ter shutdown, or the starter contacts remain energized, the configured function which defaults to 5° F (3° C). This value
oil pump and chilled water pump remain energized and can be viewed or modified on the SETUP1 table. The com-
the alarm is displayed. pressor will restart when the chiller is:
• The condenser pump shuts down when the CONDENSER • in LCW CONTROL and the LEAVING CHILLED
PRESSURE is less than the CONDENSER PRESSURE WATER temperature is greater than the CONTROL POINT
OVERRIDE threshold minus 3.5 psi (24.1 kPa) and the plus the RECYCLE RESTART DELTA T.
CONDENSER REFRIG TEMP is less than or equal to the • in ECW CONTROL and the ENTERING CHILLED
ENTERING CONDENSER WATER temperature plus WATER temperature is greater than the CONTROL POINT
3° F (−1.6° C). plus the RECYCLE RESTART DELTA T.
• If the chiller shuts down due to low refrigerant tempera-
ture, the chilled water pump continues to run until the LEAV- Once these conditions are met, the compressor initiates a
ING CHILLED WATER temperature is greater than the start-up with a normal start-up sequence.
CONTROL POINT temperature, plus 5° F (3° C). An alert condition may be generated if 5 or more recycle
start-ups occur in less than 4 hours. Excessive recycling can
Automatic Soft Stop Amps Threshold — The soft reduce chiller life; therefore, compressor recycling due to
stop amps threshold feature closes the guide vanes of the extremely low loads should be reduced.
compressor automatically if a non-recycle, non-alarm stop To reduce compressor recycling, use the time schedule to
signal occurs before the compressor motor is deenergized. shut the chiller down during known low load operation
If the STOP button is pressed, the guide vanes close to a period, or increase the chiller load by running the fan sys-
preset amperage percent until the guide vane is less than tems. If the hot gas bypass is installed, adjust the values to
4% open or 4 minutes have passed. The compressor then ensure that hot gas is energized during light load condi-
shuts off. tions. Increase the RECYCLE RESTART DELTA T on the
If the chiller enters an alarm state or if the compres- SETUP1 table to lengthen the time between restarts.
sor enters a RECYCLE mode, the compressor deenergizes The chiller should not be operated below design mini-
immediately. mum load without a hot gas bypass installed.
To activate the soft stop amps threshold feature, scroll to
the bottom of OPTIONS screen on the CVC. Use the Safety Shutdown — A safety shutdown is identical to
a manual shutdown with the exception that, during a safety
INCREASE or DECREASE softkey to set the SOFT shutdown, the CVC displays the reason for the shutdown,
STOP AMPS THRESHOLD parameter to the percent of amps the alarm light blinks continuously, and the spare alarm con-
at which the motor will shut down. The default setting is tacts are energized.
100% amps (no soft stop). The range is 40 to 100%. After a safety shutdown, the RESET softkey must be
When the soft stop amps threshold feature is being
applied, a status message, ‘‘SHUTDOWN IN PROGRESS, pressed to clear the alarm. If the alarm condition is still present,
COMPRESSOR UNLOADING’’ displays on the CVC. the alarm light continues to blink. Once the alarm is cleared,
The soft stop amps threshold function can be terminated the operator must press the CCN or LOCAL softkeys to
and the compressor motor deenergized immediately by de- restart the chiller.
pressing the STOP button twice.
45
BEFORE INITIAL START-UP To determine if there are any leaks, the chiller should
be charged with refrigerant. Use an electronic leak detector
Job Data Required to check all flanges and solder joints after the chiller is
• list of applicable design temperatures and pressures (prod- pressurized. If any leaks are detected, follow the leak test
uct data submittal) procedure.
• chiller certified prints If the chiller is spring isolated, keep all springs blocked in
both directions to prevent possible piping stress and dam-
• starting equipment details and wiring diagrams age during the transfer of refrigerant from vessel to vessel
• diagrams and instructions for special controls or options during the leak test process, or any time refrigerant is being
• 19XR Installation Instructions transferred. Adjust the springs when the refrigerant is in
• pumpout unit instructions operating condition and the water circuits are full.
Equipment Required Refrigerant Tracer — Carrier recommends the use of

an environmentally acceptable refrigerant tracer for leak test-
• mechanic’s tools (refrigeration) ing with an electronic detector or halide torch.
• digital volt-ohmmeter (DVM) Ultrasonic leak detectors can also be used if the chiller is
• clamp-on ammeter under pressure.
• electronic leak detector
• absolute pressure manometer or wet-bulb vacuum indica-
tor (Fig. 24) Do not use air or oxygen as a means of pressurizing
• 500-v insulation tester (megohmmeter) for compressor the chiller. Mixtures of HFC-134a and air can undergo
motors with nameplate voltage of 600 v or less, or a combustion.
5000-v insulation tester for compressor motor rated above
600 v
Using the Optional Storage Tank and Pumpout

System — Refer to Chillers with Storage Tanks section,
page 63 for pumpout system preparation, refrigerant trans-
fer, and chiller evacuation.
Remove Shipping Packaging — Remove any pack-
aging material from the control center, power panel, guide
vane actuator, motor cooling and oil reclaim solenoids,
motor and bearing temperature sensor covers, and the factory-
mounted starter.
Open Oil Circuit Valves — Check to ensure the oil
filter isolation valves (Fig. 4) are open by removing the valve
cap and checking the valve stem.
Tighten All Gasketed Joints and Guide Vane
Shaft Packing — Gaskets and packing normally relax
by the time the chiller arrives at the jobsite. Tighten all gas-
keted joints and the guide vane shaft packing to ensure a
leak-tight chiller.
Fig. 24 — Typical Wet-Bulb Type
Check Chiller Tightness — Figure 25 outlines the Vacuum Indicator
proper sequence and procedures for leak testing.
19XR chillers are shipped with the refrigerant contained
in the condenser shell and the oil charge in the compressor.
The cooler is shipped with a 15 psig (103 kPa) refrigerant
charge. Units may be ordered with the refrigerant shipped
separately, along with a 15 psig (103 kPa) nitrogen-holding
charge in each vessel.
46
47
Fig. 25 — 19XR Leak Test Procedures

Leak Test Chiller — Due to regulations regarding re- 5. If no leak is found during the initial start-up procedures,
frigerant emissions and the difficulties associated with sepa- complete the transfer of refrigerant gas from the
rating contaminants from the refrigerant, Carrier recommends pumpout storage tank to the chiller (see Transfer Refrig-
the following leak test procedure. See Fig. 25 for an outline erant from Pumpout Storage Tank to Chiller section,
of the leak test procedure. Refer to Fig. 26 and 27 during page 63). Retest for leaks.
pumpout procedures and Tables 5A and 5B for refrigerant 6. If no leak is found after a retest:
pressure/temperature values. a. Transfer the refrigerant to the pumpout storage tank
1. If the pressure readings are normal for the chiller and perform a standing vacuum test as outlined in the
condition: Standing Vacuum Test section, below.
a. Evacuate the holding charge from the vessels, if present. b. If the chiller fails the standing vacuum test, check for
b. Raise the chiller pressure, if necessary, by adding large leaks (Step 2b).
refrigerant until pressure is at the equivalent saturated c. If the chiller passes the standing vacuum test, dehy-
pressure for the surrounding temperature. Follow the drate the chiller. Follow the procedure in the Chiller
pumpout procedures in the Transfer Refrigerant from Dehydration section. Charge the chiller with refriger-
Pumpout Storage Tank to Chiller section, Steps 1a - e, ant (see Transfer Refrigerant from Pumpout Storage
page 63. Tank to Chiller section, page 63).
7. If a leak is found after a retest, pump the refrigerant back
into the pumpout storage tank or, if isolation valves are
Never charge liquid refrigerant into the chiller if present, pump the refrigerant into the non-leaking ves-
the pressure in the chiller is less than 35 psig sel (see Pumpout and Refrigerant Transfer procedures
(241 kPa) for HFC-134a. Charge as a gas only, with section).
the cooler and condenser pumps running, until this 8. Transfer the refrigerant until the chiller pressure is at
pressure is reached, using PUMPDOWN LOCK- 18 in. Hg (40 kPa absolute).
OUT and TERMINATE LOCKOUT mode on
the PIC II. Flashing of liquid refrigerant at low 9. Repair the leak and repeat the procedure, beginning from
pressures can cause tube freeze-up and consider- Step 2h, to ensure a leak-tight repair. (If the chiller is opened
able damage. to the atmosphere for an extended period, evacuate it be-
fore repeating the leak test.)
c. Leak test chiller as outlined in Steps 3 - 9. Standing Vacuum Test — When performing the stand-
ing vacuum test or chiller dehydration, use a manometer or
2. If the pressure readings are abnormal for the chiller a wet bulb indicator. Dial gages cannot indicate the small
condition: amount of acceptable leakage during a short period of time.
a. Prepare to leak test chillers shipped with refrigerant 1. Attach an absolute pressure manometer or wet bulb in-
(Step 2h). dicator to the chiller.
b. Check for large leaks by connecting a nitrogen bottle 2. Evacuate the vessel (see Pumpout and Refrigerant
and raising the pressure to 30 psig (207 kPa). Soap Transfer Procedures section, page 62) to at least 18 in.
test all joints. If the test pressure holds for 30 minutes, Hg vac, ref 30-in. bar (41 kPa), using a vacuum pump or
prepare the test for small leaks (Steps 2g - h). the pumpout unit.
c. Plainly mark any leaks that are found. 3. Valve off the pump to hold the vacuum and record the
d. Release the pressure in the system. manometer or indicator reading.
e. Repair all leaks. 4. a. If the leakage rate is less than 0.05 in. Hg (0.17 kPa)
f. Retest the joints that were repaired. in 24 hours, the chiller is sufficiently tight.
g. After successfully completing the test for large leaks, b. If the leakage rate exceeds 0.05 in. Hg (0.17 kPa)
remove as much nitrogen, air, and moisture as pos-
in 24 hours, repressurize the vessel and test for leaks.
sible, given the fact that small leaks may be present in If refrigerant is available in the other vessel, pres-
the system. This can be accomplished by following surize by following Steps 2-10 of Return Chiller To
the dehydration procedure, outlined in the Chiller Normal Operating Conditions section, page 64. If not,
Dehydration section, page 51. use nitrogen and a refrigerant tracer. Raise the vessel
h. Slowly raise the system pressure to a maximum of pressure in increments until the leak is detected. If
160 psig (1103 kPa) but no less than 35 psig (241 kPa) refrigerant is used, the maximum gas pressure is
for HFC-134a by adding refrigerant. Proceed with the approximately 70 psig (483 kPa) for HFC-134a at nor-
test for small leaks (Steps 3-9). mal ambient temperature. If nitrogen is used, limit the
3. Check the chiller carefully with an electronic leak detec- leak test pressure to 230 psig (1585 kPa) maximum.
tor, halide torch, or soap bubble solution. 5. Repair the leak, retest, and proceed with dehydration.
4. Leak Determination — If an electronic leak detector in-
dicates a leak, use a soap bubble solution, if possible, to
confirm. Total all leak rates for the entire chiller. Leakage
at rates greater than 1 lb/year (0.45 kg/year) for the entire
chiller must be repaired. Note the total chiller leak rate
on the start-up report.
48
Fig. 26 — Typical Optional Pumpout System Piping Schematic with Storage Tank
Fig. 27 — Typical Optional Pumpout System Piping Schematic without Storage Tank
49
Table 5A — HFC-134a Pressure — Table 5B — HFC-134a Pressure —
Temperature (F) Temperature (C)
TEMPERATURE, PRESSURE TEMPERATURE, PRESSURE GAGE
F (psig) C (kPa)
0 6.50 -18.0 44.8
2 7.52 -16.7 51.9
4 8.60 -15.6 59.3
6 9.66 -14.4 66.6
8 10.79 -13.3 74.4
10 11.96 -12.2 82.5
12 13.17 -11.1 90.8
14 14.42 -10.0 99.4
16 15.72 -8.9 108.0
18 17.06 -7.8 118.0
20 18.45 -6.7 127.0
22 19.88 -5.6 137.0
24 21.37 -4.4 147.0
26 22.90 -3.3 158.0
28 24.48 -2.2 169.0
30 26.11 -1.1 180.0
32 27.80 0.0 192.0
34 29.53 1.1 204.0
36 31.32 2.2 216.0
38 33.17 3.3 229.0
40 35.08 4.4 242.0
42 37.04 5.0 248.0
44 39.06 5.6 255.0
46 41.14 6.1 261.0
48 43.28 6.7 269.0
50 45.48 7.2 276.0
52 47.74 7.8 284.0
54 50.07 8.3 290.0
56 52.47 8.9 298.0
58 54.93 9.4 305.0
60 57.46 10.0 314.0
62 60.06 11.1 329.0
64 62.73 12.2 345.0
66 65.47 13.3 362.0
68 68.29 14.4 379.0
70 71.18 15.6 396.0
72 74.14 16.7 414.0
74 77.18 17.8 433.0
76 80.30 18.9 451.0
78 83.49 20.0 471.0
80 86.17 21.1 491.0
82 90.13 22.2 511.0
84 93.57 23.3 532.0
86 97.09 24.4 554.0
88 100.70 25.6 576.0
90 104.40 26.7 598.0
92 108.18 27.8 621.0
94 112.06 28.9 645.0
96 116.02 30.0 669.0
98 120.08 31.1 694.0
100 124.23 32.2 720.0
102 128.47 33.3 746.0
104 132.81 34.4 773.0
106 137.25 35.6 800.0
108 141.79 36.7 828.0
110 146.43 37.8 857.0
112 151.17 38.9 886.0
114 156.01 40.0 916.0
116 160.96 41.1 946.0
118 166.01 42.2 978.0
120 171.17 43.3 1010.0
122 176.45 44.4 1042.0
124 181.83 45.6 1076.0
126 187.32 46.7 1110.0
128 192.93 47.8 1145.0
130 198.66 48.9 1180.0
132 204.50 50.0 1217.0
134 210.47 51.1 1254.0
136 216.55 52.2 1292.0
138 222.76 53.3 1330.0
140 229.09 54.4 1370.0
55.6 1410.0
56.7 1451.0
57.8 1493.0
58.9 1536.0
60.0 1580.0
50
Chiller Dehydration — Dehydration is recommended
if the chiller has been open for a considerable period of time,
if the chiller is known to contain moisture, or if there has
been a complete loss of chiller holding charge or refrigerant
pressure.
Do not start or megohm-test the compressor motor or

oil pump motor, even for a rotation check, if the chiller
is under dehydration vacuum. Insulation breakdown and
severe damage may result.
Fig. 28 — Dehydration Cold Trap
Inspect Water Piping — Refer to piping diagrams pro-

Inside-delta type starters must be disconnected by an iso- vided in the certified drawings and the piping instructions
lation switch before placing the machine under a vacuum in the 19XR Installation Instructions manual. Inspect the pip-
because one lead of each phase is live with respect to ing to the cooler and condenser. Be sure that the flow
ground even though there is not a complete circuit to directions are correct and that all piping specifications have
run the motor. To be safe, isolate any starter before evacu- been met.
ating the chiller if you are not sure if there are live leads Piping systems must be properly vented with no stress on
to the hermetic motor. waterbox nozzles and covers. Water flows through the cooler
and condenser must meet job requirements. Measure the pres-
sure drop across the cooler and the condenser.
Dehydration can be done at room temperatures. Using a
cold trap (Fig. 28) may substantially reduce the time re-
quired to complete the dehydration. The higher the room tem-
perature, the faster dehydration takes place. At low room Water must be within design limits, clean, and treated
temperatures, a very deep vacuum is required to boil off any to ensure proper chiller performance and to reduce the
moisture. If low ambient temperatures are involved, contact potential of tube damage due to corrosion, scaling, or
a qualified service representative for the dehydration tech- erosion. Carrier assumes no responsibility for chiller
niques required. damage resulting from untreated or improperly treated
Perform dehydration as follows: water.
1. Connect a high capacity vacuum pump (5 cfm [.002 m3/s]
or larger is recommended) to the refrigerant charging valve Check Optional Pumpout Compressor Water
(Fig. 2). Tubing from the pump to the chiller should be Piping — If the optional pumpout storage tank and/or
as short in length and as large in diameter as possible to pumpout system are installed, check to ensure the
provide least resistance to gas flow. pumpout condenser water has been piped in. Check for field-
2. Use an absolute pressure manometer or a wet bulb vacuum supplied shutoff valves and controls as specified in the job
indicator to measure the vacuum. Open the shutoff valve data. Check for refrigerant leaks on field-installed piping.
to the vacuum indicator only when taking a reading. Leave See Fig. 26 and 27.
the valve open for 3 minutes to allow the indicator vacuum Check Relief Valves — Be sure the relief valves have
to equalize with the chiller vacuum. been piped to the outdoors in compliance with the
3. If the entire chiller is to be dehydrated, open all isolation latest edition of ANSI/ASHRAE Standard 15 and applicable
valves (if present). local safety codes. Piping connections must allow for access
4. With the chiller ambient temperature at 60 F (15.6 C) or to the valve mechanism for periodic inspection and leak
higher, operate the vacuum pump until the manometer reads testing.
29.8 in. Hg vac, ref 30 in. bar. (0.1 psia)(–100.61 kPa) or The 19XR relief valves are set to relieve at the 185 psig
a vacuum indicator reads 35 F (1.7 C). Operate the pump (1275 kPa) chiller design pressure.
an additional 2 hours.
Do not apply a greater vacuum than 29.82 in. Hg vac Inspect Wiring
(757.4 mm Hg) or go below 33 F (.56 C) on the wet bulb
vacuum indicator. At this temperature and pressure, iso-
lated pockets of moisture can turn into ice. The slow rate Do not check the voltage supply without proper equip-
of evaporation (sublimation) of ice at these low tempera- ment and precautions. Serious injury may result. Fol-
tures and pressures greatly increases dehydration time. low power company recommendations.
5. Valve off the vacuum pump, stop the pump, and record
the instrument reading.
6. After a 2-hour wait, take another instrument reading. If
the reading has not changed, dehydration is complete. If Do not apply any kind of test voltage, even for a rota-
the reading indicates vacuum loss, repeat Steps 4 and 5. tion check, if the chiller is under a dehydration vacuum.
Insulation breakdown and serious damage may result.
7. If the reading continues to change after several attempts,
perform a leak test up to the maximum 160 psig
(1103 kPa) pressure. Locate and repair the leak, and re- 1. Examine the wiring for conformance to the job wiring
peat dehydration. diagrams and all applicable electrical codes.
51
2. On low-voltage compressors (600 v or less) connect a 10. Tighten all wiring connections to the plugs on the ISM
voltmeter across the power wires to the compressor starter and CCM modules.
and measure the voltage. Compare this reading to the 11. On chillers with free-standing starters, inspect the power
voltage rating on the compressor and starter panel to ensure that the contractor has fed the wires into
nameplates. the bottom of the panel. Wiring into the top of the panel
3. Compare the ampere rating on the starter nameplate to can cause debris to fall into the contactors. Clean and
rating on the compressor nameplate. The overload trip inspect the contactors if this has occurred.
amps must be 108% to 120% of the rated load amps.
4. The starter for a centrifugal compressor motor must con- Carrier Comfort Network Interface — The Carrier
tain the components and terminals required for PIC II Comfort Network (CCN) communication bus wiring is sup-
refrigeration control. Check the certified drawings. plied and installed by the electrical contractor. It consists of
shielded, 3-conductor cable with drain wire.
5. Check the voltage to the following components and
compare it to the nameplate values: oil pump contact, The system elements are connected to the communication
pumpout compressor starter, and power panel. bus in a daisy chain arrangement. The positive pin of each
system element communication connector must be wired to
6. Ensure that fused disconnects or circuit breakers have the positive pins of the system element on either side of it.
been supplied for the oil pump, power panel, and The negative pins must be wired to the negative pins. The
pumpout unit. signal ground pins must be wired to the signal ground pins.
7. Ensure all electrical equipment and controls are prop- See installation manual.
erly grounded in accordance with job drawings, certi- NOTE: Conductors and drain wire must be 20 AWG
fied drawings, and all applicable electrical codes. (American Wire Gage) minimum stranded, tinned copper. In-
8. Ensure the customer’s contractor has verified proper op- dividual conductors must be insulated with PVC, PVC/
eration of the pumps, cooling tower fans, and associated nylon, vinyl, Teflon, or polyethylene. An aluminum/polyester
auxiliary equipment. This includes ensuring motors are 100% foil shield and an outer jacket of PVC, PVC/nylon,
properly lubricated and have proper electrical supply and chrome vinyl, or Teflon with a minimum operating tempera-
proper rotation. ture range of −4 F to 140 F (−20 C to 60 C) is required. See
9. For field-installed starters only, test the chiller compres- table below for cables that meet the requirements.
sor motor and its power lead insulation resistance with
a 500-v insulation tester such as a megohmmeter. (Use MANUFACTURER CABLE NO.
a 5000-v tester for motors rated over 600 v.) Factory- Alpha 2413 or 5463
mounted starters do not require a megohm test. American A22503
a. Open the starter main disconnect switch and follow Belden 8772
lockout/tagout rules. Columbia 02525
When connecting the CCN communication bus to a sys-

If the motor starter is a solid-state starter, the tem element, a color code system for the entire network is
motor leads must be disconnected from the starter recommended to simplify installation and checkout. The fol-
before an insulation test is performed. The voltage lowing color code is recommended:
generated from the tester can damage the starter
solid-state components. CCN BUS CONDUCTOR CVC PLUG J1
SIGNAL TYPE INSULATION COLOR PIN NO.
b. With the tester connected to the motor leads, take
+ Red 1
10-second and 60-second megohm readings as
follows: Ground White 2
− Black 3
6-Lead Motor — Tie all 6 leads together and test be-
tween the lead group and ground. Next tie the leads
in pairs: 1 and 4, 2 and 5, and 3 and 6. Test between
Check Starter
each pair while grounding the third pair.
3-Lead Motor — Tie terminals 1, 2, and 3 together
and test between the group and ground. BE AWARE that certain automatic start arrangements
can engage the starter. Open the disconnect ahead of
c. Divide the 60-second resistance reading by the the starter in addition to shutting off the chiller or pump.
10-second reading. The ratio, or polarization index,
must be one or higher. Both the 10- and 60-second Use the instruction and service manual supplied by the
readings must be at least 50 megohms. starter manufacturer to verify the starter has been installed
If the readings on a field-installed starter are unsat- correctly, to set up and calibrate the starter, and for complete
isfactory, repeat the test at the motor with the power troubleshooting information.
leads disconnected. Satisfactory readings in this sec-
ond test indicate the fault is in the power leads.
NOTE: Unit-mounted starters do not have to be meg- The main disconnect on the starter front panel may not
ohm tested. deenergize all internal circuits. Open all internal and re-
mote disconnects before servicing the starter.
52
MECHANICAL STARTER energizes the oil heater and the control circuit. When first
1. Check all field wiring connections for tightness, clear- powered, the CVC should display the default screen within
ance from moving parts, and correct connection. a short period of time.
2. Check the contactor(s) to ensure they move freely. Check The oil heater is energized by powering the control cir-
the mechanical interlock between contactors to ensure that cuit. This should be done several hours before start-up to
1S and 2M contactors cannot be closed at the same time. minimize oil-refrigerant migration. The oil heater is con-
Check all other electro-mechanical devices, such as trolled by the PIC II and is powered through a contactor in
relays, for free movement. If the devices do not move the power panel. Starters contain a separate circuit breaker
freely, contact the starter manufacturer for replacement to power the heater and the control circuit. This arrangement
components. allows the heater to energize when the main motor circuit
breaker is off for service work or extended shutdowns. The
3. Some dashpot-type magnetic overload relays must be filled oil heater relay status (OIL HEATER RELAY) can be viewed
with oil on the jobsite. If the starter is equipped with de- on the COMPRESS table on the CVC. Oil sump tempera-
vices of this type, remove the fluid cups from these mag- ture can be viewed on the CVC default screen.
netic overload relays. Add the dashpot oil to the cups
according to the instructions supplied with the starter. The SOFTWARE VERSION — The software part number is la-
oil is usually shipped in a small container attached to the beled on the backside of the CVC module. The software ver-
starter frame near the relays. Use only the dashpot oil sup- sion also appears on the CVC configuration screen as the
plied with the starter. Do not substitute. last two digits of the software part number.
Solid-state overload relays do not have oil. Software Configuration
4. Reapply starter control power (not main chiller power) to
check the electrical functions.
Ensure the starter (with relay 1CR closed) goes through Do not operate the chiller before the control configu-
a complete and proper start cycle. rations have been checked and a Control Test has been
BENSHAW, INC. REDISTART MICRO SOLID-STATE satisfactorily completed. Protection by safety controls
STARTER cannot be assumed until all control configurations have
been confirmed.
As the 19XR unit is configured, all configuration settings

This equipment is at line voltage when AC power is should be written down. A log, such as the one shown on
connected. Pressing the STOP button does not remove pages CL-1 to CL-12, provides a convenient list for con-
voltage. figuration values.
1. Ensure all wiring connections are properly terminated to Input the Design Set Points — Access the CVC set
the starter. point screen and view/modify the base demand limit set point,
2. Verify the ground wire to the starter is installed properly and either the LCW set point or the ECW set point. The
and is sufficient size. PIC II can control a set point to either the leaving or entering
3. Verify the motors are properly grounded to the starter. chilled water. This control method is set in the EQUIP-
4. Ensure all of the relays are properly seated in their MENT SERVICE (TEMP_CTL) table.
sockets. Input the Local Occupied Schedule (OCCPC01S)
5. Verify the proper ac input voltage is brought into the starter — Access the schedule OCCPC01S screen on the CVC and
according to the certified drawings. set up the occupied time schedule according to the custom-
6. Apply power to the starter. er’s requirements. If no schedule is available, the default is
factory set for 24 hours occupied, 7 days per week including
Oil Charge — The oil charge for the 19XR compressor holidays.
depends on the compressor Frame size: For more information about how to set up a time sched-
• Frame 2 compressor — 5 gal (18.9 L) ule, see the Controls section, page 10.
• Frame 3 compressor — 8 gal (30 L) The CCN Occupied Schedule (OCCPC03-99S) should be
• Frame 4 compressor — 10 gal (37.8 L) configured if a CCN system is being installed or if a sec-
ondary time schedule is needed.
• Frame 5 compressor — 18 gal (67.8 L)
NOTE: The default CCN Occupied Schedule OCCPC03S is
The chiller is shipped with oil in the compressor. When configured to be unoccupied.
the sump is full, the oil level should be no higher than the
middle of the upper sight glass, and minimum level is the Input Service Configurations — The following con-
bottom of the lower sight glass (Fig. 2). If oil is added, it figurations require the CVC screen to be in the SERVICE
must meet Carrier’s specification for centrifugal compressor portion of the menu.
use as described in the Oil Specification section. Charge the • password
oil through the oil charging valve located near the bottom of • input time and date
the transmission housing (Fig. 2). The oil must be pumped • CVC configuration
from the oil container through the charging valve due to higher • service parameters
refrigerant pressure. The pumping device must be able to lift • equipment configuration
from 0 to 200 psig (0 to 1380 kPa) or above unit pressure. • automated control test
Oil should only be charged or removed when the chiller is
shut down. PASSWORD — When accessing the SERVICE tables, a pass-
word must be entered. All CVC are initially set for a pass-
Power Up the Controls and Check the Oil Heater word of 1-1-1-1.
— Ensure that an oil level is visible in the compressor be-
fore energizing the controls. A circuit breaker in the starter
53
INPUT TIME AND DATE — Access the TIME AND DATE INPUT EQUIPMENT SERVICE PARAMETERS IF NEC-
table on the SERVICE menu. Input the present time of day, ESSARY — The EQUIPMENT SERVICE table has six serv-
date, and day of the week. The HOLIDAY TODAY param- ice tables.
eter should only be configured to YES if the present day is Configure SERVICE Tables — Access the SERVICE tables,
a holiday. depicted on the next page, to modify or view the following
NOTE: Because a schedule is integral to the chiller control to job site parameters:
sequence, the chiller will not start until the time and date
have been set. PARAMETER TABLE
Starter Type ISM_CONF — Select 0 for full voltage,
CHANGE CVC CONFIGURATION IF NECESSARY — 1 for reduced voltage, or 2 for solid state/
From the SERVICE table, access the CVC CONFIGU- variable frequency drive.
RATION screen. From there, view or modify the CVC CCN Motor Rated Line ISM_CONF — Enter actual line voltage
address, change to English or SI units, and change the pass- Voltage from power screen.
word. If there is more than one chiller at the jobsite, change Volt Transformer ISM_CONF — Enter ratio (reduced to a
the CVC address on each chiller so that each chiller has its Ratio ratio to 1) of power transformer wired to
own address. Note and record the new address. Change the terminal J3 of ISM. If no transformer is
used enter 1.
screen to SI units as required, and change the password if
Motor Rated Load ISM_CONF — Per chiller identification
desired. Amps nameplate data.
TO CHANGE THE PASSWORD — The password may be Motor Locked Rotor ISM_CONF — Per chiller identification
changed from the CVC CONFIGURATION screen. Trip nameplate data. Enter locked rotor delta
amps (LR AMPS D-).
1. Press the MENU and SERVICE softkeys. Enter the cur- Starter LRA Rating ISM_CONF — Enter value from name-
rent password and highlight CVC CONFIGURATION. plate in starter cabinet.
Motor Current ISM_CONF — Enter ratio (reduced to a
Press the SELECT softkey. Only the last 5 entries on CT Ratio ratio to 1) of current transformers wired
the CVC CONFIG screen can be changed: BUS #, to terminal J4 of ISM.
ADDRESS #, BAUD RATE, US IMP/METRIC, and Ground Fault ISM_CONF — Enter 0 if three ground
PASSWORD. Current fault CTs are wired to terminal J5 of ISM.
Transformers Enter 1 if one ground fault CT is used.
2. Use the ENTER softkey to scroll to PASSWORD. The Ground Fault CT ISM_CONF — Enter ratio (reduced to a
Ratio ratio to 1) of ground fault CT.
first digit of the password is highlighted on the screen.
Single Cycle ISM_CONF — ENABLE if motor protec-
3. To change the digit, press the INCREASE or Dropout tion required from drop in line voltage
within one cycle.
DECREASE softkey. When the desired digit is seen, press
Line Frequency ISM_CONF — Enter YES for 60 Hz or
the ENTER softkey. NO for 50 Hz.
4. The next digit is highlighted. Change it, and the third and Line Frequency ISM_CONF — ENABLE if motor protec-
Faulting tion required for drop in line frequency.
fourth digits in the same way the first was changed.
Surge LImiting or OPTIONS — Enter 1 if HGBP is
5. After the last digit is changed, the CVC goes to the BUS Hot Gas Byapss installed.
Option
parameter. Press the EXIT softkey to leave that screen
Minimum Load OPTIONS — Per job data — See modify
and return to the SERVICE menu. Points (T1/P1) load points section.
Full (Maximum) OPTIONS — Per job data — See modify
Load Points load points section.
(T2/P2)
Be sure to remember the password. Retain a copy Chilled Medium SEETUP1 — Enter water or brine.
for future reference. Without the password, access Evaporator SETUP1 — Usually 3° F (1.7° C) below
to the SERVICE menu will not be possible unless Refrigerant design refrigerant temperature.
the CVC_PSWD menu on the STATUS screen is Trippoint
accessed by a Carrier representative. Evaporator Flow SETUP1 — Enter 50% of design
Delta P Cutout pressure drop to 0.5 psi (3.4 kPa).*
Condenser Flow SETUP1 — Enter 50% of design
TO CHANGE THE CVC DISPLAY FROM ENGLISH TO Delta P Cutout pressure drop to 0.5 psi (3.4 kPa).*
METRIC UNITS — By default, the CVC displays informa- Diffuser Option SETUP2 — ENABLE for 5 size
tion in English units. To change to metric units, access the compressor only. See model number
CVC CONFIGURATION screen: nomenclature.
Diffuser Full Span SETUP2 — Enter diffuser actuator full
1. Press the MENU and SERVICE softkeys. Enter the mA Rating span mA rating for 5 size compressor
password and highlight CVC CONFIGURATION. Press only. Value is located on label on side of
diffuser actuator motor.
the SELECT softkey. Motor Rated RAMP_DEM — Enter value from chiller
2. Use the ENTER softkey to scroll to US IMP/METRIC. Kilowatts requisition form (product data submittal) if
kilowatt ramp demand is enabled.
3. Press the softkey that corresponds to the units desired for
display on the CVC (e.g., US or METRIC). *With variable flow systems this point may be configured to the lower
end of the range.
MODIFY CONTROLLER IDENTIFICATION IF NECES- NOTE: Other parameters on these screens are normally left at the
SARY — The CVC module address can be changed from default settings; however, they may be changed by the operator as
the CVC CONFIGURATION screen. Change this address required. The time and persistence settings on the ISM_CONF table
for each chiller if there is more than one chiller at the job- can be adjusted to increase or decrease the sensitivity to a fault
site. Write the new address on the CVC module for future condition. Increasing time or persistence decreases sensitivity. De-
creasing time or persistence increases sensitivity to the fault
reference. condition.
54
Modify Minimum and Maximum Load Points (DT1/P1; If surge prevention occurs too soon or too late:
D T2/P2) If Necessary — These pairs of chiller load points,
located on the OPTIONS screen, determine when to limit LOAD SURGE PREVENTION SURGE PREVENTION
guide vane travel or open the hot gas bypass valve when OCCURS TOO SOON OCCURS TOO LATE
surge prevention is needed. These points should be set based At low
loads Increase P1 by 10 psid Decrease P1 by 10 psid
on individual chiller operating conditions. (,50%) (70 kPad) (70 kPad)
If after configuring a value for these points, surge preven- At high Decrease P2 by 10 psid
tion is operating too soon or too late for conditions, these loads Increase P2 by 10 psid (70 kPad)
(.50%) (70 kPad)
parameters should be changed by the operator.
An example of such a configuration is shown below. The differential pressure (DP) and temperature (DT) can
Refrigerant: HCFC-134a be monitored during chiller operation by viewing ACTIVE
Estimated Minimum Load Conditions: DELTA P and ACTIVE DELTA T (HEAT_EX screen). Com-
44 F (6.7 C) LCW paring SURGE/AGBP DELTA T to active DETLA T will de-
45.5 F (7.5 C) ECW termine when the SURGE PREVENTION function will oc-
43 F (6.1 C) Suction Temperature cur. The smaller the difference between the SURGE/AGBP
70 F (21.1 C) Condensing Temperature DELTA T and the ACTIVE DELTA T values, the closer to
surge prevention.
Estimated Maximum Load Conditions:
44 F (6.7 C) LCW CONFIGURE DIFFUSER CONTROL IF NECESSARY —
54 F (12.2 C) ECW If the compressor is equipped with a variable diffuser,
42 F (5.6 C) Suction Temperature (5 size compressor) access the SETUP2 screen. Scroll to DIF-
98 F (36.7 C) Condensing Temperature FUSER CONTROL and press the ENABLE softkey. Enter
Calculate Maximum Load — To calculate the maximum load the correct diffuser and guide vane values (GUIDE VANE
points, use the design load condition data. If the chiller 25% LOAD PT, GUIDE VANE 50 % LOAD PT, GUIDE VANE
full load cooler temperature difference is more than 15 F 75% LOAD PT, DIFFUSER 25% LOAD PT, DIFFUSER 50%
(8.3 C), estimate the refrigerant suction and condensing tem- LOAD PT, DIFFUSER 75% LOAD PT). Default values are
peratures at this difference. Use the proper saturated pres- located on the label inside the control panel. See Fig. 10. To
sure and temperature for the particular refrigerant used. obtain proper settings for diffuser control, contact a Carrier
Engineering representative.
Suction Temperature:
42 F (5.6 C) = 37 psig (255 kPa) saturated Compressors with variable diffuser control have actuators
refrigerant pressure (HFC-134a) tested and stamped with the milliamp (mA) value that
results in 100% actuator rotation. This valve is configured
Condensing Temperature: on the SETUP2 screen. It is labeled DIFFUSER FULL
98 F (36.7 C) = 120 psig (1827 kPa) saturated SPAN mA.
refrigerant pressure (HFC-134a)
MODIFY EQUIPMENT CONFIGURATION IF NECES-
Maximum Load DT2: SARY — The EQUIPMENT SERVICE table has screens to
54 – 44 = 10° F (12.2 – 6.7 = 5.5° C) select, view, or modify parameters. Carrier’s certified draw-
Maximum Load DP2: ings have the configuration values required for the jobsite.
120 – 37 = 83 psid (827 – 255 = 572 kPad) Modify these values only if requested.
To avoid unnecessary surge prevention, add about 10 psid SERVICE Screen Modifications — Change the values on these
(70 kPad) to DP2 from these conditions: screens according to specific job data. See the certified draw-
DT2 = 10° F (5.5° C) ings for the correct values. Modifications can include:
DP2 = 93 psid (642 kPad) • chilled water reset
Calculate Minimum Load — To calculate the minimum load • entering chilled water control (Enable/Disable)
conditions, estimate the temperature difference the cooler will • 4 to 20 mA demand limit
have at 10% load, then estimate what the suction and con- • auto restart option (Enable/Disable)
densing temperatures will be at this point. Use the proper • remote contact option (Enable/Disable)
saturated pressure and temperature for the particular refrig- Owner-Modified CCN Tables— The following EQUIP-
erant used. MENT CONFIGURATION screens are described for refer-
Suction Temperature: ence only.
43 F (6.1 C) = 38 psig (262 kPa) saturated OCCDEFCS — The OCCDEFCS screen contains the Local
refrigerant pressure (HFC-134a) and CCN time schedules, which can be modified here or on
the SCHEDULE screen as described previously.
Condensing Temperature:
70 F (21.1 C) = 71 psig (490 kPa) saturated HOLIDAYS — From the HOLIDAYS screen, the days of the
refrigerant pressure (HFC-134a) year that holidays are in effect can be configured. See the
holiday paragraphs in the Controls section for more
Minimum Load DT1 (at 20% Load): 2 F (1.1 C) details.
Minimum Load DP1: BRODEF — The BRODEF screen defines the start and end
71 – 38 = 33 psid (490 – 262 = 228 kPad) of daylight savings time. Enter the dates for the start and end
Again, to avoid unnecessary surge prevention, add 20 psid of daylight savings if required for your location. BRODEF
(140 kPad) at DP1 from these conditions: also activates the Broadcast function which enables the holi-
DT1 = 2 F (1.1 C) day periods that are defined on the CVC to take effect.
DP1 = 53 psid (368 kPad) Other Tables — The CONSUME, and RUNTIME screens
contain parameters used with a CCN system. See the appli-
cable CCN manual for more information on these screens.
These tables can only be defined from a CCN Building
Supervisor.
55
Perform a Control Test — Check the safety controls Table 6 — Control Test Menu Functions
status by performing an automated control test. Access the
CONTROL TEST table and select a test to be performed TESTS TO BE DEVICES TESTED
PERFORMED
function (Table 6).
1. CCM Thermistors Entering Chilled Water
The Automated Control Test checks all outputs and inputs Leaving Chilled Water
for function. The compressor must be in the OFF mode to Entering Condenser Water
operate the controls test. The compressor can be put in OFF Leaving Condenser Water
Remote Reset Sensor
mode by pressing the STOP push-button on the CVC. Each Comp Discharge Temp
test asks the operator to confirm the operation is occurring Comp Thrust Bearing Temp
and whether or not to continue. If an error occurs, the op- Oil Sump Temp
erator can try to address the problem as the test is being done Comp Motor Winding Temp
Spare Temperature 1
or note the problem and proceed to the next test. Space Temperature 2
NOTE: Enter guide vane calibration to calibrate guide 2. CCM Pressure Evaporator Pressure
input on CCM (Plug J4 upper terminal 9 and 10). Transducers Condenser Pressure
Oil Pump Delta P
NOTE: If during the control test the guide vanes do not open, Spare Pressure Delta P
verify the low pressure alarm is not active. (An active low Condenser Water Delta P
pressure alarm causes the guide vanes to close.) Transducer Voltage Ref
NOTE: The oil pump test will not energize the oil pump if 3. Pumps Oil Pump — Confirm pressure
Chilled Water — Confirm Delta P
cooler pressure is below –5 psig (–35 kPa). Condenser Water — Confirm
Delta P
When the control test is finished or the EXIT softkey is
4. Discrete Outputs Oil Heater Relay
pressed, the test stops, and the CONTROL TEST menu dis- Hot Gas Bypass Relay
plays. If a specific automated test procedure is not com- Tower Fan Relay Low
pleted, access the particular control test to test the function Tower Fan Relay High
Alarm Relay
when ready. The CONTROL TEST menu is described in the Shunt Trip Relay
table below. 5. Guide Vane Actuator Open/Close
6. Diffuser Actuator Open/Close
CCM Pressure Thermistors Check of all thermistors. 7. Pumpdown/Lockout When using pumpdown/lockout,
CCM Pressure Transducers Check of all transducers. observe freeze up precautions when
Pump Checks operation of pump out- removing charge:
puts; pumps are activated. Also Instructs operator which valves to
tests associated inputs such as close and when.
flow or pressure. Starts chilled water and condenser
Discrete ouputs Activation of all on/off outputs water pumps and confirms flows.
individually. Monitors
Guide Vane Check of the guide vane Evaporator pressure
operation. Condenser pressure
Diffuser Actuator* Check of the diffuser actuator. Evaporator temperature during
pumpout procedures
Pumpdown/Lockout Pumpdown prevents the low re-
frigerant alarm during evacuation Turns pumps off after pumpdown.
so refrigerant can be removed Locks out compressor.
form the unit. Also locks the 8. Terminate Lockout Starts pumps and monitors flows.
compressor off and starts the
water pumps. Instructs operator which valves to
open and when.
Terminate Lockout To charge refrigerant and enable
the chiller to run after pumpdown Monitors
lockout. Evaporator pressure
Condenser pressure
Guide Vane Calibration Calibrates guide vane input on Evaporator temperature during
CCM. charging process
*Diffuser tests function only on size 5 compressor with diffuser con- Terminates compressor lockout.
trol enabled.
NOTE: During any of the tests, an out-of-range reading will have an High Altitude Locations — Because the chiller is ini-
asterisk (*) next to the reading and a message will be displayed. tially calibrated at sea level, it is necessary to recalibrate
the pressure transducers if the chiller has been moved to a
Check Optional Pumpout System Controls and high altitude location. See the calibration procedure in the
Compressor — Controls include an on/off switch, a 3-amp Troubleshooting Guide section.
fuse, the compressor overloads, an internal thermostat, a com-
pressor contactor, and a refrigerant high pressure cutout. Charge Refrigerant into Chiller
The high pressure cutout is factory set to open at 161 psig
(1110 kPa) and reset at 130 psig (896 kPa). Ensure the water-
cooled condenser has been connected. Loosen the The transfer, addition, or removal of refrigerant in spring
compressor holddown bolts to allow free spring travel. Open isolated chillers may place severe stress on external pip-
the compressor suction and discharge the service valves. En- ing if springs have not been blocked in both up and down
sure oil is visible in the compressor sight glass. Add oil if directions.
necessary.
See the Pumpout and Refrigerant Transfer Procedures and
Optional Pumpout System Maintenance sections, pages 62
and 68, for details on the transfer of refrigerant, oil speci-
fications, etc.
56
4. Once the pressures have equalized, the discharge isola-
tion valve, cooler isolation valve, optional hot gas bypass
Always operate the condenser and chilled water pumps isolation valve, and the refrigerant isolation valve can be
during charging operations to prevent freeze-ups. opened. Close valves 1a and 1b, and all pumpout unit
valves.
The standard 19XR chiller is shipped with the refrigerant
already charged in the vessels. However, the 19XR may be
ordered with a nitrogen holding charge of 15 psig (103 kPa). Whenever turning the discharge isolation valve, be
Evacuate the nitrogen from the entire chiller, and charge the sure to reattach the valve locking device. This pre-
chiller from refrigerant cylinders. vents the valve from opening or closing during serv-
CHILLER EQUALIZATION WITHOUT A PUMPOUT ice work or during chiller operation.
UNIT
The full refrigerant charge on the 19XR will vary with
chiller components and design conditions, as indicated on
the job data specifications. An approximate charge may be
When equalizing refrigerant pressure on the 19XR chiller determined by adding the condenser charge to the cooler charge
after service work or during the initial chiller start-up, as listed in Table 7.
do not use the discharge isolation valve to equalize.
Either the motor cooling isolation valve or the charging
hose (connected between the pumpout valves on top of Table 7 — Refrigerant (HFC-134a) Charge
the cooler and condenser) should be used as the equal-
ization valve. REFRIGERANT REFRIGERANT
COOLER CHARGE CONDENSER CHARGE
CODE CODE
To equalize the pressure differential on a refrigerant iso- lb kg lb kg
lated 19XR chiller, use the terminate lockout function of the 10 290 132 10 200 91
11 310 141 11 200 91
CONTROL TEST on the SERVICE menu. This helps to turn 12 330 150 12 200 91
on pumps and advises the operator on proper procedures. 15 320 145 15 250 113
The following steps describe how to equalize refrigerant 16 340 154 16 250 113
17 370 168 17 250 113
pressure in an isolated 19XR chiller without a pumpout unit. 20 345 157 20 225 102
1. Access terminate lockout function on the CONTROL TEST 21 385 175 21 225 102
22 435 197 22 225 102
screen. 30 350 159 30 260 118
2. IMPORTANT: Turn on the chilled water and con- 31 420 190 31 260 118
32 490 222 32 260 118
denser water pumps to prevent freezing. 35 400 181 35 310 141
36 480 218 36 310 141
37 550 250 37 310 141
3. Slowly open the refrigerant cooling isolation valve. The 40 560 254 40 280 127
chiller cooler and condenser pressures will gradually equal- 41 630 286 41 280 127
ize. This process takes approximately 15 minutes. 42 690 313 42 280 127
45 640 290 45 330 150
4. Once the pressures have equalized, the cooler isolation 46 720 327 46 330 150
valve, the condenser isolation valve, and the hot gas iso- 47 790 358 47 330 150
lation valve may now be opened. Refer to Fig. 26 and 27, 50 750 340 50 400 181
for the location of the valves. 51 840 381 51 400 181
52 900 408 52 400 181
55 870 395 55 490 222
56 940 426 56 490 222
57 980 445 57 490 222
Whenever turning the discharge isolation valve, be 60 940 426 60 420 190
sure to reattach the valve locking device. This pre- 61 980 445 61 420 190
vents the valve from opening or closing during serv- 62 1020 463 62 420 190
65 1020 463 65 510 231
ice work or during chiller operation. 66 1060 481 66 510 231
67 1090 494 67 510 231
70 1220 553 70 780 354
CHILLER EQUALIZATION WITH PUMPOUT UNIT — 71 1340 608 71 780 354
The following steps describe how to equalize refrigerant pres- 72 1440 653 72 780 354
sure on an isolated 19XR chiller using the pumpout unit. 75 1365 619 75 925 420
76 1505 683 76 925 420
1. Access the terminate lockout function on the CONTROL 77 1625 737 77 925 420
TEST screen. 80 1500 680 80 720 327
81 1620 735 81 720 327
2. IMPORTANT: Turn on the chilled water and con- 82 1730 785 82 720 327
85 1690 766 85 860 390
denser water pumps to prevent possible freezing. 86 1820 825 86 860 390
87 1940 880 87 860 390
3. Open valve 4 on the pumpout unit and open valves 1a
and 1b on the chiller cooler and condenser, Fig. 26 and
27. Slowly open valve 2 on the pumpout unit to equalize
the pressure. This process takes approximately
15 minutes.
57
2. Observe the default screen on the CVC: the Status mes-
sage in the upper left-hand corner reads, ‘‘Manually
Always operate the condenser and chilled water pumps Stopped.’’ Press the CCN or LOCAL softkey to start.
whenever charging, transferring, or removing refrig- If the chiller controls do not go into a start mode, go to
rant from the chiller. the Schedule screen and override the schedule or change
the occupied time. Press the LOCAL softkey to begin
Use the CONTROL TEST terminate lockout function to the start-up sequences.
monitor conditions and start the pumps. 3. Verify the chilled water and condenser water pumps
If the chiller has been shipped with a holding charge, the have energized.
refrigerant is added through the refrigerant charging valve 4. Verify the oil pump has started and is pressurizing the
(Fig. 26 and 27, valve 7) or to the pumpout charging con- lubrication system. After the oil pump has run about
nection. First evacuate the nitrogen holding charge from the 11 seconds, the starter energizes and goes through its start-up
chiller vessels. Charge the refrigerant as a gas until the sys- sequence.
tem pressure exceeds 35 psig (141 kPa) for HFC-134a. After
the chiller is beyond this pressure the refrigerant should be 5. Check the main contactor for proper operation.
charged as a liquid until all the recommended refrigerant charge 6. The PIC II eventually shows an alarm for motor amps
has been added. not sensed. Reset this alarm and continue with the initial
TRIMMING REFRIGERANT CHARGE — The 19XR is start-up.
shipped with the correct charge for the design duty of the Check Motor Rotation
chiller. Trimming the charge can best be accomplished when
the design load is available. To trim the charge, check the 1. Engage the main motor disconnect on the front of the starter
temperature difference between the leaving chilled water tem- panel. The motor is now ready for a rotation check.
perature and cooler refrigerant temperature at full load 2. After the default screen status message states ‘‘Ready
design conditions. If necessary, add or remove refrigerant to for Start’’ press the LOCAL softkey. The PIC II control
bring the temperature difference to design conditions or mini- performs start-up checks.
mum differential.
3. When the starter is energized and the motor begins to turn,
Table 7 lists the 19XR chiller refrigerant charges for each check for clockwise motor rotation (Fig. 29).
cooler and condenser code. Total refrigerant charge is the
sum of the cooler and condenser charge. IF THE MOTOR ROTATION IS CLOCKWISE, allow the
compressor to come up to speed.
IF THE MOTOR ROTATION IS NOT CLOCKWISE
INITIAL START-UP (as viewed through the sight glass), reverse any 2 of the 3
incoming power leads to the starter and recheck the rotation.
Preparation — Before starting the chiller, verify:
NOTE: Solid-state starters have phase protection and do not
1. Power is on to the main starter, oil pump relay, tower fan permit a start if the phase is not correct. If this happens, a
starter, oil heater relay, and the chiller control panel. fault message appears on the CVC.
2. Cooling tower water is at proper level and at-or-below
design entering temperature.
3. Chiller is charged with refrigerant and all refrigerant and Do not check motor rotation during coastdown. Rota-
oil valves are in their proper operating positions. tion may have reversed during equalization of vessel
4. Oil is at the proper level in the reservoir sight glasses. pressures.
5. Oil reservoir temperature is above 140 F (60 C) or re-
frigerant temperature plus 50° F (28° C).
6. Valves in the evaporator and condenser water circuits are
open.
NOTE: If the pumps are not automatic, ensure water is
circulating properly.
Do not permit water or brine that is warmer than

110 F (43 C) to flow through the cooler or con-
denser. Refrigerant overpressure may discharge through
the relief valves and result in the loss of refrigerant
charge.
7. Access the CONTROL TEST screen. Scroll down on the
TERMINATE LOCKOUT option. Press the SELECT (to
enable the chiller to start) and answer YES to restart unit
to operating mode. The chiller is locked out at the factory
in order to prevent accidental start-up.
Dry Run to Test Start-Up Sequence Fig. 29 — Correct Motor Rotation
1. Disengage the main motor disconnect on the starter front
panel. This should only disconnect the motor power. Power
to the controls, oil pump, and starter control circuit should
still be energized.
58
Check Oil Pressure and Compressor Stop REVIEW MAINTENANCE — Scheduled, routine, and
extended shutdowns, importance of a log sheet, importance
1. When the motor is at full speed, note the differential oil of water treatment and tube cleaning, and importance of main-
pressure reading on the CVC default screen. It should be taining a leak-free chiller.
between 18 and 30 psid (124 to 206 kPad).
2. Press the Stop button and listen for any unusual sounds SAFETY DEVICES AND PROCEDURES — Electrical dis-
from the compressor as it coasts to a stop. connects, relief device inspection, and handling refrigerant.
To Prevent Accidental Start-Up — A chiller STOP CHECK OPERATOR KNOWLEDGE — Start, stop, and shut-
override setting may be entered to prevent accidental start-up down procedures, safety and operating controls, refrigerant
and oil charging, and job safety.
during service or whenever necessary. Access the MAIN-
REVIEW THE START-UP, OPERATION, AND MAINTE-
STAT screen and using the NEXT or PREVIOUS soft- NANCE MANUAL.
keys, highlight the CHILLER START/STOP parameter. Override
the current START value by pressing the SELECT softkey.
Press the STOP softkey followed by the ENTER softkey. OPERATING INSTRUCTIONS
The word SUPVSR! displays on the CVC indicating the over-
ride is in place. Operator Duties
To restart the chiller the STOP override setting must be 1. Become familiar with the chiller and related equipment
removed. Access the MAINSTAT screen and using before operating the chiller.
NEXT or PREVIOUS softkeys highlight CHILLER 2. Prepare the system for start-up, start and stop the chiller,
START/STOP. The 3 softkeys that appear represent 3 choices: and place the system in a shutdown condition.
3. Maintain a log of operating conditions and document any
• START — forces the chiller ON abnormal readings.
• STOP — forces the chiller OFF 4. Inspect the equipment, make routine adjustments, and per-
• RELEASE — puts the chiller under remote or schedule form a Control Test. Maintain the proper oil and refrig-
erant levels.
control.
5. Protect the system from damage during shutdown
To return the chiller to normal control, press the periods.
RELEASE softkey followed by the ENTER softkey. For 6. Maintain the set point, time schedules, and other PIC
more information, see Local Start-Up, page 44. functions.
The default LID screen message line indicates which com-
mand is in effect. Prepare the Chiller for Start-Up — Follow the steps
described in the Initial Start-Up section, page 58.
Check Chiller Operating Condition — Check to
be sure that chiller temperatures, pressures, water flows, and To Start the Chiller
oil and refrigerant levels indicate the system is functioning 1. Start the water pumps, if they are not automatic.
properly. 2. On the CVC default screen, press the LOCAL or
Instruct the Customer Operator — Ensure the CCN softkey to start the system. If the chiller is in the
operator(s) understand all operating and maintenance pro- OCCUPIED mode and the start timers have expired, the
cedures. Point out the various chiller parts and explain their start sequence will start. Follow the procedure described
function as part of the complete system. in the Start-Up/Shutdown/Recycle section, page 44.
COOLER-CONDENSER — Float chamber, relief valves, re-
frigerant charging valve, temperature sensor locations, pres- Check the Running System — After the compres-
sure transducer locations, Schrader fittings, waterboxes and sor starts, the operator should monitor the CVC display and
tubes, and vents and drains. observe the parameters for normal operating conditions:
OPTIONAL PUMPOUT STORAGE TANK AND PUMP- 1. The oil reservoir temperature should be above 120 F
OUT SYSTEM — Transfer valves and pumpout system, (49 C) during shutdown and above 125 F (58 C) during
refrigerant charging and pumpdown procedure, and relief compressor operation.
devices. 2. The bearing oil temperature accessed on the COM-
MOTOR COMPRESSOR ASSEMBLY — Guide vane PRESS table should be 120 to 165 F (49 to 74 C). If the
actuator, transmission, motor cooling system, oil cooling bearing temperature reads more than 180 F (83 C) with
system, temperature and pressure sensors, oil sight glasses, the oil pump running, stop the chiller and determine the
integral oil pump, isolatable oil filter, extra oil and motor cause of the high temperature. Do not restart the chiller
temperature sensors, synthetic oil, and compressor until corrected.
serviceability. 3. The oil level should be visible anywhere in one of the
MOTOR COMPRESSOR LUBRICATION SYSTEM — Oil two sight glasses. Foaming oil is acceptable as long as
pump, cooler filter, oil heater, oil charge and specification, the oil pressure and temperature are within limits.
operating and shutdown oil level, temperature and pressure, 4. The oil pressure should be between 18 and 30 psid
and oil charging connections. (124 to 207 kPad) differential, as seen on the CVC de-
CONTROL SYSTEM — CCN and LOCAL start, reset, menu, fault screen. Typically the reading will be 18 to 25 psid
softkey functions, CVC operation, occupancy schedule, set (124 to 172 kPad) at initial start-up.
points, safety controls, and auxiliary and optional controls. 5. The moisture indicator sight glass on the refrigerant
AUXILIARY EQUIPMENT — Starters and disconnects, sepa- motor cooling line should indicate refrigerant flow and a
rate electrical sources, pumps, and cooling tower. dry condition.
DESCRIBE CHILLER CYCLES — Refrigerant, motor cool- 6. The condenser pressure and temperature varies with
ing, lubrication, and oil reclaim. the chiller design conditions. Typically the pressure will
range between 100 and 210 psig (690 to 1450 kPa)
59
with a corresponding temperature range of 60 to 105 F Check the cooler pressure on the CVC default screen and
(15 to 41 C). The condenser entering water temperature compare it to the original holding charge that was left in the
should be controlled below the specified design entering chiller. If (after adjusting for ambient temperature changes)
water temperature to save on compressor kilowatt any loss in pressure is indicated, check for refrigerant leaks.
requirements. See Check Chiller Tightness section, page 46.
7. Cooler pressure and temperature also will vary with the Recharge the chiller by transferring refrigerant from the
design conditions. Typical pressure range will be be- pumpout storage tank (if supplied). Follow the Pumpout and
tween 60 and 80 psig (410 and 550 kPa), with tempera- Refrigerant Transfer Procedures section, this page. Observe
ture ranging between 34 and 45 F (1 and 8 C). freeze-up precautions.
8. The compressor may operate at full capacity for a short Carefully make all regular preliminary and running sys-
time after the pulldown ramping has ended, even though tem checks. Perform a Control Test before start-up. If the
the building load is small. The active electrical demand compressor oil level appears abnormally high, the oil may
setting can be overridden to limit the compressor IkW, or have absorbed refrigerant. Ensure that the oil temperature is
the pulldown rate can be decreased to avoid a high above 140 F (60 C) or above the cooler refrigerant tempera-
demand charge for the short period of high demand ture plus 50° F (27° C).
operation. Pulldown rate can be based on load rate or tem-
perature rate. It is accessed on the Equipment SERVICE Cold Weather Operation — When the entering con-
screen, RAMP_DEM table (Table 2, Example 20). denser water temperature drops very low, the operator should
automatically cycle the cooling tower fans off to keep the
To Stop the Chiller temperature up. Piping may also be arranged to bypass the
1. The occupancy schedule starts and stops the chiller cooling tower. The PIC II controls have a low limit tower
automatically once the time schedule is configured. fan output that can be used to assist in this control (terminal
11 and 12 on ISM).
2. By pressing the STOP button for one second, the alarm
light blinks once to confirm the button has been pressed. Manual Guide Vane Operation — It is possible to
The compressor will then follow the normal shutdown manually operate the guide vanes in order to check con-
sequence as described in the Controls section. The chiller trol operation or to control the guide vanes in an emergency.
will not restart until the CCN or LOCAL softkey is Manual operation is possible by overriding the target guide
pressed. The chiller is now in the OFF control mode. vane position. Access the COMPRESS screen on the CVC
and scroll down to highlight TARGET GUIDE VANE
IMPORTANT: Do not attempt to stop the chiller by POS. To control the position, use the INCREASE or
opening an isolating knife switch. High intensity DECREASE softkey to adjust to the percentage of guide
arcing may occur.
vane opening that is desired. Zero percent is fully closed;
100% is fully open. To release the guide vanes to automatic
Do not restart the chiller until the problem is diagnosed
and corrected. control, press the RELEASE softkey.
NOTE: Manual control increases the guide vane openings
After Limited Shutdown — No special preparations and overrides the pulldown rate during start-up. Motor cur-
should be necessary. Follow the regular preliminary checks rent above the electrical demand setting, capacity overrides,
and starting procedures. and chilled water temperature below the control point over-
Preparation for Extended Shutdown — The ride the manual target and close the guide vanes. For
refrigerant should be transferred into the pumpout storage descriptions of capacity overrides and set points, see the
tank (if supplied; see Pumpout and Refrigerant Transfer Controls section.
Procedures) to reduce chiller pressure and the possibility Refrigeration Log — A refrigeration log (as shown in
of leaks. Maintain a holding charge of 5 to 10 lbs (2.27 to Fig. 30), is a convenient checklist for routine inspection and
4.5 kg) of refrigerant or nitrogen to prevent air from leaking maintenance and provides a continuous record of chiller
into the chiller. performance. It is also an aid when scheduling routine main-
If freezing temperatures are likely to occur in the chiller tenance and diagnosing chiller problems.
area, drain the chilled water, condenser water, and the pump- Keep a record of the chiller pressures, temperatures, and
out condenser water circuits to avoid freeze-up. Keep the liquid levels on a sheet similar to the one in Fig. 30. Auto-
waterbox drains open. matic recording of PIC II data is possible by using CCN
Leave the oil charge in the chiller with the oil heater devices such as the Data Collection module and a Build-
and controls energized to maintain the minimum oil reser- ing Supervisor. Contact a Carrier representative for more
voir temperature. information.
After Extended Shutdown — Ensure the water sys-
tem drains are closed. It may be advisable to flush the water
circuits to remove any soft rust which may have formed. This
is a good time to brush the tubes and inspect the Schrader
fittings on the waterside flow devices for fouling, if
necessary.
60
Date
REFRIGERATION LOG CARRIER 19XR HERMETIC CENTRIFUGAL REFRIGERATION MACHINE
Plant MACHINE MODEL NO. MACHINE SERIAL NO. REFRIGERANT TYPE
DATE COOLER CONDENSER COMPRESSOR

Refrigerant Water Refrigerant Water Oil Motor
OPER-
Pressure Temp Pressure Temp FLA ATOR REMARKS
BEARING Temp
TIME Press. Amperage INITIALS
Press. Temp Press. Temp TEMP (reser- Level
In Out GPM In Out In Out GPM In Out Diff. (or vane
voir)
position)
61
REMARKS: Indicate shutdowns on safety controls, repairs made, oil or refrigerant added or removed, air exhausted and water
drained from dehydrator. Include amounts.
Fig. 30 — Refrigeration Log
PUMPOUT AND REFRIGERANT 3. Refer to Fig. 26, 27, and 32 for valve locations and
TRANSFER PROCEDURES numbers.
Preparation — The 19XR may come equipped with an
optional pumpout storage tank, pumpout system, or pump-
out compressor. The refrigerant can be pumped for service Transfer, addition, or removal of refrigerant in spring-
work to either the chiller compressor vessel or chiller con- isolated chillers may place severe stress on external pip-
denser vessel by using the optional pumpout system. If a ing if springs have not been blocked in both up and down
pumpout storage tank is supplied, the refrigerant can be iso- directions.
lated in the storage tank. The following procedures describe
how to transfer refrigerant from vessel to vessel and perform
chiller evacuations.
Always run the chiller cooler and condenser water pumps

and always charge or transfer refrigerant as a gas when
the chiller pressure is less than 30 psig (207 kPa). Be-
low these pressures, liquid refrigerant flashes into gas,
resulting in extremely low temperatures in the cooler/
condenser tubes and possibly causing tube freeze-up.
During transfer of refrigerant into and out of the

optional storage tank, carefully monitor the storage LEGEND
tank level gage. Do not fill the tank more than 90% of C — Contactor
capacity to allow for refrigerant expansion. Overfilling FU — Fuse, 3 Amps
HP — High-Pressure Cutout
may result in damage to the tank or personal injury. OL — Compressor Overload
T’STAT — Internal Thermostat
Compressor Terminal
Contactor Terminal
Do not mix refrigerants from chillers that use different Overload Terminal
compressor oils. Compressor damage can result.
Pumpout Unit Terminal
*Bimetal thermal protector imbedded in motor winding.
Operating the Optional Pumpout Unit
Fig. 31 — 19XR Pumpout Unit Wiring Schematic
1. Be sure that the suction and the discharge service valves
on the optional pumpout compressor are open (back-
seated) during operation. Rotate the valve stem fully OIL RETURN
counterclockwise to open. Frontseating the valve closes LINE
the refrigerant line and opens the gage port to compres- CONNECTION
sor pressure.
2. Ensure that the compressor holddown bolts have been loos-
ened to allow free spring travel.
3. Open the refrigerant inlet valve on the pumpout
compressor.
4. Oil should be visible in the pumpout unit compressor sight
glass under all operating conditions and during shut-
down. If oil is low, add oil as described under Optional
Pumpout System Maintenance section, page 68. The pump-
out unit control wiring schematic is detailed in Fig. 31.
TO READ REFRIGERANT PRESSURES during pumpout
or leak testing:
1. The CVC display on the chiller control panel is suitable
for determining refrigerant-side pressures and low (soft)
vacuum. To assure the desired range and accuracy when
measuring evacuation and dehydration, use a quality vacuum CONDENSER REFRIGERANT
WATER
indicator or manometer. This can be placed on the Schrader CONNECTIONS
INLET VALVE
connections on each vessel (Fig. 7) by removing the pres-
sure transducer. Fig. 32 — Optional Pumpout Unit
2. To determine pumpout storage tank pressure, a 30 in.
-0-400 psi (-101-0-2769 kPa) gage is attached to the stor-
age tank.
62
Chillers with Storage Tanks — If the chiller has iso- TRANSFER REFRIGERANT FROM CHILLER TO
lation valves, leave them open for the following procedures. PUMPOUT STORAGE TANK
The letter ‘‘C’’ describes a closed valve. See Fig. 15, 16, 26, 1. Equalize refrigerant pressure.
and 27. a. Valve positions:
TRANSFER REFRIGERANT FROM PUMPOUT STOR- VALVE 1a 1b 2 3 4 5 6 7 8 10 11 12 13 14
AGE TANK TO CHILLER CONDITION C C C C C
1. Equalize refrigerant pressure.
a. Use the PIC II terminate lockout function on the PUMP- b. Slowly open valve 5. When the pressures are equal-
DOWN LOCKOUT screen, accessed from the CON- ized, open liquid line valve 7 to allow liquid refrig-
TROL TEST table to turn on the water pumps and erant to drain by gravity into the pumpout storage tank.
monitor pressures. VALVE 1a 1b 2 3 4 5 6 7 8 10 11 12 13 14
CONDITION C C C
If the chilled water and condenser water pumps are 2. Transfer the remaining liquid.
not controlled by the PIC II, these pumps must be a. Turn off the pumpout condenser water. Place the valves
started and stopped manually at the appropriate times in the following positions:
during the refrigerant transfer procedure. VALVE 1a 1b 2 3 4 5 6 7 8 10 11 12 13 14
CONDITION C C C
b. Close pumpout unit valves 2, 4, 5, 8, and 10, and close
chiller charging valve 7; open chiller isolation valves b. Run the pumpout compressor for approximately 30 min-
11, 12, 13, and 14 (if present). utes; then close valve 10.
c. Open pumpout unit/storage tank valves 3 and 6, open VALVE 1a 1b 2 3 4 5 6 7 8 10 11 12 13 14
chiller valves 1a and 1b. CONDITION C C C C
VALVE 1a 1b 2 3 4 5 6 7 8 10 11 12 13 14
CONDITION C C C C C C
c. Turn off the pumpout compressor.
3. Remove any remaining refrigerant.
d. Slowly open valve 5 to increase chiller pressure to a. Turn on the chiller water pumps using the PUMP-
68 psig 35 psig (141 kPa) for HFC-134a. Feed refrig- DOWN LOCKOUT screen, accessed from the CON-
erant slowly to prevent freeze up. TROL TEST table. Turn on the pumps manually, if
e. Open valve 5 fully after the pressure rises above the they are not controlled by the PIC II.
freeze point of the refrigerant. Open liquid line valves b. Turn on the pumpout condenser water.
7 and 10 until refrigerant pressure equalizes.
c. Place valves in the following positions:
VALVE 1a 1b 2 3 4 5 6 7 8 10 11 12 13 14
VALVE 1a 1b 2 3 4 5 6 7 8 10 11 12 13 14
CONDITION C C C
CONDITION C C C C
2. Transfer the remaining refrigerant.
d. Run the pumpout compressor until the chiller pres-
a. Close valve 5 and open valve 4. sure reaches 30 psig (207 kPa) for HFC-134a. Then,
VALVE 1a 1b 2 3 4 5 6 7 8 10 11 12 13 14
shut off the pumpout compressor. Warm condenser
CONDITION C C C
water will boil off any entrapped liquid refrigerant and
the chiller pressure will rise.
b. Turn off the chiller water pumps using the CVC (or e. When the pressure rises to 40 psig (276 kPa) for
manually, if necessary). HFC-134a, turn on the pumpout compressor until the
c. Turn off the pumpout condenser water, and turn on the pressure again reaches 30 psig (207 kPa), and then
pumpout compressor to push liquid out of the storage turn off the pumpout compressor. Repeat this process
tank. until the pressure no longer rises. Then, turn on the
pumpout compressor and pump until the pressure reaches
d. Close liquid line valve 7. 18 in. Hg. (40 kPa absolute).
e. Turn off the pumpout compressor. f. Close valves 1a, 1b, 3, 4, 6, 7, and 10.
f. Close valves 3 and 4.
VALVE 1a 1b 2 3 4 5 6 7 8 10 11 12 13 14
g. Open valves 2 and 5.
CONDITION C C C C C C C C C C
VALVE 1a 1b 2 3 4 5 6 7 8 10 11 12 13 14
CONDITION C C C C g. Turn off the pumpout condenser water and continue to
use the PIC II PUMPDOWN LOCKOUT screen func-
h. Turn on the pumpout condenser water. tions, which lock out the chiller compressor for
i. Run the pumpout compressor until the pumpout stor- operation.
age tank pressure reaches 5 psig (34 kPa) (18 in. Hg 4. Establish a vacuum for service.
[40 kPa absolute] if repairing the tank). To conserve refrigerant, operate the pumpout compressor
j. Turn off the pumpout compressor. until the chiller pressure is reduced to 18 in. Hg vac., ref
k. Close valves 1a, 1b, 2, 5, 6, and 10. 30 in. bar. (40 kPa abs.) following Step 3e.
VALVE 1a 1b 2 3 4 5 6 7 8 10 11 12 13 14
CONDITION C C C C C C C C C C
l. Turn off pumpout condenser water.
63
Chillers with Isolation Valves 2. Evacuate the refrigerant gas from the chiller condenser
vessel.
TRANSFER ALL REFRIGERANT TO CHILLER CON- a. Access the PUMPDOWN LOCKOUT function ac-
DENSER VESSEL — For chillers with isolation valves, cessed from the CVC CONTROL TEST table to turn
refrigerant can be stored in one chiller vessel or the other on the chiller water pumps. Turn the chiller water pumps
without the need for an external storage tank. on manually if they are not controlled by the PIC II.
1. Push refrigerant into the chiller condenser. b. Close pumpout unit valves 3 and 4; open valves 2
a. Valve positions: and 5.
VALVE 1a 1b 2 3 4 5 8 11 12 13 14 VALVE 1a 1b 2 3 4 5 8 11 12 13 14
CONDITION C C C C C C CONDITION C C C C C C C
b. Using the PIC II controls, turn off the chiller water c. Turn on the pumpout condenser water.
pumps and pumpout condenser water. If the chiller d. Run the pumpout compressor until the chiller con-
water pumps are not controlled through the PIC II, turn denser pressure reaches 18 in. Hg vac (40 kPa abs.).
them off manually. Monitor pressure at the CVC and at refrigerant gages.
c. Turn on the pumpout compressor to push the liquid e. Close valve 1b.
refrigerant out of the chiller cooler vessel.
f. Turn off the pumpout compressor.
d. When all liquid refrigerant has been pushed into
the chiller condenser vessel, close chiller isolation g. Close valves 1a, 2, and 5.
valve 11. VALVE 1a 1b 2 3 4 5 8 11 12 13 14
e. Access the PUMPDOWN LOCKOUT screen on the CONDITION C C C C C C C C C C C
PIC II CONTROL TEST table to turn on the chiller
water pumps. If the chiller water pumps are not con- h. Turn off the pumpout condenser water.
trolled by the PIC II, turn them on manually. i. Proceed to the PUMPDOWN LOCKOUT test from
f. Turn off the pumpout compressor. the CVC CONTROL TEST table to turn off the chill-
er water pumps and lock out the chiller compressor.
2. Evacuate the refrigerant gas from chiller cooler vessel. Turn off the chiller water pumps manually if they are
a. Close pumpout compressor valves 2 and 5, and open not controlled by the PIC II.
valves 3 and 4.
RETURN CHILLER TO NORMAL OPERATING
VALVE 1a 1b 2 3 4 5 8 11 12 13 14 CONDITIONS
CONDITION C C C C C C C
1. Ensure vessel that was opened has been evacuated.
b. Turn on the pumpout condenser water. 2. Access the TERMINATE LOCKOUT function CVC from
c. Run the pumpout compressor until the chiller cooler the CONTROL TEST table to view vessel pressures and
vessel pressure reaches 18 in. Hg vac (40 kPa abs.). turn on chiller water pumps. If the chiller water pumps
Monitor pressures on the CVC and on refrigerant gages. are not controlled by the PIC II, turn them on manually.
d. Close valve 1a. 3. Open valves 1a, 1b, and 3.
e. Turn off the pumpout compressor. VALVE 1a 1b 2 3 4 5 8 11 12 13 14
f. Close valves 1b, 3, and 4. CONDITION C C C C C C C C
VALVE 1a 1b 2 3 4 5 8 11 12 13 14 4. Slowly open valve 5, gradually increasing pressure in

CONDITION C C C C C C C C C C C the evacuated vessel to 35 psig (141 kPa). Feed refrig-
erant slowly to prevent tube freeze up.
g. Turn off the pumpout condenser water.
5. Leak test to ensure vessel integrity.
h. Proceed to the PUMPDOWN/LOCKOUT function
accessed from the CONTROL TEST table to turn off 6. Open valve 5 fully.
the chiller water pumps and lock out the chiller com- VALVE 1a 1b 2 3 4 5 8 11 12 13 14
pressor. Turn off the chiller water pumps manually if CONDITION C C C C C C C
they are not controlled by the PIC II.
7. Open valve 11 to equalize the liquid refrigerant level
TRANSFER ALL REFRIGERANT TO CHILLER COOLER between the vessels.
VESSEL
8. Close valves 1a, 1b, 3, and 5.
1. Push the refrigerant into the chiller cooler vessel.
9. Open isolation valves 12, 13, and 14 (if present).
a. Valve positions:
VALVE 1a 1b 2 3 4 5 8 11 12 13 14
VALVE 1a 1b 2 3 4 5 8 11 12 13 14
CONDITION C C C C C C C
CONDITION C C C C C C
10. Proceed to the TERMINATE LOCKOUT screen (ac-
b. Turn off the chiller water pumps (either through cessed from the CONTROL TEST table) to turn off the
the PIC II controls or manually, if necessary) and the water pumps and enable the chiller compressor for start-
pumpout condenser water. up. If the chiller water pumps are not controlled by the
c. Turn on the pumpout compressor to push the refrig- PIC II, turn them off manually.
erant out of the chiller condenser.
d. When all liquid refrigerant is out of the chiller con-
denser, close the cooler isolation valve 11.
e. Turn off the pumpout compressor.
64
GENERAL MAINTENANCE
Refrigerant Properties — The standard refrigerant for
the 19XR chiller is HFC-134a. At normal atmospheric pres- HFC-134a should not be mixed with air or oxygen and
sure, HFC-134a will boil at –14 F (–25 C) and must, there- pressurized for leak testing. In general, this refrigerant
fore, be kept in pressurized containers or storage tanks. The should not be present with high concentrations of air or
refrigerant is practically odorless when mixed with air oxygen above atmospheric pressures, because the mix-
and is noncombustible at atmospheric pressure. Read the ture can undergo combustion.
Material Safety Data Sheet and the latest ASHRAE Safety
Guide for Mechanical Refrigeration to learn more about safe REFRIGERANT TRACER — Use an environmentally
handling of this refrigerant. acceptable refrigerant as a tracer for leak test procedures.
TO PRESSURIZE WITH DRY NITROGEN — Another
method of leak testing is to pressurize with nitrogen only
HFC-134a will dissolve oil and some nonmetallic ma- and to use a soap bubble solution or an ultrasonic leak
terials, dry the skin, and, in heavy concentrations, may detector to determine if leaks are present.
displace enough oxygen to cause asphyxiation. When NOTE: Pressurizing with dry nitrogen for leak testing should
handling this refrigerant, protect the hands and eyes and only be done if all refrigerant has been evacuated from the
avoid breathing fumes. vessel.
1. Connect a copper tube from the pressure regulator on the
Adding Refrigerant — Follow the procedures de- cylinder to the refrigerant charging valve. Never apply
scribed in Trim Refrigerant Charge section, this page. full cylinder pressure to the pressurizing line. Follow the
listed sequence.
2. Open the charging valve fully.
Always use the compressor pumpdown function in the 3. Slowly open the cylinder regulating valve.
Control Test table to turn on the cooler pump and lock 4. Observe the pressure gage on the chiller and close the
out the compressor when transferring refrigerant. Liq- regulating valve when the pressure reaches test level. Do
uid refrigerant may flash into a gas and cause possible not exceed 140 psig (965 kPa).
freeze-up when the chiller pressure is below
30 psig (207 kPa) for HFC-134a. 5. Close the charging valve on the chiller. Remove the cop-
per tube if it is no longer required.
Removing Refrigerant — If the optional pumpout sys- Repair the Leak, Retest, and Apply Standing
tem is used, the 19XR refrigerant charge may be transferred Vacuum Test — After pressurizing the chiller, test for
to a pumpout storage tank or to the chiller condenser or cooler leaks with an electronic halide leak detector, soap bubble
vessels. Follow the procedures in the Pumpout and Refrig- solution, or an ultrasonic leak detector. Bring the chiller back
erant Transfer Procedures section when transferring refrig- to atmospheric pressure, repair any leaks found, and retest.
erant from one vessel to another. After retesting and finding no leaks, apply a standing vacuum
Adjusting the Refrigerant Charge — If the addi- test. Then dehydrate the chiller. Refer to the Standing Vacuum
tion or removal of refrigerant is required to improve chiller Test and Chiller Dehydration section (pages 48 and 51) in
performance, follow the procedures given under the Trim the Before Initial Start-Up section.
Refrigerant Charge section, this page. Checking Guide Vane Linkage — When the
Refrigerant Leak Testing — Because HFC-134a is chiller is off, the guide vanes are closed and the actuator
above atmospheric pressure at room temperature, leak test- mechanism is in the position shown in Fig. 33. If slack de-
ing can be performed with refrigerant in the chiller. Use an velops in the drive chain, do the following to eliminate
electronic halide leak detector, soap bubble solution, or ultra- backlash:
sonic leak detector. Ensure that the room is well ventilated 1. With the chiller shut down and the actuator fully closed,
and free from concentration of refrigerant to keep false read- remove the chain guard and loosen the actuator bracket
ings to a minimum. Before making any necessary repairs to holddown bolts.
a leak, transfer all refrigerant from the leaking vessel. 2. Loosen guide vane sprocket adjusting bolts.
Leak Rate — It is recommended byASHRAE that chill- 3. Pry bracket upwards to remove slack, then retighten the
ers be taken off line immediately and repaired if the refrig- bracket holddown bolts.
erant leak rate for the entire chiller is more than 10% of the 4. Retighten the guide vane sprocket adjusting bolts. En-
operating refrigerant charge per year. sure that the guide vane shaft is rotated fully in the clock-
In addition, Carrier recommends that leaks totalling less wise direction in order close it fully.
than the above rate but more than a rate of 0.1% of the total Trim Refrigerant Charge — If, to obtain optimal chiller
charge per year should be repaired during annual mainte- performance, it becomes necessary to adjust the refrigerant
nance or whenever the refrigerant is transferred for other serv- charge, operate the chiller at design load and then add or
ice work. remove refrigerant slowly until the difference between the
Test After Service, Repair, or Major Leak — If leaving chilled water temperature and the cooler refrigerant
all the refrigerant has been lost or if the chiller has been opened temperature reaches design conditions or becomes a mini-
for service, the chiller or the affected vessels must be pres- mum. Do not overcharge.
sure tested and leak tested. Refer to the Leak Test Chiller Refrigerant may be added either through the storage tank
section to perform a leak test. or directly into the chiller as described in the Charge
Refrigerant into Chiller section.
To remove any excess refrigerant, follow the procedure in
Transfer Refrigerant from Chiller to Pumpout Storage Tank
section, Steps 1a and b, page 63.
65
Service Ontime — The CVC will display a SERVICE
ONTIME value on the MAINSTAT screen. This value should
be reset to zero by the service person or the operator each
time major service work is completed so that the time be-
tween service can be viewed and tracked.
Inspect the Control Panel — Maintenance consists
of general cleaning and tightening of connections. Vacuum
the cabinet to eliminate dust build-up. If the chiller control
malfunctions, refer to the Troubleshooting Guide section for
control checks and adjustments.
Ensure power to the control center is off when cleaning

and tightening connections inside the control panel.
Check Safety and Operating Controls Monthly

— To ensure chiller protection, the automated Control Test
should be performed at least once per month. See Table 3
for safety control settings. See Table 6 for Control Test
functions.
Changing Oil Filter — Change the oil filter on a yearly
basis or when the chiller is opened for repairs. The 19XR
Fig. 33 — Guide Vane Actuator Linkage has an isolatable oil filter so that the filter may be changed
with the refrigerant remaining in the chiller. Use the follow-
ing procedure:
WEEKLY MAINTENANCE
1. Ensure the compressor is off and the disconnect for the
Check the Lubrication System — Mark the oil level compressor is open.
on the reservoir sight glass, and observe the level each week 2. Disconnect the power to the oil pump.
while the chiller is shut down.
3. Close the oil filter isolation valves located behind power
If the level goes below the lower sight glass, check the oil panel on top of oil pump assembly.
reclaim system for proper operation. If additional oil is re-
quired, add it through the oil drain charging valve (Fig. 2). 4. Connect an oil charging hose from the oil charging valve
A pump is required when adding oil against refrigerant pres- (Fig. 2) and place the other end in a clean container suit-
sure. The oil charge for the 19XR compressor depends on able for used oil. The oil drained from the filter hous-
the compressor Frame size: ing should be used as an oil sample and sent to a labo-
ratory for proper analysis. Do not contaminate this
• Frame 2 compressor — 5 gal (18.9 L) sample.
• Frame 3 compressor — 8 gal (30 L) 5. Slowly open the charging valve to drain the oil from the
• Frame 4 compressor — 10 gal (37.8 L) housing.
• Frame 5 compressor — 18 gal (67.8 L)
The added oil must meet Carrier specifications for the 19XR. The oil filter housing is at a high pressure. Relieve
Refer to Changing Oil Filter and Oil Changes section on this this pressure slowly.
page. Any additional oil that is added should be logged by
noting the amount and date. Any oil that is added due to oil
loss that is not related to service will eventually return to the 6. Once all oil has been drained, place some rags or
sump. It must be removed when the level is high. absorbent material under the oil filter housing to catch
any drips once the filter is opened. Remove the 4 bolts
An oil heater is controlled by the PIC II to maintain oil from the end of the filter housing and remove the filter
temperature (see the Controls section) when the compressor cover.
is off. The CVC COMPRESS screen displays whether the
heater is energized or not. The heater is energized if the OIL 7. Remove the filter retainer by unscrewing the retainer nut.
HEATER RELAY parameter reads ON. If the PIC II shows The filter may now be removed and disposed of
that the heater is energized and if the sump is still not heat- properly.
ing up, the power to the oil heater may be off or the oil level 8. Replace the old filter with a new filter. Install the filter
may be too low. Check the oil level, the oil heater contactor retainer and tighten down the retainer nut. Install the
voltage, and oil heater resistance. filter cover and tighten the 4 bolts.
The PIC II does not permit compressor start-up if the oil 9. Evacuate the filter housing by placing a vacuum pump
temperature is too low. The PIC II continues with start-up on the charging valve. Follow the normal evacuation
only after the temperature is within allowable limits. procedures. Shut the charging valve when done and
reconnect the valve so that new oil can be pumped into
SCHEDULED MAINTENANCE the filter housing. Fill with the same amount that was
removed; then close the charging valve.
Establish a regular maintenance schedule based on your
actual chiller requirements such as chiller load, run hours, 10. Remove the hose from the charging valve, open the iso-
and water quality. The time intervals listed in this section lation valves to the filter housing, and turn on the power
are offered as guides to service only. to the pump and the motor.
66
Oil Specification — If oil is added, it must meet the 3. Clean the chamber and valve assembly thoroughly. Be
following Carrier specifications: sure the valve moves freely. Ensure that all openings are
free of obstructions.
Oil Type for units using R-134a . . . . . . . . . . . . . . Inhibited
polyolester-based synthetic 4. Examine the cover gasket and replace if necessary.
compressor oil formatted for See Fig. 34 for a view of the float valve design. For linear
use with HFC, gear-driven, float valve designs, inspect the orientation of the float slide
hermetic compressors. pin. It must be pointed toward the bubbler tube for proper
ISO Viscosity Grade . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 operation.
The polyolester-based oil (P/N: PP23BZ103) may be

ordered from your local Carrier representative.
Oil Changes — Carrier recommends changing the oil
after the first year of operation and every five years there-
after as a minimum in addition to a yearly oil analysis. How-
ever, if a continuous oil monitoring system is functioning
and a yearly oil analysis is performed, the time between oil
changes can be extended.
TO CHANGE THE OIL
1. Transfer the refrigerant into the chiller condenser vessel
(for isolatable vessels) or to a pumpout storage tank.
2. Mark the existing oil level.
3. Open the control and oil heater circuit breaker.
4. When the chiller pressure is 5 psig (34 kPa) or less, drain
the oil reservoir by opening the oil charging valve
(Fig. 2). Slowly open the valve against refrigerant
pressure.
5. Change the oil filter at this time. See Changing Oil Filter
section.
6. Change the refrigerant filter at this time, see the next sec-
tion, Refrigerant Filter. LEGEND
7. Charge the chiller with oil. Charge until the oil level is 1 — Refrigerant Inlet from FLASC Chamber
equal to the oil level marked in Step 2. Turn on the power 2 — Linear Float Assembly
3 — Float Screen
to the oil heater and let the PIC II warm it up to at least 4 — Bubble Line
140 F (60 C). Operate the oil pump manually, using the 5 — Float Cover
Control Test function, for 2 minutes. For shutdown con- 6 — Bubble Line Connection
ditions, the oil level should be full in the lower sight glass. 7 — Refrigerant Outlet to Cooler
8 — Gasket
If the oil level is above 1⁄2 full in the upper sight glass,
remove the excess oil. The oil level should now be equal Fig. 34 — 19XR Float Valve Design
to the amount shown in Step 2.
Inspect Relief Valves and Piping — The relief valves
Refrigerant Filter — A refrigerant filter/drier, located on this chiller protect the system against the potentially dan-
on the refrigerant cooling line to the motor, should be changed gerous effects of overpressure. To ensure against damage to
once a year or more often if filter condition indicates a need the equipment and possible injury to personnel, these de-
for more frequent replacement. Change the filter by closing vices must be kept in peak operating condition.
the filter isolation valves (Fig. 4) and slowly opening the As a minimum, the following maintenance is required.
flare fittings with a wrench and back-up wrench to relieve
the pressure. A moisture indicator sight glass is located be- 1. At least once a year, disconnect the vent piping at the
yond this filter to indicate the volume and moisture in the valve outlet and carefully inspect the valve body and mecha-
refrigerant. If the moisture indicator indicates moisture, nism for any evidence of internal corrosion or rust, dirt,
locate the source of water immediately by performing a scale, leakage, etc.
thorough leak check. 2. If corrosion or foreign material is found, do not attempt
to repair or recondition. Replace the valve.
Oil Reclaim Filter — The oil reclaim system has a strainer
on the eductor suction line, a strainer on the discharge pres- 3. If the chiller is installed in a corrosive atmosphere or the
sure line, and a filter on the cooler scavenging line. Replace relief valves are vented into a corrosive atmosphere, in-
the filter once per year or more often if filter condition inspect the relief valves at more frequent intervals.
dicates a need for more frequent replacement. Change the Compressor Bearing and Gear Maintenance —
filter by closing the filter isolation valves and slowly open- The key to good bearing and gear maintenance is proper
ing the flare fitting with a wrench and back-up wrench to lubrication. Use the proper grade of oil, maintained at rec-
relieve the pressure. Change the strainers once every 5 years ommended level, temperature, and pressure. Inspect the
or whenever refrigerant is evacuated from the cooler. lubrication system regularly and thoroughly.
Inspect Refrigerant Float System — Perform this To inspect the bearings, a complete compressor teardown
inspection every 5 years or when the condenser is opened is required. Only a trained service technician should remove
for service. and examine the bearings. The cover plate on older com-
1. Transfer the refrigerant into the cooler vessel or into a pressor bases was used for factory-test purposes and is not
pumpout storage tank. usable for bearing or gear inspection. The bearings and gears
should be examined on a scheduled basis for signs of wear.
2. Remove the float access cover. The frequency of examination is determined by the hours of
67
chiller operation, load conditions during operation, and the Inspect the Starting Equipment — Before work-
condition of the oil and the lubrication system. Excessive ing on any starter, shut off the chiller and open all discon-
bearing wear can sometimes be detected through increased nects supplying power to the starter.
vibration or increased bearing temperature. If either symp-
tom appears, contact an experienced and responsible service
organization for assistance.
The disconnect on the starter front panel does not de-
Inspect the Heat Exchanger Tubes and Flow energize all internal circuits. Open all internal and
Devices remote disconnects before servicing the starter.
COOLER AND FLOW DEVICES — Inspect and clean the
cooler tubes at the end of the first operating season. Because
these tubes have internal ridges, a rotary-type tube cleaning Never open isolating knife switches while equipment is
system is needed to fully clean the tubes. Inspect the tubes’ operating. Electrical arcing can cause serious injury.
condition to determine the scheduled frequency for future
cleaning and to determine whether water treatment in the
chilled water/brine circuit is adequate. Inspect the entering Inspect starter contact surfaces for wear or pitting
and leaving chilled water temperature sensors and flow de- on mechanical-type starters. Do not sandpaper or file
vices for signs of corrosion or scale. Replace a sensor or silverplated contacts. Follow the starter manufacturer’s
Schrader fitting if corroded or remove any scale if found. instructions for contact replacement, lubrication, spare parts
ordering, and other maintenance requirements.
CONDENSER AND FLOW DEVICES — Since this water
circuit is usually an open-type system, the tubes may be sub- Periodically vacuum or blow off accumulated debris on
ject to contamination and scale. Clean the condenser tubes the internal parts with a high-velocity, low-pressure blower.
with a rotary tube cleaning system at least once per year and Power connections on newly installed starters may relax
more often if the water is contaminated. Inspect the entering and loosen after a month of operation. Turn power off and
and leaving condenser water sensors and flow devices for retighten. Recheck annually thereafter.
signs of corrosion or scale. Replace the sensor or Schrader
fitting if corroded or remove any scale if found.
Higher than normal condenser pressures, together with the Loose power connections can cause voltage spikes, over-
inability to reach full refrigeration load, usually indicate dirty heating, malfunctioning, or failures.
tubes or air in the chiller. If the refrigeration log indicates a
rise above normal condenser pressures, check the condenser
refrigerant temperature against the leaving condenser water Check Pressure Transducers — Once a year, the
temperature. If this reading is more than what the design dif- pressure transducers should be checked against a pressure
ference is supposed to be, the condenser tubes may be dirty gage reading. Check all eight transducers: the 2 oil differ-
or water flow may be incorrect. Because HFC-134a is a high- ential pressure transducers, the condenser pressure
pressure refrigerant, air usually does not enter the chiller. transducer, the cooler pressure transducer, and the waterside
pressure transducers (consisting of 4 flow devices: 2 cooler,
During the tube cleaning process, use brushes specially 2 condenser).
designed to avoid scraping and scratching the tube wall. Con-
tact your Carrier representative to obtain these brushes. Do Note the evaporator and condenser pressure readings on
not use wire brushes. the HEAT_EX screen on the CVC (EVAPORATOR PRES-
SURE and CONDENSER PRESSURE). Attach an accurate
set of refrigeration gages to the cooler and condenser Schrader
fittings. Compare the two readings. If there is a difference in
Hard scale may require chemical treatment for its pre- readings, the transducer can be calibrated as described in the
vention or removal. Consult a water treatment specialist Troubleshooting Guide section. Oil differential pressure (OIL
for proper treatment. PUMP DELTA P on the COMPRESS screen) should be zero
whenever the compressor is off.
Water Leaks — The refrigerant moisture indicator on Optional Pumpout System Maintenance — For
the refrigerant motor cooling line (Fig. 2) indicates whether pumpout unit compressor maintenance details, refer to the
there is water leakage during chiller operation. Water leaks 06D, 07D Installation, Start-Up, and Service Instructions.
should be repaired immediately.
OPTIONAL PUMPOUT COMPRESSOR OIL CHARGE —
Use oil conforming to Carrier specifications for reciprocat-
ing compressor usage. Oil requirements are as follows:
The chiller must be dehydrated after repair of water leaks. ISO Viscosity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
See Chiller Dehydration section, page 51.
Carrier Part Number . . . . . . . . . . . . . . . . . . . . PP23BZ103
Water Treatment — Untreated or improperly treated The total oil charge, 4.5 pints (2.6 L), consists of
water may result in corrosion, scaling, erosion, or algae. The 3.5 pints (2.0 L) for the compressor and one additional pint
services of a qualified water treatment specialist should be (0.6 L) for the oil separator.
obtained to develop and monitor a treatment program. Oil should be visible in one of the compressor sight glasses
during both operation and at shutdown. Always check the
oil level before operating the compressor. Before adding or
changing oil, relieve the refrigerant pressure as follows:
Water must be within design flow limits, clean, and treated
to ensure proper chiller performance and reduce the 1. Attach a pressure gage to the gage port of either com-
potential of tube damage due to corrosion, scaling, ero- pressor service valve (Fig. 33).
sion, and algae. Carrier assumes no responsibility for
chiller damage resulting from untreated or improperly
treated water.
68
2. Close the suction service valve and open the discharge • The CONTROL ALGORITHM STATUS screens (which
line to the storage tank or the chiller. include the CAPACITY, OVERRIDE, LL_MAINT,
3. Operate the compressor until the crankcase pressure drops ISM_HIST, LOADSHED, WSMDEFME, and OCCDEFCM
to 2 psig (13 kPa). screens) display information that helps to diagnose prob-
lems with chilled water temperature control, chilled water
4. Stop the compressor and isolate the system by closing temperature control overrides, hot gas bypass, surge al-
the discharge service valve. gorithm status, and time schedule operation.
5. Slowly remove the oil return line connection (Fig. 32). • The control test feature facilitates the proper operation and
Add oil as required. test of temperature sensors, pressure transducers, the guide
6. Replace the connection and reopen the compressor serv- vane actuator, oil pump, water pumps, tower control, and
ice valves. other on/off outputs while the compressor is stopped. It
OPTIONAL PUMPOUT SAFETY CONTROL SETTINGS also has the ability to lock off the compressor and turn on
(Fig. 35) — The optional pumpout system high-pressure switch water pumps for pumpout operation. The CVC shows the
opens at 161 psig (1110 kPa) and closes at 130 psig temperatures and pressures required during these
(896 kPa). Check the switch setting by operating the pump- operations.
out compressor and slowly throttling the pumpout con- • From other SERVICE tables, the operator/technician can
denser water. access configured items, such as chilled water resets, over-
ride set points, etc.
• If an operating fault is detected, an alarm message is gen-
erated and displayed on the CVC default screen. A more
detailed message — along with a diagnostic message —
is also stored into the ALARM HISTORY table.
Checking Display Messages — The first area to check
when troubleshooting the 19XR is the CVC display. If the
alarm light is flashing, check the primary and secondary mes-
sage lines on the CVC default screen (Fig. 12). These mes-
sages will indicate where the fault is occurring. These mes-
sages contain the alarm message with a specified code. This
code or state appears with each alarm and alert message. The
ALARM HISTORY table on the CVC SERVICE menu also
contains an alarm message to further expand on the alarm.
For a complete list of possible alarm messages, see Table 8.
If the alarm light starts to flash while accessing a menu screen,
press the EXIT softkey to return to the default screen to
read the alarm message. The STATUS screen can also be
accessed to determine where an alarm exists.
Checking Temperature Sensors — All tempera-
ture sensors are thermistor-type sensors. This means that the
resistance of the sensor varies with temperature. All sensors
Fig. 35 — Optional Pumpout System Controls have the same resistance characteristics. If the controls are
on, determine sensor temperature by measuring voltage drop;
if the controls are powered off, determine sensor tempera-
Ordering Replacement Chiller Parts — When ture by measuring resistance. Compare the readings to the
ordering Carrier specified parts, the following information values listed in Table 9A or 9B.
must accompany an order: RESISTANCE CHECK — Turn off the control power and,
• chiller model number and serial number from the module, disconnect the terminal plug of the sensor
• name, quantity, and part number of the part required in question. With a digital ohmmeter, measure sensor resis-
tance between receptacles as designated by the wiring dia-
• delivery address and method of shipment. gram. The resistance and corresponding temperature are listed
in Table 9A or 9B. Check the resistance of both wires to
ground. This resistance should be infinite.
TROUBLESHOOTING GUIDE VOLTAGE DROP — The voltage drop across any ener-
Overview — The PIC II has many features to help the gized sensor can be measured with a digital voltmeter while
operator and technician troubleshoot a 19XR chiller. the control is energized. Table 9A or 9B lists the relation-
ship between temperature and sensor voltage drop (volts dc
• The CVC shows the chiller’s actual operating conditions measured across the energized sensor). Exercise care when
and can be viewed while the unit is running. measuring voltage to prevent damage to the sensor leads,
• The CVC default screen freezes when an alarm occurs. connector plugs, and modules. Sensors should also be checked
The freeze enables the operator to view the chiller con- at the sensor plugs. Check the sensor wire at the sensor for
ditions at the time of alarm. The STATUS screens con- 5 vdc if the control is powered on.
tinue to show current information. Once all alarms have
been cleared (by correcting the problems and pressing the
RESET softkey), the CVC default screen returns to nor- Relieve all refrigerant pressure or drain the water be-
mal operation. fore replacing the temperature sensors.
69
CHECK SENSOR ACCURACY — Place the sensor in a CONDENSER PRESSURE parameter on the HEAT_EX
medium of known temperature and compare that temper- screen). To calibrate oil pressure or waterside flow de-
ature to the measured reading. The thermometer used to vice, view the particular reading (CHILLED WATER DELTA
determine the temperature of the medium should be of P and CONDENSER WATER DELTA P on the HEAT_EX
laboratory quality with 0.5° F (.25° C) graduations. The sen- screen, and OIL PUMP DELTA P on the COMPRESS
sor in question should be accurate to within 2° F (1.2° C). screen). It should read 0 psi (0 kPa). If the reading is not
See Fig. 7 for sensor locations. The sensors are immersed 0 psi
directly in the refrigerant or water circuits. The wiring at each (0 kPa), but within ± 5 psi (35 kPa), the value may be set
sensor is easily disconnected by unlatching the connector. to zero by pressing the SELECT softkey while the ap-
These connectors allow only one-way connection to the sen- propriate transducer parameter is highlighted on the CVC
sor. When installing a new sensor, apply a pipe sealant or
thread sealant to the sensor threads. screen. Then press the ENTER softkey. The value will
now go to zero. No high end calibration is necessary for
DUAL TEMPERATURE SENSORS — For servicing con- OIL PUMP DELTA P or flow devices.
venience, there are 2 sensors each on the bearing and motor
temperature sensors. If one of the sensors is damaged, the If the transducer value is not within the calibration range,
other can be used by simply moving a wire. The number 2 the transducer returns to the original reading. If the pres-
terminal in the sensor terminal box is the common line. To sure is within the allowed range (noted above), check the
use the second sensor, move the wire from the number 1 voltage ratio of the transducer. To obtain the voltage ra-
position to the number 3 position. tio, divide the voltage (dc) input from the transducer by
the supply voltage signal (displayed in CONTROL TEST
Checking Pressure Transducers — There are menu in the CCM PRESSURE TRANSDUCERS screen)
8 pressure transducers on 19XR chillers. They determine or measure across the positive (+ red) and negative
cooler, condenser, oil pressure, and cooler and condenser flow. (− black) leads of the transducer. For example, the con-
The cooler and condenser transducers are also used by the denser transducer voltage input is measured at CCM ter-
PIC II to determine the refrigerant temperatures. The oil sup- minals J2-4 and J2-5. The voltage ratio must be between
ply pressure transducer value and the oil transmission sump 0.80 and 0.11 for the software to allow calibration. Pres-
pressure transducer value difference is calculated by the CCM. surize the transducer until the ratio is within range. Then
The CCM module then displays the differential pressure. In attempt calibration again.
effect, the CCM reads only one input for oil pressure for a 4. A high pressure point can also be calibrated between 25
total of 5 pressure inputs: cooler pressure, condenser pres- and 250 psig (172.4 and 1723.7 kPa) by attaching a regu-
sure, oil differential pressure, cooler waterside differential lated 250 psig (1724 kPa) pressure (usually from
pressure, and condenser waterside differential pressure. See a nitrogen cylinder). The high pressure point can be cali-
the Check Pressure Transducers section (page 68) under Sched- brated by accessing the appropriate transducer parameter
uled Maintenance. on the HEAT_EX screen, highlighting the parameter, press-
These 5 pressure transducers can be calibrated if neces- ing the SELECT softkey, and then using the
sary. It is not usually necessary to calibrate at initial start-up.
However, at high altitude locations, it is necessary to cali- INCREASE or DECREASE softkeys to adjust the
brate the transducers to ensure the proper refrigerant value to the exact pressure on the refrigerant gage. Press
temperature/pressure relationship. Each transducer is sup- the ENTER softkey to finish the calibration. Pressures
plied with 5 vdc power from the CCM. If the power supply
fails, a transducer voltage reference alarm occurs. If the trans- at high altitude locations must be compensated for, so the
ducer reading is suspected of being faulty, check the supply chiller temperature/pressure relationship is correct.
voltage. It should be 5 vdc ± .5 v displayed in CONTROL The PIC II does not allow calibration if the transducer is
TEST under CCM Pressure Transducers. If the supply too far out of calibration. In this case, a new transducer must
voltage is correct, the transducer should be recalibrated or be installed and re-calibrated.
replaced. TRANSDUCER REPLACEMENT — Since the trans-
COOLER CONDENSER PRESSURE TRANSDUCER AND ducers are mounted on Schrader-type fittings, there is no
WATERSIDE FLOW DEVICE CALIBRATION — Cali- need to remove refrigerant from the vessel when replacing
bration can be checked by comparing the pressure readings the transducers. Disconnect the transducer wiring by pulling
from the transducer to an accurate refrigeration gage read- up on the locking tab while pulling up on the weather-tight
ing. These readings can be viewed or calibrated from the connecting plug from the end of the transducer. Do not pull
HEAT_EX screen on the CVC. The transducer can be checked on the transducer wires. Unscrew the transducer from the
and calibrated at 2 pressure points. These calibration points Schrader fitting. When installing a new transducer, do not
are 0 psig (0 kPa) and between 25 and 250 psig (173 and use pipe sealer (which can plug the sensor). Put the plug
1724 kPa). To calibrate these transducers: connector back on the sensor and snap into place. Check for
1. Shut down the compressor, cooler, and condenser pumps. refrigerant leaks.
NOTE: There should be no flow through the heat
exchangers.
2. Disconnect the transducer in question from its Schrader Be sure to use a back-up wrench on the Schrader fitting
fitting for cooler or condenser transducer calibration. For whenever removing a transducer, since the Schrader fit-
oil pressure or flow device calibration keep transducer in ting may back out with the transducer, causing a large
place. leak and possible injury to personnel.
NOTE: If the cooler or condenser vessels are at 0 psig
(0 kPa) or are open to atmospheric pressure, the trans- Control Algorithms Checkout Procedure — One
ducers can be calibrated for zero without removing the of the tables on the CVC SERVICE menu is CONTROL
transducer from the vessel. ALGORITHM STATUS. The maintenance screens may
3. Access the HEAT_EX screen and view the particular be viewed from the CONTROL ALGORITHM STATUS
transducer reading (the EVAPORATOR PRESSURE or table to see how a particular control algorithm is operating.
70
These maintenance screens are very useful in helping to Control Test — The Control Test feature can check all
determine how the control temperature is calculated and guide the thermistor temperature sensors, pressure transducers, pumps
vane positioned and for observing the reactions from load and their associated flow devices, the guide vane actuator,
changes, control point overrides, hot gas bypass, surge pre- and other control outputs such as hot gas bypass. The tests
vention, etc. The tables are: can help to determine whether a switch is defective or a pump
relay is not operating, as well as other useful troubleshoot-
CAPACITY Capacity This table shows all values ing issues. During pumpdown operations, the pumps are en-
Control used to calculate the chilled ergized to prevent freeze-up and the vessel pressures and
water/brine control point. temperatures are displayed. The Pumpdown/Lockout fea-
OVERRIDE Override Details of all chilled water con- ture prevents compressor start-up when there is no refrig-
Status trol override values.
erant in the chiller or if the vessels are isolated. The Termi-
HEAT_EX Surge/ The surge and hot gas bypass nate Lockout feature ends the Pumpdown/Lockout after the
HGBP control algorithm status is
Status viewed from this screen. All pumpdown procedure is reversed and refrigerant is added.
values dealing with this control
are displayed.
LL_MAINT LEAD/LAG Indicates LEAD/LAG operation
Status status.
OCCDEFCM Time The Local and CCN occupied
Schedules schedules are displayed here
Status to help the operator quickly de-
termine whether the schedule LEGEND TO TABLES 8A - 8J
is in the 9occupied9 mode or
not. CCM — Chiller Control Module
CVC — Chiller Visual Control
WSMDEFME Water The water system manager is a CHW — Chilled Water
System CCN module that can turn on ISM — Integrated Starter Module
Manager the chiller and change the PIC II — Product Integrated Control II
Status chilled water control point. This VFD — Variable Frequency Drive
screen indicates the status of
this system.
Table 8 — CVC Primary and Secondary Messages and

Custom Alarm/Alert Messages with Troubleshooting Guides
A. MANUAL STOP
PRIMARY MESSAGE SECONDARY MESSAGE PROBABLE CAUSE/REMEDY

MANUALLY STOPPED — PRESS CCN OR LOCAL TO START PIC II in OFF mode, press CCN or LOCAL softkey to start unit.
TERMINATE PUMPDOWN MODE TO SELECT CCN OR LOCAL Enter the CONTROL TEST table and select TERMINATE LOCKOUT to
unlock compressor.
SHUTDOWN IN PROGRESS COMPRESSOR UNLOADING Chiller unloading before shutdown due to soft/stop feature.
SHUTDOWN IN PROGRESS COMPRESSOR DEENERGIZED Chiller compressor is being commanded to stop. Water pumps are
deenergized within one minute.
ICE BUILD OPERATION COMPLETE Chiller shutdown from Ice Build operation.
B. READY TO START

READY TO START IN XX MIN UNOCCUPIED MODE Time schedule for PIC II is unoccupied. Chillers will start only when
occupied.
READY TO START IN XX MIN REMOTE CONTACTS OPEN Remote contacts are open. Close contacts to start.
READY TO START IN XX MIN STOP COMMAND IN EFFECT Chiller START/STOP on MAINSTAT manually forced to stop. Release
point to start.
READY TO START IN XX MIN OCCUPIED MODE Chiller timer counting down. Unit ready to start.
READY TO START IN XX MIN REMOTE CONTACTS CLOSED Chiller timer counting down. Unit ready to start. Remote contact enabled
and closed.
READY TO START IN XX MIN START COMMAND IN EFFECT Chiller START/STOP on MAINSTAT manually forced to start. Release
value to start under normal control.
READY TO START IN XX MIN RECYCLE RESTART PENDING Chiller in recycle mode.
READY TO START UNOCCUPIED MODE Time schedule for PIC II is unoccupied. Chiller will start when occupied.
Make sure the time and date are correct. Change values in TIME AND
DATE screen.
READY TO START REMOTE CONTACTS OPEN Remote contacts have stopped the chiller. Close contacts to start.
READY TO START STOP COMMAND IN EFFECT Chiller START/STOP on MAINSTAT manually forced to stop. Release
point to start.
READY TO START OCCUPIED MODE Chiller timers complete, unit start will commence.
READY TO START REMOTE CONTACTS CLOSED Chiller timer counting down. Unit ready for start.
READY TO START START COMMAND IN EFFECT Chiller START/STOP on MAINSTAT has been manually forced to start.
Chiller will start regardless of time schedule or remote contact status.
STARTUP INHIBITED LOADSHED IN EFFECT CCN loadshed module commanding chiller top stop.
71
Custom Alarm/Alert Messages with Troubleshooting Guides (cont)
C. IN RECYCLE SHUTDOWN
RECYCLE RESTART PENDING OCCUPIED MODE Unit in recycle mode, chilled water temperature is not sufficiently above
set point to start.
RECYCLE RESTART PENDING REMOTE CONTACT CLOSED Unit in recycle mode, chilled water temperature is not sufficiently above
set point to start.
RECYCLE RESTART PENDING START COMMAND IN EFFECT Chiller START/STOP on MAINSTAT manually forced to start, chilled
water temperature is not sufficiently above set point to start.
RECYCLE RESTART PENDING ICE BUILD MODE Chiller in ICE BUILD mode. Chilled fluid temperature is satisfied for ICE
BUILD conditions.
D. PRE-START ALERTS: These alerts only delay start-up. When alert is corrected, the start-up will continue. No reset is necessary.
STATE PRIMARY SECONDARY ALARM MESSAGE ADDITIONAL CAUSE/REMEDY

MESSAGE MESSAGE PRIMARY CAUSE
100 PRESTART STARTS LIMIT 100->Excessive compressor Depress the RESET softkey if additional start is
ALERT EXCEEDED starts (8 in 12 hours) required. Reassess start-up requirements.
101 PRESTART HIGH BEARING 101->Comp Thrust Bearing Check oil heater for proper operation.
ALERT TEMPERATURE Temp [VALUE] exceeded Check for low oil level, partially closed coil supply
limit of [LIMIT]*. valves, clogged oil filters, etc.
Check the sensor wiring and accuracy.
Check configurable range in SETUP1 screen.
102 PRESTART HIGH MOTOR 102->Comp Motor Winding Check motor sensors for wiring and accuracy.
ALERT TEMPERATURE Temp [VALUE] exceeded Check motor cooling line for proper operation, or
limit of [LIMIT]*. restrictions.
Check for excessive starts within a short time span.
103 PRESTART HIGH DISCHARGE 103->Comp Discharge Allow discharge sensor to cool.
ALERT TEMP Temp [VALUE] exceeded Check for sensor wiring and accuracy.
limit of [LIMIT]*. Check for excessive starts.
104 PRESTART LOW REFRIGERANT 104->Evaporator Refrig Check transducer wiring and accuracy.
ALERT TEMP Temp [VALUE] exceeded Check for low chilled fluid supply temperatures.
limit of [LIMIT]*. Check refrigerant charge.
105 PRESTART LOW OIL 105->Oil Sump Temp Check oil heater contactor/relay and power.
ALERT TEMPERATURE [VALUE] exceeded limit of Check oil level and oil pump operation.
[LIMIT]*.
106 PRESTART HIGH CONDENSER 106->Condenser Pressure Check transducer wiring and accuracy.
ALERT PRESSURE [VALUE] exceeded limit of Check for high condenser water temperatures.
[LIMIT]*.
107 PRESTART LOW LINE 107->Average Line Voltage Check voltage supply. Check voltage transformers.
ALERT VOLTAGE [VALUE] exceeded limit of Consult power utility if voltage is low.
[LIMIT]*.
108 PRESTART HIGH LINE 108->Average Line Voltage Check voltage supply.
ALERT VOLTAGE [VALUE] exceeded limit of Check power transformers.
[LIMIT]*. Consult power utility if voltage is high.
109 PRESTART GUIDE VANE 109->Actual Guide Vane Calibrate guide vane actuator in Control Test.
ALERT CALIBRATION Pos Calibration Required
Before Start-Up
*[LIMIT] is shown on the CVC as temperature, pressure, voltage, etc., predefined or selected by the operator as an override or an alert. [VALUE]
is the actual pressure, temperature, voltage, etc., at which the control tripped.
E. START-UP IN PROGRESS
PRIMARY MESSAGE SECONDARY MESSAGE
CAUSE/REMEDY
STARTUP IN PROGRESS OCCUPIED MODEChiller is starting. Time schedule is occupied.
STARTUP IN PROGRESS REMOTE CONTACT CLOSED
Chiller is starting. Remote contacts are enabled and closed.
STARTUP IN PROGRESS START COMMAND IN EFFECT
Chiller is starting. Chiller START/STOP in MAINSTAT manually
forced to start.
AUTORESTART IN PROGRESS OCCUPIED MODE Chiller is starting after power failure. Time schedule is occupied.
AUTORESTART IN PROGRESS REMOTE CONTACT CLOSED Chiller is starting after power failure. Remote contacts are enabled
and closed.
AUTORESTART IN PROGRESS START COMMAND IN EFFECT Chiller is starting after power failure. Chiller START/STOP on MAINSTAT
manually forced to start.
72
F. NORMAL RUN
PRIMARY MESSAGE SECONDARY MESSAGE CAUSE/REMEDY

RUNNING — RESET ACTIVE 4-20 mA SIGNAL Auto chilled water reset active based on external input.
RUNNING — RESET ACTIVE REMOTE TEMP SENSOR Auto chilled water reset active based on external input.
RUNNING — RESET ACTIVE CHW TEMP DIFFERENCE Auto chilled water reset active based on cooler D T.
RUNNING — TEMP CONTROL LEAVING CHILLED WATER Default method of temperature control.
RUNNING — TEMP CONTROL ENTERING CHILLED WATER Entering Chilled Water (ECW) control enabled in TEMP_CTL screen.
RUNNING — TEMP CONTROL TEMPERATURE RAMP LOADING Ramp Loading in effect. Use RAMP_DEM screen to modify.
RUNNING — DEMAND LIMITED BY DEMAND RAMP LOADING Ramp Loading in effect. Use RAMP_DEM screen to modify.
RUNNING — DEMAND LIMITED BY LOCAL DEMAND SETPOINT Demand limit set point is less than actual demand.
RUNNING — DEMAND LIMITED BY 4-20 mA SIGNAL Demand limit is active based on external auto demand limit option.
RUNNING — DEMAND LIMITED BY CCN SIGNAL Demand limit is active based on control limit signal from CCN.
RUNNING — DEMAND LIMITED BY LOADSHED/REDLINE Demand limit is active based on LOADSHED screen set-up.
RUNNING — TEMP CONTROL HOT GAS BYPASS Hot gas bypass option is energized. See surge prevention in the control
section.
RUNNING — DEMAND LIMITED BY LOCAL SIGNAL Active demand limit manually overridden on MAINSTAT table.
RUNNING — TEMP CONTROL ICE BUILD MODE Chiller is running under Ice Build temperature control.
G. NORMAL RUN WITH OVERRIDES
STATE PRIMARY SECONDARY ALARM MESSAGE ADDITIONAL

MESSAGE MESSAGE PRIMARY CAUSE CAUSE/REMEDY
120 RUN CAPACITY HIGH CONDENSER 120->Condenser Pressure Check for high condenser water temperatures.
LIMITED PRESSURE [VALUE] exceeded limit of Check setting in SETUP1.
[LIMIT]*.
121 RUN CAPACITY HIGH MOTOR 121->Comp Motor Winding Check motor cooling lines.
LIMITED TEMPERATURE Temp [VALUE] exceeded Check for closed valves.
limit of [LIMIT]*. Check setting in SETUP1.
122 RUN CAPACITY LOW EVAP 122->Evaporator Refrig Check refrigerant charge.
LIMITED REFRIG TEMP Temp [VALUE] exceeded Check for low entering cooler temperatures.
limit of [LIMIT]*.
123 RUN CAPACITY HIGH COMPRESSOR 123->Surge Prevention Check for high condenser water temperatures or low
LIMITED LIFT Override: Lift Too High For suction temperature.
Compressor.
124 RUN CAPACITY MANUAL GUIDE 124->Run Capacity Limited: Target guide vane point has been forced in
LIMITED VANE TARGET Manual Guide Vane Target. MAINSTAT screen. Release force to continue normal
operation.
125 RUN CAPACITY LOW DISCHARGE No messages. Check oil charge.
LIMITED SUPERHEAT Check refrigerant charge.
*[LIMIT] is shown on the CVC as the temperature, pressure, voltage, etc., set point predefined or selected by the operator as an override, alert, or
alarm condition. [VALUE] is the actual pressure, temperature, voltage, etc., at which the control has recorded at the time of the fault condition.
H. OUT-OF-RANGE SENSOR ALARMS

260 SENSOR LEAVING CHILLED 260->Sensor Fault: Check sensor resistance or voltage drop.
FAULT WATER Leaving Chilled Water Check for proper wiring.
261 SENSOR ENTERING CHILLED 261->Sensor Fault: Check sensor resistance or voltage drop.
FAULT WATER Entering Chilled Water Check for proper wiring.
262 SENSOR CONDENSER 262->Sensor Fault: Check sensor wiring.
FAULT PRESSURE Condenser Pressure
263 SENSOR EVAPORATOR 263->Sensor Fault: Check sensor wiring.
FAULT PRESSURE Evaporator Pressure
264 SENSOR COMPRESSOR 264->Sensor Fault: Check sensor resistance or voltage drop.
FAULT BEARING TEMP Comp Thrust Bearing Temp Check for proper wiring.
265 SENSOR COMPRESSOR 265->Sensor Fault: Check sensor resistance or voltage drop.
FAULT MOTOR TEMP Comp Motor Winding Temp Check for proper wiring.
266 SENSOR COMP DISCHARGE 266->Sensor Fault: Check sensor resistance or voltage drop.
FAULT TEMP Comp Discharge Temp Check for proper wiring.
267 SENSOR OIL SUMP TEMP 267->Sensor Fault: Check sensor resistance or voltage drop.
FAULT Oil Sump Temp Check for proper wiring.
268 SENSOR COMP OIL 268->Sensor Fault: Check sensor wiring and accuracy.
FAULT PRESS DIFF Oil Pump Delta P
269 SENSOR CHILLED WATER 269->Sensor Fault: Check sensor wiring and accuracy.
FAULT FLOW Chilled Water Delta P
270 SENSOR COND WATER 270->Sensor Fault: Check sensor wiring and accuracy.
FAULT FLOW Cond Water Delta P
73
I. CHILLER PROTECT LIMIT FAULTS

200 PROTECTIVE 1M CONTACT 200->1M Aux Contact Fault;
LIMIT FAULT Check 1M Contactor and
Aux
201 PROTECTIVE 2M CONTACT 201->2M Aux Contact Fault;
LIMIT FAULT Check 2M Contactor and
Aux
202 PROTECTIVE MOTOR AMPS 202->Motor Amps Not Check for wiring of current transformers to the ISM.
LIMIT NOT SENSED Sensed — Average Line Check main circuit breaker for trip.
Current [VALUE]
203 FAILURE TO EXCESS 203->Motor Acceleration Check to be sure that the inlet guide vanes are
START ACCELERATION Fault — Average Line closed at start-up.
TIME Current [VALUE] Check starter for proper operation.
Reduce unit pressure if possible.
204 FAILURE TO 1M/2M CONTACT 208->1M/2M Aux Contact
STOP FAULT Stop Fault; Check 1M/2M
Contactors and Aux
205 FAILURE TO MOTOR AMPS 205->Motor Amps When
STOP WHEN STOPPED Stopped — Average Line
Current [VALUE]
206 PROTECTIVE STARTER 206->Starter Fault Cutout;
LIMIT FAULT Check Optional Starter
Contacts
207 PROTECTIVE HIGH CONDENSER 207->High Cond Pressure Check for high condenser water temperatures, low
LIMIT PRESSURE cutout. [VALUE] exceeded water flow, fouled tubes.
limit of [LIMIT]*. Check for division plate/gasket bypass.
Check for noncondensables.
Check transducer wiring and accuracy.
208 PROTECTIVE EXCESSIVE 208->Compressor Motor Check motor current for proper calibration.
LIMIT MOTOR AMPS Amps [VALUE] exceeded Check inlet guide vane actuator.
limit of [LIMIT]*.
209 PROTECTIVE LINE PHASE 209->Line Phase Loss; Check transformers to ISM.
LIMIT LOSS Check ISM Fault History to Check power distribution bus.
Identify Phase Consult power company.
210 PROTECTIVE LINE VOLTAGE 210->Single Cycle Line
LIMIT DROPOUT Voltage Dropout
211 PROTECTIVE HIGH LINE 211->High Average Line Check transformers to ISM.
LIMIT VOLTAGE Voltage [VALUE] Check distribution bus.
Consult power company.
212 PROTECTIVE LOW LINE 212->Low Average Line Check transformers to ISM.
LIMIT VOLTAGE Voltage [VALUE] Check distribution bus.
213 PROTECTIVE STARTER MODULE 213->Starter Module
LIMIT RESET Power-On Reset When
Running
214 PROTECTIVE POWER LOSS 214->Power Loss: Check transformers to ISM.
LIMIT Check voltage supply Check distribution bus.
215 PROTECTIVE LINE CURRENT 215->Line Current
LIMIT IMBALANCE Imbalance; Check ISM Fault
History to Identify Phase
216 PROTECTIVE LINE VOLTAGE 216->Line Voltage
LIMIT IMBALANCE Imbalance; Check ISM Fault
History to Identify Phase
217 PROTECTIVE MOTOR OVERLOAD 217->Motor Overload Trip; Check ISM configuration.
LIMIT TRIP Check ISM configurations
218 PROTECTIVE MOTOR LOCKED 218->Motor Locked Rotor Check ISM configuration.
LIMIT ROTOR TRIP Amps exceeded; Check
Motor & ISM Config
219 PROTECTIVE STARTER LOCK 219->Starter Locked Rotor Check ISM configuration.
LIMIT ROTOR TRIP Amps Rating exceeded
220 PROTECTIVE GROUND FAULT 220->Ground Fault Trip;
LIMIT Check Motor and Current
Transformers
221 PROTECTIVE PHASE REVERSAL 221->Phase Reversal Trip;
LIMIT TRIP Check Power Supply
222 PROTECTIVE LINE FREQUENCY 222->Line Frequency —
LIMIT TRIP [VALUE] exceeded limit
of [LIMIT]. Check Power
Supply.
223 PROTECTIVE STARTER MODULE 223->Starter Module
LIMIT FAILURE Hardware Failure
74
I. CHILLER PROTECT LIMIT FAULTS (cont)

227 PROTECTIVE OIL PRESS 227->Oil Pump Delta P Check transducer wiring and accuracy.
LIMIT SENSOR FAULT [VALUE] exceeded limit of Check power supply to pump
[LIMIT]*. Check pump operation.
Check transducer calibration.
228 PROTECTIVE LOW OIL 228->Oil Pump Delta P Check transducer wiring and accuracy.
LIMIT PRESSURE [VALUE] exceeded limit of Check power supply to pump.
[LIMIT].* Check pump operation.
Check oil level.
Check for partially closed service valves.
Check oil filters.
Check for foaming oil at start-up.
229 PROTECTIVE LOW CHILLED 229->Low Chilled Water Flow; Perform pump control test.
LIMIT WATER FLOW Check Delta P Config & Check transducer accuracy and wiring.
Calibration Check water valves.
230 PROTECTIVE LOW CONDENSER 230->Low Condenser Water Perform pump control test.
LIMIT WATER FLOW Flow; Check Delta P Config & Check transducer accuracy and wiring.
Calibration Check water valves.
231 PROTECTIVE HIGH DISCHARGE 231->Comp Discharge Temp Check sensor resistance or voltage drop.
LIMIT TEMP [VALUE] exceeded limit of Check for proper wiring.
[LIMIT].* Check for proper condenser flow and
temperature.
Check for proper inlet guide vane and diffuser
actuator operation.
Check for fouled tubes or noncondensables in the
system.
232 PROTECTIVE LOW REFRIGERANT 232->Evaporator Refrig Temp Check for proper refrigerant charge.
LIMIT TEMP [VALUE] exceeded limit of Check float operation.
[LIMIT]*. Check for proper fluid flow and temperature.
Check for proper inlet guide vane operation.
233 PROTECTIVE HIGH MOTOR 233->Comp Motor Winding Check motor sensors wiring and accuracy.
LIMIT TEMPERATURE Temp [VALUE] exceeded limit Check motor cooling line for proper operation,
of [LIMIT]*. or restrictions.
Check for excessive starts within a short time
span.
234 PROTECTIVE HIGH BEARING 234->Comp Thrust Bearing Check oil heater for proper operation.
LIMIT TEMPERATURE Temp [VALUE] exceeded limit Check for low oil level, partially closed oil supply
of [LIMIT]*. valves, clogged oil filters, etc.
Check the sensor wiring and accuracy.
235 PROTECTIVE HIGH CONDENSER 235->Condenser Pressure Check for high condenser water temperatures,
LIMIT PRESSURE [VALUE] exceeded limit of low water flow, fouled tubes.
[LIMIT]*. Check for division plate/gasket bypass.
Check for noncondensables.
236 PROTECTIVE CCN OVERRIDE 236->CCN Override Stop while CCN has signaled the chiller to stop. Reset and
LIMIT STOP in LOCAL run mode restart when ready. If the signal was sent by the
CVC, release the stop signal on the STATUS01
table.
237 PROTECTIVE SPARE SAFETY 237->Spare Safety Device Spare safety input has tripped or factory installed
LIMIT DEVICE jumper is not present.
238 PROTECTIVE EXCESSIVE 238->Compressor Surge: Check condenser flow and temperatures.
LIMIT COMPR SURGE Check condenser water temp Check surge protection configuration.
and flow
239 PROTECTIVE TRANSDUCER 239->Transducer Voltage Ref
LIMIT VOLTAGE FAULT [VALUE] exceeded limit of
[LIMIT]*.
240 PROTECTIVE LOW DISCHARGE 240->Check for Oil in
LIMIT SUPERHEAT Refrigerant or Overcharge of
Refrigerant
241 LOSS OF WITH STARTER 241->Loss of Communication Check wiring to ISM.
COMMUNICATION MODULE With Starter.
242 LOSS OF WITH CCM 242->Loss of Communication Check wiring to CCM.
COMMUNICATION MODULE With CCM.
243 POTENTIAL EVAP PRESS/TEMP 243->Evaporator Refrig Temp Check for proper refrigerant charge.
FREEZE-UP TOO LOW [VALUE] exceeded limit of Check float operation.
[LIMIT]*. Check for proper fluid flow and temperature.
Check for proper inlet guide vane operation.
244 POTENTIAL COND PRESS/TEMP 244->Condenser Refrig Temp
FREEZE-UP TOO LOW [VALUE] exceeded limit of
[LIMIT]*.
245 PROTECTIVE VFD SPEED 245->Actual VFD Speed
LIMIT OUT OF RANGE [VALUE] exceeded limit of
[LIMIT]*.
75
I. CHILLER PROTECT LIMIT FAULTS (cont)

246 PROTECTIVE INVALID DIFFUSER 246->Diffuser Control Invalid Check diffuser/inlet guide vane schedule.
LIMIT CONFIG Configuration:
Check SETUP2 Entries.
247 PROTECTIVE DIFFUSER POSITION 247->Diffuser Position Fault: Check rotating stall transducer wiring and
LIMIT FAULT Check Guide Vane and Diffuser accuracy.
Actuators Check diffuser schedule.
Check for proper operation of diffuser actuator
and inlet guide vane actuator.
Check diffuser coupling.
Check inlet guide vane operation.
Check inlet guide vane calibration.
Check diffuser/inlet guide vane schedule.
Check diffuser mechanical set-up for proper
orientation.
If not using variable diffuser, check that the option
has not been enabled.
248 PROTECTIVE SPARE TEMPERATURE 248->Spare Temperature #1
LIMIT #1 [VALUE] exceeded limit of
[LIMIT]*.
249 PROTECTIVE SPARE TEMPERATURE 249->Spare Temperature #2
LIMIT #2 [VALUE] exceeded limit of
[LIMIT]*.
alarm condition. [VALUE] is the actual pressure, temperature, voltage, etc., at which the control tripped.
J. CHILLER ALERTS

140 SENSOR ALERT LEAVING COND 140->Sensor Fault: Check sensor resistance or voltage drop.
WATER TEMP Check Leaving Cond Water Check for proper wiring.
Sensor
141 SENSOR ALERT ENTERING COND 141->Sensor Fault: Check sensor resistance or voltage drop.
WATER TEMP Check Entering Cond Water Check for proper wiring.
Sensor
142 LOW OIL PRESSURE CHECK OIL 142->Low Oil Pressure Alert. Check for partially or closed shut-off valves.
ALERT FILTER Check Oil Filter. Check oil filter.
Check oil pump and power supply.
Check oil level.
Check for foaming oil at start-up.
143 AUTORESTART LINE PHASE 143->Line Phase Loss Power loss has been detected in any phase.
PENDING LOSS Chiller automatically restarting.
144 AUTORESTART LINE VOLTAGE 144->Single Cycle Line A drop in line voltage has been detected within
PENDING DROP OUT Voltage Dropout 2 voltage cycles. Chiller automatically restarting if
restart is enabled.
145 AUTORESTART HIGH LINE 145->Line Overvoltage — Check line power.
PENDING VOLTAGE Average Line Volt [VALUE]
146 AUTORESTART LOW LINE 146->Line Undervoltage — Check line power.
PENDING VOLTAGE Average Line Volt [VALUE]
147 AUTORESTART STARTER MODULE 147->Starter Module Power-On ISM has detected a hardware fault and has reset.
PENDING RESET Reset When Running Chiller automatically restarting.
148 AUTORESTART POWER LOSS 148->Control Power-Loss Check control power.
PENDING When Running
149 SENSOR ALERT HIGH DISCHARGE 149->Comp Discharge Temp Check sensor resistance or voltage drop.
TEMP [VALUE] exceeded limit of Check for proper wiring.
[LIMIT]*. Check for proper condenser flow and
temperature.
Check for high lift or low load.
Check for proper inlet guide vane and diffuser
actuator operation (XR5 Only).
Check for fouled tubes or noncondensables in the
refrigerant system.
150 SENSOR ALERT HIGH BEARING 150->Comp Thrust Bearing Check sensor resistance or voltage drop.
TEMPERATURE Temp [VALUE] exceeded limit Check for proper wiring.
of [LIMIT]*. Check for partially closed service valves.
Check oil cooler TXV.
Check oil filter.
Check oil level.
76
J. CHILLER ALERTS (cont)

151 CONDENSER PRESSURE PUMP RELAY 151->High Condenser Check sensor wiring and accuracy.
ALERT ENERGIZED Pressure [VALUE]: Pump Check condenser flow and fluid temperature.
Energized to Reduce Check for fouled tubes. This alarm is not
Pressure. caused by the High Pressure Switch.
152 RECYCLE EXCESSIVE RECYCLE 152->Excessive recycle starts. Chiller load is too low to keep compressor on
ALERT STARTS line and there has been more than 5 starts in
4 hours. Increase chiller load, adjust hot gas
bypass, increase RECYCLE RESTART DELTA
T from SETUP1 Screen.
153 no message: no message; 153->Lead/Lag Disabled: Illegal chiller address configuration in Lead/
ALERT only ALERT only Duplicate Chiller Address; Lag screen. Both chillers require a different
Check Configuration address.
154 POTENTIAL COND PRESS/TEMP 154->Condenser freeze up The condenser pressure transducer is reading
FREEZE-UP TOO LOW prevention a pressure that could freeze the condenser
tubes.
Check for condenser refrigerant leaks.
Check fluid temperature.
Check sensor wiring and accuracy.
Place the chiller in PUMPDOWN mode if the
vessel is evacuated.
155 OPTION SENSOR REMOTE RESET 155->Sensor Fault/Option Check sensor resistance or voltage drop.
FAULT SENSOR Disabled: Check for proper wiring.
Remote Reset Sensor
156 OPTION SENSOR AUTO CHILLED 156->Sensor Fault/Option Check sensor resistance or voltage drop.
FAULT WATER RESET Disabled: Check for proper wiring.
Auto Chilled Water Reset
157 OPTION SENSOR AUTO DEMAND 157->Sensor Fault/Option Check sensor resistance or voltage drop.
FAULT LIMIT INPUT Disabled: Check for proper wiring.
Auto Demand Limit Input
158 SENSOR ALERT SPARE TEMPERATURE 158->Spare Temperature #1 Check sensor resistance or voltage drop.
#1 [VALUE] exceeded limit of Check for proper wiring.
[LIMIT].*
159 SENSOR ALERT SPARE TEMPERATURE 159->Spare Temperature #2 Check sensor resistance or voltage drop.
#2 [VALUE] exceeded limit of Check for proper wiring.
[LIMIT].*
160 DIFFUSER DIFFUSER 160->Diffuser Position Alert; Check diffuser configuration in SETUP2
ALERT POSITION Check Diffuser Configuration. screen.
alarm condition. [VALUE] is the actual pressure, temperature, voltage, etc., at which the control tripped.
77
Table 9A — Thermistor Temperature (F) vs Resistance/Voltage Drop
TEMPERATURE VOLTAGE RESISTANCE TEMPERATURE VOLTAGE RESISTANCE TEMPERATURE VOLTAGE RESISTANCE
(F) DROP (V) (Ohms) (F) DROP (V) (Ohms) (F) DROP (V) (Ohms)
−25 4.821 98,010 60 3.409 7,665 145 1.211 1,141
−24 4.818 94,707 61 3.382 7,468 146 1.192 1,118
−23 4.814 91,522 62 3.353 7,277 147 1.173 1,095
−22 4.806 88,449 63 3.323 7,091 148 1.155 1,072
−21 4.800 85,486 64 3.295 6,911 149 1.136 1,050
−20 4.793 82,627 65 3.267 6,735 150 1.118 1,029
−19 4.786 79,871 66 3.238 6,564 151 1.100 1,007
−18 4.779 77,212 67 3.210 6,399 152 1.082 986
−17 4.772 74,648 68 3.181 6,238 153 1.064 965
−16 4.764 72,175 69 3.152 6,081 154 1.047 945
−15 4.757 69,790 70 3.123 5,929 155 1.029 925
−14 4.749 67,490 71 3.093 5,781 156 1.012 906
−13 4.740 65,272 72 3.064 5,637 157 0.995 887
−12 4.734 63,133 73 3.034 5,497 158 0.978 868
−11 4.724 61,070 74 3.005 5,361 159 0.962 850
−10 4.715 59,081 75 2.977 5,229 160 0.945 832
−9 4.705 57,162 76 2.947 5,101 161 0.929 815
−8 4.696 55,311 77 2.917 4,976 162 0.914 798
−7 4.688 53,526 78 2.884 4,855 163 0.898 782
−6 4.676 51,804 79 2.857 4,737 164 0.883 765
−5 4.666 50,143 80 2.827 4,622 165 0.868 750
−4 4.657 48,541 81 2.797 4,511 166 0.853 734
−3 4.648 46,996 82 2.766 4,403 167 0.838 719
−2 4.636 45,505 83 2.738 4,298 168 0.824 705
−1 4.624 44,066 84 2.708 4,196 169 0.810 690
0 4.613 42,679 85 2.679 4,096 170 0.797 677
1 4.602 41,339 86 2.650 4,000 171 0.783 663
2 4.592 40,047 87 2.622 3,906 172 0.770 650
3 4.579 38,800 88 2.593 3,814 173 0.758 638
4 4.567 37,596 89 2.563 3,726 174 0.745 626
5 4.554 36,435 90 2.533 3,640 175 0.734 614
6 4.540 35,313 91 2.505 3,556 176 0.722 602
7 4.527 34,231 92 2.476 3,474 177 0.710 591
8 4.514 33,185 93 2.447 3,395 178 0.700 581
9 4.501 32,176 94 2.417 3,318 179 0.689 570
10 4.487 31,202 95 2.388 3,243 180 0.678 561
11 4.472 30,260 96 2.360 3,170 181 0.668 551
12 4.457 29,351 97 2.332 3,099 182 0.659 542
13 4.442 28,473 98 2.305 3,031 183 0.649 533
14 4.427 27,624 99 2.277 2,964 184 0.640 524
15 4.413 26,804 100 2.251 2,898 185 0.632 516
16 4.397 26,011 101 2.217 2,835 186 0.623 508
17 4.381 25,245 102 2.189 2,773 187 0.615 501
18 4.366 24,505 103 2.162 2,713 188 0.607 494
19 4.348 23,789 104 2.136 2,655 189 0.600 487
20 4.330 23,096 105 2.107 2,597 190 0.592 480
21 4.313 22,427 106 2.080 2,542 191 0.585 473
22 4.295 21,779 107 2.053 2,488 192 0.579 467
23 4.278 21,153 108 2.028 2,436 193 0.572 461
24 4.258 20,547 109 2.001 2,385 194 0.566 456
25 4.241 19,960 110 1.973 2,335 195 0.560 450
26 4.223 19,393 111 1.946 2,286 196 0.554 445
27 4.202 18,843 112 1.919 2,239 197 0.548 439
28 4.184 18,311 113 1.897 2,192 198 0.542 434
29 4.165 17,796 114 1.870 2,147 199 0.537 429
30 4.145 17,297 115 1.846 2,103 200 0.531 424
31 4.125 16,814 116 1.822 2,060 201 0.526 419
32 4.103 16,346 117 1.792 2,018 202 0.520 415
33 4.082 15,892 118 1.771 1,977 203 0.515 410
34 4.059 15,453 119 1.748 1,937 204 0.510 405
35 4.037 15,027 120 1.724 1,898 205 0.505 401
36 4.017 14,614 121 1.702 1,860 206 0.499 396
37 3.994 14,214 122 1.676 1,822 207 0.494 391
38 3.968 13,826 123 1.653 1,786 208 0.488 386
39 3.948 13,449 124 1.630 1,750 209 0.483 382
40 3.927 13,084 125 1.607 1,715 210 0.477 377
41 3.902 12,730 126 1.585 1,680 211 0.471 372
42 3.878 12,387 127 1.562 1,647 212 0.465 367
43 3.854 12,053 128 1.538 1,614 213 0.459 361
44 3.828 11,730 129 1.517 1,582 214 0.453 356
45 3.805 11,416 130 1.496 1,550 215 0.446 350
46 3.781 11,112 131 1.474 1,519 216 0.439 344
47 3.757 10,816 132 1.453 1,489 217 0.432 338
48 3.729 10,529 133 1.431 1,459 218 0.425 332
49 3.705 10,250 134 1.408 1,430 219 0.417 325
50 3.679 9,979 135 1.389 1,401 220 0.409 318
51 3.653 9,717 136 1.369 1,373 221 0.401 311
52 3.627 9,461 137 1.348 1,345 222 0.393 304
53 3.600 9,213 138 1.327 1,318 223 0.384 297
54 3.575 8,973 139 1.308 1,291 224 0.375 289
55 3.547 8,739 140 1.291 1,265 225 0.366 282
56 3.520 8,511 141 1.289 1,240
57 3.493 8,291 142 1.269 1,214
58 3.464 8,076 143 1.250 1,190
59 3.437 7,868 144 1.230 1,165
78
Table 9B — Thermistor Temperature (C) vs Resistance/Voltage Drop
TEMPERATURE VOLTAGE RESISTANCE TEMPERATURE VOLTAGE RESISTANCE
(C) DROP (V) (Ohms) (C) DROP (V) (Ohms)
−40 4.896 168 230 45 1.898 2 184
−39 4.889 157 440 46 1.852 2 101
−38 4.882 147 410 47 1.807 2 021
−37 4.874 138 090 48 1.763 1 944
−36 4.866 129 410 49 1.719 1 871
−35 4.857 121 330 50 1.677 1 801
−34 4.848 113 810 51 1.635 1 734
−33 4.838 106 880 52 1.594 1 670
−32 4.828 100 260 53 1.553 1 609
−31 4.817 94 165 54 1.513 1 550
−30 4.806 88 480 55 1.474 1 493
−29 4.794 83 170 56 1.436 1 439
−28 4.782 78 125 57 1.399 1 387
−27 4.769 73 580 58 1.363 1 337
−26 4.755 69 250 59 1.327 1 290
−25 4.740 65 205 60 1.291 1 244
−24 4.725 61 420 61 1.258 1 200
−23 4.710 57 875 62 1.225 1 158
−22 4.693 54 555 63 1.192 1 118
−21 4.676 51 450 64 1.160 1 079
−20 4.657 48 536 65 1.129 1 041
−19 4.639 45 807 66 1.099 1 006
−18 4.619 43 247 67 1.069 971
−17 4.598 40 845 68 1.040 938
−16 4.577 38 592 69 1.012 906
−15 4.554 38 476 70 0.984 876
−14 4.531 34 489 71 0.949 836
−13 4.507 32 621 72 0.920 805
−12 4.482 30 866 73 0.892 775
−11 4.456 29 216 74 0.865 747
−10 4.428 27 633 75 0.838 719
−9 4.400 26 202 76 0.813 693
−8 4.371 24 827 77 0.789 669
−7 4.341 23 532 78 0.765 645
−6 4.310 22 313 79 0.743 623
−5 4.278 21 163 80 0.722 602
−4 4.245 20 079 81 0.702 583
−3 4.211 19 058 82 0.683 564
−2 4.176 18 094 83 0.665 547
−1 4.140 17 184 84 0.648 531
0 4.103 16 325 85 0.632 516
1 4.065 15 515 86 0.617 502
2 4.026 14 749 87 0.603 489
3 3.986 14 026 88 0.590 477
4 3.945 13 342 89 0.577 466
5 3.903 12 696 90 0.566 456
6 3.860 12 085 91 0.555 446
7 3.816 11 506 92 0.545 436
8 3.771 10 959 93 0.535 427
9 3.726 10 441 94 0.525 419
10 3.680 9 949 95 0.515 410
11 3.633 9 485 96 0.506 402
12 3.585 9 044 97 0.496 393
13 3.537 8 627 98 0.486 385
14 3.487 8 231 99 0.476 376
15 3.438 7 855 100 0.466 367
16 3.387 7 499 101 0.454 357
17 3.337 7 161 102 0.442 346
18 3.285 6 840 103 0.429 335
19 3.234 6 536 104 0.416 324
20 3.181 6 246 105 0.401 312
21 3.129 5 971 106 0.386 299
22 3.076 5 710 107 0.370 285
23 3.023 5 461
24 2.970 5 225
25 2.917 5 000
26 2.864 4 786
27 2.810 4 583
28 2.757 4 389
29 2.704 4 204
30 2.651 4 028
31 2.598 3 861
32 2.545 3 701
33 2.493 3 549
34 2.441 3 404
35 2.389 3 266
36 2.337 3 134
37 2.286 3 008
38 2.236 2 888
39 2.186 2 773
40 2.137 2 663
41 2.087 2 559
42 2.039 2 459
43 1.991 2 363
44 1.944 2 272
79
Control Modules Notes on Module Operation
1. The chiller operator monitors and modifies configura-
tions in the microprocessor by using the 4 softkeys and
Turn controller power off before servicing controls. This the CVC. Communications between the CVC and the CCM
ensures safety and prevents damage to the controller. is accomplished through the SIO (Sensor Input/Output)
bus, which is a phone cable. The communication be-
The CVC, CCM, and ISM modules perform continuous tween the CCM and ISM is accomplished through the sen-
diagnostic evaluations of the hardware to determine its con- sor bus, which is a 3-wire cable.
dition. Proper operation of all modules is indicated by LEDs 2. If a green LED is on continuously, check the communi-
(light-emitting diodes) located on the circuit board of the CVC, cation wiring. If a green LED is off, check the red LED
CCM, and ISM. operation. If the red LED is normal, check the module
There is one green LED located on the CCM and ISM address switches (Fig. 36-38).
boards respectively, and one red LED located on the CVC, All system operating intelligence resides in the CVC. Some
CCM, and ISM boards respectively. safety shutdown logic resides in the ISM in case com-
RED LED (Labeled as STAT) — If the red LED: munications are lost between the ISM and CVC. Outputs
• blinks continuously at a 2-second interval, the module is are controlled by the CCM and ISM as well.
operating properly 3. Power is supplied to the modules within the control panel
• is lit continuously, there is a problem that requires replac- via 24-vac power sources.
ing the module The transformers are located within the power panel, with
• is off continuously, the power should be checked the exception of the ISM, which operates from a 115-vac
• blinks 3 times per second, a software error has been dis- power source and has its own 24-vac transformer located
covered and the module must be replaced in the module.
If there is no input power, check the fuses and circuit breaker. In the power panel, T1 supplies power to the compressor
If the fuse is good, check for a shorted secondary of the oil heater, oil pump, and optional hot gas bypass, and T2
transformer or, if power is present to the module, replace the supplies power to both the CVC and CCM.
module.
Power is connected to Plug J1 on each module.
GREED LED (Labeled as COM) — These LEDs indicate
the communication status between different parts of the con-
troller and the network modules and should blink continu-
ously.
J5 J1 J7 MODULE PART #
KEYPAD POWER/CCN SIO SOFTWARE PART #
STAT
CONTRAST BACK OF CVC J8

(CHILLER VISUAL SERVICE
CONTROLLER)
Fig. 36 — Rear of CVC (Chiller Visual Controller)
80
Chiller Control Module (CCM) (Fig. 37) 8. Access the MAINSTAT table and highlight the TOTAL
COMPRESSOR STARTS parameter. Press the
INPUTS — Each input channel has 2 or 3 terminals. Refer
to individual chiller wiring diagrams for the correct terminal SELECT softkey. Increase or decrease the value to
numbers for your application. match the starts value recorded in Step 3. Press the
OUTPUTS — Output is 24 vac. There are 2 terminals per ENTER softkey when you reach the correct value. Now,
output. Refer to the chiller wiring diagram for your specific move the highlight bar to the COMPRESSOR ONTIME
application for the correct terminal numbers. parameter. Press the SELECT softkey. Increase or de-
crease the run hours value to match the value recorded
Integrated Starter Module (Fig. 38)
in Step 2. Press the ENTER softkey when the correct
INPUTS — Inputs on strips J3-5 and J3 are analog and dis- value is reached.
crete (on/off) inputs. The specific application of the chiller
determines which terminals are used. Refer to the individual 9. Complete the CVC installation. Following the instruc-
chiller wiring diagram for the correct terminal numbers for tions in the Input Service Configurations section,
your application. page 53, input all the proper configurations such as the
time, date, etc. Check the pressure transducer calibra-
OUTPUTS — Outputs are 24 vac and wired to strip J9. There tions. PSIO installation is now complete.
are 2 terminals per output.
Solid-State Starters — Troubleshooting information
Replacing Defective Processor Modules — The pertaining to the Benshaw, Inc., solid-state starter may be
module replacement part number is printed on a small label found in the following paragraphs and in the Carrier RE-
on the rear of the CVC module. The chiller model and DISTART MICRO Instruction Manual supplied by the starter
serial numbers are printed on the chiller nameplate located vendor.
on an exterior corner post. The proper software is factory- Attempt to solve the problem by using the following pre-
installed by Carrier in the replacement module. When liminary checks before consulting the troubleshooting tables
ordering a replacement chiller visual control (CVC) module, found in the Benshaw manual.
specify the complete replacement part number, full chiller
model number, and chiller serial number. The installer must
configure the new module to the original chiller data. Fol-
low the procedures described in the Software Configuration 1. Motor terminals or starter output lugs or wire should
section on page 53. not be touched without disconnecting the incoming
power supply. The silicon control rectifiers (SCRs)
although technically turned off still have AC mains
potential on the output of the starter.
Electrical shock can cause personal injury. Disconnect
all electrical power before servicing. 2. Power is present on all yellow wiring throughout the
system even though the main circuit breaker in the
unit is off.
INSTALLATION
1. Verify the existing CVC module is defective by using With power off:
the procedure described in the Troubleshooting Guide • Inspect for physical damage and signs of arcing, overheat-
section, page 69, and the Control Modules section, ing, etc.
page 80. Do not select the ATTACH TO NETWORK • Verify the wiring to the starter is correct.
DEVICE table if the CVC indicates a communication • Verify all connections in the starter are tight.
failure. • Check the control transformer fuses.
2. Data regarding the CVC configuration should have been TESTING SILICON CONTROL RECTIFIERS IN THE
recorded and saved. This data must be reconfigured into BENSHAW, INC., SOLID-STATE STARTERS — If an SCR
the new CVC. If this data is not available, follow the is suspected of being defective, use the following pro-
procedures described in the Software Configuration cedure as part of a general troubleshooting guide.
section.
1. Verify power is applied.
If a CCN Building Supervisor or Service Tool is avail-
able, the module configuration should have already been 2. Verify the state of each SCR light-emitting diode (LED)
uploaded into memory. When the new module is in- on the micropower card.
stalled, the configuration can be downloaded from the NOTE: All LEDs should be lit. If any red or green side
computer. of these LEDs is not lit, the line voltage is not present
Any communication wires from other chillers or CCN or one or more SCRs has failed.
modules should be disconnected to prevent the new CVC 3. Check incoming power. If voltage is not present check
module from uploading incorrect run hours into memory. the incoming line. If voltage is present, proceed to
3. To install this module, record values for the TOTAL COM- Steps 4 through 11.
PRESSOR STARTS and the COMPRESSOR ONTIME NOTE: If after completing Steps 4 - 11 all mea-
from the MAINSTAT screen on the CVC. surements are within specified limits, the SCRs are
4. Power off the controls. functioning normally. If after completing Steps 4 - 11
resistance measurements are outside the specified
5. Remove the old CVC. limits, the motor leads on the starter power lugs T1 through
6. Install the new CVC module. Turn the control power T6 should be removed and the steps repeated. This will
back on. identify if abnormal resistance measurements are being
7. The CVC now automatically attaches to the local net- influenced by the motor windings.
work device. 4. Remove power from the starter unit.
81
J11 J12
DISCRETE DISCRETE J1
OUTPUTS OUTPUTS 24 VAC
ANALOG OUT
J8
SIO
J7
SIO
J6
SW2
V/I INPUTS
J5
STAT COMM THERMISTORS DIFF PRESSURE PRESSURE

J4 J3 J2
Fig. 37 — Chiller Control Module (CCM)
J9 J8 J7 COM STAT
INTEGRATED STARTER MODULE
J1 FUSE J2 J3-1 J3-2 J3-3 J4 J5 J6
Fig. 38 — Integrated Starter Module (ISM)
82
5. Using an ohmmeter, perform the following resistance
measurements and record the results:
SCR PAIRS
Care must be taken to prevent nut rotation while tight-
MEASURE BEING RECORDED ening the bolts. If the nut rotates while tighting the
BETWEEN CHECKED VALUE bolt, SCR replacement must be started over.
T1 and T6 3 and 6
T2 and T4 2 and 5 6. Reconnect the red (cathode) wire from the SCR and the
T3 and T5 1 and 4 white (anode-gate) wire to the appropriate location on
the firing card (i.e., SCR1 wires to firing card terminal
If all measured values are greater than 5K ohms, pro- G1-white wire, and K1-red wire).
ceed to Step 10. If any values are less than 5K ohms, 7. Reconnect all other wiring and bus work.
one or more of the SCRs in that pair is shorted. 8. Return starter to normal operation.
6. Remove both SCRs in the pair (See SCR Removal/
Installation).
7. Using an ohmmeter, measure the resistance (anode to
cathode) of each SCR to determine which device has
failed.
NOTE: Both SCRs may be defective, but typically, only NUT
LOOSEN
one is shorted. If both SCRs provide acceptable resis- AND
CLAMPING
tance measurements, proceed to Step 10. BOLT TIGHTEN
A BOLTS
8. Replace the defective SCR(s). ALUMINUM FROM
HEATSINK THIS END
9. Retest the ‘‘pair’’ for resistance values indicated above.
10. On the right side of the firing card, measure the resis- ROLL PIN
tance between the red and white gate/cathode leads for
each SCR (1 through 6). A measurement between 5 and SCR
50 ohms is normal. Abnormally high values may indi-
cate a failed gate for that SCR.
If any red or white SCR gate leads are removed SCR PART CLAMP A NO OF BOLT
NUMBER SIZE DIMENSION TURNS LENGTH
from the firing card or an SCR, care must be taken BISCR (in.) (in.)
to ensure the leads are replaced EXACTLY as they 2.75 3.0
were (white wires to gates, and red wires to cath- 6601218 1030 ( 70 mm) 1 ⁄2
1
( 76 mm)
odes on both the firing card and SCR), or damage 2.75 3.0
to the starter and/or motor may result. 6601818 1030 11⁄2
( 70 mm) ( 76 mm)
2.75 3.5
8801230 1035 ( 70 mm) 13⁄4
( 89 mm)
11. Replace the SCRs and retest the pair. 2.75 3.0
8801830 1035 ( 70 mm) 13⁄4
( 89 mm)
SCR REMOVAL/INSTALLATION — Refer to Fig. 39. 4.00 4.0
15001850 2040 23⁄4
1. Remove the SCR by loosening the clamping bolts on each (102 mm) (102 mm)
side of the SCR, 4.00 5.0
15001850 2050 (102 mm) 23⁄4
(127 mm)
2. After the SCR has been removed and the bus work is loose, 220012100 Consult Benshaw Representative
apply a thin coat of either silicon based thermal joint com- 330018500 Consult Benshaw Representative
pound or a joint compound for aluminum or copper wire
connections to the contact surfaces of the replacement SCR. Fig. 39 — SCR Installation
This allows for improved heat dissipation and electrical
conductivity.
3. Place the SCR between the roll pins on the heatsink as-
semblies so the roll pins fit into the small holes in each
side of the SCR.
NOTE: Ensure the SCR is installed so the cathode side is
the side from which the red wire extends. The heatsink is
labeled to show the correct orientation.
4. Hand tighten the bolts until the SCR contacts the
heatsink.
5. Using quarter-turn increments, alternating between clamp-
ing bolts, apply the appropriate number of whole turns
referencing the table in Fig. 39.
83
Physical Data — Tables 10A-17 and Fig. 40-47 pro- and wiring schematics for the operator’s convenience during
vide additional information on component weights, com- troubleshooting.
pressor fits and clearances, physical and electrical data,
Table 10A — Heat Exchanger Data (English)
ENGLISH
NUMBER OF
TUBES Dry (Rigging) Weight Chiller Charge
(lb)
CODE
Refrigerant Water Volume
Cooler Condenser Cooler Condenser Weight (gal)
Only Only
Cooler Condenser Cooler Condenser
10 142 180 2,742 2,704 290 200 34 42
11 161 200 2,812 2,772 310 200 37 45
12 180 225 2,883 2,857 330 200 40 49
15 142 180 3,003 2,984 320 250 39 48
16 161 200 3,089 3,068 340 250 43 52
17 180 225 3,176 3,173 370 250 47 57
20 200 218 3,442 3,523 345 225 48 48
21 240 266 3,590 3,690 385 225 55 55
22 282 315 3,746 3,854 435 225 62 63
30 200 218 4,137 3,694 350 260 55 55
31 240 267 4,319 3,899 420 260 64 65
32 280 315 4,511 4,100 490 260 72 74
35 200 218 4,409 4,606 400 310 61 62
36 240 267 4,617 4,840 480 310 70 72
37 280 315 4,835 5,069 550 310 80 83
40 324 370 5,898 6,054 560 280 89 96
41 364 417 6,080 6,259 630 280 97 106
42 400 463 6,244 6,465 690 280 105 114
45 324 370 6,353 6,617 640 330 98 106
46 364 417 6,561 6,851 720 330 108 117
47 400 463 6,748 7,085 790 330 116 127
50 431 509 7,015 7,285 750 400 115 128
51 485 556 7,262 7,490 840 400 126 137
52 519 602 7,417 7,683 900 400 133 136
55 431 509 7,559 7,980 870 490 127 142
56 485 556 7,839 8,214 940 490 139 152
57 519 602 8,016 8,434 980 490 147 162
60 557 648 8,270 8,286 940 420 144 159
61 599 695 8,462 8,483 980 420 153 168
62 633 741 8,617 8,676 1020 420 160 177
65 557 648 8,943 9,204 1020 510 160 176
66 599 695 9,161 9,428 1060 510 169 187
67 633 741 9,338 9,648 1090 510 177 197
70 644 781 12,395 13,139 1220 780 224 209
71 726 870 12,821 13,568 1340 780 243 229
72 790 956 13,153 13,969 1440 780 257 248
75 644 781 13,293 14,211 1365 925 245 234
76 726 870 13,780 14,702 1505 925 266 257
77 790 956 14,159 15,160 1625 925 283 278
80 829 990 16,156 15,746 1500 720 285 264
81 901 1080 16,530 16,176 1620 720 302 284
82 976 1170 16,919 16,606 1730 720 319 304
85 829 990 17,296 17,001 1690 860 313 295
86 901 1080 17,723 17,492 1820 860 331 318
87 976 1170 18,169 17,984 1940 860 351 341
NOTES: 2. Condenser data: based on a condenser with standard wall tubing,
1. Cooler data: based on a cooler with standard wall tubing, 2-pass, 2-pass, 150 psig, nozzle-in-head waterbox with victaulic grooves.
150 psig, nozzle-in-head waterbox with victaulic grooves. Weight Weight includes the float valve, discharge elbow, and distribution
includes suction elbow, control panel, and distribution piping. Weight piping. Weight does not include unit-mounted starter, isolation valves,
does not include compressor. and pumpout unit.
84
Table 10B — Heat Exchanger Data (SI)
SI
NUMBER OF
TUBES Dry (Rigging) Weight Chiller Charge
(kg)
CODE
Refrigerant Water Volume
Cooler Condenser Cooler Condenser Weight (L)
Only Only
Cooler Condenser Cooler Condenser
10 142 180 1244 1226 132 91 129 158
11 161 200 1275 1257 141 91 140 170
12 180 225 1307 1296 150 91 152 185
15 142 180 1362 1353 145 113 149 183
16 161 200 1401 1391 154 113 163 198
17 180 225 1440 1439 168 113 178 216
20 200 218 1561 1598 157 102 183 181
21 240 266 1628 1673 175 102 207 210
22 282 315 1699 1748 197 102 234 239
30 200 218 1876 1675 159 118 208 210
31 240 267 1958 1768 190 118 242 246
32 280 315 2046 1859 222 118 271 282
35 200 218 2000 2089 181 141 232 233
36 240 267 2094 2195 218 141 266 273
37 280 315 2193 2300 249 141 301 314
40 324 370 2675 2745 254 127 338 365
41 364 417 2757 2839 286 127 368 400
42 400 463 2832 2932 313 127 396 433
45 324 370 2881 3001 290 150 372 403
46 364 417 2976 3107 327 150 407 442
47 400 463 3060 3213 358 150 438 481
50 431 509 3181 3304 340 181 435 483
51 485 556 3293 3397 381 181 477 518
52 519 602 3364 3484 408 181 502 552
55 431 509 3428 3619 395 222 481 536
56 485 556 3555 3725 426 222 527 575
57 519 602 3635 3825 446 222 557 613
60 557 648 3751 3758 426 190 546 601
61 599 695 3838 3847 444 190 578 636
62 633 741 3908 3935 462 190 604 669
65 557 648 4056 4174 462 231 605 668
66 599 695 4155 4276 481 231 641 707
67 633 741 4235 4376 494 231 671 745
70 644 781 5622 5959 553 354 848 791
71 726 870 5814 6153 608 354 919 867
72 790 956 5965 6335 653 354 974 937
75 644 781 6028 6445 619 420 927 885
76 726 870 6259 6667 683 420 1009 971
77 790 956 6421 6875 737 420 1072 1052
80 829 990 7326 7141 680 327 1080 1000
81 901 1080 7496 7336 735 327 1143 1075
82 976 1170 7673 7531 785 327 1208 1150
85 829 990 7844 7710 766 390 1183 1118
86 901 1080 8037 7933 825 390 1254 1205
87 976 1170 8240 8156 880 390 1329 1291
NOTES: 2. Condenser data: based on a condenser with standard wall tubing,
1. Cooler data: based on a cooler with standard wall tubing, 2-pass, 2-pass, 1034 kPa, nozzle-in-head waterbox with victaulic grooves.
150 psig, nozzle-in-head waterbox with victaulic grooves. Weight Weight includes the float valve, discharge elbow, and distribution
includes suction elbow, control panel, and distribution piping. Weight piping. Weight does not include unit-mounted starter, isolation valves,
does not include compressor. and pumpout unit.
85
Table 11 — 19XR Additional Data for Marine Waterboxes*
ENGLISH SI
HEAT EXCHANGER
FRAME, PASS Psig Rigging Weight Water Volume kPa Rigging Weight Water Volume
(lb) (gal) (kg) (L)
FRAME 2, 1 AND 2 PASS 150 730 84 1034 331 318
FRAME 2, 2 PASS 150 365 42 1034 166 159
FRAME 3, 1 AND 2 PASS 150 730 84 1034 331 317
FRAME 3, 2 PASS 150 365 42 1034 166 159
FRAME 4, 1 AND 3 PASS 150 1060 123 1034 481 465
FRAME 4, 2 PASS 150 530 61 1034 240 231
FRAME 5, 1 AND 3 PASS 150 1240 139 1034 562 526
FRAME 5, 2 PASS 150 620 69 1034 281 263
FRAME 6, 1 AND 3 PASS 150 1500 162 1034 680 612
FRAME 6, 2 PASS 150 750 81 1034 340 306
FRAME 7, 1 AND 3 PASS 150 2010 326 1034 912 1234
FRAME 7, 2 PASS 150 740 163 1034 336 617
FRAME 8, 1 AND 3 PASS 150 1855 406 1034 841 1537
FRAME 8, 2 PASS 150 585 203 1034 265 768
FRAME 2, 1 AND 3 PASS 300 860 84 2068 390 318
FRAME 2, 2 PASS 300 430 42 2068 195 159
FRAME 3, 1 AND 3 PASS 300 860 84 2068 390 317
FRAME 3, 2 PASS 300 430 42 2068 195 159
FRAME 4, 1 AND 3 PASS 300 1210 123 2068 549 465
FRAME 4, 2 PASS 300 600 61 2068 272 231
FRAME 5, 1 AND 3 PASS 300 1380 139 2068 626 526
FRAME 5, 2 PASS 300 690 69 2068 313 263
FRAME 6, 1 AND 3 PASS 300 1650 162 2068 748 612
FRAME 6, 2 PASS 300 825 81 2068 374 306
FRAME 7, 1 AND 3 PASS 300 3100 326 2068 1406 1234
FRAME 7, 2 PASS 300 1830 163 2068 830 617
FRAME 8, 1 AND 3 PASS 300 2745 405 2068 1245 1533
FRAME 8, 2 PASS 300 1475 203 2068 766 768
*Add to heat exchanger data for total weights or volumes.
NOTES:
1. Weight adder shown is the same for cooler and condenser of equal frame size.
2. For the total weight of a vessel with a marine waterbox, add these values to the heat
exchanger weights (or volumes).
Table 12 — Compressor Weights

FRAME 2 FRAME 3 FRAME 4 FRAME 5
COMPRESSOR COMPRESSOR COMPRESSOR COMPRESSOR
COMPONENT WEIGHT WEIGHT WEIGHT WEIGHT
lb kg lb kg lb kg lb kg
SUCTION ELBOW 50 23 54 24 175 79 400 181
DISCHARGE ELBOW 60 27 46 21 157 71 325 147
TRANSMISSION* 320 145 730 331 656 298 1000 454
SUCTION HOUSING 300 136 350 159 446 202 1200 544
IMPELLER SHROUD 35 16 80 36 126 57 250 113
COMPRESSOR BASE 1260 571 1050 476 1589 721 3695 1676
DIFFUSER 35 16 70 32 130 59 300 136
OIL PUMP 125 57 150 68 150 68 185 84
MISCELLANEOUS 100 45 135 61 144 65 220 100
TOTAL WEIGHT 2300 1043 2660 1207 3712 1684 6850 3107
(Less Motor and Elbows)
*Transmission weight does not include rotor, shaft, and gear.
86
Table 13 — 19XR Motor Weights Standard and High Efficiency Motors
ENGLISH SI
MOTOR Stator Weight* Rotor Weight† End Bell Stator Weight* Rotor Weight† End Bell
SIZE (lb) (lb) Cover (kg) (kg) Cover
60 Hz 50 Hz 60 Hz 50 Hz (lb) 60 Hz 50 Hz 60 Hz 50 Hz (kg)
BD 1030 1030 240 240 185 467 467 109 109 84
BE 1070 1070 250 250 185 485 485 113 113 84
BF 1120 1120 265 265 185 508 508 120 120 84
BG 1175 1175 290 290 185 533 533 132 132 84
BH 1175 1175 290 290 185 533 533 132 132 84
CD 1286 1358 258 273 274 583 616 117 124 125
CE 1305 1377 265 281 274 592 625 120 127 125
CL 1324 1435 280 296 274 600 651 127 134 125
CM 1347 1455 303 303 274 611 660 137 137 125
CN 1358 1467 316 316 274 616 665 143 143 125
CP 1401 1479 329 316 274 635 671 149 143 125
CQ 1455 1479 329 316 274 660 671 149 152 125
DB 1665 1725 361 391 236 755 782 164 177 107
DC 1681 1737 391 404 236 762 788 177 183 107
DD 1977 2069 536 596 318 897 938 243 248 144
DE 2018 2089 550 550 318 915 948 249 248 144
DF 2100 2139 575 567 318 952 970 261 257 144
DG 2187 2153 599 599 318 992 977 272 272 144
DH 2203 2207 604 604 318 999 1001 274 274 144
DJ 2228 2305 614 614 318 1011 1046 279 279 144
EH 3060 3120 701 751 414 1388 1415 318 341 188
EJ 3105 3250 716 751 414 1408 1474 325 341 188
EK 3180 3250 716 768 414 1442 1474 325 348 188
EL 3180 3370 737 801 414 1442 1529 334 363 188
EM 3270 3370 737 801 414 1483 1529 334 363 188
EN 3270 3520 801 851 414 1483 1597 363 386 188
EP 3340 3520 830 851 414 1515 1597 376 386 188
*Stator weight includes stator and shell.
†Rotor weight includes rotor and shaft.
NOTE: When different voltage motors have different weights the largest weight is given.
87
Table 14A — 19XR Waterbox Cover Weights — English (lb)
FRAME 1 FRAME 2 FRAME 3
HEAT WATERBOX
EXCHANGER DESCRIPTION Standard Flanged Standard Flanged Standard Flanged
Nozzles Nozzles Nozzles
NIH, 1 Pass Cover, 150 psig 177 204 320 350 320 350
COOLER/ NIH/MWB End Cover, 150 psig 136 136 300 300 300 300
CONDENSER NIH, 1 Pass Cover, 300 psig 248 301 411 486 411 486
NIH/MWB End Cover, 300 psig 175 175 400 400 400 400

HEAT WATERBOX
COOLER/ NIH/MWB End Cover, 150 psig 379 379 428 428 583 583
CONDENSER NIH, 1 Pass Cover, 300 psig 593 668 764 839 880 956
NIH/MWB End Cover, 300 psig 569 569 713 713 833 833
FRAME 7 COOLER FRAME 7 CONDENSER

HEAT WATERBOX
EXCHANGER DESCRIPTION Standard Flanged Standard Flanged
Nozzles Nozzles
NIH, 1 Pass Cover, 150 psig 1392 1469 1205 1282
COOLER/ NIH/MWB End Cover, 150 psig 1022 1022 920 920
CONDENSER NIH, 1 Pass Cover, 300 psig 1985 2150 1690 1851
NIH/MWB End Cover, 300 psig 1567 1567 1440 1440

HEAT WATERBOX
Nozzles Nozzles
COOLER/ NIH/MWB End Cover, 150 psig 1480 1480 1228 1228
CONDENSER NIH, 1 Pass Cover, 300 psig 2690 2854 2394 2549
NIH/MWB End Cover, 300 psig 1923 1923 1767 1767
LEGEND
NIH — Nozzle-in-Head
MWB — Marine Waterbox
NOTE: Weight for NIH 2-Pass Cover, 150 psig is included in the heat exchanger weights shown in Tables 10A and 10B.
88
Table 14B — 19XR Waterbox Cover Weights — SI (kg)
HEAT WATERBOX
NIH, 1 Pass Cover, 1034 kPa 80 93 145 159 145 159
COOLER/ NIH/MWB End Cover, 1034 kPa 62 62 136 136 136 136
CONDENSER NIH, 1 Pass Cover, 2068 kPa 112 137 186 220 186 220
NIH/MWB End Cover, 2068 kPa 79 79 181 181 181 181

HEAT WATERBOX
COOLER/ NIH/MWB End Cover, 1034 kPa 172 172 194 194 264 264
CONDENSER NIH, 1 Pass Cover, 2068 kPa 269 303 347 381 399 434
NIH/MWB End Cover, 2068 kPa 258 258 323 323 378 378

HEAT WATERBOX
Nozzles Nozzles
NIH, 1 Pass Cover, 1034 kPa 631 666 547 581
COOLER/ NIH/MWB End Cover, 1034 kPa 464 464 417 417
CONDENSER NIH, 1 Pass Cover, 2068 kPa 900 975 767 839
NIH/MWB End Cover, 2068 kPa 711 711 653 653

HEAT WATERBOX
Nozzles Nozzles
COOLER/ NIH/MWB End Cover, 1034 kPa 671 671 557 557
CONDENSER NIH, 1 Pass Cover, 2068 kPa 1220 1295 1085 1156
NIH/MWB End Cover, 2068 kPa 872 872 801 801
LEGEND
NIH — Nozzle-in-Head
MWB — Marine Waterbox
NOTE: Weight for NIH 2-Pass Cover, 1034 kPa is included in the heat exchanger weights shown in Tables 10A and 10B.
89
Table 15 — Optional Pumpout System Table 17 — Motor Voltage Code
Electrical Data
MOTOR VOLTAGE CODE
MOTOR CONDENSER MAX Code Volts Frequency
CODE UNIT VOLTS-PH-Hz RLA LRA
60 200 60
1 19EA47-748 575-3-60 3.8 23.0 61 230 60
4 19EA42-748 200/208-3-60 10.9 63.5 62 380 60
5 19EA44-748 230-3-60 9.5 57.5 63 416 60
6 19EA46-748 400/460-3-50/60 4.7 28.8 64 460 60
LEGEND 65 575 60
LRA — Locked Rotor Amps 66 2400 60
RLA — Rated Load Amps 67 3300 60
68 4160 60
69 6900 60
50 230 50
Table 16 — Additional Miscellaneous Weights 51 346 50
52 400 50
ITEM Lb Kg
53 3000 50
CONTROL CABINET 30 14
54 3300 50
UNIT-MOUNTED STARTER 500 227
55 6300 50
OPTIONAL ISOLATION VALVES 115 52
90
COMPRESSOR, TRANSMISSION AREA
Compressor Assembly Torques

TORQUE
ITEM DESCRIPTION
ft-lb N.m
1* Oil Heater Retaining Nut 20 28
2 Bull Gear Retaining Bolt 80-85 108-115
3 Demister Bolts 15-19 20-26
4 Impeller Retaining Bolt 44-46 60-62
5* Motor Terminals (Low Voltage) 50 68
6* Guide Vane Shaft Seal Nut 25 34
7* Motor Terminals (High Voltage)
— Insulator 2-4 2.7-5.4
— Packing Nut 5 6.8
— Brass Jam Nut 10 13.6
LEGEND
N.m — Newton meters
*Not shown.
NOTES:
1. All clearances for cylindrical surfaces are diametrical.
2. Dimensions are with rotor in thrust position.
3. Dimensions shown are in inches.
4. Impeller spacing should be performed in accordance with most
recent Carrier Service Bulletin on impeller spacing.
VIEW A
LOW SPEED SHAFT THRUST DISK
Fig. 40 — Compressor Fits and Clearances
91
VIEW B − HIGH SPEED SHAFT
19XR COMPRESSOR CLEARANCES

COMPRESSOR CODE
ITEM
221-299 321-389 421-489 521-599
.0050 .0050 .0055 .0069
A
.0040 .0040 .0043 .0059
.0050 .0050 .0053 .0065
B
.0040 .0040 .0043 .0055
.0115 .0115 .0100 .0010
C
.0055 .0080 .0050 .0060
.0190 .022 .027 .0350
D
.0040 .012 .017 .0250
− .002 − .0020 − .0029 − .0019
E
− .0005 − .0005 − .0014 − .0005
.0050 .0050 .0048 .0062
F
.0040 .0040 .0038 .0052
.157 .157 .0340 .0530
G
.0257 .0257 .0240 .0430
NOTE: All clearances for cylindrical surfaces are diametrical.
Fig. 40 — Compressor Fits and Clearances (cont)
92
93
LEGEND (cont)
FR — Frame
GV — Guide Vane
HT EXCHD — Heat Exchanger
L — Main Supply Power
LVG — Leaving
N.O. — Normally Open
PRESS — Pressure
LEGEND REQM’T — Requirement
TB — Terminal Board
AUX — Auxiliary
BRG — Bearing Denotes Oil Pump Terminal
C — Contactor
CB — Circuit Breaker Denotes Power Panel Terminal
CCM — Chiller Control Module
CCN — Carrier Comfort Network ** Denotes Motor Starter Panel Conn
COMP’R — Compressor
COND — Condenser Denotes Component Terminal
CVC — Chiller Visual Controller
DISCH — Discharge Wire Splice
ENT — Entering
EVAP — Evaporator Denotes Conductor Male/Female Connector
EXT — External Option Wiring
Fig. 41 — Electronic PIC II Control Panel Wiring Schematic (Frame 2, 3, 4 Compressor)

94
LEGEND (cont)
FR — Frame
GV — Guide Vane
HT EXCHD — Heat Exchanger
L — Main Supply Power
LVG — Leaving
PRESS — Pressure
REQM’T — Requirement
LEGEND TB — Terminal Board
AUX — Auxiliary Denotes Oil Pump Terminal
BRG — Bearing
C — Contactor
CB — Circuit Breaker Denotes Power Panel Terminal
CCM — Chiller Control Module
CCN — Carrier Comfort Network ** Denotes Motor Starter Panel Conn
COMP’R — Compressor Denotes Component Terminal
COND — Condenser
CVC — Chiller Visual Controller Wire Splice
DISCH — Discharge
ENT — Entering Denotes Conductor Male/Female Connector
EVAP — Evaporator
EXT — External Option Wiring
Fig. 42 — Electronic PIC II Control Panel Wiring Schematic (Frame 5 Compressor)

95
LEGEND
AUX — Auxiliary T — Transformer

C — Contactor TB — Terminal Board
CB — Circuit Breaker
CCM — Chiller Control Module Denotes Oil Pump Terminal
COMM — Communication
COMPR — Compressor Denotes Power Panel Terminal
DISCH — Discharge
FR — Frame * Denotes Mach. Control Panel Conn.
G — Ground
GRD — Ground ** Denotes Motor Starter Panel Conn.
GVA — Guide Vane Actuator Denotes Component Terminal
HT EXCHD — Heat Exchanger Wire Splice
L — Main Power Supply Denotes Conductor Male/Female Connector
PRESS — Pressure Option Wiring
REQMT — Requirement
Fig. 43 — Power Panel Wiring Schematic

NOTE: Power factor correction capacitors (when required)
are connected ahead of all current transformers for proper
calibration and sensing by the ISM and IQDP4130.
LEGEND
AUX — Auxiliary HPR — Horsepower
C — Contactor ISM — Integrated Starter Module
CB — Circuit Breaker L — Main Supply Power
CR — Control Relay LL — Control Power Supply
CT — Current Transformer M — Contactor
DS — Disconnect Switch RES — Resistor
FU — Fuse S — Contactor
G — Ground TB — Terminal Block
CAUTION: Yellow wires remain energized when unit main disconnect is off.
Optional features are indicated by bold dashed lines.
Dry Contact
Field Connection
For connection diagram refer to 261143 D4.
Fig. 44 — Cutler-Hammer Wye Delta Unit Mounted Starter Wiring Schematic (Low Voltage)
96
97
NOTES: LEGEND
LED status with power applied and prior to run command. AUX — Auxiliary G — Ground Wire Node Symbol
‘‘ON’’ BR — Bridge Rectifier L — Main Supply Power PC Board Terminals
1 may have terminal block
CB — Circuit Breaker LL — Control Power Supply
‘‘OFF’’ COMM — Communication M — Contactor Benshaw supplied Twisted Pair
COND — Condenser O/L — Overload Reset terminal block
Transformer T1 primary fuses FU1/FU2 value dependent on system voltage and model, per Chart 1. CPU — Central Processing Unit S — Contactor Twisted Shielded Pair
2 Transformer connections per transformer nameplate connection diagram. CVC — Chiler Visual Controller SCR — Silicone Controller Rectifier Terminal Strip
CT — Current Transformer ST — Shunt Trip
MOVs are used on power stack assemblies for system voltages of 200 thru 460 vac (as shown). Resistor/ EVAP — Evaporator TB — Terminal Block Shield Wire
3 capacitor networks (DVDTs) are used on power stack assemblies in place of MOVs for a system voltage FU — Fuse Power Connection Field Wiring
of 575 vac (not shown).
K3 relay shown in deenergized state. K3 contact will close when power is applied. K3 contact will open
4 on stop command or system fault.
Fig. 45 — Benshaw, Inc. Solid-State Unit Mounted Starter Wiring Schematic (Low Voltage)
LEGEND
98
AUX — Auxiliary
C — Contactor
COND — Condenser
CPT — Control Power Transformer
CR — Control Relay
CT — Current Transformer
DS — Disconnect Switch
EVAP — Evaporator
FU — Fuse
G — Ground
GFCT — Ground Fault Current Transformer
HPR — Horsepower
ISM — Intergrated Starter Module
L — Main Power Supply
LL — Control Power Supply
LVG — Leaving
M — Contactor
MTR — Motor
PRESS — Pressure
PT — Power Transformer
ST — Shunt Trip
STAT — Status
TB — Terminal Block
TRANS — Transition
VL — Wire Label
Starter Vendor Power Wiring
Starter Vendor Control Wiring
Field Installed Power Wiring
(supplied by others)
Field Installed Control Wiring
Option — Starter Vendor Wiring
Twisted Pair Wiring by Starter Vendor
Customer Terminal Connection
Fig. 46 — Typical Across-the-Line Starter Wiring Schematic (Medium Voltage)

LEGEND
99
AUX — Auxiliary
C — Contactor
COND — Condenser
CPT — Control Power Transformer
CR — Control Relay
CT — Current Transformer
DS — Disconnect Switch
EVAP — Evaporator
FU — Fuse
G — Ground
GFCT — Ground Fault Current Transformer
HPR — Horsepower
ISM — Intergrated Starter Module
L — Main Power Supply
LL — Control Power Supply
LVG — Leaving
M — Contactor
MTR — Motor
PRESS — Pressure
PT — Power Transformer
ST — Shunt Trip
STAT — Status
TB — Terminal Block
TRANS — Transition
VL — Wire Label
Starter Vendor Power Wiring
Starter Vendor Control Wiring
Field Installed Power Wiring
Field Installed Control Wiring
Option — Starter Vendor Wiring
Twisted Pair Wiring by Starter Vendor
Customer Terminal Connection
Fig. 47 — Typical Primary Reactor Starter Wiring Schematic (Medium Voltage)

INDEX
Abbreviations and Explanations, 4 Notes on Module Operation, 80
Adding Refrigerant, 65 Oil Changes, 67
Adjusting the Refrigerant Charge, 65 Oil Charge, 53
After Extended Shutdown, 60 Oil Cooler, 36
After Limited Shutdown, 60 Oil Pressure and Compressor Stop (Check), 59
Attach to Network Device Control, 42 Oil Reclaim Filter, 67
Automatic Soft Stop Amps Threshold, 45 Oil Reclaim System, 8
Auto. Restart After Power Failure, 37 Oil Specification, 67
Before Initial Start-Up, 46 Oil Sump Temperature Control, 35
Capacity Override, 35 Open Oil Circuit Valves, 46
Carrier Comfort Network Interface, 52 Operating Instructions, 59
Changing Oil Filter, 66 Operating the Optional Pumpout Unit, 62
Charge Refrigerant Into Chiller, 56 Operator Duties, 59
Chilled Water Recycle Mode, 44 Optional Pumpout Compressor Water Piping (Check), 51
Chiller Control Module (CCM), 81 Optional Pumpout System Controls and
Chiller Dehydration, 51 Compressor (Check), 56
Chiller Familiarization, 5 Optional Pumpout System Maintenance, 68
Chiller Information Plate, 5 Ordering Replacement Chiller Parts, 69
Chiller Operating Condition (Check), 59 Overview (Troubleshooting Guide), 69
Chiller Tightness (Check), 46 Perform a Controls Test, 56
Chillers with Isolation Valves, 64 Physical Data, 84
Chillers with Storage Tanks, 63 PIC II System Components, 10
Cold Weather Operation, 60 PIC II System Functions, 32
Compressor Bearing and Gear Maintenance, 67 Power Up the Controls and Check the Oil Heater, 53
Condenser, 5 Preparation (Initial Start-Up), 58
Condenser Freeze Prevention, 37 Preparation (Pumpout and Refrigerant Transfer
Condenser Pump Control, 36 Procedures), 62
Control Algorithms Checkout Procedure, 70 Prepare the Chiller for Start-Up, 59
Control Panel, 5 Pressure Transducers (Check), 68, 70
Control Modules, 80 Prevent Accidential Start-Up, 59
Control Test, 71 Pumpout and Refrigerant Transfer Procedures, 62
Controls, 10 Ramp Loading, 35
CVC Operation and Menus, 14 Refrigerant Filter, 67
Cooler, 5 Refrigerant Float System (Inpsect), 67
Default Screen Freeze, 35 Refrigerant Leak Detector, 36
Definitions (Controls), 10 Refrigerant Leak Testing, 65
Demand Limit Control Option, 38 Refrigerant Properties, 65
Design Set Points, (Input), 53 Refrigerant (Removing), 65
Details (Lubrication Cycle), 8 Refrigerant Tracer, 46
Display Messages (Check), 69 Refrigeration Cycle, 7
Dry Run to Test Start-Up Sequence, 58 Refrigeration Log, 60
Equipment Required, 46 Relief Valves (Check), 51
Extended Shutdown (Preparation for), 60 Relief Valves and Piping (Inspect), 67
Factory-Mounted Starter, 7 Remote Start/Stop Controls, 36
General (Controls), 10 Repair the Leak, Retest, and
General Maintenance, 65 Apply Standing Vacuum Test, 65
Guide Vane Linkage (Check), 65 Replacing Defective Processor Modules, 81
Heat Exchanger Tubes and Flow Devices (Inspect), 68 Running System (Check), 59
High Altitude Locations, 56 Safety and Operating Controls (Check Monthly), 66
High Discharge Temperature Control, 35 Safety Considerations, 1
Ice Build Control, 41 Safety Controls, 33
Initial Start-Up, 58 Safety Shutdown, 45
Initial Start-Up Checklist for 19XR Hermetic Scheduled Maintenance, 66
Centrifugal Liquid Chiller, CL-1 Service Configurations (Input), 53
Inspect the Control Panel, 66 Service Ontime, 66
Instruct the Customer Operator, 59 Service Operation, 43
Integrated Starter Module (ISM), 81 Shipping Packaging (Remove), 46
Introduction, 4 Shunt Trip (Option), 35
Job Data Required, 46 Shutdown Sequence, 45
Lead/Lag Control, 39 Software Configuration, 53
Leak Rate, 65 Solid-State Starters, 81
Leak Test Chiller, 48 Spare Safety Alarm Contacts, 36
Local Occupied Schedule (Input), 53 Spare Safety Inputs, 36
Local Start-Up, 44 Standing Vacuum Test, 48
Lubrication Cycle, 8 Starter (Check), 52
Lubrication System (Check), 66 Starting Equipment, 8
Manual Guide Vane Operation, 60 Starting Equipment (Inspect), 68
Motor and Oil Refrigeration Cooling Cycle, 7 Start-Up/Shutdown/Recycle Sequence, 44
Motor-Compressor, 5 Start the Chiller, 59
Motor Rotation (Check), 58 Stop the Chiller, 60
100
INDEX (cont)
Storage Vessel, 7 Unit Mounted Solid-State Starter, 9
Summary (Lubrication Cycle), 8 Unit Mounted Wye-Delta Starter, 10
Surge Prevention Algorithm, 38 Using the Optional Storage Tank and Pumpout
Surge Protection, 39 System, 46
System Components, 5 Water/Brine Reset, 37
Temperature Sensors (Check), 69 Water Leaks, 68
Test After Service, Repair, or Major Leak, 65 Water Piping (Inspect), 51
Tighten All Gasketed Joints and Guide Vane Packing, 46 Water Treatment, 68
Tower Fan Relay Low and High, 37 Weekly Maintenance, 66
Trim Refrigerant Charge, 65 Wiring (Inspect), 51
Troubleshooting Guide, 69
101
Copyright 1998 Carrier Corporation
Book 2 PC 211 Catalog No. 531-974 Printed in U.S.A. Form 19XR-3SS Pg 104 6-98 Replaces: New
Tab 5a
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
INITIAL START-UP CHECKLIST FOR
19XR HERMETIC CENTRIFUGAL LIQUID CHILLER
(Remove and use for job file.)
MACHINE INFORMATION:
NAME JOB NO.
ADDRESS MODEL
CITY STATE ZIP S/N
DESIGN CONDITIONS:
TONS BRINE FLOW TEMPERATURE TEMPERATURE PRESSURE PASS SUCTION CONDENSER

RATE IN OUT DROP TEMPERATURE TEMPERATURE
CUT ALONG DOTTED LINE
COOLER ******
CONDENSER ******
COMPRESSOR: Volts RLA OLTA

STARTER: Mfg Type S/N
OIL PUMP: Volts RLA OLTA
CONTROL/OIL HEATER: Volts M 115 M 230

REFRIGERANT: Type: Charge
CARRIER OBLIGATIONS: Assemble . . . . . . . . . . . . . . . Yes M No M

Leak Test . . . . . . . . . . . . . . . Yes M No M
Dehydrate . . . . . . . . . . . . . . . Yes M No M
Charging . . . . . . . . . . . . . . . . Yes M No M
Operating Instructions Hrs.
START-UP TO BE PERFORMED IN ACCORDANCE WITH APPROPRIATE MACHINE START-UP

INSTRUCTIONS
JOB DATA REQUIRED:
1. Machine Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . Yes M No M
2. Machine Assembly, Wiring and Piping Diagrams . . . . . . . . . . . . Yes M No M
3. Starting Equipment Details and Wiring Diagrams . . . . . . . . . . . . Yes M No M
4. Applicable Design Data (see above) . . . . . . . . . . . . . . . . . . . . . . Yes M No M
5. Diagrams and Instructions for Special Controls . . . . . . . . . . . . . Yes M No M
INITIAL MACHINE PRESSURE:
YES NO
Was Machine Tight?
If Not, Were Leaks Corrected?
Was Machine Dehydrated After Repairs?
CHECK OIL LEVEL AND RECORD:

ADD OIL: Yes M No M
Amount:
RECORD PRESSURE DROPS: Cooler Condenser
CHARGE REFRIGERANT: Initial Charge Final Charge After Trim
Book 2 PC 211 Catalog No. 531-974 Printed in U.S.A. Form 19XR-3SS Pg CL-1 6-98 Replaces: New
Tab 5a
INSPECT WIRING AND RECORD ELECTRICAL DATA:
RATINGS:
Motor Voltage Motor(s) Amps Oil Pump Voltage Starter LRA Rating
Line Voltages: Motor Oil Pump Controls/Oil Heater
FIELD-INSTALLED STARTERS ONLY:

Check continuity T1 to T1, etc. (Motor to starter, disconnect motor leads T4, T5, T6.) Do not megger solid-state starters, disconnect
leads to motor and megger the leads.
‘‘PHASE TO PHASE’’ ‘‘PHASE TO GROUND’’

MEGGER MOTOR
T1-T2 T1-T3 T2-T3 T1-G T2-G T3-G
10-Second Readings:
60-Second Readings:
Polarization Ratio:
STARTER: Electro-Mechanical M Solid-State M Manufacturer

Serial Number
Motor Load Current Transformer Ratio :

Solid-State Overloads Yes M No M
CONTROLS: SAFETY, OPERATING, ETC.

Perform Controls Test (Yes/No)
PIC II CAUTION Yes

COMPRESSOR MOTOR AND CONTROL PANEL MUST BE PROPERLY AND INDIVIDUALLY CON-
NECTED BACK TO THE EARTH GROUND IN THE STARTER (IN ACCORDANCE WITH CERTIFIED
DRAWINGS).
RUN MACHINE: Do these safeties shut down machine?

Condenser Water Flow Yes M No M
Chilled Water Flow Yes M No M
Pump Interlocks Yes M No M
INITIAL START:
Line Up All Valves in Accordance With Instruction Manual: Start Water Pumps and Establish Water Flow
Oil Level OK and Oil Temperature OK Check Oil Pump Rotation-Pressure
Check Compressor Motor Rotation (Motor End Sight Glass) and Record: Clockwise
Restart Compressor, Bring Up To Speed. Shut Down. Any Abnormal Coastdown Noise? Yes* M No M
*If yes, determine cause.
START MACHINE AND OPERATE. COMPLETE THE FOLLOWING:

A: Trim Charge and Record Under Charge Refrigerant Section on page 56.
B: Complete Any Remaining Control Calibration and Record Under Controls Section (pages 10-43).
C: Take At Least 2 Sets of Operational Log Readings and Record.
E: After Machine Has Been Successfully Run and Set Up, Shut Down and Mark Shutdown Oil and Refrigerant Levels.
F: Give Operating Instructions to Owner’s Operating Personnel. Hours Given: Hours
G: Call your Carrier factory representative to report chiller start-up.
SIGNATURES:
CARRIER CUSTOMER
TECHNICIAN REPRESENTATIVE
DATE DATE
CL-2
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
19XR PIC II SETPOINT TABLE CONFIGURATION SHEET
DESCRIPTION RANGE UNITS DEFAULT VALUE

Base Demand Limit 40 to 100 % 100
LCW Setpoint 10 to 120 DEG F 50.0
ECW Setpoint 15 to 120 DEG F 60.0
Ice Build Setpoint 15 to 60 DEG F 40.0
Tower Fan High Setpoint 55 to 105 DEG F 75
CVC Software Version Number:
CVC Controller Identification: BUS: ADDRESS:

CL-3
19XR PIC II TIME SCHEDULE CONFIGURATION SHEET OCCPC01S
Day Flag Occupied Unoccupied
M T W T F S S H Time Time
Period 1:
Period 2:
Period 3:
Period 4:
Period 5:
Period 6:
Period 7:
Period 8:
NOTE: Default setting is OCCUPIED 24 hours/day.
ICE BUILD 19XR PIC II TIME SCHEDULE CONFIGURATION SHEET OCCPC02S

Period 1:
Period 2:
Period 3:
Period 4:
Period 5:
Period 6:
Period 7:
Period 8:
NOTE: Default setting is UNOCCUPIED 24 hours/day.
19XR PIC II TIME SCHEDULE CONFIGURATION SHEET OCCPC03S

Period 1:
Period 2:
Period 3:
Period 4:
Period 5:
Period 6:
Period 7:
Period 8:
NOTE: Default setting is OCCUPIED 24 hours/day.
CL-4
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19XR PIC II ISM_CONF TABLE CONFIGURATION SHEET

Starter Type 0 to 2 1
(0=Full, 1=Red, 2=SS/VFD)
Motor Rated Line Voltage 200 to 13200 VOLTS 460
Volt Transformer Ratio: 1 1 to 33 1
Overvoltage Threshold 105 to 115 % 115
Undervoltage Threshold 85 to 95 % 85
Over/Under Volt Time 1 to 10 SEC 5
Voltage % Imbalance 1 to 10 % 5
Voltage Imbalance Time 1 to 10 SEC 5
Motor Rated Load Amps 10 to 5000 AMPS 200
Motor Locked Rotor Trip 100 to 60000 AMPS 1000
Locked Rotor Start Delay 1 to 10 cycles 5
Starter LRA Rating 100 to 60000 AMPS 2000
Motor Current CT Ratio: 1 10 to 1000 100
Current % Imbalance 5 to 40 % 15
Current Imbalance Time 1 to 10 SEC 5
3 Grnd Fault CT’s? (1=No) 0/1 NO/YES YES
Ground Fault CT Ratio: 1 150 150
Ground Fault Current 1 to 25 AMPS 15
Ground Fault Start Delay 1 to 20 cycles 10
Ground Fault Persistence 1 to 10 cycles 5
Single Cycle Dropout 0/1 DSABLE/ENABLE DSABLE
Frequency-60 Hz? (No=50) 0/1 NO/YES YES
Line Frequency Faulting 0/1 DSABLE/ENABLE DSABLE
CL-5
19XR PIC II OPTIONS TABLE CONFIGURATION SHEET

Auto Restart Option 0/1 DSABLE/ENABLE DSABLE
Remote Contacts Option 0/1 DSABLE/ENABLE DSABLE
Soft Stop Amps Threshold 40 to 100 % 100
Surge/Hot Gas Bypass

Surge Limit/HGBP Option 0/1 0
Select: Surge=0, HGBP=1
Min. Load Point (T1/P1)
Surge/HGBP Delta T1 0.5 to 15 ^F 1.5
Surge/HGBP Delta P1 30 to 170 PSI 50
Full Load Point (T2/P2)
Surge/HGBP Delta T2 0.5 to 15 ^F 10
Surge/HGBP Delta P2 50 to 170 PSI 85
Surge/HGBP Deadband 0.5 to 3 ^F 1
Surge Protection
Surge Delta % Amps 5 to 15 % 10
Surge Time Period 7 to 10 MIN 8
Ice Build Control

Ice Build Option 0/1 DSABLE/ENABLE DSABLE
Ice Build Termination 0 to 2 0
0=Temp, 1=Contacts,2=Both
Ice Build Recycle 0/1 DSABLE/ENABLE DSABLE
Refrigerant Leak Option 0/1 DSABLE/ENABLE DSABLE

Refrigerant Leak Alarm mA 4 to 20 mA 20
CL-6
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
19XR PIC II SETUP1 TABLE CONFIGURATION SHEET

Comp Motor Temp Override 150 to 200 DEG F 200
Cond Press Override 90 to 165 PSI 125
Comp Discharge Alert 125 to 200 DEG F 200
Comp Thrust Brg Alert 165 to 185 DEG F 175
Chilled Medium 0/1 WATER/BRINE WATER

Chilled Water Deadband .5 to 2.0 ^F 1.0

Evap Refrig Trippoint 0.0 to 40.0 DEG F 33
Refrig Override Delta T 2.0 to 5.0 ^F 3
Condenser Freeze Point −20 to 35 DEG F 34
Evap Flow Delta P Cutout 0.5 to 50.0 PSI 5.0

Cond Flow Delta P Cutout 0.5 to 50.0 PSI 5.0
Water Flow Verify Time 0.5 to 5 MIN 5
Oil Press Verify Time 15 to 300 SEC 40
Recycle Control
Recycle Restart Delta T 2.0 to 10.0 DEG F 5
Recycle Shutdown Delta 0.t to 4.0 DEG F 1
SPARE ALERT/ALARM ENABLE

Disable=0, Lo=1/3, Hi=2/4
Spare Temp #1 Enable 0 to 4 0

Spare Temp #1 Limit −40 to 245 DEG F 245
Spare Temp #2 Enable 0 to 4 0

Spare Temp #2 Limit −40 to 245 DEG F 245
CL-7
19XR PIC II SETUP2 TABLE CONFIGURATION SHEET
DESCRIPTION STATUS UNITS DEFAULT VALUE

Capacity Control
Proportional Inc Band 2 to 10 6.5
Proportional Dec Band 2 to 10 6.0
Proportional ECW Gain 1 to 3 2.0
Guide Vane Travel Limit 30 to 100 % 80
Diffuser Control
Diffuser Option 0 to 1 DSABLE/ENABLE DSABLE
Guide Vane 25% Load Pt 0 to 78 % 25
Diffuser 25% Load Pt 0 to 100 % 0
Diffuser Full Span mA 15 to 22 mA 18
VFD Speed Control

VFD Option 0/1 DSABLE/ENABLE DSABLE
VFD Gain 0.1 to 1.5 0.75
VFD Increase Step 1 to 5 % 2
VFD Minimum Speed 65 to 100 % 70
VFD Maximum Speed 90 to 110 % 100
CL-8
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
19XR PIC II LEADLAG TABLE CONFIGURATION SHEET
DESDRIPTION RANGE UNITS DEFAULT VALUE

Lead Lag Control
LEAD/LAG Configuration 0 to 3 0
DSABLE=0, LEAD=1,
LAG=2, STANDBY=3
Load Balance Option 0/1 DSABLE/ENABLE DSABLE
Common Sensor Option 0/1 DSABLE/ENABLE DSABLE
LAG Percent Capacity 25 to 75 % 50

LAG Address 1 to 236 92
LAG START Timer 2 to 60 MIN 10
LAG STOP Timer 2 to 60 MIN 10
PRESTART FAULT Timer 2 to 30 MIN 5
STANDBY Chiller Option 0/1 DSABLE/ENABLE DSABLE
STANDBY Percent Capacity 25 to 75 % 50
STANDBY Address 1 to 236 93
CL-9
19XR PIC II RAMP_DEM TABLE CONFIGURATION SHEET

Pulldown Ramp Type: 0/1 1
Select: Temp=0, Load=1
Demand Limit + kW Ramp
Demand Limit Source 0/1 0
Select: Amps=0, kW=1
Motor Load Ramp % Min 5 to 20 10
Demand Limit Prop Band 3 to 15 % 10
Demand Limit At 20 mA 40 to 100 % 40
20 mA Demand Limit Opt 0/1 DSABLE/ENABLE DSABLE
Motor Rated Kilowatts 50 to 9999 kW 156
Demand Watts Interval 5 to 60 MIN 15
19XR PIC II TEMP_CTL TABLE CONFIGURAITON SHEET

Control Point
ECW Control Option 0/1 DSABLE/ENABLE DSABLE
Temp Pulldown Deg/Min 2 to 10 ^F 3
Temperature Reset
RESET TYPE 1
Degrees Reset At 20 mA −30 to 30 ^F 10
RESET TYPE 2
Remote Temp (No Reset) −40 to 245 DEG F 85
Remote Temp (Full Reset) −40 to 245 DEG F 65
Degrees Reset −30 to 30 ^F 10
RESET TYPE 3
CHW Delta T (No Reset) 0 to 15 ^F 10
CHW Delta T (Full Reset) 0 to 15 ^F 0
Degrees Reset −30 to 30 ^F 5
Select/Enable Reset Type 0 to 3 0
CL-10
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BROADCAST (BRODEF) CONFIGURATION SHEET

Time Broadcast Enable DISABLE/ENABLE DSABLE
Daylight Savings
Start Month 1 to 12 4
Start Day of Week 1 to 7 7
Start Week 1 to 5 3
Start Time 00:00 to 24:00 HH:MM 02:00
Start Advance 0 to 360 MIN 60

Stop Month 1 to 12 10
Stop Day of Week 1 to 7 7
Stop Week 1 to 5 3
Stop Time 00:00 to 24:00 02:00
Stop Back 0 to 360 MIN 60
CL-11
Copyright 1998 Carrier Corporation
Book 2 PC 211 Catalog No. 531-974 Printed in U.S.A. Form 19XR-3SS Pg CL-12 6-98 Replaces: New
Tab 5a
30GX and 30HXC series
PRO-DIALOG Control
Screw-Compressor Air- and

Water-Cooled Liquid Chillers
50 Hz
GLOBAL CHILLER
The cover illustrations are solely for illustration, and form no part of any offer for sale or any sale contract. The manufacturer
reserves the right to change the design at any time without notice.
2
Table of contents
1 - SAFETY CONSIDERATIONS ............................................................................................................................................... 4

1.1 - General ................................................................................................................................................................................ 4
1.2 - Avoiding electrocution ........................................................................................................................................................ 4
2 - GENERAL DESCRIPTION .................................................................................................................................................... 4
2.1 - General ................................................................................................................................................................................. 4
2.2 - Abbreviations used .............................................................................................................................................................. 4
3 - HARDWARE DESCRIPTION ................................................................................................................................................ 5
3.1 - General ................................................................................................................................................................................. 5
3.2 - Electronic boards ................................................................................................................................................................. 5
3.3 - The controls ........................................................................................................................................................................ 6
3.4 - User connections .................................................................................................................................................................. 8
4 - SETTING UP PRO-DIALOG PLUS CONTROL ................................................................................................................. 9
4.1 - Local interface general features ........................................................................................................................................... 9
4.2 - Unit start/stop control ........................................................................................................................................................ 10
4.3 - Menus ................................................................................................................................................................................. 11
4.4 - General menu structure ...................................................................................................................................................... 12
4.5 - Menu tree structure ............................................................................................................................................................ 13
5 - PRO-DIALOG PLUS CONTROL OPERATION ............................................................................................................... 27
5.1 - Start/stop control ................................................................................................................................................................ 27
5.2 - Heating/cooling selection .................................................................................................................................................. 27
5.3 - Evaporator water pump control ......................................................................................................................................... 28
5.4 - Condenser water pump control .......................................................................................................................................... 28
5.5 - Control interlock contact ................................................................................................................................................... 28
5.6 - Evaporator heater control .................................................................................................................................................. 28
5.7 - Control point ...................................................................................................................................................................... 28
5.8 - Demand limit ..................................................................................................................................................................... 29
5.9 - Limiting the unit running current ...................................................................................................................................... 29
5.10- Capacity control ................................................................................................................................................................ 29
5.11 - Determining the lead circuit ............................................................................................................................................ 29
5.12 - Circuit loading sequence ................................................................................................................................................. 29
5.13 - Compressor start-up sequence in one circuit ................................................................................................................... 29
5.14 - EXV control ..................................................................................................................................................................... 29
5.15 - Motor cooling valve control ............................................................................................................................................ 30
5.16 - Head pressure control on air-cooled units ....................................................................................................................... 30
5.17 - Head pressure control on water-cooled units ................................................................................................................... 30
5.18 - Head pressure setpoint selection ...................................................................................................................................... 30
5.19 - High pressure load shedding function ............................................................................................................................. 30
5.20 - High current load shedding function ............................................................................................................................... 30
5.21 - Start-up procedure - prelubrication .................................................................................................................................. 30
5.22 - Master/slave assembly ..................................................................................................................................................... 30
5.23 - Controlling Pro-Dialog Plus units with a System Manager ............................................................................................ 31
5.24 - Optional heat reclaim module .......................................................................................................................................... 31
6 - DIAGNOSTICS - TROUBLESHOOTING .......................................................................................................................... 32
6.1 - General ............................................................................................................................................................................... 32
6.2 - Displaying alarms .............................................................................................................................................................. 32
6.3 - Resetting alarms ................................................................................................................................................................ 32
6.4 - Alarm codes ....................................................................................................................................................................... 33
3
1 - SAFETY CONSIDERATIONS 2 - GENERAL DESCRIPTION
1.1 - General 2.1 - General
Installation, start-up and servicing of equipment can be hazard- PRO-DIALOG Plus is a system for controlling units which use
ous if factors particular to the installation are not considered: screw compressors:
operating pressures, electrical components, voltages and the • Single or dual circuit
installation site itself (elevated plinths, rooftops and built-up • Air or water-cooled condensers
structures). • Non-reversible heat pumps
Only highly trained and qualified installation engineers and PRO-DIALOG Plus controls compressor start-up and demand
technicians, who are fully trained on the product, are limits needed to maintain the desired entering or leaving tem-
authorised to install and start up this equipment. perature setpoint for water. It automatically sets the position of
the electronic expansion valve (if used) to optimise the evapo-
During all servicing operations, it is important to read, under- rator charge. It controls operation of the fans (on air-cooled
stand and follow all the recommendations and instructions units) or water valves (on water-cooled units) to maintain the
given in the installation and service instructions for the correct head pressure in each circuit.
product, including the tags and labels affixed to the equipment,
compo-nents and any parts supplied separately, and to comply Safety circuits are constantly monitored by PRO-DIALOG
with all other relevant safety regulations. Plus to ensure safe operation of the unit. PRO-DIALOG Plus
also gives access to a Quick Test program covering all inputs
• Apply all safety codes and practices. and outputs.
• Wear safety glasses and gloves.
• Use the proper tools to move heavy objects. Move units All PRO-DIALOG Plus controls can work in accordance with
carefully and set them down gently. three independent modes:
• Local mode: the machine is controlled by commands from
1.2 - Avoiding electrocution the user interface.
• Remote mode: the machine is controlled by remote
Only personnel qualified in accordance with the recommenda- contacts (volt-free contacts, analogue signals).
tions of the IEC (International Electrotechnical Commission) • CCN mode: the machine is controlled by commands from
may be permitted access to electrical components. It is the Carrier Comfort Network (CCN). In this case a data
particularly recommended that all sources of electricity to the communication cable is used to connect the unit to the
unit be shut off before any work is begun. Shut off the main CCN communication bus.
power supply at the main circuit breaker or isolator. The operating mode must be chosen with the Operating Type
selection button described in section 4.2.1.
IMPORTANT:
Risk of electrocution: Even when the main power isolator or When the PRO-DIALOG Plus system operates autonomously
circuit breaker is off, it is still possible for certain components (Local or Remote mode) it retains all of its own control capa-
such as crankcase heaters and trace heaters to be energised, bilities but does not offer any of the features of the CCN
since they are connected to a separate power source. network.
Risk of burns: Electrical currents cause components to get
hot either temporarily or permanently. Handle power cables, 2.2 - Abbreviations used
electrical cables and conduits, terminal box covers and motor
frames with very great care. In this manual the circuits are called circuit A and circuit B.
The compressors in circuit A are labelled A1 and A2. Those in
IMPORTANT: Even when the unit is switched off, the power circuit B are labelled B1 and B2.
circuit remains energized as long as the unit or circuit dis-
connect is not open. Refer to the wiring diagram for details. The following abbreviations are frequently used:
Use the adapted safety guidelines. AI - Analogue Input
AO - Analogue Output
IMPORTANT: This equipment uses and emits electromag- CCn - Operating type: CCN
netic signals. The tests carried out on this product have CCN - Carrier Comfort Network
shown that it complies with all applicable codes regarding DI - Discrete Input
electromagnetic compatibility. DO - Discrete Output
EXV - Electronic Expansion Device
IMPORTANT : If the boards need to be handled wear anti- LED - Light Emitting Diode
static gloves to avoid exposing the electronic components to a Loader - Compressor capacity step
destructive voltage. Only unpack the boards from their anti- LOFF - Operating type: Local off
static bag when they need to be installed. rEM - Operating type: by remote control contacts
SCPM - Compressor Protection Module
SCT - Saturated disCharge Temperature
SIO - Standard Input/Output - internal communication
bus linking the basic board to the slave boards
SST - Saturated Suction Temperature
4
3 - HARDWARE DESCRIPTION The various control components are arranged in modules
within the control cabinet:
3.1 - General
• Control module: This comprises the basic board, the user
Control board interface, the EXV control board and option boards, as
well as the customer’s terminal block.
2 • Start-up module: This consists of the start-up boards,
9
1
3 compressor protection boards, as well as the compressor
circuit breakers and contactors.
• Fan module (air-cooled unit): Consists of one or two
8xDO boards together with the fan circuit breakers and
contactors.
8 4
3.2 - Electronic boards
3.2.1 - The basic board

It can be used alone or in conjunction with slave boards. It
holds the program that controls the machine. It continuously
manages the information coming in from the various pressure
and temperature sensors, and communicates with the slave
boards via the SIO bus. It can also communicate with elements
7 6 5
of the Carrier Comfort Network via the CCN bus.
Legend
1 CCN connector NOTE: After a power cut the unit restarts in the same
2 Red LED, status of the board operating mode as before the power cut.
3 Green LED, communication bus SIO
4 Orange LED, communication bus CCN
5 Remote master board customer control connection contacts 3.2.2 - Slave boards
6 Remote master board customer control connection signal
7 Remote master board customer report connection contacts • Compressor board SCPM: This board is used to control
8 Master PD4 basic board a compressor. Up to four SCPM boards can be connected
9 CCN/clock board
to the basic board. It also controls the inputs and outputs
connected to the compressor, such as oil level, oil pump,
The control system consists of at least a PD4 basic board, a
loaders, motor cooling valves, etc.
user interface, a PD4-EXV slave board and, depending on the
• 8xDO board (auxiliary type 2): This board can be used to
application, one or more SCPM compressor boards, 8xDO
control fan stages.
boards (auxiliary type 2) or 8xDO-4xAI-2xAO boards
• PD4-EXV board: This board can control two EXV valves.
(auxiliary type 1).
• 8xDO-4xAI-2xAO board (auxiliary type 1): This
optional board allows:
Slave boards are connected to the basic board via an internal
- control of the fan stages
communication bus (SIO).
- reading the temperature in the heat reclaim condensers
- control of the variable-speed fans (air-cooled units) or
The CCN/clock board is connected and screwed to the master
the condenser valve (water-cooled units).
basic board. It permits communication with elements of the
Carrier Comfort Network via the CCN bus.
Control box
1 2 3 4 5
Legend 3 Compressor start-up module

1 Power supply disconnect switch 4 Control system
2 Fan start-up module 5 User interface
5
3.2.3 - The user interface 3.2.7 - Light emitting diodes on boards
The user interface is in two parts: All boards continuously check and indicate the proper
• The main interface: This gives access to all of the operation of their electronic circuits. A light emitting diode
control parameters for the unit. It consists of a 2-digit (LED) lights on each board when it is operating properly.
primary display block and a secondary 4-digit display
block with 10 LEDs and 5 buttons. Red LED
• The summary interface: This gives quick access to just
the main control parameters for the unit. It comprises 12 • The MAIN red LED flashes at about 2 second intervals to
buttons and 16 LEDs, and includes a schematic diagram show that the module is working properly.
of the unit. • Irregular flashing or no flashing is a sign of a defective
board.
3.2.4 - Connections between boards
The basic board and slave boards communicate with each Green LED
other over an internal three-wire RS485 communication bus (item SIO on the board)
(SIO bus). These three wires link all the boards in parallel.
• This LED flashes continuously to show that the board is
Terminals 1, 2 and 3 on connector J9 (A, B, C are connected communicating correctly over its internal bus.
internally) of the basic board are connected to terminals 1, 2 • If this LED is not flashing, check the wiring of the SIO
and 3 of connector J12 of the SCPM boards, terminal J4 of the bus and the address of the board (slave board only). If the
PD4-EXV board, and terminal J9 of auxiliary boards type 1 or basic board is not linked to any slave boards, this LED
2 respectively. should not flash.
• If all slave boards indicate a communication fault, check
Incorrect connection will render the system inoperative. the SIO bus connection on the basic board. If this
connection is correct and the fault persists, replace the
3.2.5 - Slave board addresses basic board.
Every slave board has a unique address controlled by 8 DIP
switches. The switch is disabled when it is in the open position Orange LED - CCN/clock board
(OPEN or OFF). On SCPM boards SIO address switch is
labelled 'ADDR'. • This LED flashes to show that the basic board is commu-
nicating via the CCN bus.
NOTE: Any incorrect address will prevent the unit from
starting. Turn off the power before amending the address of 3.3 - The controls
any auxiliary board.
3.3.1 - Electronic expansion valve (EXV)
Board addresses The EXV is used to adjust the refrigerant flow to changes in
the operating conditions of the machine. For this purpose, a
Board DIP switch (0 = open) series of calibrated orifices are machined into the wall of the
1 2 3 4 5 6 7 8 refrigerant inlet port. As the refrigerant passes through these
PD4-EXV 1 0 1 1 1 0 0 0 orifices, it expands and becomes a bi-phase mixture (liquid and
Auxiliary board type 1 or 2 - # 1 1 0 0 0 1 1 0 0 gas).
Auxiliary board type 1 or 2 - # 1 0 0 0 1 1 1 0 0
SCPM # 1 (compressor A1) 0 0 1 0 1 0 1 0 To adjust the refrigerant flow to changes in operating conditions,
SCPM # 2 (compressor A2) 1 1 1 1 1 0 1 0
a piston moves constantly up or down to vary the cross-section
SCPM # 3 (compressor B1) 0 1 0 1 0 1 1 0
of the refrigerant path. This piston is driven by an electronically
SCPM # 4 (compressor B2) 1 0 1 0 1 1 1 0
controlled linear stepper motor. The high degree of accuracy
with which the piston is positioned ensures that the flow of
3.2.6 - Power supply to the boards refrigerant is precisely controlled.
All boards are supplied by a 24 V source, referred to earth. In
the event of a power supply interrupt, the unit restarts automa- NOTE: The external connector of the EXV must be cleaned
tically without the need for an external command. However, and coated with silicone grease (Part No. 397 EE) to keep out
any faults active when the supply is interrupted are saved and condensation and prevent corrosion.
may in certain cases prevent a circuit or unit from restarting.
3.3.2 - The head pressure controls
NOTE: When connecting the power supply for the boards, The controller can deal with the following:
maintain polarity. • in the case of air-cooled units, for each circuit, fan stages
together with, if necessary, a variable speed fan (controlled
by an auxiliary board type 1)
• in the case of water-cooled units, a water valve. This valve
is controlled by an auxiliary board type 1 which supplies a
0-10 V d.c. signal.
6
3.3.3 - The evaporator pump 3.3.7 - Thermistors
In appropriate cases the controller can also regulate an evapo- These all have similar characteristics.
rator pump. This facility does not require an additional board.
Evaporator entering and leaving water temperature sensor
3.3.4 - The condenser pump The evaporator entering water temperature sensor and the
In appropriate cases the controller can also regulate a condenser leaving water temperature sensor are installed in the entering
pump (for water-cooled units). This control does not require an and leaving side water box.
additional board.
Discharge gas sensor
3.3.5 - The evaporator heater This sensor is used to measure the discharge gas temperature,
The evaporator heater can be regulated by the unit control on and permits control of the discharge temperature superheat. It
air-cooled units to protect the evaporator against frost. This is located in the discharge line of each compressor.
control requires an additional board.
Motor sensor
3.3.6 - Pressure sensors This is used to control the motor temperature of each compressor.
These are used to measure the following pressures in each The terminals of this sensor are situated on the compressor
circuit: terminal board.
• Discharge gas pressure (high pressure type)
• Suction pressure (low pressure type) Condenser entering and leaving water temperature sensors
• Oil pressure (high pressure type, except for the low These are used to control the heating capacity on heat pumps.
ambient temperature option when the sensor used is a In cooling only units they have no control function. They are
wide-band sensor) installed in the common condenser entering and leaving line.
• Economizer pressure (high pressure type)
Heat reclaim condenser entering/leaving water temperatures
These electronic sensors deliver 0 to 5 V d.c. The economizer These sensors measure the entering and leaving water tempera-
and oil pressure sensors are connected to the SCPM board and, tures of heat reclaim condensers and are used on air-cooled
as the others, are measured by the basic board. units. They may be fitted as options.
Discharge pressure sensors Temperature setpoint reset sensor

These are on the high pressure side of each circuit. They This is an optional 0-10 V sensor which can be installed
replace the usual discharge gas pressure gauges and are used to remotely from the unit. It is used to reset the cooling and
control head pressure or high pressure load shedding. heating setpoint on the unit as a function of either the outdoor
air temperature or ambient room temperature. The sensor is not
Oil pressure sensors supplied by Carrier, and must be configured in the User Menu.
These sensors are located at the oil pressure port of each
compressor. The economizer pressure is subtracted from this Outdoor temperature sensor
value to arrive at the differential oil pressure. Mounted on the control box. It is used for start-up, setpoint
temperature reset and frost protection control.
Suction pressure sensors
They are located in the high-pressure side of the evaporator, Master/slave assembly temperature control
and measure the low-pressure side of each circuit. The optional water temperature sensor can be used for
master/slave assembly control.
Economizer pressure sensors
These sensors measure the intermediate pressure between high
and low pressure. They are used to control the oil pressure
differential. They are located at the plate heat exchanger outlet
(for units equipped with economizers) or on the motor cooling
line of each motor.
7
3.4 - User connections
The connections below are available at the customer’s terminal

block. Some of them can only be used in special operating
modes. For further details see the sections that describe the
functions (section 5) and the configurations (section 4.2.1).
CONNECTION TERMINALS
DESCRIPTION CONNECTOR/ TERMINAL DESCRIPTION REMARKS
CHANNEL
Alarm relay output, circuit A J3 / CH24 30A - 31A Indicates alarms in circuit A Volt-free contacts 24 V a.c. 48 V d.c.
max, 20 V a.c. or V d.c., 3 A max, 80
mA min, external power supply.
Alarm relay output, circuit B J3 / CH25 30B - 31B Indicates alarms in circuit B Connector: 6 pin WAGO 231-306/
026000 pitch 5.08.
Critical fault relay output J3 / CH26 37-38 Indicates that the compressor control contactor is stuck
closed
User safety loop and chilled J4 / CH15a 34 - 35 This contact is mounted in series with the water flow 24 V a.c., 20 mA
water pump interlock control contact. It can be used for any user safety loop that Connector: 10 pin WAGO 734-110,
requires that the unit is shut down, if it is open. The chilled pitch 3.5
water pump operation auxiliary contact is connected
between these two terminals.
Remote start/stop J4 / CH11 32 - 33 The remote start/stop command is only used if the unit is
under remote operation control (rEM). See section 4.2.1.
Remote cooling setpoint J4 / CH12 65 - 66 The remote cooling setpoint selection command is only
selection used if the unit is under remote operation control (rEM).
See section 4.2.1.
Remote heating/cooling J4 / CH13 63 - 64 The remote heating/cooling control command is only used
control if the unit is under remote operation control (rEM). See
section 4.2.1.
or J4 / CH13 63 - 64 The command allows selection of the second condensing
remote heat reclaim control setpoint or of the heat reclaim mode. It is only used if the
unit is under remote operation control (rEM). See section
4.2.1.
Demand limit command J4 / CH14 73 - 74 This contact permits activating the unit demand limit
function. See section 5.8. This contact is active, whatever
the operating type.
0-10 V d.c. setpoint reset or J8 / CH10 71 - 72 This 0-10 V d.c. input is used for setpoint reset or unit Connector: 2 pin WAGO 231-302/
demand limit entry demand limit. It is active, whatever the unit operating type. 026000 pitch 5.08
This 0-10 V signal can be supplied by a user command or a
0-10 V temperature sensor.
Connection to CCN J12 1-2-3 A RS-485 bus is used for connection to the CCN. Use of a shieled cable (max. length:
The CCN connector is located on the CCN/clock board 1000m).
(inserted on the PD4 BASIC board) Shielding: braiding on 95%-100% of
- Pin 1: signal + the cable surface.
- Pin 2: ground Shielding connection at the two cable
- Pin 3: signal - ends.
AVAILABLE TERMINALS
DESCRIPTION CONNECTOR/ TERMINAL DESCRIPTION REMARKS
CHANNEL
Condenser water flow switch J5/CH17 This contact is used to detect lack of condenser water flow 24 V a.c - 20mA
input and shuts down the unit.
Evaporator 1 and 2 pump J5/CH18 This contact is used to detect an evaporator pump operation
operation input fault and switches over to the other evaporator pump*.
Evaporator 1 control J2/CH19 This contact permits control of evaporator 1 pump by the 24 V a.c. internal supply.
unit*. Max. consumption
Evaporator 2 control J2/CH20 This contact permits control of evaporator 2 pump by the - each output: 20 VA/10W
unit*. - for all 3: 40 VA/20 W if all are used
Condenser pump control J2/CH21 This contact permits control of condenser pump by the unit*.
Legend
* Associated functions, if selected: automatic changeover, pump 1 and 2; manual or CCN selection; periodical; by default.
8
4 - SETTING UP PRO-DIALOG PLUS CONTROL
4.1 - Local interface general features
MAIN INTERFACE SUMMARY INTERFACE MAIN INTERFACE SUMMARY INTERFACE
DUAL-CIRCUIT AIR-COOLED DUAL-CIRCUIT WATER-COOLED

MENU BLOCK CHILLER INTERFACE MENU BLOCK CHILLER INTERFACE
The local interface enables a number of operating parameters Main interface

to be displayed and modified. It gives access to all PRO-DIALOG PLUS data and operating
functions. It consists of:
The interface consists of two distinct parts: the main interface • A two-digit display showing the number of the item
(left hand section) and the summary interface (right hand selected.
section). • A four-digit display showing the contents of the item
selected.
• LEDs and buttons for unit start/stop, menu selection,
menu item selection and value adjustment.
MAIN INTERFACE
BUTTON NAME DESCRIPTION
Menu Permits the selection of a main menu. Each main menu is represented by an icon. The icon is lit if active.
Up arrow Permits scrolling through the menu items (in the two-digit display). If the modification mode is active this button authorises
increase of the value of any parameter.
Down arrow Permits scrolling through the menu items (in the two-digit display). If the modification mode is active this button authorises
decrease of the value of any parameter.
Enter Gives access to the modification mode, validates a modification or displays expanded item description.
Start/stop Authorises start or stop of the chiller in local mode or modification of its operating type.
MAIN INTERFACE MENU LEDS

LED NAME DESCRIPTION
INFORMATION menu Displays the general operating parameters for the unit.
TEMPERATURES menu Displays the unit operating temperatures.
kPa PRESSURES menu Displays the unit operating pressures.
SETPOINTS menu Displays the unit setpoints and enables them to be modified.
INPUTS menu Displays the status of the unit digital and analogue inputs.
OUTPUTS/TESTS menu Displays the status of the unit outputs and enables them to be tested.
CONFIGURATIONS menu Displays the unit configuration and enables it to be modified.
ALARMS menu Displays active alarms.
ALARMS HISTORY menu Displays the history of the alarms.
OPERATING LOG menu Displays the operating times and number of starts for the unit and the compressors.
9
The summary interface (right hand section) includes a mimic The following operating types can be selected using the
diagram of the unit, together with push-buttons and LEDs. It Start/Stop button:
gives quick access to the main operating parameters of the unit.
OPERATING TYPES
SUMMARY INTERFACE LEDS 4-DIGIT DISPLAY DESCRIPTION
LED INDICATION WHEN LIT LOFF Local Off. The unit is halted in local mode.
Green LED: L-On Local On. The unit is in local control mode and is authorised
The unit is authorised to start or is already running to start.
Red LED: L-Sc* Local On - timer control. The unit is in local control mode. It
- Lit: circuit A or unit shut down by alarm is authorised to start if the period is occupied. If the timer
- Flashing: circuit A or unit running with alarm present program for unit operation is unoccupied, the unit remains shut
Red LED: down until the period next becomes occupied.
- Lit: circuit B or unit shut down by alarm CCN* CCN. The unit is controlled by CCN commands.
- Flashing: circuit B or unit running with alarm present
rEM* Remote. The unit is controlled by remote control contacts.
Red LED:
Water flow switch default or user safety lock open. MAST* Master Unit. The unit runs as a master in a two unit lead/lag
arrangement. This is displayed if the unit is configured for
Green LED: master/slave control. See section 5.21.
The evaporator pump is running.
Legend
Yellow LEDs: * Displayed if the configuration requires it.
From top to bottom - start/stop status of compressor A1 and A2 Section 5.1 gives a more detailed description of the commands to start/stop
or B1 and B2. Flashing LED indicates that the circuit is in the the unit, analysed by operating type.
protection or defrost mode (A or B).
Green LED: 4.2.2 - Stopping the unit in local mode
The unit operates in heating mode.
The unit can be stopped in local mode at any time by
Green LED:
The unit operates in cooling mode. pressing the Start/Stop button.
TO STOP THE UNIT

SUMMARY INTERFACE PUSH BUTTONS BUTTON ACTION 2-DIGIT DISPLAY 4-DIGIT DISPLAY
BUTTON DISPLAY Press the Start/Stop C LOFF
Blue button: evaporator leaving or entering water temperature in °C button for less than
Gray button: outdoor air temperature in °C 4 seconds (one short
press is enough).
Control point (setpoint + reset) in °C
If the button is t LOFF
released, the unit stops
Press 1: circuit A/B discharge pressure in kPa without the need for
Press 2: circuit A/B saturated condensing temperature in °C further action.
kPa Press 1: circuit A/B suction pressure in kPa
Press 2: circuit A/B saturated suction temperature in °C
Press 1: compressor A1/B1 operating hours in h/10 or h/100 4.2.3 - Starting unit and selecting an operating type
Press 2: compressor A2/B2 operating hours in h/10 or h/100 The unit can be started in local mode, or unit operating type
can be changed at any time using the Start/Stop button. In the
4.2 - Unit start/stop control example that follows, the unit is stopped (LOFF) and the user
wants to start the unit in local mode.
4.2.1 - Description CHANGING THE OPERATING TYPE
The unit start/stop can be controlled by one of the BUTTON ACTION 2-DIGIT 4-DIGIT
following methods: DISPLAY DISPLAY
• Locally on the actual unit (Local control type) Continually press the operating type selection C LOFF
button for more than 4 seconds.
• By remote control with the aid of user contacts (remote
Hold down the Start/Stop button. L-On
control type) The available operating types are displayed L-Sc
• By CCN control with the aid of the CCN (CCN control one by one until the button is released.
type)
The main interface includes a Start/Stop button which can be rEM

used to stop or start the unit in the local operating type or to Release the Start/Stop button if the operating L-On
select the remote or CCN operating type. type you want is displayed (in this example L-
On). "C" flashes in the 2-digit display to show
that the controller is awaiting confirmation.
The available operating types are described in the following Press the Enter button to confirm the operating t L-On
table. type selected (in this example: L-On). "t" is
displayed in the 2-digit display to indicate the
operating type selected. If the Enter button is
not pressed soon enough, the controller will
cancel the change and continue to use the
previous operating type.
10
4.3 - Menus NOTE: The access to a sub-menu may require entering a
password. This is automatically requested. See section 4.5.7.2.
4.3.1 - Selecting a menu
The MENU button authorises you to select a menu from the The example below shows how to modify the value of item 1
10 main menus that are available. Each time you press this in the Setpoint menu.
button one of the 10 LEDs lights up in turn alongside each
of the icons representing a main menu. The active menu is MODIFYING THE VALUE OF A PARAMETER
the one against which the LED is lit. If a menu is empty then OPERATION PRESS MENU LED ITEM ITEM
button NUMBER NUMBER
its LED is not lit. To scroll quickly through the menus, hold 2-DIGIT 4-DIGIT
the MENU button down. DISPLAY DISPLAY
Hold on the MENU button until the 0
LED for SETPOINT lights.
4.3.2 - Selecting a menu item
The up and down Arrow buttons let you scroll through the 0
menu items. Menu item numbers are displayed in the two-digit
Press one of the Arrow buttons until 1
display. The item number increases or decreases every time you the two-digit display shows 1 (item
number 1- cooling setpoint 2).
press the up or down Arrow button. The menu items that are The value for setpoint 2 is displayed
not in use or incompatible with the configuration are not in the four-digit display (6.0°C in 1 6.0
this example).
displayed. The value or status associated with the active item is
displayed in the four-digit display. To scroll quickly through Press the Enter button for more
than 2 seconds to enable the value
the items, hold the up or down Arrow button down. associated with item 1 to be modified. 1 6.0
The Setpoint menu LED flashes
indicating that modification mode
The following example shows how to access item 3 in the is active.
Pressures menu. Keep pressing the Down Arrow 1 5.9

button until the value 5.7 is
displayed in the four-digit display.
SELECTING A MENU ITEM The Setpoint menu LED keeps
flashing. 1 5.8
OPERATION PRESS MENU LED ITEM NUMBER
BUTTON 2-DIGIT
DISPLAY
1 5.7
Press the MENU button until the
LED marked PRESSURE lights. 0 Press the Enter button again to
validate the change. The new
kPa setpoint is 5.7°C. The Setpoint menu 1 5.7
0 LED stops flashing, indicating that
modification mode no longer applies.
Press one of the Arrow buttons 1

until the two-digit display shows 3
(item number 3).
4.3.4 - Expand display
kPa
2 Pressing the Enter button causes a 23 character text expansion
to be scrolled across the four-digit display. All user menus
3 provide an expansion of the current displayed parameters. If
the expansion is complete the four-digit display reverts to item
value. This function can be inhibited through the User Configu-
4.3.3 - Modifying the value of a parameter/access to a sub- ration menu.
menu
Press the Enter button for more than 2 seconds to enter the
modification mode or to select a sub-menu. This lets you
correct the value of an item or select a sub-menu with the aid of
the up and down Arrow buttons (if you are authorised to over-
write the item concerned). When modification mode is activated,
the LED for the main menu to which the item belongs flashes
in menu block. Once the required value is obtained, press the
Enter button again to validate the change or to access the sub-
menu. The LED for the menu to which the item belongs then
stops flashing, indicating that modification mode no longer
applies.
In modification mode, the value to be modified increases or

decreases in steps of 0.1 every time you press the Arrow
buttons. Holding one of these buttons down increases the rate
of increase or decrease.
11
4.4 - General menu structure
MAIN MENUS
12
STATUS TEMPERATURES PRESSURES SETPOINTS INPUTS OUTPUTS CONFIGURATION ALARMS ALARMS HISTORY RUNTIME
SUB-MENUS
USER SERVICE FACTORY RUNTIME 1 MAINTE-
[USEr] [SErviCE] [FACtorY] [RuntiME 1] NANCE
SUB-SUB-MENUS
OUTPUT 1 OUTPUT 2 USER 1 USER 2 SCHEDULE 1 SCHEDULE 2 HOLIDAYS HOUR + DATE BROADCAST SERVICE 1 SERVICE 2 SERVICE 3 MASTER/SLAVE FACTORY 1 FACTORY 2
[OUTPUT 1] [OUTPUT 2] [USEr 1] [USEr 2] [SCHEduLE 1] [SCHEduLE 2] [HoLidAy] [dAtE] [brodCASt] [SErviCE 1] [SErviCE 2] [SErviCE 3] [FACTORY 1] [FACTORY 2]
[MAStEr SLAvE]
PERIOD 1 PERIOD 1 HOLIDAYS 1

[PEriod 1] [PEriod 1] [HoLidAy 1]

SUB-SUB-SUB-MENUS PERIOD 3 PERIOD 3 HOLIDAYS 3






---
---
---
HOLIDAYS 15
[HoLidAy15]
NOTE: The items in brackets show what is

HOLIDAYS
16 displayed on the user interface.
user interface.
NOTE: The items in brackets show what is displayed on the
4.5 - Menu tree structure

MENU
ITEM STATUS TEMP PRESSURES SETPOINTS INPUTS OUTPUTS CONFIG ALARMS ALARMS HIST RUNTIMES
0 Default display Evaporator water Discharge pressure, Cooling setpoint 1 Contact 1: remote on/ SUB-MENU: SUB-MENU: Number of Historic alarm SUB-MENU:
entering temp. circuit A off Outputs 1 User Configuration active alarms/ code 1 Runtimes
[OUTPUTS1] [USEr] resets
1 Active modes Evaporator water Suction pressure, circuit Cooling setpoint 2 Contact 2: remote SUB-MENU: SUB-MENU: Active alarm Historic alarm SUB-MENU:
leaving temp. A setpoint Outputs 2 Service Configura- code 1** code 2 Maintenance
[OUTPUTS2] tion [SErviCE]
2 Chiller occupied/ Condenser water Oil pressure, compressor Heating setpoint Contact 3: remote - SUB-MENU: Active alarm Historic alarm -
unoccupied entering temperature A1 heating/cooling Factory Configura- code 2** code 3
tion [FACtorY]
3 Minutes left Condenser water Oil pressure, Condensing Contact 4: remote heat - - Active alarm Historic alarm -
leaving temperature compressor A2 setpoint reclaim operation code 3** code 4
4 Cooling/heating Heat reclaim water Oil differential pressure, Heat reclaim Demand limit selection - - Active alarm Historic alarm -
selection entering temperature compressor A1 setpoint code 4** code 5
5 Heat reclaim Heat reclaim water Oil differential pressure, Demand limit Water flow control and - - Active alarm Historic alarm -
selection leaving temperature compressor A2 setpoint in % customer interlock code 5** code 6
6 Unit capacity in % Saturated discharge Economizer A1 pressure Cooling mode Evaporator pump fault - - - Historic alarm -
temperature, circuit A ramp detection code 7
7 Capacity circuit A Saturated suction Economizer A2 pressure Heating mode Water flow control, - - - Historic alarm -
in % temperature, circuit A ramp condenser code 8
8 Capacity circuit B Gas discharge Discharge pressure, Cooling - threshold Control box thermostat - - - Historic alarm -
-
** Displayed if the alarm exists
Legend
in % temperature, circuit A circuit B for zero reset and phase reversal code 9
Not in use
interlock control
9 Present demand Discharge superheat, Suction pressure, circuit Cooling - threshold Oil level, circuit A - - - Historic alarm -
limit in % circuit A B for max. reset code 10
10 Present lag limit in Temperature motor Oil pressure, Cooling - max. Oil level, circuit B - - - - -
% A1 compressor B1 reset value
11 Setpoint in local Temperature motor Oil pressure, Heating - threshold External 0-10 V d.c. - - - - -
control A2 compressor B2 for zero reset signal
12 Setpoint occupied/ Saturated discharge Oil differential pressure, Heating - threshold Compressor current A1 - - - - -
unoccupied mode temperature, circuit B compressor B1 for max. reset
13 Active setpoint Saturated suction Oil differential pressure, Heating - max. Compressor current A2 - - - - -
temperature, circuit B compressor B2 reset value
14 Control point Gas discharge Economizer B1 pressure - Compressor current B1 - - - - -
temperature, circuit B
15 Controlled water Discharge superheat, Economizer B2 - Compressor current B2 - - - - -
temperature circuit B pressure
16 Condensing point Temperature motor Remote discharge - Total compressor - - - - -
B1 pressure, circuit A operating current
17 Heat reclaim Temperature motor Remote discharge - - - - - - -
indicator, circuit A B2 pressure, circuit B
18 Heat reclaim Outdoor temperature Heat reclaim pressure, - - - - - - -
indicator, circuit B circuit A
19 - Water loop Heat reclaim pressure, - - - - - - -
13
temperature, master/ circuit B

slave assembly
4.5.1 - Description of the Information menu
INFORMATION MENU (3)
ITEM FORMAT UNITS DESCRIPTION
0 Automatic display mode. It cycles through the following displays:
±nn.n °C 1: Controlled water temperature: temperature of the water that the unit tries to maintain at the control point.
2: Unit operating type
LOFF - Local Off
L-On - Local On
L-Sc - Local On - based on unit clock.
CCn - CCN Control.
rEM - Remote Control
MASt - Master unit
3: Unit status
OFF - Off: Unit is stopped and not authorised to start.
rEADY - Ready: Unit is authorised to start
dELAY - Delay: Unit is in delay at start-up. This delay is active after the unit has been switched on. The delay can be
configured in the User Configuration menu.
StOPPing - Stopping: Unit is currently stopping.
running - On: Unit is running or authorised to start.
triPout - Fault shutdown.
OvErridE - Limit: The operating conditions do not allow total unit operation.
4. Unit occupied/unoccupied status
OCCUPIEd - Occupied: Unit in occupied mode
UNOCCUPIEd - Unoccupied: Unit in unoccupied mode
5. Heating/cooling operating mode
COOL - Cooling: Unit operates in cooling mode
HEAT - Heating: Unit operates in heating mode
rECLAIM - Cooling: Unit is in auto cooling and heat reclaim demand is active
6. Alarm mode
ALArM - Alarm: Unit is totally stopped because of failure.
ALErt - Alert: Unit is in failure but not completely stopped.
7. Master/Slave status
MAStEr - Master: The master/slave control is active and the unit is the master
SLAvE - Slave: The master/slave control is active and the unit is the slave
1 [1] nn - Active mode codes. Each active mode is displayed in turn. This Item is masked when nil. Pressing the enter button when a mode
code is displayed causes a character text expansion to be scrolled accross the four-digit display. See the description in the following
table
2 [2] - This item indicates the current chiller occupied/unoccupied mode.

occu Occupied
unoc Unoccupied
Forc The value is displayed in turn with 'Forc' when the unit is in CCN control and if this variable if forced through CCN.
3 nn.n minutes Start-up delay. This item indicates the minutes left before the unit can be started. This delay at start-up is always active after the unit
has been switched on. The delay can be configured in the User Configuration 1 menu.
4 [2] - Heating/cooling on selection: This item is accessible in read/write, if the unit is in local control mode. It is only displayed, if the unit is
in LOFF, L-On or L-Sc operating type. Displayed for heat pumps.
HEAt - Heating mode selection
COOL - Cooling mode selection
5 [2] Heat reclaim mode selection: This item is accessible in read/write, if the unit is in local control mode. It is only displayed, if the unit is
in LOFF, L-On or L-Sc operating type. Displayed for air-cooled or water-cooled units with a condenser water valve.
YES - Heat reclaim mode selection, use of heat reclaim condensing setpoint.
NO - Normal cooling mode selection, use of standard condensing setpoint
6 Nnn % Total active capacity of unit.
7 nnn % Total active capacity of circuit A.
8 [2] nnn % Total active capacity of circuit B.
9 [2] nnn Present demand limit. This is the authorised operating capacity of the unit. See section 5.8.
Forc % The value is displayed in turn with 'Forc' when the unit is in CCN control and if this variable if forced through CCN.
10 nnn % Present lag chiller demand limit. Displayed when the master/slave control is selected.
11 [2] - Setpoint select in local mode. This point is read/write accessible. Displayed only when the unit is LOFF, L-On or L-Sc operating type.
SP-1 SP-1 = cooling setpoint 1
SP-2 SP-2 = cooling setpoint 2
AUtO AUtO = active setpoint depends on schedule 2 (setpoint selection schedule). See section 5.7.1 & 4.5.7.6.
12 [2] - Setpoint occupied mode.
occu Occupied: cooling setpoint 1 is active
unoc Unoccupied: cooling setpoint 2 is active
Forc The value shall be displayed in turn with 'Forc' when the unit is in CCN control and if this variable if forced through CCN.
13 ±nn.n °C Active setpoint. This is the current cooling/heating setpoint: it refers to cooling/heating setpoint 1 or 2.
14 ±nn.n Control point. This is the setpoint used by the controller to adjust the temperature of the leaving or entering water (according to
Forc °C configuration).
Control point = active setpoint + reset. See section 5.7
The value is displayed in turn with 'Forc' when the unit is in CCN control and if this variable if forced through CCN.
15 ±nn.n °C Controlled water temperature. Water temperature that the unit tries to maintain at the control point.
16 ±nn.n °C Condensing setpoint. The value is displayed in turn with 'Forc' if the unit is in CCN mode and this parameter is forced by CCN.
Forc °C
17 n Heat reclaim function indicator, circuit A (see heat reclaim section)
18 n Heat reclaim function indicator, circuit B (see heat reclaim section)
Legend
1 This item is masked when nil.
2 This item is displayed in certain unit configurations only.
3 Access to this menu is read-only except for item 10 that can be forced when the unit is in Local operating type.
14
DESCRIPTION OF OPERATING MODES (ITEM 1 OF THE INFORMATION MENU)
MODE # MODE NAME DESCRIPTION
7 Delay at start-up active The delay at start-up operates after the unit has been switched on. If the delay has not expired, the mode is active.
The delay is configured in the User1 configuration menu.
8 2nd cooling setpoint active The second cooling setpoint is active. See section 5.7.1
9 Setpoint reset active In this mode, the unit uses the reset function to adjust the leaving or entering water temperature setpoint. See section
5.7.2.
10 Demand limit active In this mode, the capacity at which the unit is allowed to operate is limited. See section 5.8.
11 Ramp loading active Ramp loading is active. In this mode, the controlled high or low water temperature value (in °C/min) in heating mode is
limited to a preset value in order to prevent compressor overload. The ramp function must be configured (see User1
configuration menu). The ramp values can be modified (see setpoint menu).
12 Low entering water temperature The unit is in heating mode and the temperature of the evaporator leaving water is lower than the lesser of the two
protection in heating mode cooling setpoints. A capacity stage is removed. This mode only applies to heat pumps.
13,14 Low suction temperature protection 13 = circuit A & 14 = circuit B. Protection for evaporator suction low temperature circuit is active. In this mode, circuit
capacity is not authorised to rise if the unit is in cooling mode, and saturated suction temperature in the circuit is lower
than the frost protection threshold.
15,16 Low discharge superheat protection 15 = circuit A & 16 = circuit B.
In this mode the circuit capacity is not authorised to rise.
17,18 High pressure protection 17 = circuit A & 18 = circuit B. The circuit is in high pressure protection mode because the HP protection threshold
has been exceeded. The circuit capacity is not authorised to rise and any slave compressor can be stopped in order
to prevent a high pressure break.
19,20 High current protection 19 = circuit A & 20 = circuit B. Circuit capacity is not allowed to rise, as the compressor has reached the high current
protection threshold and could be shut down.
21 Heat reclaim active Circuit A or circuit B operates in heat reclaim mode and not in standard cooling mode (pumpdown phase is activated).
22 Evaporator heater active Mode active if risk of frost exists.
23 Evaporator pump reversal active Two evaporator water pumps installed on the unit and pump reversal is active. See section 5.3
24 Periodic evaporator pump start-up The unit is shut down and is started every day at 14:00 hours for 2 seconds. This function must be configured in the
User1 menu. See sections 5.3 and 4.5.7.3.
25 Low night-time capacity Unit capacity is limited. The period when this mode starts, as well as the limited capacity in night-time mode are
controlled in Costomer 1 menu.
26 Unit under SM control Unit is under control of a System Manager (FSM or CSM III).
27 Master/slave link active Unit is connected to a secondary unit by a master slave link and either:
- the unit is configured as a master and this master is operating, or
- the unit is configured as a slave and this slave is operating.
4.5.2 - Description of the Temperatures menu 4.5.3 - Description of the Pressures menu
TEMPERATURES MENU [2] PRESSURES MENU [2]
ITEM FORMAT UNITS COMMENTS
0 ±nn.n °C Evaporator entering water temperature
0 nnnn kPa Discharge pressure circuit A
1 ±nn.n °C Evaporator leaving water temperature
1 nnnn kPa Suction pressure circuit A
2[1] ±nn.n °C Condenser entering water temperature
2 nnnn kPa Oil pressure compressor A1
3[1] ±nn.n °C Condenser leaving water temperature
3[1] nnnn kPa Oil pressure compressor A2
4[1] ±nn.n °C Reclaim condenser entering water temperature
4 nnnn kPa Differential oil pressure compressor A1
5[1] ±nn.n °C Reclaim condenser leaving water temperature
5[1] nnnn kPa Differential oil pressure compressor A2
6 ±nn.n °C Saturated discharge temperature circuit A
6 nnnn kPa Economizer pressure A1
7 ±nn.n °C Saturated suction temperature circuit A
7[1] nnnn kPa Economizer pressure A2
8 ±nn.n °C Discharge gas temperature circuit A
8 nnnn kPa Discharge pressure circuit B
9 ±nn.n °C Discharge superheat temperature circuit A
9 nnnn kPa Suction pressure circuit B
10 ±nn.n °C Motor temperature A1
10 nnnn kPa Oil pressure compressor B1
11[1] ±nn.n °C Motor temperature A2
11[1] nnnn kPa Oil pressure compressor B2
12 ±nn.n °C Saturated discharge temperature circuit B
12 nnnn kPa Differential oil pressure compressor B1
13 ±nn.n °C Saturated suction temperature circuit B
13[1] nnnn kPa Differential oil pressure compressor B2
14 ±nn.n °C Discharge gas temperature circuit B
14 nnnn kPa Economizer pressure B1
15 ±nn.n °C Discharge superheat temperature circuit B
15[1] nnnn kPa Economizer pressure B2
16 ±nn.n °C Motor temperature B1
16[1] nnnn kPa Remote discharge pressure, circuit A
17[1] ±nn.n °C Motor temperature B2
17[1] nnnn kPa Remote discharge pressure, circuit B
18 ±nn.n °C Outdoor temperature
18[1] nnnn kPa Pumpdown pressure, heat reclaim, circuit A
19[1] ±nn.n °C Water loop temperature, master/slave assembly
19[1] nnnn kPa Pumpdown pressure, heat reclaim, circuit B
Legend
Legend
1 This item is displayed in certain unit configurations only
2 Access to this menu is read-only.
2 Access to this menu is read-only
15
4.5.4 - Description of the Setpoints menu
SETPOINTS MENU [2]

ITEM FORMAT UNITS RANGE COMMENTS
0 ±nn.n °C See table below This item lets you display and modify Cooling setpoint 1*
1 ±nn.n °C See table below This item lets you display and modify Cooling setpoint 2*
2 nnn °C See table below This item lets you display and modify Heating setpoint*, only displayed for heat pumps.
3 [1] nnn °C See table below This item lets you display and modify the condensing setpoint*. It is used by the control to regulate the fan
stages or a variable-speed fan (air-cooled units) or the condenser water valve control (water-cooled units),
if the unit is not in heat reclaim mode.
4 [1] nnn °C See table below This item lets you display and modify the heat reclaim setpoint*. As item 3, this is used for condensing
setpoint control.
5 nnn % 0 to 100 Capacity limit setpoint. Limitation by volt-free contact. This item is used to define the maximum capacity
that the unit is authorised to use, if the capacity limit contact activate the limit. See section 5.8.
6 [1] ±nn.n °C/min 0.1 to 1.1 Cooling ramp loading rate. This parameter is only accessible if the ramp function is validated in the User
Configuration 1 menu. This item refers to the maximum rate of temperature rise in °C in the water heat
exchanger in cooling mode. When capacity loading is effectively limited by the ramp, mode 11 is active.
7 [1] ±nn.n °C/min 0.1 to 1.1 Heating ramp loading rate. This parameter is only accessible if the ramp function is validated in the User
Configuration 1 menu. This item refers to the maximum rate of temperature drop in °C in the water heat
exchanger in heating mode. When capacity loading is effectively limited by the ramp, mode 11 is active.
8 [1] ±nn.n [3] See table below Zero reset threshold, cooling mode**
9 [1] ±nn.n [3] See table below Full reset threshold, cooling mode**
10 [1] ±nn.n °C See table below Full reset value, cooling mode**
11 [1] ±nn.n [3] See table below Zero reset threshold, heating mode**
12 [1] ±nn.n [3] See table below Full reset threshold, heating mode**
13 [1] ±nn.n °C -16 to 16 Full reset value, heating mode**
Legend
2 All points contained in this table can be modified.
* Those setpoints can be used for entering or leaving water temperature control. By default the unit controls the evaporator entering fluid temperature.
Leaving fluid temperature control requires a parameter modification in the Service Configuration menu.
** These parameters are only accessible when reset based on OAT or delta T has been selected in the User Configuration 1 menu. See section 4.5.7.3.
SETPOINT DESCRIPTION CONTROL FOR CONTROL FOR

LEAVING WATER ENTERING WATER
Cooling Minimum setpoint
- Water 3.3°C 9.3°C
- Medium Brine -10°C -4°C
- Low Brine -20°C -14°C
Maximum setpoint
Heating* Maximum setpoint MCT - 4.0 K MCT - 10.0 K
Note:
Three setpoint reset configuration modes can be selected in the Customer 1
menu:
1 Reset using an external 0-10 V d.c. signal
2 Reset using Delta T
3 Reset by external temperature sensor (air-cooled units only)
The items with zero reset or maximum reset are based on these three modes.
* MCT = Maximum Condensing Temperature (depending on the application)
16
4.5.5 - Description of the Inputs menu
INPUTS MENU [2]

0 OPEn/CLoS - Remote contact 1 status
This contact is used to start (contact closed) and stop (contact open) the chiller. It is only valid, if the unit is in the remote operating
control (rEM) mode.
1 OPEn/CLoS - Remote contact 2 status
This contact is used to select a cooling only setpoint, if the unit is in cooling mode and in the remote operating control (rEM) type.
Contact open = csp1
Contact closed = csp2
2[1] OPEn/CLoS - Remote contact 3 status
This contact is used to select the heating or cooling mode, only if the unit is in the remote operating control type.
Contact open: unit in cooling mode
Contact closed: unit in heating mode
3[3] OPEn/CLoS - Remote contact 4 status
This contact is used to select the second condensing setpoint or the heat reclaim mode (for a heat reclaim unit), only if the unit is in
the remote operating control type.
Contact open = unit uses the normal condensing setpoint and is in normal mode (no heat reclaim)
Contact closed = unit uses the heat reclaim setpoint and is in heat reclaim mode.
4 OPEn/CLoS - Remote contact 5 status*
If this contact is closed, it permits limiting the unit demand, based on the demand limit setpoint, if the demand limit method by contact
has been selected.
5 OPEn/CLoS - Water flow contact status* and customer interlock control
Opening of this contact shuts the unit off or prevents its start-up and generates an alarm. It is used to control the water circulation.
6[1] OPEn/CLoS - Water pump operation status. If the contact opens when the evaporator pump has received a command to operate, this trips a
pump failure alarm.
7[1] OPEn/CLoS - Condenser water flow control. Controls the condenser water circulation.
8[1] OPEn/CLoS - Control box thermostat and phase reversal interlock status. Opening of this contact shuts the unit off or prevents its start-up and
generates an alarm.
9 OPEn/CLoS - Oil level, circuit A
10 OPEn/CLoS - Oil level, circuit B
11 0 - 10 Volts External signal
12 nnn Amp. Compressor A1 current
13[1] nnn Amp. Compressor A2 current
14[1] nnn Amp. Compressor B1 current
15[1] nnn Amp. Compressor B2 current
16 nnnn Amp. Total compressor operating current
Legend
2 Access to this menu is read-only
* Active in all operating types
See section 3.4
17
4.5.6 - Description of the Outputs/Tests menu
4.5.6.1 - General
This menu displays the status of the controller outputs. More-
over, when the machine is fully stopped (LOFF) the outputs
can be activated for manual or automatic tests (the access to
the tests is password controlled).
4.5.6.2 - Menu description

OUTPUTS STATUS AND TESTS MENU [2] [3]
0 This item returns you to the previous menu.
1 Compressor status
- b1 = compressor A1
- b2 = compressor A2
- b3 = compressor B1
- b4 = compressor B2
The compressor status cannot be forced
2 [1] Loader status
- b1 = loader 1 circuit A
- b2 = loader 2 circuit A
- b3 = loader 1 circuit B
- b4 = loader 2 circuit B
This item permits display of the loader status in circuits A or B. It also permits independent testing. In test mode the direction
arrows permit successive display of 0001, 0010, 0100 and 1000, so as to in turn force authorisation of each output.
3 [1] tEST Motor cooling valve status/test circuit A
- b1 = main valve compressor A1
- b2 = additional valve or economizer compressor A1
- b3 = main valve compressor A2
- b4 = additional valve or economizer compressor A2
This item permits display of the motor cooling valve status in circuit A. It also permits independent testing. In test mode the
direction arrows permit successive display of 0001, 0010, 0100 and 1000, so as to in turn force authorisation of each output.
4 [1] tEST Motor cooling valve status/test circuit B
- b1 = main valve compressor B1
- b2 = additional valve or economizer compressor B1
- b3 = main valve compressor B2
- b4 = additional valve or economizer compressor B2
This item permits display of the motor cooling valve status in circuit B. It also permits independent testing. In test mode the
direction arrows permit successive display of 0001, 0010, 0100 and 1000, so as to in turn force authorisation of each output.
5 tEST % Motor cooling valve cycle status/test, circuit A
Only for units with economizer
6 tEST % Motor cooling valve cycle status/test, circuit B
Only for units with economizer
7 tESt Oil solenoid valve status/test
- b1 = oil solenoid valve compressor A1
- b2 = oil solenoid valve compressor A2
- b3 = oil solenoid valve compressor B1
- b4 = oil solenoid valve compressor B2
This item permits display of the different compressor valves.
It also permits independent testing. In test mode the direction arrows permit successive display of 0001, 0010, 0100 and 1000, so
as to in turn force authorisation of each output.
8 tESt Refrigerant shut-off valve status/test
Only for units with evaporator heater
- b1 = Shut-off valve, circuit A
- b2 = Shut-off valve, circuit B
In test mode the direction arrows permit successive display of 01 and 10, so as to in turn force authorisation of each heater output.
9 tESt Oil heater output status/test, circuits A and B
- b1 = oil heater, circuit A
- b2 = oil heater, circuit B
In test mode the direction arrows permit successive display of 01 and 10, so as to in turn force authorisation of each heater output.
10 tESt Oil pump output status/test, circuits A and B
- b1 = oil pump, circuit A
b2 = oil pump, circuit B
In test mode the direction arrows permit successive display of 01 and 10, so as to in turn force authorisation of each oil pump
output.
Legend
2 A test is only possible if the units are in local off mode and if all compressors have stopped
3 The password is only valid for the test. 'Test' is displayed during the test, alternating with the item number
18
OUTPUTS STATUS 2 AND TESTS MENU [2] [3]
0 This item returns you to the previous menu.
1 [1] tESt 0-8 Fan contactor status/test, circuit A
This item permits display of the number of fan stages. It also permits them to be tested in a sequentially. In test mode the
direction arrows permit successive display from 0 to 8, so as to authorise the forcing the outputs.
2 [1] tESt 0-8 Fan contactor status/test, circuit B
This item permits display of the number of fan stages. It also permits them to be tested in a sequentially. In test mode the
direction arrows permit successive display from 0 to 8, so as to authorise the forcing the outputs.
3 tESt Alarm command status/test
- b1 = alarm circuit A
- b2 = alarm circuit B
In test mode the direction arrows permit successive display of 01 and 10, so as to in turn force authorisation of each alarm
output.
4 tESt % EXV position, circuit A
In the test mode the direction arrows permit forcing the valve to its fully open position.
5 tESt % EXV position, circuit B
In the test mode the direction arrows permit forcing the valve to its fully open position.
6 [1] tESt % Variable speed fan, circuit A or condenser water valve position in %
7 [1] tESt % Variable speed fan, circuit B or condenser water valve position in %
8 On - Evaporator water pump No. 1 command status. Not displayed if unit does not control a pump.
Stop - On: the pump operates
tESt - Stop: the pump has stopped
FAIL - Forc: This item is only displayed if the unit is in local off mode (LOFF). Selecting this item permits energising the pump without
Good - delay and for an unlimited period. The pump continues to operate, until any key on the user interface is pressed: it is then
Forc - immediately switched off. If the unit is in CCN control mode, the pump status is displayed alternately with 'Forc' if its status is
forced by CCN.
During the test phase, pump supply is energised for 10 seconds only. When the test has finished, the following display
appears:
- Fail: displayed if the test has failed, because the pump is not started
- Good: displayed if the test succeeds
9 On - Evaporator water pump No. 2 command status. Not displayed if unit does not control a pump.
OFF - On: the pump operates
tESt - Stop: the pump has stopped
FAIL - Forc: This item is only displayed if the unit is in local off mode (LOFF). Selecting this item permits energising the pump without
Good - delay and for an unlimited period. The pump continues to operate, until any key on the user interface is pressed: it is then
Forc - immediately switched off. If the unit is in CCN control mode, the pump status is displayed alternately with 'Forc' if its status is
forced by CCN.
appears:
10 On - Condenser pump status/test
OFF - On: the pump operates
tESt Stop: the pump has stopped
FAIL Forc: This item is only displayed if the unit is in local off mode (LOFF). Selecting this item permits energising the pump without
Good delay and for an unlimited period. The pump continues to operate, until any key on the user interface is pressed: it is then
Forc immediately switched off. If the unit is in CCN control mode, the pump status is displayed alternately with 'Forc' if its status is
- forced by CCN.
appears:
11[1] nn Evaporator heater and heat reclaim condenser status
- b1 = evaporator heater
- b2 = heat reclaim condenser heater
12[1] tESt % Condenser water valve position in heat reclaim mode
13[1] Solenoid valve status/test, heat reclaim function
- b1 = heat reclaim coil shutoff solenoid valve, circuit A
- b2 = heat reclaim coil drain solenoid valve, circuit A
- b3 = heat reclaim coil shutoff solenoid valve, circuit B
- b4 = heat reclaim coil drain solenoid valve, circuit B
In test mode the direction arrows permit successive display of 0001, 0010, 0100 and 1000, so as to in turn force authorisation
of each output.
14 YES Used only for local interface
no Cause all diodes and blocks to light up or flash, to verify that they are operating correctly
tESt
Legend
2 A test is only possible if the units are in local off mode and if all compressors have stopped
3 The password is only valid for the test. 'Test' is displayed during the test, alternating with the item number
19
4.5.6.3 - Manual tests The menus User 1 [USEr 1] and User 2 [USEr 2] are pass-
This function allows the user to test the outputs individually, if word-protected. The other menus are directly accessible,
the machine is completely shut down (LOFF). To carry out a except if item 6 of the User 1 menu (password for all
manual test use the arrow keys to access the output to be tested configurations) has been validated.
and press the Enter key (longer than 2 seconds) to activate the
modification mode. The password is automatically requested, if 4.5.7.2 - Password
it has not previously been verified. The Outputs/Test LED on A password must be entered in order to access the test function
the user interface begins to flash. Enter the desired test value or to modify a configuration. It is automatically requested, if
and again press Enter to start the test. 'TESt' is displayed on the necessary: 'EntEr PASS' is displayed on the 4-digit display and
4-digit display alternately with the value tested. The Outputs/ the configuration menu LED flashes, indicating that the
Test LED stops flashing. Press the Enter key or an arrow key to modifi-cation mode is active. Press the arrow keys until the
stop the test. value '11' is displayed on the 4-digit display. Press Enter to
validate this. The configuration menu LED stops flashing. If
4.5.7 - Description of the Configuration menu the password is correct, 'Good' is displayed. If the password is
incorrect, 'PASS incorrEct' is displayed. The User password has
4.5.7.1- General a default value of 11.
This menu can be used to display and modify all configura-
tions: Factory, Service and User. Only the User Configuration This value can be modified through the Service configuration.
can be modified by the end-user. The Factory, Service and The password can be entered if the unit is fully stopped, other-
master/slave configurations are not described in this docu- wise 'ACCES dEniEd' (access denied) will be displayed on the
ment. A configuration can only be modified if the unit is fully 4-digit display. The controller automatically deactivates the
stopped (LOFF). password after 5 minutes without activity (i.e. no buttons
pressed) or after powering up.
SUB-MENU USER CONFIGURATION

ITEM USER 1 USER 2 DATE SCHEDULE 1 SCHEDULE2 HOLIDAYS BROADCAST
[USER1] [USER2]* [DATE]* [SCHEDULE 1MENU]* [SCHEDULE 2 MENU]* [HOLIDAY MENU]* [BRODCAST]*
0 Return to previous Return to previous Return to Return to previous Return to previous Return to previous menu Return to previous
menu menu* previous menu menu menu menu
1 Circuit selection Periodic pump Hour* SUB-MENU: SUB-MENU: SUB-MENU: Broadcast
start-up* Period 1 [PErIod 1] Period 1 [PErIod 1] Holidays 1 [HOLidAy 1] acknowledger selection
2 Circuit capacity Night mode - start Day of the SUB-MENU: SUB-MENU: SUB-MENU: Broadcast activation
increase sequence hour* week* Period 2 [PErIod 2] Period 2 [PErIod 2] Holidays 2 [HOLidAy 2]
3 Ramp selection* Night mode - end Day and SUB-MENU: SUB-MENU: SUB-MENU: Outdoor temperature
hour* month* Period 3 [PErIod 3] Period 3 [PErIod 3] Holidays 3 [HOLidAy 3] broadcast bus
4 Start-up delay* Night mode - Year* SUB-MENU: SUB-MENU: SUB-MENU: Outdoor temperature
demand limit in % Period 4 [PErIod 4] Period 4 [PErIod 4] Holidays 4 [HOLidAy 4] broadcast element
5 Water pump selection Number clock 1* - SUB-MENU: SUB-MENU: SUB-MENU: Start month daylight
Period 5 [PErIod 5] Period 5 [PErIod 5] Holidays 5 [HOLidAy 5] saving time
6 Water pump changover Number clock 2* - SUB-MENU: SUB-MENU: SUB-MENU: Start day daylight
delay* Period 6 [PErIod 6] Period 6 [PErIod 6] Holidays 6 [HOLidAy 6] saving time
7 Automatic reset CCN address * - SUB-MENU: SUB-MENU: SUB-MENU: Start hour daylight
selection* Period 7 [PErIod 7] Period 7 [PErIod 7] Holidays 7 [HOLidAy 7] saving time
8 Demand limit selection CCN bus* - SUB-MENU: SUB-MENU: SUB-MENU: Minutes to add
Period 8 [PErIod 8] Period 8 [PErIod 8] Holidays 8 [HOLidAy 8]
9 Voltage corresponding - - - - SUB-MENU: End month daylight
to 100% of demand limit Holidays 9 [HOLidAy 9] saving time
10 Voltage corresponding - - - - SUB-MENU: End day daylight saving
to 0% of demand limit Holidays 10 [HOLidAy 10] time
11 Extended display - - - - SUB-MENU: End hour daylight
selection Holidays 11 [HOLidAy 11] saving time
12 Password for all user - - - - SUB-MENU: Minutes to subtract
configurations Holidays 12 [HOLidAy 12]
13 Software version - - - - SUB-MENU: -
number Holidays 13 [HOLidAy 13]
14 Total compressor - - - - SUB-MENU: -
current limit Holidays 14 [HOLidAy 14]
15 - - - - - SUB-MENU: -
Holidays 15 [HOLidAy 15]
16 - - - - - SUB-MENU: -
Holidays 16 [HOLidAy 16]
Legend:
* Only displayed if configuration requires.
20
CONFIGURATION
USER
[USEr]
USER1 USER2 SCHEDULE 1 SCHEDULE 2 HOLIDAYS HOUR + DATE BROADCAST

[USEr 1] [USEr 2] [SCHEduLE 1]* [SCHEduLE 2]* [HOLIDAYS]* [dAtE]* [broAdCASt]*
PERIOD 1 PERIOD 1 HOLIDAY 1
PERIOD 2 PERIOD 2 HOLIDAY 2
PERIOD 3 PERIOD 3
HOLIDAY 3
PERIOD 4 PERIOD 4
HOLIDAY 4
PERIOD 5 PERIOD 5
HOLIDAY 5
PERIOD 6 PERIOD 6
HOLIDAY 6
PERIOD 7 PERIOD 7
HOLIDAY 7
PERIOD 8 PERIOD 8
HOLIDAY 8
...
...
...
HOLIDAY 15
HOLIDAY 16
SUB-MENU PERIOD CONFIGURATION* SUB-MENU HOLIDAY CONFIGURATION*

Item PERIOD 1 to 8 Item HOLIDAYS 1 to 16
[PEriod X MEnu]* [HoLidAy X MEnu]*
0 Return to previous menu 0 Return to previous menu
1 Start of occupied period 1 Start month holidays
2 End of occupied period 3 Start day holidays
3 Selection Monday 4 Number of days, holidays
4 Selection Tuesday
5 Selection Wednesday Legend
* Only displayed if configuration requires.
6 Selection Thursday
7 Selection Friday
8 Selection Saturday NOTE: The items in brackets show what is displayed on the
9 Selection Sunday user interface.
10 Selection holidays
21
4.5.7.3 - Description of the User 1 Configuration sub-menu
USER 1 CONFIGURATION SUB-MENU [2]
ITEM FORMAT UNITS DEFAULT COMMENTS
0 USEr MEnu - - When selected this item authorises return to the previous menu.
1 [1] 0/1/2 0 Lead circuit selection
0 = automatic based on the number of start-ups and the operating hours of each circuit
1 = lead circuit A
2 = lead circuit B
2 [1] 0/1 - 0 Circuit capacity increase sequence
0 = equal charge for both circuits
1 = priority charge on one circuit
3 [1] YES/no - no Ramp loading select. For units with more than one compressor per circuit.
Yes = ramp enabled
No = ramp disabled
This configuration enables the ramp to be activated for heating or cooling (depending on configuration): the
maximum rate (in °C/min) of temperature drop or rise for the heat exchanger water (leaving or entering, upon
configuration). Ramp setting value can be configured in the Setpoint menu.
4 1 to 15 min 1 Delay at start-up. This value is reinitialised after power-up or when both circuits are halted by local, remote or
CCN command. No compressor will be started up until this pause has expired. However, the evaporator pump
command will be activated immediately. The safety lockout loop will not be checked until the pause has expired.
5 0/1/2/3/4 - 0 Pump sequence select
0 = no pump
1 = one pump only
2 = two pumps with auto rotation
3 = pump #1 manual select
4 = pump #2 manual select
If the auto sequence is selected, the pump change-over occurs when the rotation delay is elapsed. If the
manual sequence is selected then, the selected pump is used in priority. Change-over occurs if one pump fails.
6 [1] 24 to 3000 hours 48 Pump changeover delay. Displayed if auto pump sequence is selected. This parameter is used for pump
auto-rotation: the control tries to limit the pump run time difference to the pump changeover delay value.
Change-over between pumps occurs when this difference becomes greater than the configured pump
changeover delay.
7 0/1/2/3 - 0 Automatic reset selection. Permits activation of automatic reset type
0 = none
1 = 0-10 V d.c. reference voltage
2 = temperature difference
3 = outdoor temperature
8 0/1/2 - 0 Demand limit selection
0 = demand limit not selected
1 = demand limit by contact
2 = demand limit by external signal 0-10 V d.c.
9 [1] 0 to 10 Volts 0 Voltage corresponding to 100% of the demand limit
10 [1] 0 to 10 Volts 0 Voltage corresponding to 0% of the demand limit
11 «YES/no» - yes Extended menu select
Yes = menu description available
No = menu description not available
This item authorises activating or inhibiting the menu item expanded display.
12 «YES/no» - no Password for all User Configurations
Yes = password required for all User Configurations (Date, Time Schedule, Broadcast)
No = password require for User menu only
When this item is validated, the User Password will be required for all configurations accessible by the User.
13 nn.n - - Software version number
This item shows the number of the software version used by this controller. Access is read only.
14 nnnn Amp 1500 Total compressor current limit
This item is used to set the maximum limit for the total compressor running current (see paragraph “Pro-
Dialog Plus control operations/Limiting the unit running current”)
Legend
1 This item is masked when not used.
2 Access to menu is read/write.
22
4.5.7.4 - Description of the User 2 Configuration sub-menu
USER 1 CONFIGURATION SUB-MENU

ITEM FORMAT UNITS DEFAULT COMMENTS
0 USEr 2 Menu When selected this item authorises return to the previous menu.
1[1] YES/no - no Periodic pump quick-start of the water pump(s)
Yes = the pump is started periodically when the unit is manually stopped.
No = periodic pump start is disabled
When the unit is manually stopped (e.g. during the winter season) the pump is started each day at 14.00 hours
for 2 seconds. If two pumps are available, pump #1 is started on odd days and pump #2 on even days.
2 [1] n1n2n3 n4 Night control mode - start time*
00:00 to 23:59 - 00:00 Authorises entering the time of day at which the night control mode starts. During this period the fan runs at
low speed (to reduce fan noise) if permitted by operating conditions, and unit capacity is limited to the
maximum night values.
3 [1] n1n2n3 n4 Night control mode - end time*
00:00 to 23:59 - 00:00 Authorises entering the time of day at which the night control mode ends.
4 [1] 0 to 100 % - Night mode demand limit value.
Authorises configuration of the maximum capacity authorised during the night mode.
5 [1] 0 or 65 to 99 - 0 Schedule 1 clock number (for unit on/off schedule, see section 4.5.7.6).
0 = schedule in local operating mode
65 to 99 = schedule in CCN operating mode
6 [1] 0 or 65 to 99 - 0 Schedule 2 clock number (schedule for setpoint selection, see section 4.5.7.6).
0 = schedule in local operating mode
65 to 99 = schedule in CCN operating mode
7 [1] 1 to 239 - 1 CCN element address.
No two network elements can have the same element number and bus number at the same time.
8 [1] 0 to 239 - 0 CCN bus number.
No two network elements can have the same element number and bus number at the same time.
Legend
* n1n2: hours (00 to 23). The first time the Enter button is continuously pressed, the first two characters in the 4-digit display flash so that hours can be adjusted.
n3n4: minutes (00 to 59). Continuous pressing of the Enter key again causes the last two characters to flash so that minutes can be adjusted.
4.5.7.5 - Description of Date and Time configuration sub- 4.5.7.6 - Description of the Time Schedules sub-menus
menu The control provides two timer programs. If the CCN/clock
board is not installed, the two schedules are permanently in
DATE & TIME CONFIGURATION SUB-MENU occupied mode.
ITEM FORMAT COMMENTS
0 dAtE MEnu When selected this item authorises return to the
previous menu.
The first timer program (schedule #1) provides a means to
1 n 1n 2n 3n 4 Current time setting.
automatically switch the unit from an occupied mode to an
00:00 to 23:59 n1n2: hours (00 to 23). The first time the Enter button is unoccupied mode: the unit is started during occupied periods.
continuously pressed, the first two characters in the 4-
digit display flash so that hours can be adjusted.
n3n4: minutes (00 to 59). Continuous pressing of the The second timer program (schedule #2) provides a means to
Enter key again causes the last two characters to flash automatically switch (when auto mode is selected) the active
and minutes can be adjusted.
setpoint from an occupied setpoint to an unoccupied setpoint.
2 Current day of week setting.
«Mon» Monday Cooling or heating setpoint 1 is used during occupied periods.
«tUe» Tuesday Cooling setpoint 2 is used during unoccupied periods. For
«uEd» Wednesday
«tHu» Thursday additional information on setpoint activation see section 5.7.1.
«FrI» Friday
«SAt» Saturday
«Sun» Sunday
Each schedule consists of eight time periods set by the
3 n 1n 2n 3n 4 Current day and month setting. operator. These time periods can be flagged to be in effect or
01:01 to 31:12 n1n2:day (01 to 31). The first time the Enter button is not in effect on each day of the week plus a holiday period (see
continuously pressed, the first two characters in the 4-
digit display flash so that day can be adjusted.
section 4.5.7.7 on public holidays). The day begins at 00.00
n3n4:month (01 to 12). Continuous pressing of the Enter hours and ends at 24.00 hours.
key again causes the last two characters to flash so
that month can be adjusted.
Program is in unoccupied mode unless a schedule time period
4 nnnn Current year setting.
is in effect. If two periods overlap and are both active on the
same day, the occupied mode takes priority over the
unoccupied period.
Each of the eight periods can be displayed and changed with

the aid of a sub-sub-menu. The table below shows how to
access the period configuration. Method is the same for the
time schedule #1 or the time schedule #2.
23
PERIOD X CONFIGURATION SUB-MENUS (X = 1 to 8) 4.5.7.7 - Description of the Holidays sub-menus
ITEM # FORMAT COMMENTS This function is used to define 16 public holiday periods. Each
0 Period X Menu Indicates the period (X) you are going to configure.
When selected this item authorises a return to the
period is defined with the aid of three parameters: the month,
main menu. starting day and duration of the public holiday period. During
1 n1n2n3n4 Occupied period - Start time*. these public holidays the controller will be in occupied or
00:00 to 24:00 Authorises entering the time of day at which the unoccupied mode, depending on the programmed periods
occupied period starts.
2 n1n2n3n4 Occupied period - End time*.
validated for public holidays (see section 4.5.7.8).
00:00 to 24:00 Authorises entering the time of day at which the
occupied period ends. Each of these public holiday periods can be displayed and
3 Mo- 0 or Mo- 1 1 = the period is in effect on Monday.
0 = period not in effect on Monday
changed with the aid of a sub-menu.
4 tu- 0 or tu- 1 1 = the period is in effect on Tuesday.
0 = period not in effect on Tuesday. ATTENTION: The broadcast function must be activated to
5 UE-0 or UE- 1 1 = the period is in effect on Wednesday. utilise the holiday schedule, even if the unit is running in
0 = period not in effect on Wednesday.
stand-alone mode (not connected to CCN). See section
6 tH- 0 or tH- 1 1 = the period is in effect on Thursday.
0 = period not in effect on Thursday.
4.5.7.6.
7 Fr-0 or Fr- 1 1 = the period is in effect on Friday. HOLIDAY PERIOD X CONFIGURATION SUB-MENUS (X = 1 to 16)
0 = period not in effect on Friday.
ITEM # FORMAT COMMENTS
8 SA- 0 or SA- 1 1 = the period is in effect on Saturday.
0 = period not in effect on Saturday. 0 HoLidAy X Sub-menu When selected this item authorises a return to
the configuration menu.
9 Su- 0 or Su- 1 1 = the period is in effect on Sunday.
0 = period not in effect on Sunday. 1 0 to 12 Start month of public holiday period
0 = period not in use
10 Ho- 0 or Ho- 1 1 = the period is in effect on public holidays. 1 = January, 2 = February, etc.
0 = period not in effect on public holidays.
2 0 to 31 Start day of public holiday period. 0 period
Legend not in use.
* n1n2: hours (00 to 24). The first time the Enter button is continuously pressed,
the first two characters in the 4-digit display flash so that hours can be 3 0 to 99 days Duration of the public holiday period in
adjusted. days.
n3n4: minutes (00 to 59). Continuous pressing of the Enter key again causes
the last two characters to flash so that minutes can be adjusted. Typical programming for public holidays:
A public holiday period lasting 1 day on 20th May, for instance, is configured as
Typical timer program: follows: start month = 5, start day = 20, duration = 1
A public holiday period lasting 2 day on 25th May, for instance, is configured as
follows: start month = 5, start day = 25, duration = 2
Time MON TUE WES THU FRI SAT SUN HOL
0 P1 4.5.7.8 - Description of the Broadcast sub-menu

1 P1 The controller provides a broadcast configuration menu which
2 P1 you can use to configure the unit to be the CCN’s broadcaster,
3
responsible for transmitting the time, outdoor temperature, and
4
5
holiday flags to all system elements.
6
7 P2 P2 P3 P4 P4 P5 This menu also authorises setting the date to begin and end
8 P2 P2 P3 P4 P4 P5 daylight saving time. There should be only one broadcaster in a
9 P2 P2 P3 P4 P4 P5
CCN, so this table should not be configured if any other system
10 P2 P2 P3 P4 P4 P5
11 P2 P2 P3 P4 P4 P5
element is acting as broadcaster.
12 P2 P2 P3 P4 P4
13 P2 P2 P3 P4 P4 ATTENTION: If the unit operates in standalone mode (not
MON : Monday
14 P2 P2 P3 P4 P4
CCN connected) this menu must be used if the holiday function
TUE : Tuesday
15 P2 P2 P3 P4 P4 WED : Wednesday
THU : Thursday
is used, or to correct for daylight saving time.
16 P2 P2 P3 P4 P4
FRI : Friday
17 P2 P2 P3 SAT : Saturday
18 P3 SUN : Sunday
19 P3 HOL : Public holidays
20 P3 P6
21
22
23 Occupied
Unoccupied
24
Starts at Ends at Active on

P1: period 1, 0h00, 3h00, Monday
P2: period 2, 7h00, 18h00, Monday and Tuesday
P3: period 3, 7h00, 21h00, Wednesday
P4: period 4, 7h00, 17h00, Thursday and Friday
P5: period 5, 7h00, 12h00, Saturday
P6: period 6, 20h00, 21h00, Public holidays
P7: period 7, Not used in this example
P8: period 8, Not used in this example
24
BROADCAST CONFIGURATION SUB-MENU
0 broAdCASt MEnu When selected this item authorises a return to the main menu.
1 YES/no Determines whether or not the unit is a broadcast acknowledger when the unit is connected on a CCN network. There must be only
one broadcast acknowledger in a CCN.
Warning: if the unit operates in standalone mode (not CCN connected) this choice must be set to Yes if the holiday function is used
(see section 4.5.7.8) or if you want to configure the daylight saving time function.
2 YES/no This item authorises enabling or disabling the Broadcast function. When it is set to Yes, the control will make a periodic broadcast
on the CCN. When it is set to No, the control is not the broadcaster and there is no need to configure the other choice in this table.
There must be only one broadcaster in a CCN and this item should not be configured if any other system element is acting as
broadcaster.
Warning: if the unit operates in standalone (not CCN connected) this choice must be set to Yes if the holiday function is used (see
section 4.5.7.8) or if you want to configure the daylight saving time function.
3 nnn OAT Broadcaster bus number: it is the bus number of the system that has the outside air temperature sensor connected to it.
0 to 239 Used for CCN network function only.
4 nnn OAT Broadcaster element number: it is the element number of the system element that has the outside air temperature sensor
0 to 239 connected to it. Used for CCN network function only.
5 nn Daylight saving start month. In this mode you enter the month in which the broadcaster will adjust its time for the start of
1 to 12 daylight saving time.
6 nn Daylight saving start day. In this mode you enter the day on which the broadcaster will adjust its time for the start of daylight
1 to 31 saving time.
7 n 1n 2n 3n 4 Authorises entering the hours and minutes for saving start. In this mode you enter the time of day when the broadcaster will
00:00 to 24:00 adjust its time for the start of daylight saving time.
n1n2: hours (00 to 24). The first time the Enter button is continuously pressed, the first two characters in the 4-digit display flash so that
hours can be adjusted.
n3n4: minutes (00 to 59). Continuous pressing of the Enter key again causes the last two characters to flash so that minutes can be
adjusted.
8 nnnn Daylight saving start minutes to add: number of minutes by which the broadcaster will adjust its time for the start of daylight
1 to 1440 minutes saving time.
9 nn Daylight saving stop month. In this mode you enter the month in which the broadcaster will adjust its time for the end of
1 to 12 daylight saving time.
10 nn Daylight saving stop day. In this mode you enter the day on which the broadcaster will adjust its time for the end of daylight
1 to 31 saving time.
11 n 1n 2n 3n 4 Authorises entering the hours and minutes for saving stop. In this mode you enter the time of day when the broadcaster
00:00 to 24:00 will adjust its time for the end of daylight saving time.
12 nnnn Daylight saving start minutes to subtract: number of minutes by which the broadcaster will adjust its time for the end of
1 to 1440 minutes daylight saving time.
Legend
n1n2: hours (00 to 24). The first time the Enter button is continuously pressed, the first two characters in the 4-digit display flash so that hours can be adjusted.
n3n4: minutes (00 to 59). Continuous pressing of the Enter key again causes the last two characters to flash so that minutes can be adjusted.
4.5.8 - Description of the Alarms menu 4.5.9 - Description of the Alarms History menu
This menu is used to display and reset up to 5 active alarms. It
ALARMS HISTORY MENU
also permits alarm reset. If no alarm is active this menu is not
accessible. See section 6 for a complete description of the 1 [1] nn Alarm history code 1*
alarm codes and alarm reset. 2 [1] nn Alarm history code 2*
3 [1] nn Alarm history code 3*
ALARMS MENU
ITEM # FORMAT DESCRIPTION
0 [1] X ALArM X alarms are active
rESEt ALArM Reset of alarms is requested
To reset all active alarms, continuously press the Enter 8 [1] nn Alarm history code 8*
key. ‘rESET ALArM’ is then displayed. Press the select
key again: all alarms are reset.
1 [1] nn Current alarm code 1*
Legend
1 This item is masked when nil
3 [1] nn Current alarm code 3* * Pressing the Enter key when alarm code is displayed causes the following
4 [1] nn Current alarm code 4* message to be scrolled:
“time of alarm” “date of alarm” “full CCN alarm message”
- “time of alarm”: hh-mm
Legend - “date”: dd-mm
1 This item is masked when nil - “full CCN alarm message”: up to 64 characters
* Pressing the Enter key when alarm code is displayed causes the following
message to be scrolled:
“time of alarm” “date of alarm” “full CCN alarm message”
- “time of alarm”: hh-mm
- “date”: dd-mm
- “full CCN alarm message”: up to 64 characters
25
4.5.10 - Runtime menu description 4.5.10.2 - Maintenance menu description
To be active, the maintenance function must be preset in the
RUNTIMES
Service configuration.
ITEM # FORMAT DESCRIPTION
RUNTIMES 1 RUNTIMES 2 MAINTENANCE

0 MAintEnAnCE MEnu When selected this item authorises return to the
[runtiMES 1] [runtiMES 2] [MAintEnAnCE] previous menu.
1 [1] Accessible with the Service password.
2 [1] For future use
NOTE: The items in brackets show what is displayed on the
3 [1] For future use
user interface. 4 [1] ALErt Water loop rate to low
5 [1] nnn/ALErt Next primary pump maintenance operation in nnn
4.5.10.1 - Description of the Runtimes 1 menu days. 'ALErt' is displayed, when the delay before
maintenance has elapsed.
RUNTIMES MENU [2] 6 [1] nnn/ALErt Next secondary pump maintenance operation in
nnn days. 'ALErt' is displayed, when the delay
iTEM # FORMAT UNIT COMMENTS
before maintenance has elapsed.
0 - - When selected this item
7 [1] nnn/ALErt Next water filter maintenance operation in nnn
authorises return to the previous
days. 'ALErt' is displayed, when the delay before
menu
maintenance has elapsed.
1 nnnn | M 10 | M100 hrs/10 or 100 Unit operating hours*
Legend
2 [1] nnnn | M 10 | M100 hrs/10 or 100 Compressor A1 operating hours* 1 This item is masked when not used.
3 [1] nnnn | M 10 | M100 hrs/10 or 100 Compressor A2 operating hours*
4[1] nnnn | M 10 | M100 hrs/10 or 100 Compressor B1 operating hours*
5 [1] nnnn | M 10 | M100 hrs/10 or 100 Compressor B2 operating hours*
6 nnnn | M 10 | M100 -/10 or 100 Machine starts*
7 nnnn | M 10 | M100 -/10 or 100 Compressor A1 starts*
8 [1] nnnn | M 10 | M100 -/10 or 100 Compressor A2 starts*
9 [1] nnnn | M 10 | M100 -/10 or 100 Compressor B1 starts*
10 [1] nnnn | M 10 | M100 -/10 or 100 Compressor B2 starts*
11 nnnn - Number of start-ups for the
compressor with the highest
number during the last hour
12 [1] nnnn - Average number of compressor
start-ups/hour for the last 24
hours
13 [1] nnnn | M 10 | M100 hrs/10 or 100 Pump #1 operating hours*
14 [1] nnnn | M 10 | M100 hrs/10 or 100 Pump #2 operating hours*
15 [1] nnnn | M 10 | M100 hrs/10 or 100 Condenser pump operating
hours
NOTES
1 This item is masked when not used
* Certain values are divided by 10 or by 100, so that number of hours or start-
ups of less then 10 are displayed as 0.
When the value is divided by 10 or by 100 it is displayed in turn with “M 10” or

“M100”.
26
5 - PRO-DIALOG PLUS CONTROL OPERATION - Start/Stop schedule: occupied or unoccupied status of
the unit as determined by the chiller start/stop program
5.1 - Start/stop control (Schedule #1). Used when the unit is equipped with an
optional CCN/clock board, otherwise the chiller occupied
The table below summarises the unit control type and stop or mode is forced to occupied all the time.
go status with regard to the following parameters. - Master control type. This parameter is used when the
- Operating type: this is selected using the start/stop unit is the master unit in a two chiller lead/lag arrange-
button on the front of the user interface. ment. The master control type determines whether the
- Remote start/stop contacts: these contacts are used unit is to be controlled locally, remotely or through CCN
when the unit is in remote operating type (rEM). See (this parameter is a Service configuration).
sections 3.6.2 and 3.6.3. - CCN emergency shutdown: if this CCN command is
- CHIL_S_S: this network command relates to the chiller activated, it shuts the unit down whatever the active
start/stop when the unit is in CCN control (CCn). Vari- operating type.
able forced to disable: the unit is halted. Variable forced to - General alarm: the unit is totally stopped due to failure.
Enable: the unit runs in accordance with schedule 1.
ACTIVE OPERATING TYPE PARAMETER STATUS CONTROL UNIT

TYPE MODE
REMOTE MASTER START/STOP CCN GENERAL
START/STOP CONTROL SCHEDULE EMERGENCY ALARM
LOFF L-ON L-SC rEM CCN MASt CHIL_S_S CONTACT TYPE MODE SHUTDOWN
- - - - - - - - - - Enable - - Off
- - - - - - - - -. -. - Yes - Off
Active - - - - - - - - - - - Local Off
- - Active - - - - - - Unoccupied - - Local Off
- - - Active - - - Off - - - - Remote Off
- - - Active - - - - - Unoccupied - - Remote Off
- - - - Active - Disable - - - - - CCN Off
- - - - Active - - - - Unoccupied - - CCN Off
- - - - - Active - - Local Unoccupied - - Local Off
- - - - - Active - Off Remote - - - Remote Off
- - - - - Active - - Remote Unoccupied - - Remote Off
- - - - - Active Disable - CCN - - - CCN Off
- - - - - Active - - CCN Unoccupied - - CCN Off
- Active - - - - - - - - Disable No Local On
- - Active - - - - - - Occupied Disable No Local On
- - - Active - - - On - Occupied Dsable No Remote On
- - - - Active - Enable - - Occupied Disable No CCN On
- - - - - Active - - Local Occupied Disable No Local On
- - - - - Active - On Remote Occupied Disable No Remote On
- - - - - Active Enable - CCN Occupied Disable No CCN On
5.2 - Heating/cooling selection The current heat/cool operating mode on the unit is indicated
by item 4 in the Information menu and by the heat/cool LEDs
On heat pumps, heating/cooling selection can be controlled on the summary interface.
differently depending on the active operating type:
• Locally on the unit, using operating types L-C1, L-C2,
LC1r and LC2r (for cooling) and L-H (for heating).
• Remotely using the heat/cool selection volt-free contact
when the unit is in Remote operating type (rEM).
• Via a CCN command when the unit is in CCN operating
type (CCn).
PARAMETER STATUS
ON/OFF CONTROL HEATING/COOLING SELECTION REMOTE HEATING/COOLING HC_SEL OPERATING MODE
STATUS TYPE IN LOCAL MODE CONTACTS
Off - - - - Cooling
On Local Cooling - - Cooling
On Local Heating - - Heating
On Remote - Cooling mode - Cooling
On Remote - Heating mode - Heating
On CCN - - Cooling Cooling
On CCN - - Heating Heating
27
5.3 - Evaporator water pump control 5.5 - Control interlock contact
The unit can control one or two evaporator water pumps. The This contact can prevent unit start-up if it is open and if the
evaporator water pump is turned on when this option is confi- start-up delay has passed. Furthermore, this contact must
gured (see User configuration) and when the unit is in one of remain closed when the unit is not in local off, remote or CCN
the on modes described above or in delay mode. Since the control mode. Opening this contact for more than 8 seconds
minimum value for the delay at start-up is 1 minute (configurable while the unit is operating, will cause immediate shut-down of
between 1 and 15 minutes), the pump will run for at least one the faulty unit.
minute before the first compressor starts.
5.6 - Evaporator heater control
The pump is kept running for 20 seconds after the unit goes to
stop mode. The pump keeps working when the unit switches The evaporator heater can be activated to protect an evaporator
from heating to cooling mode or vice-versa. It is turned off if that may be damaged by ice, if the unit is shut down for a long
the unit is shut down due to an alarm unless the fault is a frost period at low outdoor air temperature. If the heater is not
protection error. sufficient to increase the water temperature, the evaporator
pump can be started.
The pump can be started in particular operating conditions
when the evaporator heater is active. See section 5.21 for the NOTE: The evaporator heater control parameters may be
particular evaporator pump control for the follower unit (master/ modified using the Service Configuration menu.
slave assembly). If two pumps are controlled and the reversing
function has been selected (see User 1 configuration), the 5.7 - Control point
control tries to limit the pump run time delta to the configured
pump change-over delay. If this delay has elapsed, the pump Control point represents the leaving water temperature that the
reversing function is activated, when the unit is running. unit must produce.
During the reversing function both pumps run together for two • In cooling mode: control point = active setpoint + reset
seconds. If a pump has failed and a secondary pump is • In heating mode: control point = active setpoint - reset
available, the unit is stopped and started again with this pump.
5.7.1 - Active setpoint
The control provides a means to automatically start the pump Two setpoints can be selected as active in cooling mode.
each day at 14.00 hours for 2 seconds when the unit is off. If Usually, the second setpoint is used for unoccupied periods or
the unit is fitted with two pumps, the first pump is started on for ice storage (medium or low brine unit). A single setpoint is
odd days and the second pump is started on even days. Starting available in heating mode.
the pump periodically for few seconds increases the life-time
of the pump bearings and the tightness of the pump seal. Depending on the current operating mode, the active setpoint
can be selected with the operating type selector button, or with
NOTE: If this function is used, there should not be any the user’s volt-free contacts, or with network commands (see
chilled water pump interlock between terminals 34 and 35 section 3.4).
(see section 3.4).
5.7.2 - Reset
5.4 - Condenser water pump control Reset means that the active setpoint is modified so that less
machine capacity is required (in cooling mode, the setpoint is
Only available on water-cooled units. increased, in heating mode it is decreased). This modification is
in general a reaction to a drop in the load. For the Pro-Dialog
The condenser pump can be controlled by two modes, depend- Plus control system, the source of the reset can be configured
ing on the configuration (only accessible by Carrier Service). in the User 1 configuration: it can be based on an external 0-10 V
1 - Control based on unit start/stop control. In this case it is signal, provided either by the outdoor temperature (that gives a
controlled in the same way as the evaporator pump. measure of the load trends for the building) or by the return
2 - Control based on compressor status. In this case the pump water temperature (delta T that gives an average building load).
is activated at the same time as the first compressor. It In response to a drop in the outdoor temperature or to a drop in
only switches off when no compressor is activated. delta T, the cooling setpoint is normally reset upwards in order
to optimise unit performance:
In both cases the reset parameters, i.e. slope, source and maxi-
mum value, are configurable in the Setpoints menu (see section
4.5.4). Reset is a linear function based on three parameters.
• A reference at which reset is zero (outdoor temperature or
delta T - no reset value).
• A reference at which reset is maximum (outdoor
temperature or delta T - full reset value).
• The maximum reset value.
28
5.8 - Demand limit The control system continuously takes account of the tempera-
ture error with respect to the setpoint, as well as the rate of
Generally, demand limit is used by an energy management change in this error and the difference between entering and
system in order to restrict the unit electricity consumption. leaving water temperatures, in order to determine the optimum
moment at which to add or withdraw a capacity stage.
The PRO-DIALOG Plus control system for 30GX & 30HX
provides two methods of demand limit: NOTE: If the same compressor undergoes too many starts
• By reference to a limiting signal from a user-controlled (per hour) this automatically brings about reduction of
volt-free contact: the capacity of the unit cannot exceed compressor starts, which makes leaving water temperature
the demand limit setpoint (which can be modified in the control less precise.
Setpoints menu) when the limit contact is closed.
• By reference to an external 0-10 V d.c. signal: the capacity 5.11 - Determining the lead circuit
of the unit cannot exceed the demand limit imposed by
this external signal. It is a linear function and its para- This function commands the start/stop sequence of the two
meters are configurable in the User1 menu (voltages at 0% refrigerant circuits called A and B. The circuit authorised to
limitation and 100% of limitation). This function is not start first is the lead circuit. Three methods can be configured
available if reset by reference to an external 0-10 V d.c. by the user in the Configuration menu:
signal has already been selected. • Auto mode: the control system determines the lead
circuit so as to equalise the number of starts on each
Whatever the method used, demand limit is active in all circuit (value weighted by the operating times of each
operating types: Local, Remote or CCN. However, in circuit). Thus, the circuit with the least number of starts is
Local operating type, demand limit can be disabled with always given precedence to start. The lead circuit is
keypad commands (see section 4.3.3) and in CCN stopped last.
operating type, demand limit can be controlled directly • Circuit A as leader: Circuit A is always the lead circuit.
with the aid of CCN commands. It is the first to start and the last to stop.
• Circuit B as leader: Circuit B is always the lead circuit.
NOTE: A limitation value of 100% means that the unit may It is the first to start and the last to stop.
call upon the full array of its capacity stages.
5.12 - Circuit loading sequence
Here is an example of demand limit by an external 0-10 V d.c.
signal. This example assumes that the limitation parameters are Two circuit loading sequences are available. The choice of
such that at 0 volt the authorised capacity shall be maximum sequence can be configured by the user in the Configuration
capacity, and at 10 volts the authorised capacity shall be zero menu (see section 4.5.7.3).
(this is the default configuration). • Balanced circuit loading: If this sequence is selected,
the control system tries to keep the capacity of circuits A
Demand limit by 0-10 V d.c. signal and B equal as the total load on the unit increases or
decreases.
No demand limit • Loading with priority given to one circuit: If this
sequence is selected, the control system loads the lead
Maximum permitted capacity
circuit completely before the second circuit starts up. When

there is a demand limit, the second circuit is unloaded first.
Total demand limit NOTE: 30HX and 30GX units use 06N twin screw compres-
sors. The screw compressor efficiency is better at full load
than at part load. By default the 'close control'* configuration
is not validated, and the control will always try to optimise
0-10 V dc demand limit unit efficiency.
*
temperature precision has priority over compressor capacity. This parameter
is only accessible to Carrier Service.
5.9 - Limiting the unit running current
5.13 - Compressor start-up sequence in one circuit
This feature is used to avoid tripping the circuit breaker by:
• prohibiting an increase in compressor capacity when the The first compressor to start is the one with the least number of
current reaches a first threshold. start-ups and operating hours. If both compressors are operat-
• unloading one or more capacity stages when a second ing and the load decreases, the compressor that started first
protection threshold is reached. shuts down. This avoids cycling of ther same compressor.
See chapter: Description of the user 1 configuration sub-menu.
5.14 - EXV control
5.10 - Capacity control
The electronic expansion valves (EXVs) control charging and the
This function adjusts the number of active compressors and refrigerant flow in the evaporator, maintaining the optimum
loaders to keep the leaving water temperature at its setpoint. The evaporator throttle and a correct discharge superheat. Opening the
precision with which this is achieved depends on the capacity valve permits reduction of the throttle, and thus improves the
of the water loop, the flow rate, the load, and the number of heat exchange in the evaporator. This opening can be limited to
stages available on the unit. maintain the condenser subcooling and correct superheat,
29
avoiding liquid slugging at the compressors and ensuring In the event of capacity stages being shed, no capacity increase
operating stability. will be authorised on the circuit concerned for a period of 5
minutes.
5.15 - Motor cooling valve control
NOTE: The last capacity stage cannot be shed by this protec-
The temperature of the motor windings is controlled to a set- tion function. An alarm is activated, if the high pressure is
point of 82°C. This is achieved by cycling of the motor cooling still too high.
valves to allow the liquid refrigerant to flow across the motor
windings, if necessary. On units equipped with economizers 5.20 - High current load shedding function
with plate heat exchangers, a thermostatic valve controls the
necessary refrigerant flow entering this heat exchanger and This function does not require an additional board. It prevents
continuously flowing over the motor windings. All refrigerant high current breaks on each compressor by the following
used for motor cooling returns to the rotors through an orifice means:
situated mid-way along the compression cycle and is • Preventing any capacity increase on the compressor once
compressed to the discharge pressure. the high current value has reached an initial threshold
• Shedding one or more capacity stages once a second
5.16 - Head pressure control on air-cooled units protection threshold has been reached.
The saturated condensing temperature is controlled by reference In the event of capacity stages being shed, no capacity increase
to a fixed setpoint (user-definable in the Setpoints menu). This will be authorised on the circuit concerned for a period of 5
temperature is maintained by cycling fans on and off, as well as minutes.
by varying the speed of a fan.
5.21 - Start-up procedure - prelubrication
NOTE: Certain units can have up to 8 fan stages, of which
one per circuit is a variable speed fan, depending on their This procedure describes the necessary procedures to ensure
configuration and wiring. the lubrication of the compressor before start-up.
5.17 - Head pressure control on water-cooled units The control follows the sequence below:
The saturated condensing temperature is controlled by reference For the lead compressor (the first compressor in the circuit to
to a user-definable fixed setpoint. start):
1. Start the oil pump and measure the initial oil pressure.
This temperature is maintained by using the valve to control 2. Wait approximately 30 seconds.
the flow of water in each condenser circuit. 3. Verify the oil solenoid valve tightness, i.e.: if oil pressure
increases and the solenoid valve is not open, the oil
5.18 - Head pressure setpoint selection solenoid valve failure alarm is activated and prelubrica-
tion is stopped. The procedure is aborted.
There are two head pressure setpoints available: the first is called 4. If not, the oil solenoid valve is activated.
“head pressure setpoint” and the second “reclaim setpoint”. 5. Wait approximately 15 seconds.
These setpoints only have an effect when the control system is 6. If oil pressure increases, prelubrication is assured and the
controlling head pressure: air or water-cooled units operating in compressor can start.
cooling mode (only when they are fitted with condenser water 7. If not, a further prelubrication cycle is started. Return to
valves). point 1.
The active setpoint can be selected in one of the following NOTE: After three cycles, the low oil pressure alarm at pre
ways: start-up is acctivated, and prelubrication is also stopped.
• With item 5 of the information menu.
• With a volt-free selection contact connected to the customer For the lag compressor (one compressor in the circuit is already
terminal block when the unit is in Remote operating type in operation).
(rEM). See section 3.4, description of the control contacts. 1. Activate the oil solenoid valve.
• With a network command when the unit is in CCN opera- 2. Wait approximately 15 seconds.
ting type (CCn). 3. If oil pressure increases, prelubrication is assured and the
compressor can now start.
5.19 - High pressure load shedding function 4. If not, the low oil pressure at start-up alarm is activated
and the prelubrication is also stopped.
This function does not require an additional board. It prevents
high pressure breaks on a circuit by the following means: 5.22 - Master/slave assembly
• Preventing any capacity increase on the circuit once the
high pressure value has reached an initial threshold. Two PRO-DIALOG Plus units can be linked to produce a master/
• Shedding one or more capacity stages once a second slave assembly. The two machines are interconnected over the
protection threshold has been reached. CCN bus. All parameters required for the master/slave function
must be configured through the Service configuration menu.
30
Master/slave operation requires the connection of a temperature 5.24 - Optional heat reclaim module
probe at the common manifold on each machine, if the heat
exchanger leaving water temperature is controlled. This option only applies to air-cooled units, equipped with a
water-cooled heat reclaim condenser. An additional 4 x DO
The master/slave assembly can operate with constant or variable board must be installed. This board permits control of:
flow. In the case of variable flow each machine must control its • two solenoid shutoff valves for the heat reclaim coil, one
own water pump and automatically shut down the pump, if the per circuit.
cooling capacity is zero. For constant flow operation the pumps • two drain solenoid valves, one per circuit. These permit
for each unit are continuously operating, if the system is opera- draining the refrigerant from the inactive coil, when the
ting. The master unit can control a common pump that will be unit changes over from the cooling mode to the heat
activated, when the system is started. In this case the slave unit reclaim mode.
pump is not used.
Selecting the heat reclaim mode can be done with either the
All control commands to the master/slave assembly (start/stop, local interface or remotely with the (recl_sw) contact or by CCN.
setpoint, heating/cooling operation, load shedding, etc.) are
handled by the unit which is configured as the master, and must The heat reclaim function is active when: the heat reclaim
therefore only be applied to the master unit. They will be trans- entering water temperature is lower than the heat reclaim
mitted automatically to the slave unit. The master unit can be setpoint, minus half of the heat reclaim dead band.
controlled locally, remotely or by CCN commands. Therefore
to start up the assembly, simply validate the Master operating The heat reclaim function is not active when: the heat reclaim
type (MASt) on the master unit. If the Master has been confi- entering water temperature is higher than the heat reclaim
gured for remote control then use the remote volt-free contacts setpoint, plus half of the heat reclaim dead band.
for unit start/stop. The slave unit must stay in CCN operating
type continuously. To stop the master/slave assembly, select In the dead band the function remains in its active mode. The
Local Off (LOFF) on the master unit or use the remote volt- default value of the dead band is 4.4°C. This value can be
free contacts if the unit has been configured for remote control. modified by Carrier Service.
One of the functions of the master unit (depending on its con- Change-over procedure from cooling mode to heat reclaim
figuration) may be the designation, whether the master or slave mode:
is to be the lead machine or the follower. The roles of lead • Start-up of the condenser pump
machine and follower will be reversed when the difference in • Verification of the condenser flow switch control contact.
running hours between the two units exceeds a configurable If this remains open after one minute of condenser pump
value, ensuring that the running times of the two units are operation, the circuit remains in cooling mode and alarm
automatically equalised. The changeover between lead machine 83 for circuit A (alarm 84 for circuit B) will be activated.
and follower may take place when the assembly is started up, • As soon as the saturated condensing temperature reaches
or even whilst running. The running time balancing function is 30°C and the superheat reaches 8.3 K, the pumpdown
not active if it has not been configured: in this case the lead sequence is activated.
machine is always the master unit. • Pumpdown: closing of the cooling mode coil shutoff
valve. Opening of the drain valve, closing of the EXV
The lead machine will always be started first. When the lead valve.
machine is at its full available capacity, start-up delay (confi- • When the pumpdown pressure reaches the end of the
gurable) is initialised on the follower. When this delay has pump-down threshold, the pumpdown valve is closed and
expired, and if the error on the control point is greater than 1.7°C, the heat reclaim function is effective.
the follower unit is authorised to start and the pump is activated.
The follower will automatically use the master unit active set- Item 17 and 18 of the INFORMATION menu permits consulting
point. The lead machine will be held at its full available capa- different heat reclaim function sequences:
city for as long as the active capacity on the follower is not 17 = sequence of circuit A
zero. When the follower unit receives a command to stop, its 18 = sequence of circuit B
evaporator water pump is turned off with 20 seconds delay. 0 = cooling mode
1 = heat reclaim mode selection
In the event of a communication fault between the two units, 2 = pumpdown sequence
each shall return to an autonomous operating mode until the 3 = effective heat reclaim mode
fault is cleared. If the master unit is halted due to an alarm, the 4 = pumpdown fault*
slave unit is authorised to start without prior conditions. 5 = water flow switch fault*
5.23 - Controlling Pro-Dialog Plus units with a System * Alarm 83 for circuit A or 84 for circuit B is activated. Consulting the items 17
and 18 gives cause as (4) or (5). Resetting of the alarms re-initialises the
Manager information.
Up to eight PRO-DIALOG Plus units (or System Manager

compatible units) can be controlled by one control module of
the FSM or CSM III type which can handle multi-tasking of
control functions such as starting units in sequence.
31
6 - DIAGNOSTICS - TROUBLESHOOTING RESET OF ACTIVE ALARMS
OPERATION ITEM NUMBER ITEM VALUE PRESS MENU
2-DIGIT DISPLAY 4-DIGIT DISPLAY BUTTON LED
6.1 - General Hold down the MENU
button until the LED 0
The PRO-DIALOG Plus control system has many fault tracing for alarms lights. The
4-digit display shows 0 2 ALArM
aid functions. The local interface and its various menus give the number of active
access to all unit operating conditions. The test function makes alarms (2 in this
example).
it possible to run a quick test of all devices on the unit. If an
Press the Enter button 0 rESEt ALArM
operating fault is detected, an alarm is activated and an alarm until "rESEt ALARrM"
code is stored in the Alarm menu. is shown in the 4-digit
display.
Press the Enter button 0 Good
6.2 - Displaying alarms again to validate the then, 2 AL
reset. "Good" is dis- then, no ALArM
played for 2 seconds
The alarm LEDs on the summary interface (see section 4.1) then, "2 ALArM" and
give a quick display of the status of each circuit and the unit as then, "no ALArM".
a whole.
• A flashing LED shows that the circuit is operating but
there is an alarm.
• A steady LED shows that the circuit has been shut down
due to a fault.
The Alarm menu on the main interface displays up to 5 fault

codes that are active on the unit.
6.3 - Resetting alarms
When the cause of the alarm has been corrected the alarm can
be reset, depending on the type, either automatically on return
to normal, or manually when action has been taken on the unit.
Alarms can be reset even if the unit is running.
This means that an alarm can be reset without stopping the

machine. In the event of a power supply interrupt, the unit
restarts automatically without the need for an external com-
mand. However, any faults active when the supply is inter-
rupted are saved and may in certain cases prevent a circuit or a
unit from restarting.
A manual reset must be run from the main interface using the
following procedure:
32
6.4 - Alarm codes
The following list gives a complete description of each alarm
code and its possible cause.
ALARM DESCRIPTION WHY WAS THIS ACTION TAKEN BY RESET TYPE PROBABLE
CODE ALARM GENERATED? THE CONTROL CAUSE
1 Evaporator entering fluid thermistor failure Thermistor outside range -40 to Unit shut down Auto, if the temperature Thermistor or
118°C measured by the sensor wiring fault or
becomes normal again cable/wire
damaged
2 Evaporator leaving fluid thermistor failure Ditto Unit shut down Ditto Ditto
3 Condenser entering fluid thermistor failure Ditto None, simple message Ditto Ditto
4 Condenser leaving fluid thermistor failure Ditto None in cooling mode Ditto Ditto
Unit shut down in heating mode
5 Condenser entering fluid thermistor failure Ditto None, simple message Ditto Ditto
6 Condenser leaving fluid thermistor failure Ditto None Ditto Ditto
7 Outdoor temperature sensor fault Ditto Reset based on deactivated outdoor Ditto Ditto
sensor
8 CHWS (master/slave) fluid thermistor fault Ditto Master/slave function deactivated Ditto Ditto
9 Compressor A1, discharge gas sensor Ditto Compressor A1 shut down Ditto Thermistor,
solenoid, motor
cooling or wiring
fault
10 Compressor A2, discharge gas sensor Ditto Compressor A2 shut down Ditto Ditto
11 Compressor B1, discharge gas sensor Ditto Compressor B1 shut down Ditto Ditto
12 Compressor B2, discharge gas sensor Ditto Compressor B2 shut down Ditto Ditto
13 External 0-10 V dc signal fault Signal outside range 1- Loadshed: not used Ditto Defective input or
2- Demand limit: deactivated wiring fault
14 Discharge pressure transducer failure,circuit A Measured signal = 0V dc Circuit A shut down Ditto Defective
transducer, wiring
fault
15 Discharge pressure transducer failure, circuit Ditto Circuit B shut down Ditto Ditto
B
16 Suction pressure transducer failure, crt A Ditto Circuit A shut down Ditto Ditto
17 Suction pressure transducer failure, crt B Ditto Circuit B shut down Ditto Ditto
18 Oil pressure transducer failure, compr A1 Ditto Compressor A1 shut down Ditto Ditto
19 Oil pressure transducer failure, compr A2 Ditto Compressor A2 shut down Ditto Ditto
20 Oil pressure transducer failure, compr B1 Ditto Compressor B1 shut down Ditto Ditto
21 Oil pressure transducer failure, compr B2 Ditto Compressor B2 shut down Ditto Ditto
22 Economizer A1 transducer failure Ditto Circuit A shut down for unit with Ditto Ditto
economizer. Otherwise compressor
A1 shut down.
23 Economizer A2 transducer failure Ditto Compressor A2 shut down Ditto Ditto
24 Economizer B1 transducer failure Ditto Circuit B shut down for unit with Ditto Ditto
economizer. Otherwise compressor
B1 shut down.
25 Economizer B2 transducer failure Ditto Compressor B2 shut down Ditto Ditto
26 Pressure sensor failure - coil pump down Ditto Circuit A remains in cooling mode Ditto Ditto
circuit A
27 Pressure sensor failure - coil pump down Ditto Circuit B remains in cooling mode Ditto Ditto
circuit B
28 Fault in the motor cooling valve position Ditto None Ditto Ditto
sensor, circuit A
29 Fault in the motor cooling valve position Ditto None Ditto Ditto
sensor, circuit B
30 Loss of communication with SCPM A1 board SCPM A1 board does not respond Compressor A1 shut down Ditto Wiring fault,
incorrect address
or defective board
31 Loss of communication with SCPM A2 board SCPM A2 board does not respond Compressor A2 shut down Ditto Ditto
32 Loss of communication with SCPM B1 board SCPM B1 board does not respond Compressor B1 shut down Ditto Ditto
33 Loss of communication with SCPM B2 board SCPM B2 board does not respond Compressor B2 shut down Ditto Ditto
34 Loss of communication with EXV board 4xDO board associated with the Unit shut down Ditto Ditto
EXV does not respond
35 Loss of communication with fan board #1 4xDO board controlling the first four Unit shut down if number of fan Ditto Ditto
fan stages does not respond stages by circuit is lower than three.
Otherwise circuit A shut down.
36 Loss of communication with fan board # 2 4xDO board controlling the fan Circuit B shut down Ditto Ditto
stages of circuit B does not
respond
37 Loss of communication with auxiliary board Board does not respond Unit shut down if heating mode has Automatic Bus wiring fault,
type 1 been selected. incorrect address
or defective board
38 Loss of communication with heat reclaim or Analogue board does not respond Unit shut down if heat reclaim mode is Automatic if board is again Auxiliary board
evaporator heater board selected. detected faulty
Faulty connection
39 'CCN/clock board' fault CCN/clock board is no longer Unit shut down Ditto Defective CCN/
detected clock board
40** Control box thermostat fault or phase reversal Sensor overheated Unit shut down Auto if the same alarm has Badly ventilated
not tripped the same day control box
33
ALARM DESCRIPTION WHY WAS THIS ALARM ACTION TAKEN BY RESET PROBABLE CAUSE
CODE GENERATED? THE CONTROL TYPE
41 Unit emergency stop CCN command to stop the unit received Unit shut down CCN/ Control network
Automatic
42 Initial factory configuration All factory parameters are 0 Unit cannot start Auto No factory configuration
required
43-n Illegal initial factory configuration Bad factory configuration Ditto Ditto Factory configuration error
43-1 Compr A capacity too high
43-2 Compr B2 configured and
compressor B1 absent
43-3 Fan configured for a water-cooled
condenser
43-4 Fans not configured
43-5 Heat reclaim option configured
and reclaim sensors configured
44 Discharge pressure circuit A too SCT>loadshed threshold. Max. satur. condensing Circuit A shut down Auto in the Transducer/high pressure switch or fan
high pressure (mct_sp) if only one capacity stage remains 10mn that circuit defective, water flow obstructed in
in operation. follow the condenser, water entering
temperature or condenser air too high
45 Discharge pressure circuit B too SCT>loadshed threshold. Max. satur. condensing Circuit B shut down Ditto Ditto
high pressure (mct_sp) if only one capacity stage
remains in operation.
46 Oil solenoid failure, compressor Oil pressure differential >17kPa during the period Compressor A1 not Auto if the Oil valve defective
A1 following pump start-up and before opening of the oil authorised to start same alarm
solenoid (see prelubrication) has not
tripped the
same day
47 Oil solenoid failure, compressor Ditto Compressor A2 not Ditto Ditto
A2 authorised to start
48 Oil solenoid failure, compressor Ditto Compressor B1 not Ditto Ditto
B1 authorised to start
49 Oil solenoid failure, compressor Ditto Compressor B2 not Ditto Ditto
B2 authorised to start
50 Pre-start oil pressure, Oil pump does not sufficiently increase the pressure Compressor A1cannot start Ditto Low oil level, oil pump, oil solenoid or oil
compressor A1 during several prelubrication cycles transducer failure
51 Pre-start oil pressure, Oil pump does not sufficiently increase the pressure Compressor A2 cannot start Ditto Ditto
compressor A2 during several prelubrication cycles
52 Pre-start oil pressure, Oil pump does not sufficiently increase the pressure Compressor B1 cannot start Ditto Ditto
compressor B1 during several prelubrication cycles
53 Pre-start oil pressure, Oil pump does not sufficiently increase the pressure Compressor B2 cannot start Ditto Ditto
compressor B2 during several prelubrication cycles
54 Oil level circuit A low Oil level control contact open during operation Circuit A shut down Manual Oil level detector defective, oil quantity
insufficient
55 Oil level circuit B low Oil level control contact open during operation Circuit B shut down Manual Ditto
56 Low saturated suction temp, crt A SST under defrost theshold* for 3 minutes Circuit A shut down Auto if the Low refrigerant charge, filter drier
same alarm obstructed, expansion valve and
has not transducer defective, low water flow, low
tripped the evaporator water temperature
same day
57 Low saturated suction temp, SST under defrost threshold* for 3 minutes Circuit B shut down Ditto Ditto
circuit B
58 High saturated suction temp, After 90 seconds of operation if SST > 12,8°C & EXVCircuit A shut down Manual Expansion valve, liquid level sensor or
circuit A < 1% transducer defective, high evaporator
temp.
59 High saturated suction temp, After 90 seconds of operation if SST > 12,8°C & Circuit B shut down Manual Ditto
crt B EXV < 1%
60 Low discharge superheat, Superheat <2,8 K for 10 minutes Circuit A shut down Auto if the Thermistor, transducer, EXV or
circuit A same alarm economizer defective
has not
tripped the
same day
61 Low discharge superheat, crt B Superheat <2,8 K for 10 minutes Circuit B shut down Ditto Ditto
62 Max. oil pressure difference, (Discharge pressure - oil pressure) >340 kPa for Compressor A1 shut down Manual Obstructed oil filter, oil solenoid or shut-
compressor A1 more than 6 seconds off valve blocked, or manual oil valve
closed
63 Max. oil pressure difference, (Discharge pressure - oil pressure) >340 kPa for Compressor A2 shut down Manual Ditto
compressor A2 more than 6 seconds
64 Max. oil pressure difference, (Discharge pressure - oil pressure) >340 kPa for Compressor B1 shut down Manual Ditto
compressor B1 more than 6 seconds
65 Max. oil pressure difference, (Discharge pressure - oil pressure) >340 kPa for Compr B2 shut down Manual Ditto
compressor B2 more than 6 seconds
66 Loss of commuincation with The unit is controlled by a System Manager Unit returns to autonomous Auto Defective CCN BUS wiring or system
System Manager (Flotronic or Chiller) and communication with this operating mode module failure
module is lost for more than two minutes
67 Loss of communication with The master/slave link is broken due to a loss of Unit returns to autonomous Auto Defective CCN BUS wiring or loss of
master or slave unit communication between the two units for more than operating mode supply
2 minutes
68 Low oil pressure compr A1 Oil pressure differential below the setpoint Compressor A1 shut down Auto if the Low condenser air or water
(dynamically calculated) for 15 seconds same alarm temperature, oil filters obstructed, oil
has not valve blocked, oil solenoid and oil
tripped the pressure transducer defective
same day
69 Low oil pressure compr A2 Oil pressure differential below the setpoint Compressor A2 shut down Ditto Ditto
(dynamically calculated) for 15 seconds
70 Low oil pressure compr B1 Oil pressure differential below oil setpoints 1 or 2 Compressor B1 shut down Ditto Ditto
(see alert criteria for low oil pressure and setpoint)
34
ALARM CODE DESCRIPTION (CONT.)
ALARM DESCRIPTION WHY WAS THIS ALARM ACTION TAKEN BY RESET PROBABLE CAUSE
CODE GENERATED? THE CONTROL TYPE
71 Low oil pressure compr B2 Oil pressure differential below the setpoint Compressor B2 shut down Auto if the Ditto
(dynamically calculated) for 15 se same alarm
conds has not
tripped the
same day
72 Evaporator frost protection 1 - Evaporator EWT or LWT below defrost Unit shut down. Evaporator Ditto Defective thermistor, low water flow
setpoint pump and if applicable heater
2 - On units equipped with an evaporator start-up, if unit has shut down
heater, heater operates for more than 15 air-cooled units)
minutes but does ot heat the evaporator
73 Condenser frost protection, circuit For water-cooled units and fluid type = Unit shut down. Condenser Automatic Discharge pressure
A water, if SCT<1,1°C pump start-up, if unit has transducer defective,
shut down refrigerant leak or low
condenser water temperature
74 Condenser frost protection, circuit For water-cooled units and fluid type = Unit shut down. Condenser Automatic Ditto
B water, if SCT<1,1°C pump start-up, if unit has shut
down
75 Evaporator water flow control 1 - Control not closed, before end of the Unit shut down. Pump shut Manual Evaporator pump control or
failure start-up delay or open during operation down water flow switch failure
2 - Pump shut down for 2 mins and water
flow contact closed
76 Condenser water flow loss Water flow switch (water-cooled units) not Unit shut down Manual Condenser pump, low water
closed during the minute after start-up flow, water flow switch
77 High current, compressor A1 Current higher than threshold value detected Compressor A1 shut down Auto after Operation above the compressor
10 mn capacity
delay
78 High current, compressor A2 Ditto Compressor A2 shut down Ditto Ditto
79 High current, compressor B1 Ditto Compressor B1 shut down Ditto Ditto
80 High current, compressor B2 Ditto Compressor B2 shut down Ditto Ditto
81 Pump 1 fault Evaporator water pump contact open, when Unit shut down Manual Pump overheat or bad pump
the pump has received a command to run connection
82 Pump 2 fault Ditto Ditto Manual Ditto
83 Heat reclaim mode fault, circuit A 1. Interlock not closed 1 minute after Circuit A remains in cooling Manual 1. Water flow switch defective.
condenser pump start-up or open during mode 2. Leak or heat reclaim shutoff or
heat reclaim operation drain solenoid valve open.
2. More than two consecutive pumpdown
sequences not successful.
84 Heat reclaim mode fault, circuit B Ditto Circuit B remains in cooling Manual Ditto
mode
85 Water flow fault, heat reclaim Water flow detector (water-cooled units) not Unit remains in cooling mode Manual Ditto
condenser closed for one minute
86-nn Master/slave configuration fault Bad master/slave configuration Master/slave control not Auto/ Master/slave configuration error
allowed manual for
heating/
cooling
mode fault
87-n Maintenance alert A maintenance alert is active None Manual
87-1 Charge too low
87-2 Water loop too low
87-3 Air filter maintenance delay elapsed
87-4 Pump 1 maintenance delay elapsed
87-5 Pump 2 maintenance delay elapsed
87-6 Water filter maintenance delay
elapsed
35
ALARM FUNCTION DESCRIPTION ACTION RESET NOTE
1xx Defect compressor A1 See SCPM subcodes below See SCPM subcodes below Manual
2xx Defect compressor A2 See SCPM subcodes below See SCPM subcodes below Manual
3xx Defect compressor B1 See SCPM subcodes below See SCPM subcodes below Manual
4xx Defect compressor B2 See SCPM subcodes below See SCPM subcodes below Manual
SCPM SUBCODES (XX)

ALARM FUNCTION DESCRIPTION ACTION RESET NOTE
01 High motor SCPM detects high motor temperature, if Compressor shut down Manual Solenoid, cooling motor defect, low
temperature temperature is higher than 110°C for 10 refrigerant charge. Wiring, motor
seconds temperature sensor or SCPM board fault
02 Motor temperature SCPM measures a temperature outside Ditto Manual Thermistor, solenoid, motor cooling or wiring
sensor the -40°C to 118°C temperature range fault
03 High pressurestat HPS port to SCPM module open Ditto Manual Lack of condenser water flow. Condenser
tripped valve blocked, fan circuit fault, high
condenser entering air or water temperature
04 High motor current SCPM detects high current, based on MTA Ditto Manual Operation outside the compressor capacity.
rating Configuration block badly perforated, motor
fault
05 Rotor blocked Ditto Manual Load too high
06 Ground current fault SCPM detects ground current (2.5 +2/- 0 Ditto Manual Ground current fault on motor winding, wiring
amps) fault
07 Current drop in one SCPM measures a current drop > = 65% Ditto Manual Motor fault, wiring fault
phase L1
phase L2
phase L3
10 Current imbalance SCPM measures a current imbalance None, simple message Manual, if Loss of power supply, wiring fault, loose
>14% between phases as more than 14% for 25 threshold alarm is terminal, core defective
minutes validated.
Otherwise auto
reset.
11 Current imbalance SCPM measures a current imbalance Compressor shut down, Ditto Poor power supply, loose terminal, core
>18% between phases of more than 18% for 25 if threshold alarm is defective
minutes validated.
12 No motor current SCPM module shows less than 10% of the Shut down Manual Power supply interrupted, fuse(s) blown,
MTA for more than 3 seconds wiring fault, core defective
13 Star-delta start-up Compressor shut down Manual Defective connector
14 Contactor failure SCPM detects 10% of the MTA for 10 Unit shut down Manual Defective/blocked contactor
seconds after shutdown of the compressor
contactor. Oil solenoid still has supply.
15 Compressor shut- Circuit shut down Manual Contact stuck
down not possible
16 Current phase reversal SCPM detects a current phase reversal Compressor shut down Manual Supply phases or cables reversed, core
via the core wiring reversed after replacement
17 Configuration block SCPM detects a reading fault at the block Compressor shut down Manual Configuration block on SCPM board badly
fault perforated or badly placed. Defective board.
Legend:
* Defrost threshold = 1,1°C for water or for the lowest cooling setpoint less 4,4°C for brine or low brine.
** This safety circuit is controlled by two contacts, 16A and 16B, which are connected in series internally. If there is only a single control box there is a jumper on
16B, otherwise 16B controls the control box safety of the circuit. If one of the two contacts 16A and 16B is open, the whole unit is in fault status.
SCPM: Compressor protection module
FSM: Flotronic System ManagerTM
CSM: Chiller System Manager
MTA: Compressor Must Trip Amperes
Order No. 13054-76 (Phase 3 ), 04.2002. Supersedes order No.: 13054-76, 04.2000 Manufactured by: Carrier S.A., Montluel, France.
Manufacturer reserves the right to change any product specifications without.notice. Printed in the Netherlands on totally chlorine-free paper.
SARAWAK (O&M)
3.2
AIR HANDLING UNIT
INSTALLATION, START-UP AND
Carrier
International SERVICE INSTRUCTIONS
Sdn. Bhd.
® Malaysia CENTRAL STATION AIR HANDLING UNITS
INTRODUCTION
These instructions apply to the
Carrier 39G Galaxy Air Handling Unit.
CONTENTS 1.0 SAFETY CONSIDERATION
1.0 Safety Consideration 1 Air handling units are designed to provide safe and
reliable service, when operated within design
specifications. To avoid injury to personnel and damage
2.0 Pre-Installation 2
to equipment or property when operating this
equipment, use good judgement and follow safe
3.0 Rigging 2
practices as out lined below.
4.0 Installation 3
WARNING
5.0 Unit Identification 5 a) Check the assembly and component weights to
be sure that the rigging equipment can handle
6.0 Section Joining Instruction 6 them safely.
b) Check for adequate ventilation so that fumes will
7.0 Fan Motor & Drives 7 not migrate through ductwork to occupy space
when welding or cutting inside air handling unit.
8.0 Installation Of Variable Inlet Vane Actuator 8 c) Do not remove access panel or door until fan is
completely stopped.
9.0 Refrigerant Piping, Direct Expansion Coils 8 d) Do not work on dampers until their operators are
disconnected.
10.0 Guide To Starting Up 11 e) Be sure that the fan motors are properly grounded
before working on them.
11.0 Guide To Servicing 12 f) Never enter an enclosed fan cabinet or reach into
the unit while the fan is running.
g) Disconnect power to the fan motor (Lock open and
tag) before working on the fan.
h) Disconnect power to electric heaters (Lock open
and tag) before working on or near heaters.
i) Never pressurise equipment in excess of specified
test pressure.
j) Protect adjacent flammable material when welding
or flame cutting. Use sheet metal or asbestos cloth
to contain sparks. Have a fire extinguisher at hand
and ready for immediate use.
A United Technologies Company

1
2.0 PRE-INSTALLATION 3.0 RIGGING
2.1 Check items received against packing list. Notify 3.1 All 39G units are equipped with rigging hole. As
Carrier of any discrepancies. such, the units can be rigged by means of the rigging
2.2 Examine for damage incurred during shipment. File rod.
claim with transit company if any damage is found.
2.3 Refer to rigging details as shown in (Fig.1) to transfer
unit from truck to storage site.
2.4 If unit is to be stored for more than 2 weeks prior Shipping Bracket Picture shown typical shipping bracket for
standard offering of rubber isolator. It applies
to installation, please exercise the following also to spring isolator configuration.
precautions :-
a) Choose a dry storage site that is reasonably level
and sturdy to prevent undue stress and damage
to the unit structure or components. Do not store
on vibrating surface - damage to stationary bearing
can occur.
b) Remove all fasteners and other small parts - tag
and store these items in a safe place until needed.
c) Unit are shipped from the factory wrapped in protective
plastic sheet. The plastic sheets may be damaged
during transit or after inspection. Cover entire unit
with tarpaulin or plastic coverall. Extend cover under
unit if stored on ground. Secure cover with adequate
tie downs.
d) When unit is stored over an extended period we Fig. 2 Shipping Bracket
recommend a monthly procedure as follows -:
Remove the tarpaulin from the unit, enter fan through
access door or fan section inlet, remove the belt CAUTION
ties (if any) and rotate fan and motor (if any) slowly
by hand. This helps to re-distribute bearing grease If a fork lift truck is used, lift only from the heavy end.
and to prevent bearing corrosion.
3.2 Units are shipped fully assembled or in sections,
depending on size and application. The 39G Galaxy
central station air handling unit are built up in "Modules"
(Refer to Fig. 3). Any unit which is 22M (module)
or longer in length will be shipped in shorter sections.
3.3 Do not remove skids or protective covering until
unit or section is ready for final replacement.
IMPORTANT:
a) Do not lift unit by coil connections or headers.
b) Do not remove protective caps from coil piping
connections until ready to connect piping.
c) Do not remove protective cover on grease from fan
shaft until ready to install sheave.
d) When fan and motor drives are supplied from the
factory, the pulleys are installed but the belts are
supplied loose to avoid shipping damage. These
belts should be tag and stored at a safe place until
needed. This will help to minimise theft at job site.
e) Do not remove the shipping bracket (Refer to Fig. 2)
that are supplied to prevent the fan housing and
motor base from moving during transit. These
shipping bracket should only be removed after the
air handling unit is positioned and just immediately
after the fan motor and drive is installed.
f) Do not remove the shipping wood block, unless the
Fig. 1 Rigging Of Units fan motor and drive is going to operate.
2
DIMENSION OF FUNCTIONS (MODULES)
LENGTH OF SECTIONS IN MILLIMETRES

NO. OF MODULES 25MM CASING
1M 100
2M 200
3M 300
4M 400
5M 500
6M 600
7M 700
8M 800
9M 900
10M 1000
Fig. 3 Dimension Of Functions
Note:-
Add 110mm for overall casing dimension which
includes the aluminium frames.
Fig. 4 Installation At Ground Level
4.0 INSTALLATION
4.1 Ground/Floor Mounted Units.

a) When installing the air handling unit on the ground/
floor, a raised concrete plinth is recommended
(Refer to Fig. 4 & 5).
b) Provide adequate clearance for unit service access
(fan shaft and coil removal, filter removal, motor
access, etc) (Refer Fig. 7).
c) An adequate trap must be provided to the condensate
drain line to prevent excessive built up of condensate
in the drain pan.
4.2 Condensate Drain -

Install a trapped condensate drain line at unit drain
connection. Use 40mm (nominal) (43mm OD)
standard pipe. See (Fig. 6), for proper trap design
for a draw-through unit.
Determine design negative static pressure. This

pressure is not the same as fan total pressure,
which includes pressure losses downstream as
well as upstream from the indoor air fan. Always
assume the worst conditions such as having return
air filters clogged with dirt.
Fig. 5 Suspended Installation
Referring to (Fig. 6), Differential 'A' must be equal
to or larger than negative static pressure at design
operating seal. (Differential 'B'). This differential
must be equal to or larger than one-half the maximum
negative static pressure. When the fan starts.
Differential ‘C’ is equal to the maximum negative
static pressure.
3
FAN OFF
TRAP CONDITION WHEN FAN STARTS
FAN RUNNING AND CONDENSATE DRAINING
Fig. 6
4
4.3 Typical Assemblies, Dimensions And Service Areas
Air Flow Direction

Unit Size A B C D E Unit Size A B C D E Note:
39G0508A 800 1000 1100 500 600 39G1422 2200 1500 2200 1300 900 (1) For dimension A & D and other
39G0508B 800 1000 1100 500 600 39G1522 2200 1500 2400 1500 900 numerical value, add the frame
39G0511 1100 1000 1400 500 600 39G1722 2200 1500 2400 1500 900 thickness respectively
39G0612 1200 1000 1500 600 600 39G1724 2400 1500 2400 1500 900
39G0713 1300 1000 1600 700 600 39G1725 2500 1500 2800 1600 900
~ 110mm for 25mm casing
39G0813 1300 1000 1600 800 600 39G1926 2600 1500 2800 1600 1300 ~ 160mm for 50mm casing
39G0914 1400 1000 1700 900 600 39G2127 2700 2000 2900 1800 1300 (2) Dimension C is where the access door
39G0916 1600 1000 1700 900 600 39G2230 3000 2000 3100 2000 1300 and coil connection end applied
39G1018 1800 1000 1900 1000 600 39G2234 3400 2000 3600 2000 1300 accordingly
39G1118 1800 1000 2100 1000 600 39G2434 3400 2000 3600 2000 1300
39G1319 1900 1000 2100 1100 600 39G2636 3600 2000 3800 2000 1300
Fig. 7 Typical Assemblies Dimension And Service Area
4.4 The 39G Air Handling Units are as standard fitted * Refer to your nearest Carrier representatives
with factory installed spring or rubber type anti-vibrations for the nomenclature.
mounts. Externally mounted anti-vibration mounts
in addition to the factory installed anti-vibration are
not recommended.
4.5 When the 39G Air Handling Units are required to

be suspended a platform is required. The platform
must be constructed such that it is strong enough
to support the whole air handling unit under operating
condition. In doubt, please consult your nearest
Carrier representatives.
5.0 UNIT IDENTIFICATION
Each air handling unit will have the identification

sticker on the outer skin of the door to the fan section.
If shipping tags or labels should become lost or

unreadable at job site, the following procedure can
help the installer to identify the components and Fig. 8 Identification Sticker
assembly sequences.
5
6.0 SECTION JOINING INSTRUCTION
6.1 25mm & 50mm
The installation procedure for joining bracket (Pre drilled holes) are as follows:
a. Identify the correct sections which need to be joined together.
b. Make sure all proper action are taken to level the two separate sections.
c. Affix the gasket (that is supplied with the unit) along the edges of the aluminium frame that is required to be joined
together. (refer figure 1)
d. Locate the pre-drilled holes along the horizontal and vertical frame.(refer figure 1)
e. To install the correct quantity of joining bracket, refer to SECTION JOINING INSTRUCTION sticker. Start by placing
the joining bracket between the frame and insert the bolt, nut and washer set.(refer figure 2)
f. Tighten the bolt and nut until it compress the gasket and make sure there is no leakage. The purpose of gasket is to prevent
any air leakage.
IMPORTANT use the hole for bolt proportionately
AHU Internal Joining Bracket Qty For Two Section

Size Vertical Horizontal Total
0508A 1 2 6
0508B 1 2 6
0511 1 2 6
0612 1 3 8
0713 1 3 8
0813 2 3 10
0914 2 3 10
0916 2 3 10
1018 2 3 10
1118 2 3 10
1319 3 3 12
1422 3 4 14
1522 3 4 14
1722 3 4 14
1724 3 4 14 ITEM 25mm Qty 50mm Qty
1725 3 4 14 BOLT STUD AH07AB181 1 39FJ560-322 1
1926 3 4 14 WASHER AU02AB202 2 AU02AB261 2
2127 4 4 16 NUT AT39AB171 1 AT39AB261 4
2230 4 5 18 BRACKET 39GH539-013 1 39GH539-013A 1
2234 4 5 18
2434 4 5 18 Note: For 39G 50mm, Use 2 Nuts with Stud to Attach Joining Bracket
2636 4 5 18 with Aluminium Frame.
This Unit Size is ______________________
PART NO: 39GH512-050
Fig. 9.1 Joining Bracket

6
7.0 FAN MOTOR & DRIVES alignment of fixed pitch pulleys. If the pulleys are
properly lined up, the string will touch them at the
The 39G unit will be supplied with or without the point indicated by the arrows (Refer Fig 10). For
fan motor and drive from the factory. In either case, variable pitch pulleys, use a block of wood or other
a motor base will be supplied installed on the fan material to compensate for the difference in pulley
and motor base channel. width. To check the alignment of these pulleys, make
sure that the centre lines of both pulleys are in line
7.1 Factory Installed Fan Motor & Drive and parallel to the (“H” frame) bearing support channel.
All motors and pulleys are mounted with only a The variable pitch pulley is normally installed on
“rough” alignment. All drives belts are loosely the motor shaft.
installed to the sheaves and a warning tag is
attached to the belt with a nylon/wire tie. The installer 7.4 Proper Belt Tension
is responsible for final alignment as described in (i) Correct tension of a V-Belt drive is carried out as follows:
the procedure. (a) Fix the belts into the grooves and increase the centre
distance until the belts are snug. Note : Never lever
belts over sheaves.
(b) Operate the drive for a few minutes and observe the
“bow” in the slack side. Tighten until only a slight “bow”
appeares in the slack side of the belts while they are
in operation under load.
(c) During normal operation a V-Belt will seat itself in
sheaves grooves and will require periodical check
to maintain tension. The seating occurs more rapidly
during the first 24 hours of operation, and it is very
important to check drive tension carefully during this
period and to retension as required.
(ii) For drives where tension may be critical factor, the

following procedure is recommended:
(a) Using the diagram shown below, measure the
span length of the drive.
(b) At the centre of the span, apply a force K (perpendicular
to the span) large enough to deflect the belt 15mm
per 1 meter of span.
Fig. 10 Sheave Alignment
(c) The deflection force for any V-belt should be within
the minimum and maximum force shown in the table.
When the tension drops to the minimum value, readjust
7.2 Field Supplied Fan Motor & Drive
to the maximum value.
Ensure that the motor is of the correct HP/kW
frame size & electrical characteristics.
Deflection Force K (Newton)
7.3 Installation of Pulleys Deflection force (Newton)
Install the pulley on the fan shaft and motor shaft
Gross section dia. SPZ SPA SPB SPC
for minimum overhang. Exercise care when mounting
of smaller sheave min. max. min. max. min. max. min. max.
the pulley to the fan shaft. Excessive force may
result in bearing damage. Remove rust preventing 63-80 12 19 - - - - - -
coating or grease from the shaft. Make sure that 90-122 16 24 19 29 - - - -
the shaft is clean and free of burrs. Lubricate the 125-160 19 28 26 40 33 50 - -
bore of the pulley before installing. Ensure that 180-224 19 29 30 46 43 64 58 87
the fan and motor shafts are parallel and level. Use 250-355 - - 32 48 51 77 79 119
straight edge or a piece of string to check the 400-630 - - - - 55 82 103 154
7
8.0 INSTALLATION OF VARIABLE INLET VANE 9.0 REFRIGERANT PIPING, DIRECT
ACTUATOR (OPTIONAL) EXPANSION COILS
8.1 Backward Curved Fans – Inlet vane linkage is factory Direct expansion coils are split into 2, 4 or 8 splits
installed on both inlets of fan. Install actuator and depending upon the unit size and coil circuiting. Each
checked linkage operation as follows:- split requires its own distributor nozzle, expansion
(a) Position Actuator – Locate inlet guide vane actuator valve and suction piping. Suction connections are
inside fan section. Actuator is to be mounted to any on the entering side connections for each coil split
suitable structural member (such as bearing support). are on the air leaving side in the same order from
Actual location will vary with unit size and fan discharge to bottom. Refer to example on (Fig. 12).
arrangement.
(b) Check Linkage - Align actuator and lever arm,
before connecting actuator to linkage for freedom of
movement from fully closed to fully open position. CAUTION
Then connect actuator and recheck linkage for proper
operation. Linkage adjustment must allow maximum Direct expansion coils are shipped pressurized with
travel actuator. dry air. Release pressure from each coil split through
valves in protective caps before removing caps. Do
not leave piping open to the atmosphere unnecessarily.
Water and water vapor are detrimental to the refrigerant
CAUTION system. Until the piping is complete, recap the system
and charge with nitrogen at the end of each work-day.
Improper adjustment of linkage for actuator travel Clean all piping connections before soldering joints.
may cause linkage to slip. The lower split of face split coils should be first on,
last off. Row split coils utilize special intertwined circuits:
either splits of these row split coils can be first on,
last off.
Fan Type
Backward curved Max Torque Force (Nm)
BCG 400 8.3
BCG 450 12.3
BCG 500 18.6
BCG 560 19.6
BCG 630 27.5
BCG 710 39.2
BCG 800 63.8
BCG 900 78.5
BCG 1000 98.1
Fig. 11 Inlet Vane Operator Data
CAUTION
Do not force vanes past full open or closed position.
Fig. 12 Example Of Direct-Expansion Coil

Distributor And Suction Connections
8
9.1 Suction Piping
Connect suction piping as shown in (Fig.13) for face
split coil or (Fig 14) for row split coil. Suction line from
coil connection to end of the 15-diameter-long riser
should be same tube size as coil connection to ensure
proper refrigerant velocity. Refer to Carrier System
Design Manual, Part 3, and size remaining suction
line header pressure drop equivalent to approximately
2.50F. Refer to Fig 16 for piping risers to the compressor.
To minimize the possibility of flooded starts and

compressor damage during prolonged shutdown,
install an accumulator in the suction line or a solenoid
in the liquid line of last-on, first-off split in row
applications.
Fig. 14 Row Split Coil Suction Line Piping
9.2 Expansion Valve Piping

Distributor nozzles and thermostatic expansion
valves are factory or field supplied.
Note:-
Factory supplied distributor nozzle sizes are
marked on coil cover label. Be sure that correct
nozzle is installed in each distributor before installing
expansion valve.
Fig. 13 Face Split Coil Suction Line Piping
9
Fig. 15 Double-Circuited Face Split Coil Manifolding (Typical)
Fig. 16 Suction Line Riser Piping
Fig. 17 Double-Circuited Row Split Coil Manifolding (Typical)

10
10.0 GUIDE TO STARTING UP Check that this fan RPM measured or calculated
is approximately equal to the speed shown on
10.1 Ensure that all construction debris are removed the sticker. If the fan RPM measured or calculated,
from the interior of the unit. exceeds the value shown on the sticker by much,
re-balancing of the fan in the field may be required.
10.2 Install filter media in all filter section. When roll In doubt, please refer to your nearest Carrier
filter are used , ensure that the filter media is representatives.
correctly installed and that the roll filter mechanism
is functioning property. 10.10 Check the direction of rotation arrow label on the
drive side of the fan housing indicates the correct
10.3 Check that the fan, motor bearing and linkages direction of rotation. (Refer Fig 18)
are adequately lubricated.
a) Bearings are normally shipped full of grease
for corrosion protection and may run warm
temporarily on start up until excess grease
has been discharged.
10.4 Hand operate all linkages, such as variable inlet

guide vanes and dampers to check for freedom
of movement.
10.5 Check tightness of bearing set screws or locking

collars.
Backward Curved Forward Curved
10.6 Check tightness of set screws on blower wheel
Fig. 18
hub and pulley.
10.7 Double check the alignment and tension of the

V-belts. 10.11 Check the vibration level. If excessive vibration
occurs, check the following :-
10.8 VERY IMPORTANT a) Variable pitch pulleys.
Before energising any power to the unit, double Normally variable pitch pulley specified to make
check that all restraints that might have been used the job of air balancing easier. Once the air
during shipping are removed from the fan shaft. balance of the system has been accomplished,
The fan shaft and motor shaft must both be free- replace the variable pitch pulley with the correct
wheeling before the power is turned on. Remove fixed pitch pulley for continuous application.
all holding down bracket used to prevent the fan b) Drive misalignment.
and motor base moving during transit. c) Mismatched, worn or loose V-belts.
d) Blower wheel or pulley loose on the shaft.
10.9 Check the fan speed with a strobe type tachometer, e) Loose bearings.
or use an approximation technique with the f ) Loose mountings.
following formula. Obtain the motor RPM from g) Motor out of balance.
the fan motor plate. Measure the fan and motor h) Pulleys (eccentric) or out of balance.
pulley outer diameter (OD). i ) Vibration isolation improperly adjusted.
j ) Out of balance or corroded blower wheel
Fan RPM = Motor RPM x Motor Pulley OD (re-balance or replace as necessary).
Fan Pulley OD k) Accumulation of material on blower material
(remove as necessary).
eg. Nameplate Motor RPM = 1500 l) Shipping brackets preventing the fan housing
from moving during shipment. These must
be removed prior to start-up.
Motor Pulley OD = 200mm
Fan Pulley OD = 300mm
Fan RPM = 1500 x 200 = 1000

300
11
10.12 Chilled Water and Hot Water Coil. 11.4 To clean the coil, spray mild detergent solution
To vent the coils, proceed as follows :- on the coils with garden type sprayer. Rinse with
a) Close all coil water supply and return main fresh water. Check to ensure that the condensate
valves. line is not clogged up.
b) Open all vents but no more than 2 full turns.
c) If vent is clogged up with dirt it may be necessary 11.5 Winter shutdown for chilled water coil, proceed
to remove needle valves from vents and clean as follows :-
as necessary. 1) Anti freeze methods of coil protection.
d) Open coil water supply and return valves. Fill a) Close coil water supply and return valves.
coil with water until all air is expelled. This b) Drain coil as follows :
occurs when the hissing sound from the vent Method 1
stops and only water is oozing out from the vent. “Break” flange of coupling at each header location,
e) Close vent needle valves. separate flange or coupling connection to facilitate
coil drawing.
Method 2
CAUTION It is recommended that the auxillary drain be
added to coil piping if yearly “Winterizing” of coils
The venting procedure for hot water coil must be
is anticipated. This auxillary piping should be located
done when the water is not heated up.
at the highest and lowest point on the respective
header connection for each coil. Hence, to drain
the coil, open both valves to the auxillary drain
10.13 Direct Expansion Coil piping.
Charge refrigerant in accordance with the c) After coil is drained, Method 1, connect line
recommendation as shown in the Installation with a service valve and union from upper
Operating and Maintenance instructions for the nozzle to an anti freeze reservoir. Connect a
condensing unit. self priming reversible pump between the low
header connection and the reservoir. Method
11.0 GUIDE TO SERVICING 2, make connection to auxillary drain valves.
d) Fill reservoir with any inhibited anti-freeze
11.1 Review the safety considerations at the beginning
acceptable to local authority codes.
of these instructions. Good safety habits are
e) Open service valve and circulate solution for
important tools when performing servicing
15 minutes, then check its strength.
procedures.
f) If solution is too weak, add more anti-freeze
until desired strength is reached, then circulate
11.2 Use a strobe type tachometer or calculate as per
solution through coil for 15 minutes or until
item 10.9.
concentration is satisfactory.
g) Remove upper line from reservoir to reversible
11.3 To replace the fan motor, proceed as follows :-
pump. Drain coil to reservoir and close service
a) Shut off the power of the motor.
valve.
b) Disconnect the tag power wires at motor
h) Break union and remove reservoir and it lines.
terminals.
i) Leave coil flanges or coupling open and auxillary
c) Loosen motor brace-to-mounting rails attaching
drain valves open until spring.
bolts. Loosen belt tensioning bolts to adjust
the motor position so V-Belts can be removed
11.6 Coil Removal
without stretching over grooves.
a) (Refer to Fig. 6 and 7) for service clearance area.
d) Mark belts as to position. Remove and set aside
b) For chilled water coil, shut off the valves.
belts, tag as necessary.
c) Disconnect the chilled water and condensate
e) Remove motor to motor bracket hold down bolts.
piping.
f) Remove motor pulley and set aside.
d) Remove coil section panel (all screws are located
g) Remove the motor.
on the inside of the unit).
h) Install the new motor. Re-assemble by reversing
e) On header end, remove screws holding the
steps a to f. Be sure to re-install multiple belts
block off and the coil casing.
in their original position. Use a new set if
f) Slide coil and baffles out of unit.
required. Do not stretch belts over the pulleys.
g) Lift coil using hooks at the coil casing. Do not
Align belts as per item 7.3.
lift by header or center of coil.
i) Re-connect motor leads and restore power.
h) Reinsert coil by reversing order of procedures
Check fan proper rotation as described in
listed.
item 10.10 Start-Up procedure.
i) Apply sealant as necessary to edges to ensure
air tightness.
12
11.7 Fan Shaft and Bearing 11.9 Lubrication
a) Disconnect power supply to fan motor. Fan bearings are not permanently lubricated.
b) Use wooden blocks to prevent the fan and Advisable to top-up grease every 3 months.
motor assembly from free floating over the
anti-vibration mounts. 11.10 Filters
c) Loosen motor frame adjustment to release The 39G unit can be supplied with or without filters
belt tension. Remove belts. from the factory. There are 3 types of standard
Caution: Do not stretch belts over the pulley. filters available.
Damage to belt can result. a) High velocity panel filters (Side withdrawal
d) Loosen bolts on bushing of pulley and remove type).
bushing, then the pulley. b) Low velocity panel filters (Side withdrawal
e) Loosen bearing set screw and locking collar. type).
Drive eccentric type collar in direction opposite c) Bag filters (Side withdrawal type).
to shaft rotation. d) HEPA filter EU13 particle board frame.
f) Remove bearing while observing the following
precaution. (Refer 11.8). Notes:-
The high velocity filter frame are design to accept
11.8 Blower Wheel Replacements filter media cells with aluminium or steel frame.
a) There are two type of DIDW centrifugal fans * HVF & LVF Media-these filters shall be of the
used with the 39G unit. washable /disposable 48mm deep plated panel
i) Backward Curved. type, gravimetric efficiency 85% to 93% to ASHRAE
ii) Forward Curved. 52-76.
b) All blower wheel and fan shaft are designed to BF Media-these bag filters shall be of the disposable
be removed through fan housing inlet. Generally, dry media type, deep bed, fixed panel type, 600mm,
there should be no need to disconnect the average gravimetric efficiency 85% to ASHRAE
flexible connection and duct work. 52-76.
For other types of filters, please contact your
nearest Carrier representatives.
CAUTION
1) Block fan wheel when removing the shaft to

prevent damage to the inlet cones.
2) Use wooden blocks to prevent the fan and motor
assembly from free floating over the anti-
vibration mounts.
3) There may be instances where the location
of the access door is not directly in line with
the centre of the shaft. Here, it is necessary
to remove the intermediate post, adjacent
panel and door assembly. Apply sealant
as necessary when these items are re-installed.
4) Exercise procedure to remove fan shaft and
bearing as outlined earlier.
5) Remove bolts and nuts holding frame to the
fan housing. Only the frame on the side where
the blower wheel is to be removed out is required
to be dismantled.
6) Removed bolts holding frame inlet cone or inlet
guide vane assembly and remove accordingly.
7) Remove fan wheel and shaft as assembly.
13
14
Item Description
1 Belt Tensioner
2 Bolt, HEX HD M10-30L(S)
3 Bolt, HEX HD M12-30L
4 Bolt, HEX HD M12-40L
APPENDIX 1 : ASSEMBLY FAN AND MOTOR BASE (PHASE 1)
5 Fan, Channel Notes:-

6 Hat, Channel 1. Spring isolator can be offered
7 HEX, Bolt M8-25L 2. The design will be changes when Fan size is FCG / BCG 500 and above.
8 Motor, Channel
9 Nutsert 8MM, Large Flange
10 Rubber, Isolator
11 Unistrut Nut M12
Item Description
1 Belt Tensioner
2 Bolt, 5/8”Dia.80mm LG Adjustment
3 Bolt, 5/8”Dia.40mm LG
4 Bolt, 5/8”Dia.40mm LG C/W Tapered Washer
APPENDIX 2 : ASSEMBLY FAN AND MOTOR BASE (PHASE 2)
5 Fan, Base ‘L’ angle 3” x 3” x 5mm THK

6 Hat, Channel
7 Adjustment bracket
8 Motor, Base ‘L’ angle 3” x 3” x 5mm THK Notes:-
9 Angle support 1. The “REF” dimension to be changed according to the Fan & Motor size.
10 Spring, Isolator 2. Spring isolator size and quantity depend on Fan & motor size.
11 Assy, Cap isolator
15
16
FILTER TYPE, DIMENSION AND QUANTITY FOR EACH AHU SIZE.
MODEL
PART NAME PART NO.
0508A 0508B 0511 0612 0713 0813 0914 0916 1018 1118 1319 1422 1522 1722 1724 1725 1926 2127 2230 2234 2434 2636
a) HEPA Filter EU13 Particle Board Frame (Media Thickness 292mm)
(H305 x W305)mm 39GA509-320 - - 1 - - - - - - - - - - - - - - - - - - -
(H305 x W610)mm 39GA509-321 1 1 1 - - - - - 2 2 - - - 3 - - - - - - 5 -
(H508 x W508)mm 39GA509-322 - - - 2 2 2 - - - - 6 - - - 12 12 12 - 20 24 - -
(H610 x W610)mm 39GA509-323 - - - - - - 2 2 2 2 - 6 6 6 - - - 9 - - 15 20
b) 1” Bag Filter 402mm L
(H289 x W391)mm 39GA509-388 - - 1 - - - - - - - - - - - - - - - - - - -
(H391 x W595)mm 39GA509-384 - 1 1 - - 2 - - - - - - - - - - - - - - - -
(H289 x W595)mm 39GA509-381 1 - - 4 - 2 2 3 3 3 - 2 5 5 5 4 - 4 7 8 4 4
(H595 x W595)mm 39GA509-386 - - - - 2 - 2 2 3 3 6 6 6 6 6 8 12 12 12 15 20 20
c) 1” Bag Filter 450mm L
(H289 x W391)mm 39GA509-396 - - 1 - - - - - - - - - - - - - - - - - - -
(H391 x W595)mm 39GA509-392 - 1 1 - - 2 - - - - - - - - - - - - - - - -
(H289 x W595)mm 39GA509-389 1 - - 4 - 2 2 3 3 3 - 2 5 5 5 4 - 4 7 8 4 4
(H595 x W595)mm 39GA509-394 - - - - 2 - 2 2 3 3 6 6 6 6 6 8 12 12 12 15 20 20
d) 1” Bag Filter 529mm L
(H289 x W391)mm 39GA509-380 - - 1 - - - - - - - - - - - - - - - - - - -
(H391 x W595)mm 39GA509-376 - 1 1 - - 2 - - - - - - - - - - - - - - - -
(H289 x W595)mm 39GA509-373 1 - - 4 - 2 2 3 3 3 - 2 5 5 5 4 - 4 7 8 4 4
(H595 x W595)mm 39GA509-378 - - - - 2 - 2 2 3 3 6 6 6 6 6 8 12 12 12 15 20 20
e) 1” HVF Filter Washable
(H289 x W391)mm 39GA509-130 - - 1 - - - - - - - - - - - - - - - - - - -
(H391 x W595)mm 39GA509-035 - 1 1 - - 2 - - - - - - - - - - - - - - - -
(H289 x W595)mm 39GA509-032 1 - - 4 - 2 2 3 3 3 - 2 5 5 5 4 - 4 7 8 4 4
(H595 x W595)mm 39GA509-037 - - - - 2 - 2 2 3 3 6 6 6 6 6 8 12 12 12 15 20 20
f) 2” HVF Filter Washable
(H289 x W391)mm 39GA509-131 - - 1 - - - - - - - - - - - - - - - - - - -
(H391 x W595)mm 39GA509-041 - 1 1 - - 2 - - - - - - - - - - - - - - - -
(H289 x W595)mm 39GA509-038 1 - - 4 - 2 2 3 3 3 - 2 5 5 5 4 - 4 7 8 4 4
(H595 x W595)mm 39GA509-043 - - - - 2 - 2 2 3 3 6 6 6 6 6 8 12 12 12 15 20 20
g) 1” HVF Filter Disposable
(H289 x W391)mm 39GA509-128 - - 1 - - - - - - - - - - - - - - - - - - -
(H391 x W595)mm 39GA509-023 - 1 1 - - 2 - - - - - - - - - - - - - - - -
(H289 x W595)mm 39GA509-020 1 - - 4 - 2 2 3 3 3 - 2 5 5 5 4 - 4 7 8 4 4
(H595 x W595)mm 39GA509-025 - - - - 2 - 2 2 3 3 6 6 6 6 6 8 12 12 12 15 20 20
h) 2” HVF Filter Disposable
(H289 x W391)mm 39GA509-129 - - 1 - - - - - - - - - - - - - - - - - - -
(H391 x W595)mm 39GA509-029 - 1 1 - - 2 - - - - - - - - - - - - - - - -
(H289 x W595)mm 39GA509-026 1 - - 4 - 2 2 3 3 3 - 2 5 5 5 4 - 4 7 8 4 4
(H595 x W595)mm 39GA509-031 - - - - 2 - 2 2 3 3 6 6 6 6 6 8 12 12 12 15 20 20
Note: Dimension in mm
INTERNAL SPRING ISOLATOR ARRANGEMENT
SPRING SELECTION (UBF/DBF) (For UBR/DBR, A<->B; C<->D)
MOTOR FAN SIDE A/B FREE SIDE C MOTOR SIDE D
UNIT (39G) FAN SIZE HP WGT(kg) A B C D
FCG02-160 (7kg) 1 15 514 513 513 515
1.5 20 514 513 513 516
0508A
1.5 20 515 514 513 516
FCG02-180 (9kg)
2 22 515 514 513 516
1.5 20 514 515 513 516
0508B FCG02-180 (9kg)
2 22 515 515 513 516
1.5 20 515 514 513 516
0511 FCG02-200 (10kg) 2 22 515 514 513 516
3 30 515 514 513 516
2 22 515 514 513 516
3 30 515 514 513 516
FCG02-225 (12kg)
4 30 515 514 513 516
5 42 515 514 513 516/524
0612
2 22 515 514 514 516
3 30 515 514 514 516
BCG12-225 (15kg)
4 30 515 514 514 516
5 42 515 514 514 516/524
3 30 515 515 514 516
4 30 515 515 515 516
FCG02-280 (20kg) 5 42 516 515 515 516/524
5.5 42 516 515 515 516/524
7.5 65 516 515 515 517
0713
3 30 516 515 514 516
4 30 516 515 515 516
BCG12-280 (23kg) 5 42 516 515 515 516/524
5.5 42 516 515 515 516/524
7.5 65 516 515 515 517
4 30 516 515 515 516/524
5 42 516 515 515 516/524
FCG02-315 (23kg)
5.5 42 516 515 515 516/524
7.5 65 516 515 515 517
0813
4 30 516 515 515 516
5 42 516 515 515 516/524
BCG12-315 (27kg)
5.5 42 516 515 515 516/524
7.5 65 516 515 515 517
4 30 516 516 516 516/524
5 42 516 516 516 516/524
FCG02-355 (30kg) 5.5 42 516 516 516 516/524
7.5 65 516 516 516 517
10 76 516 516 516 517/524
0914
4 30 516 516 516 516/524
5 42 516 516 516 516/524
BCG12-355 (36kg) 5.5 42 516 516 516 516/524
7.5 65 516 516 516 517/524
10 76 516 516 516 517/524
4 30 516 516 515 516/524
5 42 516 516 515 516/524
FCG02-355 (30kg)
5.5 42 516 516 515 516/524
7.5 65 516 516 515 517/524
0916
4 30 516 516 515 516
5 42 516 516 515 516/524
5.5 42 516 516 515 516/524
BCG12-355 (36kg) 7.5 65 516 516 515 517/524
10 76 516 516 515 517/524
15 118 516/524 516 515 518/524
UBF/DBF UBR/DBR
(4-SPRING POINTS) (4-SPRING POINTS)
A D A D
MOTOR
FAN FAN
MOTOR
B C B C
AIR FLOW AIR FLOW
17
INTERNAL SPRING ISOLATOR ARRANGEMENT (Con’t)
5 42 516 516 516 516/524
FCG02-400 (45kg) 5.5 42 516/524 516 516 516/524
7.5 65 516/524 516 516 517/524
10 76 516/524 516 516 517/524
5 42 516 516 516 517
FCG05-450 (65kg) 5.5 42 516 516 516 517
7.5 65 516/524 516 516 517/524
10 76 516/524 516 516 518
1018
5.5 42 516 516 516 517
BCG15-400 (61kg) 7.5 65 516/524 516 516 517/524
10 76 516/524 516 516 517/524
15 118 516/524 516 516 519
5.5 42 516 516/524 516 517
BCG15-450 (73kg) 7.5 65 516/524 516/524 516 517/524
10 76 516/524 516/524 516 518
15 118 516/524 516/524 516 519
FCG05-450 (65kg) 7.5 65 516/524 516 516 517/524

10 76 516/524 516 516 517/524
1118
BCG15-450 (73kg) 10 76 516/524 516 516 517/524
15 118 516/524 516/524 516 519
7.5 65 516/524 516 516 517/524
FCG05-450 (65kg) 10 76 516/524 516 516 517/524
15 118 517/524 516/524 516 519
7.5 65 516/524 516/524 516 517/524
1319 FCG05-500 (80kg) 10 76 516/524 516/524 516 518
15 118 516/524 516/524 516 519
15 118 516/524 516/524 516 519
BCG15-450 (73kg)
20 139 517 516/524 516 519/524
15 118 517 517 517 519
BCG15-500 (94kg)
20 139 517 517 517 519/524
10 76 517 516/524 516/524 518
1422 FCG05-500 (80kg) 15 118 517 516/524 517 518
20 139 517 516/524 517 518/524
25 189 517 516/524 517 519/524
10 76 516/524 516/524 516 517
1422 BCG15-500 (94kg) 15 118 517 517 516/524 518
20 139 517/524 517 516/524 518/524
25 189 517/524 517 517 519/524
1422 10 76 517 516/524 516 517/524
1522 15 118 517/524 517/524 516/524 518
FCG02-560 (97kg)
20 139 517/524 517/524 517 518/524
25 189 517/524 517/524 517 519/524
1422 15 118 517/524 517 517 518
1522 BCG15-560 (125kg) 20 139 517/524 517/524 517/524 519/524
25 189 517/524 517/524 517/524 519/524
1522 15 118 517/524 518 516/524 519
1722 FCG02-630 (115kg) 20 139 517/524 518 516/524 519
1724 25 189 517/524 518 517 520
30 203 517/524 518 517 520
1522 15 118 517/524 517/524 517 518/524
1722 BCG15-630 (149kg) 20 139 517/524 518 517 519
1724 25 189 518 518 517 520
30 203 518 518 517 520/524
UBF/DBF UBR/DBR
A D A D
MOTOR
FAN FAN
MOTOR
B C B C
AIR FLOW AIR FLOW
18

15 118 517/524 517/524 516/524 518/524
1725 BCG15-630 (149kg) 20 139 517/524 517/524 516/524 519
25 189 518 517/524 517 520
30 203 518/524 518 517/524 520/524
1722 20 139 518/524 518 517 519
1724 FCG02-710 (175kg) 25 189 518/524 518 517 520
1725 30 203 518/524 518 517 520/524
1926 40 290 518/524 518 517/524 522
1722 20 139 519 518 517/524 519
1724 25 189 519 518 517/524 520
1725 BCG15-710 (201kg) 30 203 519 518/524 517/524 520/524
1926 40 290 519 518/524 517/524 522/524
50 320 519 518/524 517/524 523
15 118 517/524 517 516/524 518/524
1725 FCG05-630 (137kg) 20 139 517/524 518 516/524 519
25 189 518 518 517 520
30 203 518/524 518 517/524 520
20 139 518/524 518/524 517 519/524
25 189 519 518/524 517 520/524
1926 FCG05-800/GI (233kg) 30 203 519 518/524 517 520/524
40 290 519/524 518/524 517/524 522/524
50 320 519/524 518/524 517/524 523
60 355 519/524 518/524 518 525
20 139 519 518/524 517 519/524
25 189 519 518/524 517 520/524
1926 BCG15-800/GI (250kg) 30 203 519 519 517 521
40 290 519/524 519 517/524 522/524
50 320 520 519 518 523/524
60 355 520 519 518 525
UBF/DBF UBR/DBR
A D A D
MOTOR
FAN FAN
MOTOR
B C B C
AIR FLOW AIR FLOW
19
SPRING SELECTION (UBF/DBF) (For UBR/DBR, A<->B; C<->D; E<->F)
MOTOR FAN SIDE A/B FREE SIDE C MOTOR SIDE C MIDDLE SIDE E/F
UNIT (39G) FAN SIZE HP WGT(kg) A B C D E F
20 139 517 517/524 516 517/524 517/524 519
25 189 517 517/524 516 518 517/524 519/524
2127 FCG05-710 (183kg) 30 203 517 517/524 516 518/524 517/524 519/524
40 290 517 517/524 516/524 519/524 518 521
50 320 517 517/524 516/524 520 518 521
20 139 517/524 518 516 517/524 517/524 519
25 189 517/524 518 516 518 517/524 519/524
2127 BCG15-710 (201kg) 30 203 517/524 518 516 518/524 517/524 519/524
40 290 517/524 518 516/524 519/524 518 521
50 320 517/524 518 516/524 520 518 521
2127 20 139 518 518/524 516 517/524 517/524 519
2230 25 189 518 518/524 516 518/524 517/524 519/524
2234 FCG05-800/GI (233kg) 30 203 518 518/524 516 518/524 517/524 520
40 290 518 518/524 516/524 520 518 521
50 320 518 518/524 516/524 520 518 521/524
60 355 518 518/524 516/524 520/524 518/524 522
2127 20 139 518 518/524 516 517/524 517/524 519
2230 25 189 518 518/524 516 518/524 518 520
2234 BCG15-800/GI (250kg) 30 203 518 518/524 516 518/524 518 520
40 290 518 519 516/524 519/524 518 521
50 320 518 519 517 520/524 518/524 521/524
60 355 518 519 517 520/524 518/524 522
2230 25 189 518/524 519/524 516 518/524 518/524 520/524
2234 30 203 518/524 519/524 516 518/524 518/524 520/524
2434 FCG05-900/GI (316kg) 40 290 518/524 519/524 516/524 520 518/524 521/524
2636 50 320 518/524 519/524 516/524 520 519 522
60 355 518/524 519/524 516/524 520/524 519 522/524
75 520 518/524 519/524 517 523 519 525/524
2230 25 189 519 520 516 518/524 518/524 520/524
2234 30 203 519 520 516 518/524 518/524 521
2434 BCG15-900/GI (358kg) 40 290 519 520 516/524 520 519 522
2636 50 320 519 520 516/524 520 519 522/524
60 355 519 520 516/524 520/524 519 523
75 520 519 520 517 523 519/524 525/524
2434 25 189 518/524 520 516 519 519 520/524
2636 30 203 518/524 520 516 519 519 521
FCG05-1000/GI (376kg) 40 290 518/524 520 516 520/524 519 522
50 320 518/524 520 516 521 519 522/524
60 355 518/524 520 516 521/524 519/524 523
75 520 518/524 520 516/524 525 519/524 525/524
2434 25 189 519 520/524 516 519 519/524 520/524
2636 30 203 519 520/524 516 519 519/524 521
BCG15-1000/GI (416kg) 40 290 519 520/524 516 520/524 519/524 522
50 320 519 520/524 516 521 519/524 522/524
60 355 519 520/524 516 521/524 519/524 523
75 520 519 520/524 516/524 525 520 525/524
UBF/DBF UBR/DBR
A F D A F D
MOTOR
FAN FAN
MOTOR
B E C B E C
AIR FLOW AIR FLOW
20
SPRING SELECTION (THF/BHF) (For THR/BHR, A<->B; C<->D)
MOTOR FAN SIDE A/B MOTOR SIDE C FREE SIDE D
1 15 513 514 515 513
FCG02-160 (7kg)
1.5 20 513 514 516 513
0508A
1.5 20 513 515 516 513
FCG02-180 (9kg)
2 22 513 515 516 513
1.5 20 514 515 516 513
0508B FCG02-180 (9kg)
2 22 514 515 516 513
1.5 20 515 513 515 515
0511 FCG02-200 (10kg) 2 22 515 513 515 515
3 30 515 513 516 515
2 22 514 515 516 515
FCG02-225 (12kg) 3 30 514 516 516 515
4 30 514 516 516 515
0612 5 42 515 516 516/524 515
2 22 515 515 516 515
BCG12-225 (15kg) 3 30 515 515 516 515
4 30 515 515 516 515
5 42 515 515 516/524 515
3 30 515 515 516 514
4 30 515 516 516 515
FCG02-280 (20kg) 5 42 515 516 516/524 515
5.5 42 515 516 516/524 515
7.5 65 515 516 517 515
0713
3 30 515 516 516 514
4 30 515 516 516 515
BCG12-280 (23kg) 5 42 515 516 516 515
5.5 42 515 516 516 515
7.5 65 515 516 517 515
4 30 515 516 516/524 515
FCG02-315 (23kg) 5 42 515 516 516/524 515
5.5 42 515 516 516/524 515
7.5 65 515 516/524 517 515
0813
4 30 515 516 516 515
BCG12-315 (27kg) 5 42 515 516 516/524 515
5.5 42 515 516 516/524 515
7.5 65 515 516 517 515
4 30 515 516 516/524 515
5 42 515 516 516/524 515
FCG02-355 (30kg) 5.5 42 515 516 516/524 515
7.5 65 515 516 517/524 515
10 76 515 516 517/524 515
0914
4 30 515 516 516/524 515
5 42 515 516 516/524 515
BCG12-355 (36kg) 5.5 42 515 516 516/524 515
7.5 65 516 516 517/524 515
10 76 516 516 517/524 515
4 30 515 516 516/524 515
FCG02-355 (30kg) 5 42 515 516 516/524 515
5.5 42 515 516 516/524 515
7.5 65 515 516 517 515
0916 4 30 516 516 516 515
5 42 516 516 516/524 515
5.5 42 516 516 516/524 515
BCG12-355 (36kg)
7.5 65 516 516 517 515
10 76 516 516/524 517/524 515
15 118 516 516/524 518/524 515
THF/BHF THR/BHR
A D A D
MOTOR
FAN FAN
MOTOR
B C B C
AIR FLOW AIR FLOW
21
5 42 516 516 516/524 516
FCG02-400 (45kg) 5.5 42 516 516 516/524 516
7.5 65 516 516 517/524 516
10 76 516 516 517/524 516
5 42 516 516 517 516
FCG05-450 (65kg) 5.5 42 516 516 517 516
7.5 65 516 516 518 516
1018 10 76 516 516 518 516
5.5 42 516 516 517 516
BCG15-400 (61kg) 7.5 65 516 516/524 517/524 516
10 76 516 516/524 517/524 516
15 118 516 516/524 519 516
5.5 42 516 516 517 516
BCG15-450 (73kg) 7.5 65 516 516/524 517/524 516
10 76 516 516/524 518 516
15 118 516 516/524 519 516
FCG05-450 (65kg) 7.5 65 516 516/524 517/524 516

1118 10 76 516 516/524 517/524 516
BCG15-450 (73kg) 10 76 516 516/524 517/524 516
15 118 516 516/524 519 516
7.5 65 516 516/524 517/524 516
FCG05-450 (65kg) 10 76 516 516/524 517/524 516
15 118 516 516/524 519 516
7.5 65 516/524 516/524 517/524 516
1319 FCG05-500 (80kg) 10 76 517 517 518 516
15 118 517 517 519 516
BCG15-450 (73kg) 15 118 516 516/524 519 516
20 139 516 517 519/524 516
15 118 517 517 519 516/524
BCG15-500 (94kg)
20 139 517 517 519/524 516/524
10 76 516/524 516/524 517 516/524
1422 FCG05-500 (80kg) 15 118 516/524 516/524 517/524 516/524
20 139 516/524 517 518 517
25 189 517 517 519 517
10 76 517 516/524 517 516/524
1422 BCG15-500 (94kg) 15 118 517 516/524 518 516/524
20 139 517 516/524 518 517
25 189 517 517 519 517/524
1422 10 76 517 516/524 517 516
1522 FCG02-560 (97kg) 15 118 517 516/524 518 516/524
20 139 517 516/524 518/524 516/524
25 189 517 517 519/524 517
1422 15 118 517/524 517 518 516/524
1522 BCG15-560 (125kg) 20 139 517/524 517 518/524 517
25 189 517/524 517/524 519/524 517
1522 15 118 517/524 517/524 518 517
1722 FCG02-630 (115kg) 20 139 517/524 517/524 518/524 517
1724 25 189 517/524 517/524 519/524 517/524
30 203 517/524 517/524 520 517/524
1522 15 118 517/524 517/524 518 517
1722 BCG15-630 (149kg) 20 139 518 517/524 519 517
1724 25 189 518 517/524 519/524 517/524
30 203 518 517/524 520 517/524
THF/BHF THR/BHR
A D A D
MOTOR
FAN FAN
MOTOR
B C B C
AIR FLOW AIR FLOW
22
UNIT (39G) FAN SIZE HP WGT (kg) A B C D
15 118 517/524 517 518 517
1725 BCG15-630 (149kg) 20 139 518 517/524 518/524 517
25 189 518 517/524 519/524 517/524
30 203 518 517/524 520 517/524
1722 20 139 518 517/524 518/524 517
1724 FCG02-710 (175kg) 25 189 518 517/524 519/524 517/524
1725 30 203 518 517/524 520 517/524
1926 40 290 518/524 518 521/524 518/524
1722 20 139 518/524 518/524 518/524 517/524
1724 25 189 518/524 518/524 519/524 517/524
1725 BCG15-710 (201kg) 30 203 518/524 518/524 520 518
1926 40 290 519 518/524 521/524 518/524
50 320 519 518/524 523 518/524
15 118 518 517 518/524 517
1725 FCG05-630 (137kg) 20 139 518 517 518/524 517
25 189 518 517/524 519/524 517/524
30 203 518 517/524 520 517/524
20 139 519 518 519 517
25 189 519 518/524 520 517/524
30 203 519 518/524 520/524 517/524
1926 FCG05-800/GI (233kg)
40 290 519/524 518/524 522 518
50 320 519/524 519 522/524 518/524
60 355 519/524 519 523/524 518/524
20 139 519/524 518 519 517/524
25 189 519/524 518/524 520 517/524
30 203 519/524 518/524 520/524 517/524
1926 BCG15-800/GI (250kg)
40 290 519/524 519 522 518
50 320 519/524 519 522/524 518/524
60 355 519/524 519 523/524 518/524
THF/BHF THR/BHR
A D A D
MOTOR
FAN FAN
MOTOR
B C B C
AIR FLOW AIR FLOW
23
SPRING SELECTION (THF/BHF) (For THR/BHR, A<->B; C<->D; E<->F)
MOTOR FAN SIDE A/B FREE SIDE C MOTOR SIDE C MIDDLE SIDE E/F
UNIT (39G) FAN SIZE HP WGT(kg) A B C D E F
20 139 517/524 517 518 516 519 518
25 189 517/524 517 518/524 516 519 518
2127 FCG05-710 (183kg) 30 203 517/524 517 518/524 516 519/524 518
40 290 517/524 517 520 516/524 520/524 518
50 320 517/524 517 520 516/524 521 518/524
20 139 518 517 517/524 516 518/524 517/524
25 189 518 517 518 516/524 519 518
2127 BCG15-710 (201kg) 30 203 518 517 518 516/524 519 518
40 290 518 517 519/524 516/524 520 518/524
50 320 518 517 519/524 517 520/524 518/524
2127 20 139 518/524 517/524 517/524 516 518/524 518
2230 25 189 518/524 517/524 518 516/524 519 518
2234 30 203 519 518 518/524 516/524 519/524 518
FCG05-800/GI (233kg)
40 290 519 518 519/524 516/524 520/524 518/524
50 320 519 518 519/524 517 521 518/524
60 355 519 518 520 517 521 519
2127 20 139 519 517/524 517/524 516 518/524 518
2230 25 189 519 517/524 518 516 519/524 518/524
2234 30 203 519 517/524 518/524 516/524 519/524 518/524
BCG15-800/GI (250kg)
40 290 519 517/524 519/524 516/524 520/524 518/524
50 320 519 517/524 519/524 517 521 519
60 355 519 517/524 520 517 521/524 519
2230 25 189 519/524 518 518/524 516 519/524 519
2234 30 203 519/524 518 518/524 516/524 520 519
2434 40 290 519/524 518 519/524 516/524 521 519
FCG05-900/GI (316kg)
2636 50 320 519/524 518 520 517 521/524 519/524
60 355 519/524 518 520/524 517 522 519/524
75 520 519/524 518 523 517/524 525 520
2230 25 189 521 519 518/524 516 520 519
2234 30 203 521 519 519 516/524 520 520
2434 40 290 521 519 519/524 516/524 521 520
BCG15-900/GI (358kg)
2636 50 320 521 519 520 516/524 521/524 520
60 355 521 519 520/524 517 522 520
75 520 521 519 523 517/524 525 520/524
2434 25 189 520 518/524 519 516 520/524 519
2636 30 203 520 518/524 519 516 520/524 519
40 290 520 518/524 520/524 516 522 519/524
FCG05-1000/GI (376kg)
50 320 520 518/524 521 516 522/524 519/524
60 355 520 518/524 521/524 516 523 519/524
75 520 520 518/524 525 516/524 525/524 520
2434 25 189 520/524 519 519 516 520/524 519/524
2636 30 203 520/524 519 519 516 521 519/524
40 290 520/524 519 520/524 516 522 519/524
BCG15-1000/GI (416kg)
50 320 520/524 519 521 516 522/524 519/524
60 355 520/524 519 521/524 516/524 523 520
75 520 520/524 519 525 516/524 525/524 520
THF/BHF THR/BHR
A F D A F D
MOTOR
FAN FAN
MOTOR
B E C B E C
AIR FLOW AIR FLOW
24
DIMENSION
Nominal Nominal Section Length Unit Unit Unit

Unit Range
Fan Size Capacity A/Flow Filter Access HH* Width HV**
Size Of Hp MXB (G) Coil (B) Fan (A)
(kW) @2.5m m/s HVF (F) LVF (E) BF (D) (C) (mm) (mm) (mm)
FCG 02-160 1 ~ 1.5
0508A 7.9 425 600 300 600 600 600 500 500 500 800 1000
FCG 02-180 1.5 ~ 2
0508B FCG 02-180 1.5 ~ 2 11.4 614 600 300 600 600 600 500 500 500 800 1000
0511 FCG 02-200 1.5 ~ 3 15.8 850 600 300 600 600 600 500 600 500 1100 1000
FCG 02-225 2~4
0612 22.9 1227 600 300 600 600 600 500 600 600 1200 1200
BCG 12-225 3~5
FCG 02-280 3~5
0713 32.5 1746 600 300 600 600 600 500 700 700 1300 1400
BCG 02-280 4 ~ 7.5
FCG 02-315 4~5
0813 37.8 2030 600 300 600 600 600 500 800 800 1300 1600
BCG 12-315 5 ~ 7.5
FCG 02-355 4 ~ 7.5
0914 48.8 2620 600 300 600 600 600 500 900 900 1400 1800
BCG 12-355 5 ~ 10
FCG 02-355 4 ~ 7.5
0916 53.6 2879 600 300 600 600 600 500 900 900 1600 1800
BCG 12-355 7.5 ~ 15
FCG 02-400 5 ~ 10 2000
1018 66.8 3587 600 300 600 600 600 500 1000 1000 1800
BCG 15-400 7.5 ~ 15 2100
FCG 05-450 7.5 ~ 15
1118 78.2 4201 600 300 600 600 600 500 1000 1100 1800 2200
BCG 15-450 10 ~ 15
FCG 05-450 7.5 ~ 15
600 300 600 600 600 500 1000 2400
1319 BCG 15-450 10 ~ 15
96.7 5192 1300 1900
FCG 05-500 10 ~ 20
600 300 600 600 600 500 1100 2500
BCG 15-500 15 ~ 20
FCG 05-500 10 ~ 15
900 300 600 600 600 500 1100 2600
BCG 15-500 10 ~ 15
1422 109.8 5900 1400 2200
FCG 02-560 15 ~ 20
900 300 600 600 600 500 1200 2700
BCG 15-560 15 ~ 20
FCG 02-560 10 ~ 20
900 300 600 600 600 500 1200 2800
BCG 15-560 15 ~ 20
1522 118.6 6372 1500 2200
FCG 02-630 15 ~ 25
900 300 600 600 600 500 1400 3000
BCG 15-630 20 ~ 25
FCG 02-630 15 ~ 20
900 300 600 600 600 500 1400 3200
BCG 15-630 15 ~ 25
1722 136.2 7316 1700 2200
FCG 02-710 20 ~ 25
900 300 600 600 600 500 1500 3300
BCG 15-710 20 ~ 30
FCG 02-630 15 ~ 25
900 300 600 600 600 500 1400 3200
BCG 15-630 15 ~ 25
1724 153.6 8280 1700 2400
FCG 02-710 20 ~ 30
900 300 600 600 600 500 1500 3300
BCG 15-710 20 ~ 30
FCG 05-630 15 ~ 25
900 300 600 600 600 500 1400 3200
BCG 15-630 15 ~ 25
1725 166.9 8988 1700 2500
FCG 02-710 20 ~ 30
900 300 600 600 600 500 1500 3300
BCG 15-710 25 ~ 40
FCG 02-710 15 ~ 25
1300 300 600 600 600 500 1500 3500
BCG 15-710 20 ~ 30
1926 184.5 9912 1900 2600
FCG 05-800 25 ~ 40
1300 300 600 600 600 500 1700 3700
BCG 15-800 25 ~ 40
FCG 05-710 15 ~ 25
1300 300 600 600 600 500 1500 3700
BCG 15-710 20 ~ 30
2127 215.3 11564 2100 2700
FCG 05-800/GI 25 ~ 40
1300 300 600 600 600 500 1700 3900
BCG 15-800/GI 30 ~ 50
FCG 05-800 20 ~ 30
1300 300 600 600 600 500 1700 4000
BCG 15-800 20 ~ 30
2230 254.8 13688 2200 3000
FCG 05-900 30 ~ 50
1300 300 600 600 600 500 1900 4200
BCG 15-900 40 ~ 50
FCG 05-800/GI 20 ~ 40
1300 300 600 600 600 500 1700 4000
BCG 15-800/GI 20 ~ 40
2234 298.7 16048 2200 3400
FCG 05-900/GI 30 ~ 60
1300 300 600 600 600 500 1900 4200
BCG 15-900/GI 40 ~ 60
FCG 05-900 25 ~ 40
1300 300 600 600 600 500 1900 4400
2434 BCG 15-900 25 ~ 40
325.1 17464 2400 3400
FCG 05-1000 40 ~ 60
1300 300 600 600 600 500 2000 4500
BCG 15-1000 40 ~ 60
FCG 05-900/GI 25 ~ 50
1300 300 600 600 600 500 1900 4600
BCG 15-900/GI 25 ~ 50
2636 377.8 20296 2600 3600
FCG 05-1000 40 ~ 75
1300 300 600 600 600 500 2000 4700
BCG 15-1000 40 ~ 75
*HH - Height Horizontal **HV - Height Vertical
25
1) External AHU Length = (Section Length + K) mm
K = 110mm for 25mm casing thickness
160mm for 50mm casing thickness
2) External AHU Width = (Unit Width + K) mm
3) For Horizontal Unit, External AHU Height = (HH + K + 100*) mm

For Vertical Unit, External AHU Height = (HV + 2K + 100*) mm
*100mm is for unit base
4) If the External AHU Length is > 1900mm, section will be split into several casing for shipping purposes.
G F E D C B A
A
C
C
HH
E
S
S
HV
26
MEMO
27
Carrier
International
Sdn. Bhd.
® Malaysia
Carrier International Sdn. Bhd. (3385-T)

Lot 4, Jalan P/6, 43650 Bandar Baru Bangi,
Selangor, Malaysia.
Tel: 03-8925 8001
Fax: 03-8925 3578
39G Rev. 4
05 2003
Manufacturer reserves the right to discontinue, or

change at any time, specifications or designs without
39GA 509-058 notice and without incurring obligations.
28
SARAWAK (O&M)
3.3
FAN COIL UNIT
SARAWAK (O&M)
3.4
AIR-COOL SPLIT UNIT
Before using your air conditioner, please read
this manual carefully and keep it for future reference.
SPLIT-TYPE
ROOM AIR CONDITIONER
The design and specifications are subject to change without prior notice for
Read This Manual
product improvement. Consult with the sales agency or manufacturer for details.
Keep this manual where the operator can easily
find them.Inside you will find many helpful hints
on how to use and maintain your air conditioner
properly. Just a little preventative care on your
part can save you a great deal of time and money
CS152U-11D1(L) over the life of your air conditioner. You'll find many
answers to common problems in the chart of
202000192449 troubleshooting tips. If you review the chart of
20130906 Troubleshooting Tips first, you may not need
to call for service.
CONTENTS When using this air conditioner in the European countries, please read the
following information:
SAFETY PRECAUTIONS
Warning .....................................................................................................................................3 This appliance is can be used by children aged from 8 years and above and persons with
Caution ......................................................................................................................................4 reduced physical, sensory or mental capabilities, or lack of experience and knowledge if they
. have been given supervision or instruction concerning use of the appliance in a safe way and
understand the hazards involved. Children shall not play with the appliance. Cleaning and user
NAMES OF PARTS
maintenance shall not be made by children without supervision.
Indoor unit ........... .....................................................................................................................5
outdoor unit ...............................................................................................................................5 DISPOSAL: Do not dispose of this product as unsorted municipal waste. Collection of such waste
Indication lamp...........................................................................................................................5 separately for special treatment is necessary.
It is prohibited to dispose of this appliance in domestic household waste. For disposal, there are
OPERATING INSTRUCTIONS several possibilities:
Special functions .......................................................................................................................6 A) The municipality has established collection systems, where electronic waste can
Operating temperature................................................................................................................7 be disposed of at least free of charge to the user.
Manual operation ......................................................................................................................7 B) When buying a new product, the retailer will take back the old product at least
Airflow direction control ............................................................................................................8
How the air conditioner works ..................................................................................................9 free of charge.
C) The manufacturer will take back the old appliance for disposal at least free of
charge to the user.
CARE AND MAINTENANCE D) As old products contain valuable resources, they can be sold to scrap metal
Before maintenance...... ...........................................................................................................10 dealers.
Cleaning the unit.......................................................................................................................10
Cleaning the air filter and air freshening filter ..........................................................................10 Wild disposal of waste in forests and landscapes endangers your health when hazardous
Replacement of the air filter and air freshening filter ...............................................................11 substances leak into the ground-water and find their way into the food chain.
Preparation for extended non-operation....................................................................................11
Pre-season inspection...............................................................................................................11
TROUBLESHOOTING TIPS
Normal function of the air conditioner.......................................................................................12
Troubleshooting guide .............................................................................................................14
1 2
SAFETY PRECAUTIONS SAFETY PRECAUTIONS
To prevent injury to the user or other people and property damage, the following instructions
CAUTION
must be followed. Incorrect operation due to ignoring of instructions may cause harm or damage.
The seriousness is classified by the following indications.
WARNING This symbol indicates the possibility of death or serious injury.

Never actuate any switches with a wet If the air conditioner is to be used in
hand. It may cause an electric shock. conjunction with other heaters, the air
CAUTION This symbol indicates the possibility of injury or damage to property. Never use the device for any other should be refreshed periodically, otherwise
purpose than the intended use. Never there is a risk of lack of oxygen.
Meanings of symbols used in this manual are as shown below. place food, precision instruments, plants, Always pull out the power plug if the unit
animals, paint, etc. on the unit. is not going to be used for any lengthy
Do not expose plants or animals directly period of time. Collections of dust can
Strictly prohibited. to the air flow. cause fire.
Never clean the air conditioner with water. Always switch off the air conditioner and
Be sure to follow the instructions. Never use combustible cleaning agents pull out the power plug during a storm.
as these could cause a fire or deformation. Electrical parts may get damaged.
Never place any burning objects close to Check that the drainage line is correctly
WARNING the device if they could be directly affected connected. If not, water will escape.
by the emitted air. Check that the condensation water can
Never step onto the outdoor device and run off unhindered. It may cause water
never place anything on it. damage if the condensation water cannot
Never use an unsteady or rusty base. run off properly.
Never install the air conditioner in places The air conditoner must be earthed in
Do not extend the cable and never use Remove all dirt from the power plug and where combustible gas can be emitted. accordance with the local codes.
multiple plugs. A poor electrical connection, plug it firmly. Soiled plugs can cause fire Emmitted gas may collect and cause an For electrical safety purposes we
poor insulation or voltage which is higher or an electric shock. explosion. recommend that you install an earth-
than permitted can cause fire. In the event of any abnormalities such Never allow the air conditioner to run for leakage circuit-breaker.
Do not expose your body directly to the cool as smell of burning, immediately switch too long with the doors or windows open, If the power cord is damaged, it must be
air for prolonged period. off the device and pull the plug. Contact or if the humidity is very high. replaced by the manufacturer, its service
Never poke fingers, sticks or other objects your service partner. agent or similary qualified persons in order
in the air inlet and outlet vents. Always switch off the device and pull the to avoid a hazard.
Never attempt to repair, relocate, modify the plug before you start to clean it.
air conditioner yourself. Always contact your Use specified power cord.
service partner if it requires. Contact the authorized installer for
Never pull the plug out by pulling on the installation of this unit.
cable. Hold the plug firmly and pull it out of Contact an authorized service technician
the plug socket, otherwise there is a risk of for repair or maintenance of this unit.
damaging the cable. This appliance is not intended for use by
Do not operate your air conditioner in a wet persons(including children) with reduced
room such as a bathroom or laundry room. physical, sensory or mental capabilities, or
lack of experience and knowledge, unless
they have been given supervision or
instruction concerning use of the appliance
by a person responsible for their safety.
Children should be supervised to ensure
that they do not play with the air
conditioner.
3 4
NAMES OF PARTS OPERATING INSTRUCTIONS
2 1 3 7 Special functions
Names of parts
Refrigerant Leakage Detection , ,
Indoor unit With this new technology, the dipsplay area will appear EC and the indication lamps
continue flashing when the outdoor unit detects refrigerant leakage.
1. Front panel
4 2. Air inlet
5 6 Louver Angle Memory Function(optional):
3. Air filter
8 Within the scope of safety angle, it will memorize the open angle of horizontal louver.
4. Air outlet
If it exceeds, it will memorize the boundry of safety angle. In the following circumstances,
5. Horizontal air flow grille
it will return to standard angle: 1) pressing the turbo or manual control button, 2)unplug
6. Vertical air flow louver(inside)
and then plug in the machine. So we strongly suggest that the open angle of the horizontal
7. Display panel louver should not be set too small, in case the condensed water forms and drops from the
Air inlet(side) Air inlet(rear) horizontal louver.
Outdoor unit
8. Connecting pipe SELF CLEAN function Optional
9. Connecting cable Function used after the shut down of cooling operation to clean the Evaporator
9 10. Stop valve ,it keeps the air fresh for the next operation.
Air outlet For cooling models, the unit will operate under FAN ONLY mode
10 NOTE:
at LOW fan speed for half an hour, and then turn off automatically.
All the pictures in this manual are for For cooling & heating models, the unit will operate as in the below sequence :
explanation purposes only. The actual shape FAN ONLY mode at Low fan speed--Heating operation with LOW fan speed
of the indoor unit you purchased may be slight ---FAN ONLY operation--Stop Operation---Turn off.
Signal receiver different on front panel and display window.The Note:
actual shape shall prevail. This function is only available under COOL(AUTO COOL, FORCED COOL) and
DRY mode.
Before selecting the function, it is recommended to run the air conditioner under
Indication lamp cooling operation for about half an hour. Once the Self Clean function is activated,
all TIMER setting will be cancelled.
A OPERATION indication lamp During SELF CLEAN operation, when pressing the SELF CLEAN button on the remote
This lamp illuminates when the air controller again,the unit will stop the operation and turn off the unit automatically.
Signal receiver conditioner is in operation.
TIMER indication lamp CLEAN AIR function(on some models)
Lights up during Timer operation. Improving the quality of indoor air is one of the purposes of an air conditioner. Thisair
DEFROST indication lamp conditioner is equipped with ionizer or Plasma Dust Collector(Depending on specific
B configuration of the model). With the anions generated by Ionizer, the air circulation
(Enabled on cooling & heating models only):
Lights up when the air conditioner starts of the air conditioner fills the room with refreshing, natural and healthy air. The Plasma
defrosting automatically or when the warm Dust Collector generates a high voltage ionization zone, through which the air is
air control feature is activated in heating converted to plasma. Inside the air most of the dust, smoke, and pollen particles are
operation. captured by the electrostatic filter.
Temperature indicator
Displays the temperature settings when the Anti-mildew function Optional
air conditioner is operational.
Displays the malfunction code. When turns off the unit on COOL, DRY, AUTO (Cool) mode, the air conditioner will continue
operating for about 10 minutes (depending on models) with soft wind.This will help to
dry up the condensed water inside the evaporator, and prevent the breeding of mildew.
Under Anti-mildew operation, do not restart the air conditioner until the unit iscompletely off.
5 6
OPERATING INSTRUCTIONS OPERATING INSTRUCTIONS
NOTE: This manual does not include Remote Controller Operations, see the Airflow direction control
<<Remote Controller Instruction>> packed with the unit for details.
Adjust the air flow direction properly, otherwise it
Operating temperature might cause discomfort or cause uneven room
temperatures.
Mode Adjust the horizontal louver using the remote controller.
Cooling operation Heating operation Drying operation
Temperature Adjust the vertical louver manually.
Room temperature
17 32 0 30 10 32 50 90 To set the vertical air flow(Up--Down) direction
62 90 32 86 Perform this function while the unit is in operation.
Range
Use the remote controller to adjust the air flow
Outdoor temperature 18 43 11 43 52 109 direction. The horizontal louver can be moved at
64 109 a range of 6O for each press, or swing up and down
-7 43 20 109
,,
automatically. Please refer to the REMOTE
( For the models with low
-7
20
24
76
,,
temperature cooling system 18 52 64 126
CONTROLLER OPERATION MANUAL for details.
(For special tropical models)
18 52 64 126 To set the horizontal air flow direction (left - right)
(For special tropical models)
Move the deflector rod manually to adjust the air flow
NOTE: in the direction you prefer.
1. Optimum performance will be achieved within these operating temperatures.If air IMPORTANT:Do not put your fingers into the panel of
conditioner is used outside of the above conditions, certain safety protection features blower and suction side.The high-speed fan inside may
might come into operation and cause the unit to function abnormally. cause danger.
Deflector rod
2. If the air conditioner runs for a long time in cooling mode and the humidity is high(over (two places) NOTE:
80%) , condensed water may drip out of the unit. Please sets the vertical air flow louver to Best working conditions(the energy efficiency can be
its maximum angle (vertically to the floor), and set HIGH fan mode. affected if not set under these conditions):
The best angle of louvers is the default angle of cooling
Manual operation mode
The best way of setting the angle of louvers at heating
Units are equipped with a switch to run emergency operation mode. It can be accessed by mode is: run the unit for 5 minutes and then use the
opening the front panel. This switch is used for manual operation in case the remote controller remote controller to set the louvers at the default angle
fails to work or maintenance necessary. of cooling mode.
1 Hold the panel sides and lift the front panel CAUTION
up to an angle until it remains fixed with a Range Do not operate the air conditioner for long periods with
clicking sound. For some models, please the air flow direction set downward in cooling or
use suspension bars to prop up the panel. dehumidifying mode. Otherwise, condensation may
AUTO/COOL
2 Once you push the manual button, the occur on the surface of the horizontal louver causing
Manual switch moisture to drop on to the floor or on furnishings.
operation mode is shifted in an order as:
AUTO, COOL, OFF. The temperature will When the air conditioner is started immediately after it
1 was stopped, the horizontal louver might not move for
Suspension bars
be set at 24OC/76OF and the fan on Auto.
3 After operation, close the panel firmly to its approximately 10 seconds.
Open angle of the horizontal louver should not be set
original position.
too small, as COOLING or HEATING performance may
be impaired due to too restricted air flow area.
CAUTION:
This switch is used for testing purposes Do not move the horizontal louver manually, otherwise
only. You had better not choose it. the horizontal louver will be out of sync. Please cease
AUTO/COOL To restore the remote controller operation, operating, unplug power for a few seconds,then restart
Manual switch use the remote controller directly. the air conditioner.
2
7 8
OPERATING INSTRUCTIONS CARE AND MAINTENANCE
How the air conditioner works Care and Maintenance

AUTO operation
SLEEP operation When you set the air conditioner in AUTO mode, it will
7 hours timer off automatically select cooling, heating(cooling/heating Before mainatenance
models only), or fan only operation depending on set Turn the system off before cleaning. To clean, wipe with
temperature and the room temperature. a soft, dry cloth. Do not use bleach or abrasives.
Set The air conditioner will control room temperature
Temperature NOTE: Power supply must be disconnectd before
automatically to the temperature point you set.
If you feel uncomfortable in the AUTO mode, you can set cleaning the indoor unit.
1 hour 1 hour
your desired temperature.
Cooling CAUTIONS
SLEEP operation
When you push SLEEP button on remote controller A cloth dampened with cold water may be used
SLEEP operation during cooling, heating(cooling & heating models only), on the indoor unit if it is very dirty. Then wipe it
7 hours timer off or AUTO operation , the air conditioner will with a dry cloth.
automatically increase (cooling) or decrease (heating) Do not use a chemically treated cloth or duster to
Set 1OC/2OF per hour for the first 2 hours, then hold steadily clean the unit.
Temperature for the next 5 hours, after that it will switch off. Do not use benzine, thinner, polishing powder, or
This mode saves you energy and brings you comfort similar solvents for cleaning. These may cause
1 hour 1 hour at night. the plastic surface to crack or deform.
Filter Handle Never use water hotter than 40 C/104 F to clean
Heating DRYING operation the front panel, it could cause deformation of
The temperature is regulated while dehumidifying by discoloration.
repeating turning on and off of the cooling operation or
fan only. The fan speed is LOW.
Cleaning the unit
Optimal operation
To achieve optimal performance, please note the wipe the unit with a soft dry cloth only. If the unit is
following: very dirty, wipe it with a cloth soaked in warm water.
Adjust the air flow direction correctly so that it is not
forwards people.
Adjust the temperature to achieve the highest comfort Cleaning the air filter and air freshening filter
level. Do not adjust the unit to excessive temperature A clogged air filter reduces the cooling efficiency of
levels. this unit. Please clean the filter once every 2 weeks.
Close doors and windows on COOL or HEAT modes, 1. Lift the indoor unit panel up to an angle until it
or performance may be reduced. stops with a clicking sound.For some models,
Use TIMER ON button on the remote controller to please use suspension bars to prop up the panel.
select a time you want to start your air conditioner. 2. Take hold of the handle of the air filter and lift it
Do not put any object near air inlet or air outlet, as the Air freshening filter up slightly to take it out from the filter holder,
efficiency of the air conditioner may be reduced and then pull it downwards.
the air conditioner may stop running. 3. Remove the AIR FILTER from the indoor unit.
Clean the air filter periodically, otherwise cooling or Clean the AIR FILTER once two weeks.
heating performance may be reduced. Clean the AIR FILTER with a vacuum cleaner
Do not operate unit with horizontal louvre in closed or water, then dry it up in cool place.
position. 4. Remove the Air Freshening Filter from its supporting
frame (on some models).
Clean the air freshening filter at least once a
month, and replace it every 4-5 months.
Clean it with vacuum cleaner, then dry it in cool
place.
9 10
CARE AND MAINTENANCE TROUBLESHOOTING TIPS
5. Install the air freshening filter back into position. Normal function of the air conditioner
6. Insert the upper portion of air filter back into the
unit, taking care that the left and right edges line The following events may occur during normal operation.
up correctly and place filter into position. 1. Protection of the air conditioner.
Compressor protection
Replacement of air filter and air freshening filter The compressor can't restart for 3-4 minutes after it stops.
1. Remove the air filter. Anti-cold air (Cooling and heating models only)
2. Remove the air freshening filter. The unit is designed not to blow cold air on HEAT mode, when the indoor heat exchanger is in
3. Install a new air freshening filter.
one of the following three situations and the set temperature has not been reached.
4. Reinstall the air filter and securely close the front
A) When heating has just started.
panel.
B) Defrosting.
C) Low temperature heating.
Preparation for extended non-operation The indoor or outdoor fan stop running when defrosting (Cooling and heating models only).
Defrosting (Cooling and heating models only)
If you plan to idle the unit for a long time, perform
Frost may be generated on the outdoor unit during heat cycle when outdoor temperature is low
the following:
(1) Clean the indoor unit and filters. and humidity is high resulting in lower heating efficiency of the air conditioner.
(2) Operate the fan for about half a day to dry the During this condition air conditioner will stop heating operation and start defrosting automatically.
inside of the unit. The time to defrost may vary from 4 to 10 minutes according to the outdoor temperature and
(3) Stop the air conditioner and disconnect power. the amount of frost built up on the outdoor unit.
(4) Remove the batteries from the remote controller.
The outdoor unit requires periodic maintenance 2. A white mist coming out from the indoor unit
and cleaning. Do not attempt to do this yourself. A white mist may generate due to a large temperature difference between air inlet and air outlet
Contact your dealer or service provider. on COOL mode in an indoor environment that has a high relative humidity.
A white mist may generate due to moisture generated from defrosting process when the air
Pre-season inspection conditioner restarts in HEAT mode operation after defrosting.
Check that the wiring is not broken off or 3. Low noise of the air conditioner
disconnected. You may hear a low hissing sound when the compressor is running or has just stopped running.
Clean the indoor unit and filters.
It is the sound of the refrigerant flowing or coming to a stop.
Check that the air filter is installed.
You can also hear a low "squeak" sound when the compressor is running or has just stopped
Check if the air outlet or inlet is blocked after the
air conditioner has not been used for a long time. running. This is caused by heat expansion and cold contraction of the plastic parts in the unit
when the temperature is changing.
A noise may be heard due to louver restoring to its original position when power is turned on.
Caution
Do not touch the metal parts of the unit when 4. Dust is blown out from the indoor unit.
removing the filter. Injuries can occur when This is a normal condition when the air conditioner has not been used for a long time or during first
handling sharp metal edges. use of the unit.
Do not use water to clean inside the air conditioner.
Exposure to water can destroy the insulation, 5. A peculiar smell comes out from the indoor unit.
leading to possible electric shock. This is caused by the indoor unit giving off smells permeated from building material, from furniture,
When cleaning the unit, first make sure that the or smoke.
power and circuit breaker are turned off.
Do not wash air filter with hot water at more than 6. The air conditioner turns to FAN only mode from COOL or HEAT (For cooling and
40OC/104OF. Shake off moisture completely and dry heating models only) mode.
it in the shade. Do not expose it directly to the sun, When indoor temperature reaches the temperature setting on air conditioner, the compressor will
it may shrink. stop automatically, and the air conditioner turns to FAN only mode. The compressor will start again
when the indoor temperature rises on COOL mode or falls on HEAT mode (For cooling and heating
models only) to the set point.
11 12
TROUBLESHOOTING TIPS TROUBLESHOOTING TIPS
7.The air conditioner runs Anti-mildew function after turning off the unit. Troubleshooting guide
When turning off the unit under COOL(AUTO COOL, FORCED COOL) and DRY mode, the air
conditioner will run Anti-mildew function for 7-10 minutes, then stop the operation and turn The unit may stop operation or continue
OPERATION(RUN) indicator or other to run in a safety condition(depending
off the unit automatically. indicators continue flashing. on models). Waiting for about 10
minutes, the fault may be recovered
8. Dripping water may generate on the surface of the indoor unit when cooling in a high automatically, if not, disconnect the
relatively humidity (relative humidity higher than 80%). Adjust the horizontal louver to If one of the following code appears on the power and then connect it in again. If
the maximum air outlet position and select HIGH fan speed. Trouble display area : E0,E1,E2,E3.....or P0,P1,P2, the problem still exists, disconnect
P3..... the power and contact the nearest
9. Heating mode (For cooling and heating models only) customer service center.
The air conditioner draws in heat from the outdoor unit and releases it via the indoor unit Fuse blows frequently or circuit breaker trips
during heating operation. When the outdoor temperature falls, heat drawn in by the air
frequently . Stop the air conditioner immediately,
conditioner decreases accordingly. At the same time, heat loading of the air conditioner
disconnect the power and contact the
increases due to larger difference between indoor and outdoor temperature. If a Other objects or water fall into the air conditioner.
nearest customer service center.
comfortable temperature can't be achieved by the air conditioner, we suggest you use a
The remote controller won't work or works
supplementary heating device.
abnormally.
10. Auto-restart function
Malfunctions Cause What should be done?
Power failure during operation will stop the unit completely.
For the unit without Auto-restart feature, when the power restores, the OPERATION indicator Unit does not Power cut Wait for power to be restored.
on the indoor unit starts flashing. To restart the operation, push the ON/OFF button on the start
remote controller. For the unit with Auto-restart feature, when the power restores, the unit Unit may have become Unplugged. Check that plug is securely in wall
restarts automatically with all the previous settings preserved by the memory function. receptacle.
Fuse may have blown. Replace the fuse.
Battery in Remote controller may Replace the battery.
have been exhausted.
The time you have set with timer Wait or cancel timer setting.
is incorrect.
Unit not cooling Inappropriate temperature Set temperature correctly. For
or heating setting. detailed method please refer to
(Cooling/ heating "Using remote control" section.
models only)
Air filter is blocked. Clean the air filter.
room very well
while air flowing Doors or Windows are open. Close the doors or windows.
out from the air Air inlet or outlet of indoor or Clear obstructions away first, then
conditioner outdoor unit has been blocked. restart the unit.
Compressor 3 or 4 minutes Wait.

protection has been activated.
If the trouble has not been corrected, please contact a local dealer or the nearest customer
service center. Be sure to inform them of the detailed malfunctions and unit model number.
Notes: Do not attempt to repair the unit yourself.

Always consult an authorized service provider.
13 14
OWNER'S MANUAL
Ceiling And Floor Type
Thank you very much for purchasing our air conditioner,

Before using your air conditioner, please read this manual carefully and keep it for future reference.
3
INDOOR UNIT
4 2
AU
TO
6
CO
OL
DR TEM
Y
SE P
HE T
AT CLOC
FAN K
SET
HOU
FAN R
SPEE
MO D
DE
M
FAN
SPE
ED
SW
ING
SW AIR
DIRE
ING CTIO
N
RESE CLO
T LOCK OK CK
C/H
TIM
ECO E ON
TIM
E OFF
5
8 8
7
9
OUTDOOR UNIT
OR
9
7
8 7
8
8
8 8
Fig.1
INDOOR UNIT OUTDOOR UNIT
1 Air flow louver (at air outlet) 7 Connecting pipe
2 Air inlet (with air filter in it) 8 Air inlet
3 Installation part 9 Air outlet
4 Display panel
5 Remote controller
6 Drain pipe
NOTE
All the pictures in this manual are for explanation purpose only. They may be slightly different from the air
conditioner you purchased(depend on model). The actual shape shall prevail.
CONTENTS PAGE It is not good for your health to expose your body to the
air flow for a long time.
Do not insert fingers, rods or other objects into the air

IMPORTANT SAFETY INFORMATION........................................................1 inlet or outlet.
TEMPORARY OPERATIONS.....................................................................2 When the fan is rotating at high speed, it will cause injury.
AIR CONDITIONER OPERATIONS AND PERFORMANCE............................3
Never use a flammable spray such as hair spray, lacquer
HINTS FOR ECONOMICAL OPERATION.....................................................3 or paint near the unit.
It may cause a fire.
ADJUSTING AIR FLOW DIRECTION.........................................................4
MAINTENANCE........................................................................................4 Never touch the air outlet or the horizontal blades while
FOLLOWING SYMPTOMS ARE NOT AIR CONDITIONER TROUBLES.........5 the swing flap is in operation.
Fingers may become caught or the unit may break down.
TROUBLESHOOTING................................................................................6
Never put any objects into the air inlet or outlet.
Objects touching the fan at high speed can be dangerous.
Never inspect or service the unit by yourself.

Ask a qualified service person to perform this work.
Do not dispose this product as unsorted municipal

waste. Collection of such waste separately for special
treatment is necessary.
1. IMPORTANT SAFETY INFORMATION Do not dispose of electrical appliances as unsorted
municipal waste, use separate collection facilities.
To prevent injury to the user or other people and property Contact you local government for information regarding the
damage, the following instructions must be followed. Incorrect connection systems available.
operation due to ignoring of instructions may cause harm or
damage. If electrical appliances are disposed of in landfills or
dumps, hazardous substances can leak into the
The safety precautions listed are divided into two categories. In either
groundeater and get into the food chain, damaging your
case, important safety information is listed which must be read.
health and well-being.
To prevent refrigerant leak, contact your dealer.

WARNING When the system is installed and runs in a small room, it is
Failure to observe a warning may result in death. The required to keep the concentration of the refrigerant, if by any
appliance shall be installed in accordance with national chance coming out, below the limit. Otherwise, oxygen in the
wiring regulations. room may be affected, resulting in a serious accident.
The refrigerant in the air conditioner is safe and normally

CAUTION does not leak.
Failure to observe a caution may result in injury or damage If the refrigerant leaks in the room, contact with a fire of a
to the equipment. burner, a heater or a cooker may result in a harmful gas.
Turn off any combustible heating devices, ventilate the

room, and contact the dealer where you purchased the
WARNING unit.
Do not use the air conditioner until a service person confirms
that the portion where the refrigerant leaks is repaired.
Ask your dealer for installation of the air conditioner.
Incomplete installation performed by yourself may result in a
water leakage, electric shock, and fire.
CAUTION
Ask your dealer for improvement, repair, and
maintenance.
Incomplete improvement, repair, and maintenance may result Do not use the air conditioner for other purposes.
in a water leakage, electric shock, and fire. In order to avoid any quality deterioration, do not use the unit
for cooling precision instruments, food, plants, animals or
In order to avoid electric shock, fire or injury, or if you works of art.
detect any abnormality such as smell of fire, turn off the
power supply and call your dealer for instructions. Before cleaning, be sure to stop the operation, turn the
breaker off or pull out the supply cord.
Never let the indoor unit or the remote controller get wet. Otherwise, an electric shock and injury may result.
It may cause an electric shock or a fire.
In order to avoid electric shock or fire, make sure that an
Never press the button of the remote controller with a earth leak detector is installed.
hard, pointed object.
The remote controller may be damaged. Be sure the air conditioner is grounded.
In order to avoid electric shock, make sure that the unit is
Never replace a fuse with that of wrong rated current or grounded and that the earth wire is not connected to gas or
other wires when a fuse blows out. water pipe, lightning conductor or telephone earth wire.
Use of wire or copper wire may cause the unit to break down
or cause a fire. In order to avoid injury, do not remove the fan guard of
the outdoor unit.
owner’s manual
1
Do not operate the air conditioner with a wet hand.
An electric shock may happen.
2. TEMPORARY OPERATIONS
The air conditioner consists of the indoor unit, the outdoor unit,
Do not touch the heat exchanger fins. the connecting pipe and the remote controller. (See Fig.1)
These fins are sharp and could result in cutting injuries.
Function indicators on indoor unit display panel
Do not place items which might be damaged by moisture
under the indoor unit. PRE-DEF indicator(cooling and heating type)
Condensation may form if the humidity is above 80%, the or fan only indicator(cooling only type)
drain outlet is blocked or the filter is polluted.
Infrared signal receiver
After a long use, check the unit stand and fitting for
damage.
If damaged, the unit may fall and result in injury.
MANUAL
To avoid oxygen deficiency, ventilate the room

sufficiently if equipment with burner is used together
with the air conditioner.
Arrange the drain hose to ensure smooth drainage.

Incomplete drainage may cause wetting of the building, Operation indicator Timer indicator Alarm indicator
furniture etc.
Never touch the internal parts of the controller. Display panel　　　　Fig. 2-1
Do not remove the front panel. Some parts inside are
dangerous to touch, and a machine trouble may happen.
Never expose little children, plants or animals directly to

the air flow. This function is used to operate the unit temporarily in case you
Adverse influence to little children, animals and plants may misplace the remote controller or its batteries are exhausted.
result. Two modes including AUTO and FORCED COOL can be
selected through the MANUAL BUTTON on the display panel of
Do not allow a child to mount on the outdoor unit or the indoor unit. Once you push this button with the thin stick, the
avoid placing any object on it. air conditioner will run in such order: AUTO, FORCED COOL,
Falling or tumbling may result in injury. OFF, and back to AUTO.
Do not operate the air conditioner when using a room 1 AUTO

fumigation - type insecticide. The OPERATION lamp is lit, and the air conditioner will run
Failure to observe could cause the chemicals to become under AUTO mode. The remote controller operation is enabled
deposited in the unit, which could endanger the health of to operate according to the received signal.
those who are hypersensitive to chemicals.
2 FORCED COOL
Do not place appliances which produce open fire in The OPERATION lamp flashes, the air conditioner will turn to
places exposed to the air flow from the unit or under the AUTO after it is enforced to cool with a wind speed of HIGH for
indoor unit. 30 minutes. The remote controller operation is disabled.
It may cause incomplete combustion or deformation of the
unit due to the heat. 3 OFF
The OPERATION lamp goes off. The air conditioner is OFF
Do not install the air conditioner at any place where while the remote controller operation is enabled.
flammable gas may leak out.
If the gas leaks out and stays around the air conditioner, a
fire may break out.
The appliance is not intended for use by young children NOTE

or infirm persons without supervision.
This manual does not include Remote Controller
Operations, see the<<Remote Controller Owner's
manual>> packed with the unit for details.
owner’s manual
2
3. AIR CONDITIONER OPERATIONS AND 4. HINTS FOR ECONOMICAL OPERATION
PERFORMANCE The following should be noticed to ensure an economical operation.
Use the system in the following temperature for safe and (Refer to corresponding chapterfor details)
effective operation. The Max operation temperature for
the air conditioner.(Cooling/Heating) Adjust the air flow direction properly to avoid winding toward
your body.
Table 3-1
Adjust the room temperature properly to get a comfortable
Temperature situation and to avoid supercooling and superheat.
Outdoor Room
Mode temperature temperature
In cooling, close the curtains to avoid direct sunlight.
Cooling operation 18°C~43°C 17°C~32°C
To keep cool or warm air in the room, never open doors or
windows more often than necessary.
Heating operating
(Cooling only -7°C~24°C 17°C~27°C Set the timer for the desired operating time.
type without)
Never put obstructions near the air outlet or the air inlet. Or it
Dry operation 18°C~43°C 17°C~32°C will cause lower efficiency, even a sudden stop.
If you don't plan to use the unit for a long time, please discon-
nect power and remove the batteries from the remote control-
ler. When the power switch is connected, some energy will be
NOTE consumed, even if the air conditioner isn't in operation. So
please disconnect the power to save energy. And please
1 If air conditioner is used outside the above conditions, it may switch the power on 12 hours before you restart the unit to
cause the unit to function abnormally. ensure a smooth operation.
2 The phenomenon is normal that the surface of air A clogged air filter will reduce cooling or heating efficiency,
conditioning may condense water when the relative larger please clean it once two weeks.
humidity in room, please close the door and window.
3 Optimum performance will be achieved within these

operating temperature range.
5. ADJUSTING AIR FLOW DIRECTION
Auto-swing
Press SWING button, the louver will swing up and down
automatically.
Three-minute protection feature Manual Swing

Adjust the louver to achieve better cooling/heating effects
A protection feature prevents the air conditioner from being when cooling /heating.
activated for approximately 3 minutes when it restarts immedi-
ately after operation.
Power failure
Power failure during operation will stop the unit completely. Fig. 5-1
The OPERATION lamp on the indoor unit will start When cooling
flashing when power is restored. Adjust the louver horizontally.
To restart operation, push the ON/OFF button on the

remote controller.
Lighting or a car wireless telephone operating nearby

may cause the unit to malfunction.
Disconnect the unit with the power and then connect the unit
Fig. 5-2
with the power again. Push the ON/OFF button on the remote
controller to restart operation. When heating
Adjust the louver downwards. (vertically)
Fig. 5-3
owner’s manual
3
6. MAINTENANCE 1 3.2-10.5KW
Open the air intake.(Refer to Fig.6-1)
Take out the air filter.(Refer to Fig.6-2)
CAUTION Clean the air cleaning filter with water or vacuum cleaer,then
dry it in cool place.
Before you clean the air conditioner, be sure the power Re-install the air filter in the reverse order of Fig.6-2.
supply is off.
Check if the wiring is not broken off or disconnected. 2 14-16KW

Directly pull out the air filter from air inlet as indicated in
Use a dry cloth to wipe the indoor unit and remote Fig.6-3.
controller. Clean the air cleaning filter with water or vacuum cleaner,
then dry it in cool place.
A wet cloth may be used to clean the indoor unit if it is Re-install the air filter in the reverse order of Fig.6-3.
very dirty.
Never use a damp cloth on the remote controller. NOTE

Do not use a chemically-treted duster for wiping or leave The air-in side should face up when using vacuum cleaner.
such material on the unit for long.
it may damage or fade the surface of the unit. The air-in side should face down when using water.
Do not use benzine, thinner, polishing powder, or similar

solvents for cleaning. CAUTION
These may cause the plastic surface to crack or deform.
Do not dry out the air filter under direct sunshine or with fire.
Maintenance after a long stop period

(eg. at the beginning of the season)
Check and remove everything that might be blocking inlet

and outlet vents of indoor units and outdoor units.
Clean air filters and casings of indoor units.

Refer to "Cleaning the air filter" for details on how to
proceed and make sure to install cleaned air filters back in
the same position.
Turn on the power at least 12 hours before operating the

unit in order to ensure smoother operation. As soon as he
power is turned on, the remote controller displays appear.
Maintenance before a long stop period

(eg. at the end of the season)
Let the indoor units run in fan only operation for about half
a day in order to dry the interior of the units.
Clean air filters and casings of indoor units. Refer to "

Cleaning the air filter" for details on how to proceed and
make sure to install cleaned air filters back in the same
position.
Cleaning the air filter

The air filter can prevent the dust or other particulate from
going inside. In case of blockage of the filter, the working
efficiency of the air conditioner may greatly decrease.
Therefore, the filter must be cleaned once two weeks
during long time usage.
If the air conditioner is installed in a dust place, clean the

the air filter frequent.
If the accumulated dust is too heavy to be cleaned, please

replace the filter with a new one(replaceable air filter is an
optional fitting).
owner’s manual
4
Symptom 3: White mist comes out of a unit
Symptom 3.1: Indoor unit
When humidity is high during cooling operation If the interior of

an indoor unit is extremely contaminated, the temperature
distribution inside a room becomes uneven. It is necessary to
Air Inlet clean the interior of the indoor unit. Ask your dealer for details
on cleaning the unit. This operation requires a qualified service
erson
Fig.6-1 Symptom 3.2: Indoor unit, outdoor unit
When the system is changed over to heating operation after

defrost operation Moisture generated by defrost becomes
steam and is exhausted.
Air filter
Sptom 4: Noise of air conditionerscooling
A continuous low "shah" sound is heard when the system is in

cooling operation or at a stop.
When the drain pump (optional accessories) is in operation,this
Fig.6-2
noise is heard.
A "pishi-pishi" squeaking sound is heard when the system stops

after heating operation.
Expansion and contraction of plastic parts caused by
temperature change make this noise.
Symptom 4.2: Indoor unit, outdoor unit
A continuous low hissing sound is heard when the system is in

operation.
This is the sound of refrigerant gas flowing through both indoor
Fig.6-3 and outdoor units.
A hissing sound which is heard at the start or immediately after

stopping operation or defrost operation.
This is the noise of refrigerant caused by flow stop or flow
change.
Symptom 4.3: Outdoor unit
7. FOLLOWING SYMPTOMS ARE NOT AIR When the tone of operating noise changes.
CONDITIONER TROUBLES This noise is caused by the change of frequency.
Symptom 1: The system does not operate Symptom 5: Dust comes out of the unit
The air conditioner does not start immediately after the ON/OFF When the unit is used for the first time in a long time.
button on the romote controller is pressed. This is because dust has gotten into the unit.
If the operation lamp lights, the system is in normal condition.To
prevent overloading of the compressor motor, the air
conditioner starts 3 minutes after it is turned ON.
Symptom 6: The units can give off odours
The unit can absorb the smell of rooms, furniture, cigarettes,
If the operation lamp and the "PRE-DEF indicator(cooling and
etc., and then emit it again.
heating type) or fan only indicator(cooling only type)" light, it
means you choose the heating model, When just starting, if the
compressor has not started, the indoor unit appears "anti cold Symptom 7: The outdoor unit fan does not
wind" protection because of its overlow outlet temperature. spin.
Symptom 2: Change into the fan mode during During operation. The speed of the fan is controlled in order to
cooling mode optimize product operation.
In order to prevent the indoor evaporator frosting, the system

will change into fan mode automatically, restore to the cooling
mode after soon.
When the room temperature drops to the set temperature, the

compressor goes off and the indoor unit changes to fan mode;
when the temperature rises up, the compressor starts again. It
is same in the heating mode.
owner’s manual
5
8. TROUBLESHOOTING
8.1 Troubles and causes of air conditioner
If one of the following malfunctions occur, stop operation, shut
off the power, and contact with your dealer.
The operation lamp is flashing rapidly (5Hz) This lamp is still

flashing rapidly after turn off the power and turn on again.　　
(See in Table 8-1)
Remote controller receives malfunction or the button does not

work well.
A safety device such as a fuse, a breaker frequently actuates.
Obstacles and water enter the unit.
Water leaks from indoor unit.
Other malfunctions.
If the system does not properly operate except the above

mentioned cases or the above mentioned malfunctions is
evident, investigate the system according to the following
procedures. (See in Table 8-2)
8.2 Troubles and causes of remote controller

Before asking for serving or repairing, check the following
points.(See in Table 8-3)
owner’s manual
6
Table 8-1
NO. Malfunction Running lamp Timer lamp Defrosting lamp Alarm lamp
In-outdoor unit communication LED

1 checking channel is abnormal flash
Room temperature senson LED

2 checking channel is abnormal flash
LED
3 Water-level alarm malfunction
flash
4 Collision model malfunction LED

flash
LED
5 Outdoor unti malfunction
Slow flash
Table 8-2
Symptoms Causes Solution

Power failure. Wait for the comeback of power.
Power switch is off. Switch on the power.
Unit does not start Fuse of power switch may have burned. ReplLocation:
Batteries of remote controller exhausted Replace the batterises or check the
or other problem of controller. controller.
Air flowing normally but Temperature is not set correctly. Set the temperature properly.
completely can't cooling Be in 3 minutes protection of Wait.
compressor.
Refrigerant is too little or too much. Check leakage, and rightly recharge
Air or no concretingc gas in the refrigerant.
refrigerating circuit. Vacuum and recharge refrigerant.
Units start or stop frequently Compressor is malfunction. Maintenance or change compressor.
Voltage is too high or too low. Install manostat.
System circuit is blocked. Find reasons and solution.
Outdoor unit and indoor unit heat Clean the heat exchanger.
exchanger is dirty. Clean the air filter.
The air filter is dirty. Eliminate all dirties and make air
Inlet/outlet of indoor/outdoor units is smooth.
blocked. Close doors and windows.
Doors and windows are open Make curtains in order to shelter from
Low cooling effect Sunlight directly shine. sunshine.
Too much heat resource. Reduce heat source.
Outdoor temp. is too high. AC cooling capacity reduces (normal).
Leakage of refrigerant or lack of Check leakage and rightly recharge
refrigerant. refrigerant.
Outdoor temperature is lower than 7 C Use heating device.

Doors and windows not completely Close doors and windows.
Low heating effect closed. Check leakage and rightly recharge
Leakage of refrigerant or lack of refrigerant.
refrigerant.
owner’s manual
7
Table 8-3

Check whether the MODE When the automatic mode is
indicated on the display is selected, the air conditioner will
"AUTO" automatically change the fan
The fan speed can not be speed.
changed.
Check whether the MODE When dry operation is selected,
the air conditioner automatically
indicated on the display is
change the fan speed. The fan
"DRY" speed can be selected during
"COOL" , "FAN ONLY", and "HEAT".
The remote controller signal is Check whether the batteries

not transmitted even when in the remote controller are The power supply is off.
the ON/OFF button is pushed. exhausted.
Check whether the MODE The temperature cannot be set during

The TEMP. indicator does indicated on the display is FAN mode.
not come on. FAN ONLY
The indication on the display Check whether the timer The air conditioner operation will
disappears after a lapse of operation has come to an stop up to the set time.
time. end when the TIMER OFF
is indicated on the display.
Check whether the timer Up to the set time, the air conditioner
The TIMER ON indicator operation is started when will automatically start and the
goes off after a lapse of the TIMER ON is indicated appropriate indicator will go off.
certain time. on the display.
Check whether the signal Directly transmit the signal transmitter

No receiving tone sounds transmitter of the remote of the remote controller to the infrared
from the indoor unit even controller is properly directed signal receiver of the indoor unit, and
when the ON/OFF button is to the infrared signal receiver then repeatly push the ON/OFF button
pressed. of the indoor unit when the twice.
ON/OFF button is pressed.
owner’s manual
8
QSDLU-001AEN
The design and s pecifications are subject to change wi thout prior notic e for product
improvement. Cons ult with the s ales agency or manufa cturer for details.
OWNER'S MANUAL
Four-way Cassette Type
Thank you very much for purchasing our air conditioner,

Before using your air conditioner, please read this manual carefully and keep it for future reference.
2
1
3
INDOOR UNIT
4
6 7 8
5
AU
TO
CO
OL
DR TEM
Y
SE P
HE T
AT CLOC
FAN K
SET
10
HOU
FAN R
SPEE
MO D
DE
M
FAN
SPE
ED
SW
ING
SW AIR
DIRE
ING CTIO
9
N
RESE CLO
T LOCK OK CK
C/H
TIM
ECO E ON
TIM
E OFF
11
11
OUTDOOR UNIT
12
OR 12
10 11 10
11
12
11
11 11
Fig.1
1 Air flow louver(at air outlet) 7 Air-in grill

2 Drain pump(drain water from indoor unit) 8 Display panel
3 Drain pipe 9 Remote controller
4 Air outlet 10 Refrigerant pipe
5 Air filter(inside air-in grill) 11 Air inlet
6 Air inlet 12 Air outlet
NOTE
All the pictures in this manual are for explanation purpose only. They may be slightly different from the air
conditioner you purchased(depend on model).The actual shape shall prevail.
CONTENTS PAGE It is not good for your health to expose your body to the
air flow for a long time.
IMPORTANT SAFETY INFORMATION...........................................................1 Do not insert fingers, rods or other objects into the air
PARTS NAMES.........................................................................................2 inlet or outlet.
When the fan is rotating at high speed, it will cause injury.
AIR CONDITIONER OPENRATIONS AND PERFORMANCE...........................2
HINTS FOR ECONOMICAL OPERATION......................................................3 Never use a flammable spray such as hair spray, lacquer
or paint near the unit.
ADJUSTING AIR FLOW DIRECTION...........................................................3
It may cause a fire.
MAINTENANCE........................................................................................3
Never touch the air outlet or the horizontal blades while
FOLLOWING SYMPTOMS ARE NOT AIR CONDITIONER TROUBLES...........5
the swing flap is in operation.
TROUBLESHOOTING................................................................................5 Fingers may become caught or the unit may break down.
Never put any objects into the air inlet or outlet.

Objects touching the fan at high speed can be dangerous.
Never inspect or service the unit by yourself.

Ask a qualified service person to perform this work.
Do not dispose this product as unsorted municipal

waste. Collection of such waste separately for special
treatment is necessary.
1. IMPORTANT SAFETY INFORMATION Do not dispose of electrical appliances as unsorted
municipal waste, use separate collection facilities.
To prevent injury to the user or other people and property Contact you local government for information regarding the
damage, the following instructions must be followed. Incorrect connection systems available.
operation due to ignoring of instructions may cause harm or
damage. If electrical appliances are disposed of in landfills or
dumps, hazardous substances can leak into the
The safety precautions listed are divided into two categories. In either
groundeater and get into the food chain, damaging your
case, important safety information is listed which must be read
carefully. health and well-being.
To prevent refrigerant leak, contact your dealer.

WARNING When the system is installed and runs in a small room, it is
Failure to observe a warning may result in death. The required to keep the concentration of the refrigerant, if by any
appliance shall be installed in accordance with national chance coming out, below the limit. Otherwise, oxygen in the
wiring regulations. room may be affected, resulting in a serious accident.
The refrigerant in the air conditioner is safe and normally

CAUTION does not leak.
Failure to observe a caution may result in injury or damage If the refrigerant leaks in the room, contact with a fire of a
to the equipment. burner, a heater or a cooker may result in a harmful gas.
Turn off any combustible heating devices, ventilate the

room, and contact the dealer where you purchased the
WARNING unit.
Do not use the air conditioner until a service person confirms
that the portion where the refrigerant leaks is repaired.
Ask your dealer for installation of the air conditioner.
Incomplete installation performed by yourself may result in a
water leakage, electric shock, and fire. CAUTION
Ask your dealer for improvement, repair, and
maintenance. Do not use the air conditioner for other purposes.
Incomplete improvement, repair, and maintenance may result In order to avoid any quality deterioration, do not use the unit
in a water leakage, electric shock, and fire. for cooling precision instruments, food, plants, animals or
works of art.
In order to avoid electric shock, fire or injury, or if you
detect any abnormality such as smell of fire, turn off the Before cleaning, be sure to stop the operation, turn the
power supply and call your dealer for instructions. breaker off or pull out the supply cord.
Otherwise, an electric shock and injury may result.
Never let the indoor unit or the remote controller get wet.
It may cause an electric shock or a fire. In order to avoid electric shock or fire, make sure that an
earth leak detector is installed.
Never press the button of the remote controller with a
hard, pointed object. Be sure the air conditioner is grounded.
The remote controller may be damaged. In order to avoid electric shock, make sure that the unit is
grounded and that the earth wire is not connected to gas or
Never replace a fuse with that of wrong rated current or water pipe, lightning conductor or telephone earth wire.
other wires when a fuse blows out.
Use of wire or copper wire may cause the unit to break down In order to avoid injury, do not remove the fan guard of
or cause a fire. the outdoor unit.
owner’s manual
1
Do not operate the air conditioner with a wet hand. Temporary button Infrared signal receiver
An electric shock may happen.
Do not touch the heat exchanger fins.

These fins are sharp and could result in cutting injuries.
Do not place items which might be damaged by moisture

under the indoor unit.
Operation lamp Timer indicator Alarm indicator
Condensation may form if the humidity is above 80%, the
drain outlet is blocked or the filter is polluted. PRE-DEF indicator(cooling and heating type)
or fan only indicator(cooling only type)
After a long use, check the unit stand and fitting for Display panel　　　　　　　Fig.2-2
damage.
This function is used to operate the unit temporarily in case you
If damaged, the unit may fall and result in injury.
misplace the remote controller or its batteries are exhausted.
Two modes including AUTO and FORCED COOL can be
To avoid oxygen deficiency, ventilate the room
selected through the TEMPORARY BUTTON on the air-in grill
sufficiently if equipment with burner is used together
control box of the indoor unit. Once you push this button, the air
with the air conditioner.
conditioner will run in such order: AUTO, FORCED COOL,
OFF, and back to AUTO.
Arrange the drain hose to ensure smooth drainage.
Incomplete drainage may cause wetting of the building, 1 AUTO
furniture etc. The OPERATION lamp is lit, and the air conditioner will run
under AUTO mode. The remote controller operation is enabled
Never touch the internal parts of the controller. to operate according to the received signal.
Do not remove the front panel. Some parts inside are 2 FORCED COOL
dangerous to touch, and a machine trouble may happen. The OPERATION lamp flashes, the air conditioner will turn to
AUTO after it is enforced to cool with a wind speed of HIGH for
Never expose little children, plants or animals directly to 30 minutes. The remote controller operation is disabled.
the air flow. 3 OFF
Adverse influence to little children, animals and plants may The OPERATION lamp goes off. The air conditioner is OFF
result. while the remote controller operation is enabled.
Do not allow a child to mount on the outdoor unit or NOTE

avoid placing any object on it.
Falling or tumbling may result in injury. This manual does not include Remote Controller
Operations, see the<<Remote Controller Owner's
Do not operate the air conditioner when using a room manual>> packed with the unit for details.
fumigation - type insecticide.
Failure to observe could cause the chemicals to become
deposited in the unit, which could endanger the health of
3. AIR CONDITIONER OPENRATIONS AND
those who are hypersensitive to chemicals. PERFORMANCE
Use the system in the following temperature for safe and
Do not place appliances which produce open fire in effective operation. The Max operation temperature for
places exposed to the air flow from the unit or under the the air conditioner (Cooling/Heating).
indoor unit.
It may cause incomplete combustion or deformation of the Table 3-1
unit due to the heat.
Temperature Outdoor Room
Do not install the air conditioner at any place where Mode temperature temperature
flammable gas may leak out.
If the gas leaks out and stays around the air conditioner, a 18°C ~ 43°C / 64 °F~109°F
fire may break out. -7°C ~ 43°C / 20 °F~109°F
Cooling operation (for models with low
temperature cooling system) 17°C ~ 32°C
The appliance is not intended for use by young children ( 62 °F ~ 90°F)
18°C ~ 52°C / 64 °F~126°F
or infirm persons without supervision. (for special tropical models)
Heating operation
(cooling only type without) -7°C ~ 24°C / 20 °F ~ 76°F 0°C ~ 30°C / 32 °F~86°F
2. PARTS NAMES 18°C ~ 43°C / 64 °F~109°F
Dry operation 17°C ~ 32°C
The air conditioner consists of the indoor unit, the outdoor unit, 18°C ~ 52°C / 64 °F~126°F ( 62 °F ~ 90°F)
the connecting pipe and the remote controller. (See Fig.2 ) (for special tropical models)
Function indicators on indoor unit display panel
Table 3-2(for inverter type air conditioner)
Temporary button Infrared signal receiver
Temperature Outdoor Room
Mode temperature temperature
0°C ~ 50°C / 32 °F~122°F

Cooling operation -15°C ~ 50°C / 5 °F~122°F >17°C / 62°F
(for models with low
temperature cooling system)
Operation lamp Timer indicator Alarm indicator
Heating operation
PRE-DEF indicator(cooling and heating type) -15°C ~ 24°C / 5 °F~76°F < 30°C / 86°F
(cooling only type without)
or fan only indicator(cooling only type)
Dry operation 0°C ~ 50°C / 32 °F~122°F >17°C / 62°F
Display panel　　　　　　　Fig.2-1
owner’s manual
2
5. ADJUSTING AIR FLOW DIRECTION
NOTE
While the unit is in operation, you can adjust the air flow louver
1 If air conditioner is used outside the above conditions, it to change the flow direction and naturalize the room
may cause the unit to function abnormally. temperature evenly. Thus you can enjoy it more comfortably.
2 The phenomenon is normal that the surface of air

conditioning may condense water when the relative
larger humidity in room, please close the door and
window.
3 Optimum performance will be achieved within these

operating temperature range.
Three-minute protection feature

A protection feature prevents the air conditioner from being Adjust it up and down
Fig 5-1
activated for approximately 3 minutes
when it restarts immediately after operation.
Power failure Set the air flow direction.

Power failure during operation will stop the unit completely. Press the SWING button to adjust the louver to the desired
position and press this button again to maintain the louver at
The OPERATION lamp on the indoor unit will start this position.
flashing when power is restored.
Adjust the air flow direction automatically.
To restart operation, push the ON/OFF button on the Press the SWING button, the louver will swing automatically.
remote controller. While this function is set, the swing fan of indoor unit runs;
otherwise, the swing fan doesn't run. The swing scale of every
Lightning or a car wireless telephone operating nearby side is 30°. When the air conditioner isn't in operation (including
may cause the unit to malfunction. when TIMER ON is set), the SWING button will be invalid.
Disconnect the unit with the power and then connect the unit
with the power again. Push the ON/OFF button on the remote
controller to restart operation.
4. HINTS FOR ECONOMICAL OPERATION

The following should be noticed to ensure an economical
operation. 6. MAINTENANCE
Adjust the air flow louver properly and avoid direct air flow to
room inhabitants.
CAUTION
Adjust the room temperature properly for a comfortable
environment. Avoid excessive heating or cooling. Before you clean the air conditioner, be sure the power
supply is off.
Prevent direct sunlight during cooling operation by using
curtains or blinds. Check if the wiring is not broken off or disconnected.
Ventilate often. Extended use requires special attention to Use a dry cloth to wipe the indoor unit and remote
ventilation. controller.
Keep doors and windows closed. If the doors and windows A wet cloth may be used to clean the indoor unit if it is
remain open, air will flow out of your room causing a decrease very dirty.
in the cooling or heating effect.
Never use a damp cloth on the remote controller.
Never place objects near the air inlet or the air outlet of the unit.
It may cause deterioration in the effect or stop the operation. Do not use a chemically-treted duster for wiping or leave
such material on the unit for long.
Set the timer . it may damage or fade the surface of the unit.
If you don't plan to use the unit for a long time, please take the Do not use benzine, thinner, polishing powder, or similar
batteries from the remote controller. When the power is on, solvents for cleaning.
some energy will be consumed,even if the air conditioner isn't in These may cause the plastic surface to crack or deform.
operation. So please disconnect the power to save energy.
Keep the indoor unit and remote controller at least 1 m away

from televisions, radios, stereos, and other similar equipment.
Failing to do so may cause static or distorted pictures.
A dirty air filter will reduce cooling or heating efficiency, please

clean it once two weeks.
owner’s manual
3
Maintenance after a long stop period 5 Re-install the air filter.
(eg. at the beginning of the season)
6 Install and close the air-in grill in the reverse order of step 1
and 2 and connect the control box cables to the
Check and remove everything that might be blocking inlet
corresponding terminators of the main body .
and outlet vents of indoor units and outdoor units.
Clean air filters and casings of indoor units.

Refer to "Cleaning the air filter" for details on how to proceed
and make sure to install cleaned air filters back in the same
position.
Turn on the power at least 12 hours before operating the unit

in order to ensure smoother operation. As soon as he power
is turned on, the remote controller displays appear.
Maintenance before a long stop period

Fig.6-1
(eg. at the end of the season)
Let the indoor units run in fan only operation for about half a
day in order to dry the interior of the units.
Clean air filters and casings of indoor units. Refer to "

Cleaning the air filter" for details on how to proceed and
make sure to install cleaned air filters back in the same
position.
Cleaning the air filter

Fig.6-2
The air filter can prevent the dust or other particulate from
going inside.　In case of blockage of the filter, the working
efficiency of the air conditioner may greatly decrease .
Therefore, the filter must be cleaned once two weeks during
long time usage.
If the air conditioner is installed in a dust place, clean the air

filter frequent.
If the accumulated dust is too heavy to be cleaned, please

replace the filter with a new one(replaceable air filter is an
optional fitting).
1 Open the air-in grill

Push the grill switches towards the middle simultaneously as Fig.6-3
indicated in Fig.6-1. Then pull down the air-in grill.
The control box cables ,which are originally connected with
the main body electrical terminators must be pulled off before
doing as indicated above.
2 Take out the air-in grill (together with the air filter shown in
Fig.6-1).
Pull the air-in grill down at 45 and lift it up to take out the
grill.
3 Dismantle the air filter.
4 Clean the air filter

Vacuum cleaner or pure water may be used to clean the air
filter.If the dust accumulation is too heavy , please use soft
brush and mild detergent to clean it and dry out in cool place. Fig.6-4
The air-in side should face up when using vacuum cleaner.
(See Fig. 6-3)
The air-in side should face down when using water.
(See Fig. 6-4)
CAUTION
Do not dry out the air filter under direct sunshine or with
fire.
owner’s manual
4
7. FOLLOWING SYMPTOMS ARE NOT AIR operation.
CONDITIONER TROUBLES This is the sound of refrigerant gas flowing through both indoor
and outdoor units.
Symptom 1: The system does not operate
A hissing sound which is heard at the start or immediately after
The air conditioner does not start immediately after the ON/OFF stopping operation or defrost operation.
button on the romote controller is pressed. This is the noise of refrigerant caused by flow stop or flow
If the operation lamp lights, the system is in normal condition.To change.
prevent overloading of the compressor motor, the air
conditioner starts 3 minutes after it is turned ON.
If the operation lamp and the "PRE-DEF indicator(cooling and

heating type) or fan only indicator(cooling only type)" light, it Symptom 4.3: Outdoor unit
means you choose the heating model, When just starting, if the
When the tone of operating noise changes.
compressor has not started, the indoor unit appears "anti cold
This noise is caused by the change of frequency.
wind" protection because of its overlow outlet temperature.
Symptom 5: Dust comes out of the unit

Symptom 2: Change into the fan mode during cooling When the unit is used for the first time in a long time.
mode This is because dust has gotten into the unit.
In order to prevent the indoor evaporator frosting, the system
will change into fan mode automatically, restore to the cooling
Symptom 6: The units can give off odours
mode after soon.
The unit can absorb the smell of rooms, furniture, cigarettes,
When the room temperature drops to the set temperature, the
etc., and then emit it again.
compressor goes off and the indoor unit changes to fan mode;
when the temperature rises up, the compressor starts again. It
is same in the heating mode.
Symptom 7: The outdoor unit fan does not spin.
Symptom 3: White mist comes out of a unit During operation. The speed of the fan is controlled in order to
optimize product operation.
When humidity is high during cooling operation If the interior of
an indoor unit is extremely contaminated, the temperature
clean the interior of the indoor unit. Ask your dealer for details
on cleaning the unit. This operation requires a qualified service
8. TROUBLESHOOTING
person
8.1 Troubles and causes of air conditioner
When humidity is high during cooling operation If the interior of If one of the following malfunctions occur, stop operation, shut
an indoor unit is extremely contaminated, the temperature off the power, and contact with your dealer.
clean the interior of the indoor unit. Ask your dealer for details The operation lamp is flashing rapidly (5Hz).
on cleaning the unit. This operation requires a qualified service This lamp is still flashing rapidly after turn off the power and turn
person. on again. (See in Table 8-1 and Table 8-2)
Remote controller receives malfunction or the button does not

When the system is changed over to heating operation after work well.
defrost operation Moisture generated by defrost becomes
steam and is exhausted. A safety device such as a fuse, a breaker frequently actuates.
Symptom 4: Noise of air conditioners cooling Obstacles and water enter the unit.
Symptom 4.1: Indoor unit Water leaks from indoor unit.

A continuous low "shah" sound is heard when the system is in
Other malfunctions.
cooling operation or at a stop.
When the drain pump (optional accessories) is in operation,this
noise is heard. If the system does not properly operate except the above
mentioned cases or the above mentioned malfunctions is
A "pishi-pishi" squeaking sound is heard when the system stops evident, investigate the system according to the following
after heating operation. procedures. (See in Table 8-3)
Expansion and contraction of plastic parts caused by
temperature change make this noise.
8.2 Troubles and causes of remote controller
Before asking for serving or repairing, check the following points.
operation. (See in Table 8-4)
This is the sound of refrigerant gas flowing through both indoor
and outdoor units.
owner’s manual
5
Table 8-1 (Applicable to inverter air conditioner only)
NO. Malfunction running lamp timer lamp defrosting lamp alarm lamp display (nixie tube)
1 Collision model malfunction Quick-flash E0

In-outdoor unit communication
2 checking channel is abnormal
Quick-flash E1
Room temperature sensor

3 Quick-flash E2
checking channel is abnormal
Pipe temperature sensor (T2)
4 Quick-flash E3
checking channel is abnormall
Pipe temperature sensor (T2B)
5 checking channel is abnormal
Quick-flash E4
6 EEPROM malfunction Quick-flash E7
7 In door fan unit stall malfunction Quick-flash Quick-flash E8
8 Outdoor unit malfunction Slow-flash Ed
9 Water-level alarm malfunction Quick-flash EE

Indoor master/slave unit
10 communication checking channel Quick-flash Quick-flash F3
is abnormal
Other malfunctions of master/
11 Quick-flash Quick-flash F4
slave unit
Table 8-2 (Applicable to fixed-frequency air conditioner only)
Malfunction running lamp timer lamp defrosting lamp alarm lamp display
NO. (nixie tube)
Room temperature sensor

1 Quick-flash E2
checking channel is abnormal
2 Evaporator sensor malfunction Quick-flash E3
3 Condenser sensor malfunction Quick-flash E4
4 Water pump temperature

Quick-flash E5
sensor
5 Outdoor malfunction Quick-flash Quick-flash Quick-flash Quick-flash E6
6 EEPROM malfunction Quick-flash Quick-flash E7
7 Water-level alarm malfunction Quick-flash E8
owner’s manual
6
Table 8-3

Power failure. Wait for the comeback of power.
Power switch is off. Switch on the power.
Unit does not start Fuse of power switch may have burned. Replace the fuse.
Batteries of remote controller exhausted Replace the batteries or check the
or other problem of controller. controller.
Temperature is not set correctly. Set the temperature properly.

Air flowing normally but Be in 3 minutes protection of Wait.
completely can't cooling compressor.
Refrigerant is too little or too much. Check leakage, and rightly recharge
refrigerant.
Air or no concreting gas in the Vacuum and recharge refrigerant.
Units start or stop frequently refrigerating circuit.
Compressor is malfunction. Maintenance or change compressor.
Voltage is too high or too low. Install manostat.
System circuit is blocked. Find reasons and solution.
Outdoor unit and indoor unit heat Clean the heat exchanger.
exchanger is dirty.
The air filter is dirty. Clean the air filter.
Inlet/outlet of indoor/outdoor units is Eliminate all dirties and make air
blocked. smooth.
Doors and windows are open Close doors and windows.
Low cooling effect Sunlight directly shine. Make curtains in order to shelter from
sunshine.
Too much heat resource. Reduce heat source.
Outdoor temp. is too high. AC cooling capacity reduces (normal).
Outdoor temperature is lower than 7 C . Use heating device.

Doors and windows not completely Close doors and windows.
Low heating effect closed.
owner’s manual
7
Table 8-4

Check whether the MODE When the automatic mode is
indicated on the display is selected, the air conditioner will
"AUTO" automatically change the fan
The fan speed can not be speed.
changed.
Check whether the MODE When dry operation is selected,
the air conditioner automatically
indicated on the display is
change the fan speed. The fan
"DRY" speed can be selected during
"COOL" , "FAN ONLY", and "HEAT".
The remote controller signal is Check whether the batteries

not transmitted even when in the remote controller are The power supply is off.
the ON/OFF button is pushed. exhausted.
Check whether the MODE The temperature cannot be set during

The TEMP. indicator does indicated on the display is FAN mode.
not come on. FAN ONLY
The indication on the display Check whether the timer The air conditioner operation will
disappears after a lapse of operation has come to an stop up to the set time.
time. end when the TIMER OFF
is indicated on the display.
Check whether the timer Up to the set time, the air conditioner
The TIMER ON indicator operation is started when will automatically start and the
goes off after a lapse of the TIMER ON is indicated appropriate indicator will go off.
certain time. on the display.
Check whether the signal Directly transmit the signal transmitter

No receiving tone sounds transmitter of the remote of the remote controller to the infrared
from the indoor unit even controller is properly directed signal receiver of the indoor unit, and
when the ON/OFF button is to the infrared signal receiver then repeatly push the ON/OFF button
pressed. of the indoor unit when the twice.
ON/OFF button is pressed.
owner’s manual
8
QS01U-007AW
The d e sign a nd s pecif ica tio ns ar e subj ect t o cha ng e with o ut pr ior no tice f or p ro duct
improv emen t. C o nsul t w ith the s al es a gen cy or man u factu rer for d et ails.
202000171405
2012.12.25
SARAWAK (O&M)
3.5
COOLING TOWER
Operation & Maintenance
Manual
TXS SERIES
COOLING TOWER
TRUWATER COOLING TOWERS SDN BHD

(Company No: 188113-A)
EXECUTIVE SUITE 702, BLOCK B,
KELANA BUSINESS CENTRE
NO.97, JALAN SS7/2 KELANA JAYA,
47301 PETALING JAYA, SELANGOR DARUL EHSAN
TEL: +603 7880 8800 FAX: +603-7804 5519
EMAIL: Tw.Cooling@truwater.com.my,
WEBSITE: http://www.truwater.com.my
TXS SERIES
COOLING TOWER
Operation & Maintenance Manual
CONTENTS PAGE
1.0 INTRODUCTION 1
2.0 CONSTRUCTION 1
2.1 GENERAL
2.2 TOWER BODY
2.3 FAN
2.4 INFILL
2.5 WATER DISTRIBUTION SYSTEM
3.0 PREPARATION FOR START UP & OPERATION 3

3.1 CLEANING
3.2 ELECTRICAL WIRING
3.3 WATER FEEDING
3.4 INSPECTION
4.0 OPERATION 54
4.1 PRECAUTION DURING OPERATION
4.1 CARES FOR LONG-TERM SHUT DOWN
5.0 PREVENTIVE MAINTENANCE 75
6.0 WATER REPLENISHMENT 10

8
6.1 EVAPORATION LOSS
6.2 CARRY-OVER LOSS
6.3 BLOW-DOWN LOSS
6.4 MAKE-UP FLOW RATE
7.0 TROUBLESHOOTING 10
12
Operation & Maintenance Manual - TXS Series
1.0 INTRODUCTION
Dear Customer,
You have chosen a Truwater TXS Series Cooling Towers for your plant, thank you for trusting
us. This instruction manual has been prepared to furnish the operator with detailed information to
ensure continued efficient and safe operation of cooling tower at all times. Therefore, the
operator is urged to thoroughly read this manual not only at the time of star-up, but also during
routine maintenance services to acquaint himself fully with the construction and operation of the
equipment.
2.0 CONSTRUCTION
2.1 GENERAL
The major sections of the cooling tower are shown in Figure 1. The functional key points
of the cooling tower are the fan and infill. The cooling tower, which cools recirculating
water based on the principles of heat exchange between water and air, is designed and
built to the highest standard of workmanship and efficiency, backed by the specialized
experience of the industry’s most competent engineering staff.
2.2 TOWER BODY

2.2.1 Main Frame Structure
The mainframe structure of the cooling tower is steel fabricated and is hot-dip-
galvanized to achieve a high resistance to corrosion.
2.2.2 Casing, Louvers & Basins

The casing and louvers are made of PVC; while basins are made of fiberglass-
reinforced polyester (FRP) that is highly resistance to corrosion, chemicals and
weather.
2.3 MOTOR
The AC induction, three phase squirrel cage motors are totally enclosed fan cooled (TEFC)
enclosure installed outside the hot moist discharged air-stream. The protective class of outside
frame is IP55. The normal ambient temperature limits are -20oC to + 40oC. The maximum
altitude is 1000m above sea level.
2.4 FAN
The specially designed low-noise axial fans are propeller-type, incorporating heavy-duty
blades of aluminum alloy. Blades are freely adjustable. The manufacturer must be
contacted for readjusting the blades to ensure proper fan balancing afterwards.
2.5 INFILL
The performance of the cooling tower depends very much upon the efficiency of the infill
used. The high-density film infill is fabricated from rigid, corrugated PVC sheets that are
conductive to cooling tower. The infill is resistance to rot, fungi, bacteria and acids and
alkalis as commonly found in cooling towers.
1 Rev-2 (Dec 2010)

2.6 WATER DISTRIBUTION SYSTEM

Good water distribution is essential for the operation of the cooling tower. The open
gravity type of water distribution system need only a low pump pressure to achieve a
more uniform water distribution. The sizes of the distribution holes are chosen such that
they cannot be easily clogged.
1
2
No. Parts
1 V-Belt & Pulley System
2 Fan Assembly
3 Motor
4 Infill
5 Louver
6 PVC Casing
7 Inspection Door
8 Ladder
9 Cold Water Basin
FIGURE 1: Cooling Tower Structure
2 Rev-2 (Dec 2010)

3.0 PREPARATION FOR START- UP & OPERATION

3.1 CLEANING
Remove any dirt and trash, which has accumulated in the hot and cold-water basin.
Remove any sediment from the hot and cold-water collection basin, sump, and screens.
3.2 ELECTRICAL WIRING

i.) Connect the ground wire to an appropriate point.
ii.) There are 6 connector bases on the connection board of the motors and marked as
follow:
Phase Order A B C
Head U1 V1 W1
Tail U2 V2 W2
iii.) For motor horsepower 4HP and below, the wiring connection is Y Connection and
others is ∆ Connection as shown above.
Note: The above wiring connection is only applicable for single speed motor, FEM brand,
for others type / brands motor, please refer attached Motor Service Manual.
3.3 WATER FEEDING

i.) Open the drain valve located at the sump and wash off the dust and dirt in the basin.
iv.) Feed water through the make-up water inlet pipe until the water level is near the top
of the overflow pipe.
v.) Run the circulating pump for a while to force air out of the pipes as well as to fill the
pipes and cold-water basin with water.
vi.) Adjust the ball tap of the automatic make-up water inlet pipe so that the valve will
close when the water level is slightly below the overflow level.
3.4 INSPECTION
It is imperative that all operating assemblies be inspected before they are placed in
operation. The following is a list of components to be checked before starting the tower:
3.4.1 Inspection of fan

i.) Turn the fan by hand to make sure that the blade tips do not touch the fan
stack. Ensure tip clearance is within the allowable range (5mm-40mm).
ii.) Check and adjust the blade angle (if necessary) within a maximum tolerance
of 1°:
For all modular class TX Tower range from 100 – 250 tons (CBU), the
pitch angle shall be preset by factory.
For all other CKD towers, pitch angle shall be adjusted at site by installer.
iii.) If fan hub plate, center hub or one or more blades are replaced, the complete
fan assembly may require rebalancing.
3 Rev-2 (Dec 2010)

iv.) Now start the fan intermittently and check if the motor is operating in the
proper direction of rotation. Also check if any abnormal noise is developing or
if vibration is occurring. The fan should never be exposed to a vibration level
of more than 7.1mm/sec rms measured at the drive shaft bearings,
3.4.2 Inspection of Motor

i) Ensure the capacity of the power source is sufficient and supply horsepower,
phase, voltage & frequency ratings are identical to those on the nameplate
ii) Make sure the switches, fuses and wires are suitable for the motor capacity.
iii) Keep the motor surface clean and ensure free ventilation airflow.
iv) Check the wiring connections, mounting and assembly bolts.
v) Ensure the frame and terminal box are grounded.
vi) Ensure the rotor freely without rubbing.
vii) Ensure the motor is properly assembled and aligned.
viii) Ensure the motor bearing have adequate grease before operating.
ix) Check carefully whether the motor is out of shape and damage, tight sets are
hard up or fall off duping transporter, operating the motor with hands to see
it is nimble or not.
x) Measure insulation resistance with 500V Meggar and must be not less than
1 megaohm
Note: Windings should be discharged immediately after measurement to avoid
risk of electric shock.
Always shut off the electrical power to the tower fan motor prior to entering the
tower or performing any work on the tower. Any electrical switches should be
locked out and tagged out to prevent others from turning the power back on.
3.4.3 Check v-belts tensions. Re-adjust if necessary.

(Refer to Section 5.3)
3.4.4 Check tightness of bolts that attach mechanical equipment support to the tower
framing. Check tightness of bolts in fan cylinder joints and fan cylinder anchorage.
Re-tighten if necessary.
3.4.5 Check tightness of bolts at diagonals and columns, and grits and columns in the
area between fan and cold water basin.
3.4.5 Check tightness of the following bolted joints in the fan and drive
assemblies:
i.) Fan hub clamp bolts.
ii.) Fan shaft lock nuts.
iii.) Motor mounting bolts.
3.4.6 Check functioning of make-up water float valve.
4 Rev-2 (Dec 2010)

4.0 OPERATION
i.) Start the cooling water circulation pump. Adjust the flow rate with the flow control valve.
Inspect the water distribution system via the inspection door to ensure even water
distribution.
ii.) Check to see if the water level of the cold-water basin is kept at the operating water level.
iii.) Make sure the cooling water is not dirty and contaminated. If it is dirty, drain the tower and
fill it with clean water.
iv.) The motor should bring the fan up to speed in less than 15 seconds. The motor should bring
the fan up to speed in less than 15 seconds. If it does not, check the connections, fuses,
overloads and voltage at motor terminals during start-up period.
v.) Do not cycle a motor on and off more than necessary. Generally, the total starting time
should not exceed 30 seconds each hour. Too frequent cycling may cause the windings to
burn out.
vi.) Run the fan to check the following points.
The fan turns in normal direction (clockwise as viewed from the air delivery side).
There is no unusual sound and vibration.
The fan motor is within the rated value; the excess of electric current may be caused by
low voltage.
The supply voltage to the motor is proper.
4.1 PRECAUTION DURING OPERATION

i.) Several days after running the cooling tower, check the belt tension. Readjust, as
required.
ii.) The cooling tower performance depends on the circulating water flow rate. See if the
flow rate is in accordance with the design specifications.
iii.) Make sure the water level of the cold water basin is kept at a proper level at every
time. If the level is too low, the pump may be damaged.
iv.) Pay enough attention to noise, vibration, cooling water temperature, current, etc. and
if a trouble occurs, refer to the troubleshooting chart for proper correction.
v.) Check the bearing condition of motor by listening for unusual noise, vibration
measurement, bearing temperature, inspection of spent grease or SPM bearing
monitoring.
vi.) The infill can resist temperatures of up to 50°C for the standard type. Care must be
taken to keep the cooling water temperature below the respective limits.
vii.) Normal operating temperatures of electric motors can be hot enough to cause burns.
Avoid any unprotected contact with the operated motor surface.
viii.) Always maintain good cooling water quality. See Table 1 and for recommended
cooling water quality criteria.
ix.) See if the casing, framework and louvers are dirty. Clean them up with fresh water, if
required.
5 Rev-2 (Dec 2010)

Items Value of Criteria Tendency

Corrosion Scale
pH (at 25°C) 6.5 ~ 8.0
Items Electric conductivity (µs / cm) below 800
To Chloride ion (mg C1¯ / l) below 200
Be Sulfate ion (mg SO42¯ / l) below 200
Controlled M-alkalinity (mg CaCO3 / l) below 100
Total hardness (mg CaCO3 / l) below 200
Items Iron (mg Fe / l) below 1.0

to Sulfide ion (mg S2¯ / l) not detectable
+
be Ammonium ion (mg NH4 / l) below 1.0
referred Silica ion (mg SiO2 / l) below 50
Table 1: Recommended Cooling Water Quality Criteria for Circulation Water
Items Value of Criteria
pH (at 25°C) 6.5 ~ 8.0

Items Electric conductivity (µs / cm) below 200
to Chloride ion (mg C1¯ / l) below 50
be Sulfate ion (mg SO42¯ / l) below 50
controlled M-alkalinity (mg CaCO3 / l) below 50
Total hardness (mg CaCO3 / l) below 50
Items Iron (mg Fe / l) below 0.3
to Sulfide ion (mg S2¯ / l) not detectable
+
be Ammonium ion (mg NH4 / l) below 0.2
referred Silica ion (mg SiO2 / l) below 30
Table 2: Recommended Cooling Water Quality Criteria for Makeup Water
4.2 CARES FOR LONG-TERM SHUT-DOWN

i.) In cold climates, the water pipes may become cracked by freezing in winter. For such
conditions and for long-term shutdown, it is imperative to discharge the circulating
water.
ii.) Drain the water basin and clean the inside of the tower. Keep the drain cock and plug
open to avoid any standing water.
iii.) Check all the bolts for looseness.
iv.) Loosen the fan drive V belt free from excessive tension.
v.) It is desirable to cover the tower, especially the suction and exhaust pipe.
vi.) Check fan blades for dust and other deposits. Such deposit may cause the blades to
become out of balance.
6 Rev-2 (Dec 2010)

vii.) For long-term storage (in excess of 6 months) it is necessary to check the fan
condition of the rust preventive coating on all machine surfaces in order to prevent
corrosion. Reapply or repair where necessary, using Esso Rust ban 397 or equivalent.
viii.) The motor should be run for three hours at least once a month. This serves to dry out
windings and re-lubricate bearing surfaces.
ix.) At start of new operating season, make sure bearings are adequately lubricated before
returning motor to service.
5.0 PREVENTIVE MAINTENANCE

i.) It is recommended that the circulating water be replaced with fresh water every month or so.
ii.) Check the fan bearings and replenish their grease every three months or so (assuming a daily
operation of 8 to 10 hours). Shell Alvania Grease No. 2 or equivalent is recommended. The
replenishment amount is about 10 grams per bearing.
iii.) Check the fan bolts torque. De-energize the fan and make a visual inspection for deposits or
damages. Deposits shall be removed from fan and fan bearing housing using brushes and/or
water jet with a maximum water pressure of 3 bar or 45 Psi.
iv.) Refer Table 3 for routine inspection schedule.
v.) If the belt is elongated, use the adjusting bolts to shift the motor position for proper belt
tension. If required, all the belts should be replaced at the same time.
vi.) For every 5000 operating hours, the lubricant grease of motor should be replenished or
changed (should not change lubricant grease when the close bearing is in life of operation).
Lithium-base grease is recommended. Please refer section 5.3 for the motor re-lubrication
procedures.
Note: The above statement is only applicable for FEM motor, for others brands motor,
please refer attached Motor Service Manual for more information.
5.1 V- BELT TENSIONING

i.) Open the Pulley and V-belt cover
ii.) Measure the center distance between fan pulley and motor pulley
iii.) Confirm type of belt (Either SPZ, SPA, SPB or SPC)
iv.) Confirm the small pulley diameter and determine the force required to deflect belt
16mm per meter of span.
vii.) Use belt tension indicator to measure belt deflection
viii.) Check the tension, re-setting to design value if necessary
a. Sample calculation of belt deflection
7 Rev-2 (Dec 2010)

Belt tension
Center distance indicator applied to
mid center distance
16mm deflection
per 1 meter of span
Belt Deflection
Center distance (meter) x 16mm(deflection) = actual belt deflection
If Center Distance = 1000mm = 1meter
Deflection (l) = 16mm
Example:
SPA Belt, small pulley diameter = 150mm
Force value should be 36N (Referring to Table 2)
If F<36, too loose
F>36, too tight
Force required to deflect belt 16mm per meter span

Belt Section
Small Pulley Diameter (mm) Newton (N) Kilogram-force (kg-f)
56 to 71 16 1.6
SPZ 75 to 90 18 1.8
95 to 125 20 20
over 125 22 2.2
80 to 100 22 2.2
106 to 140 30 3.0
SPA
150 to 200 36 3.7
over 200 40 4.0
112 to 160 40 4.0
170 to 224 50 5.1
SPB
236 to 355 62 6.3
over 355 65 6.6
224 to 250 70 7.1
SPC 265 to 355 92 9.4
Over 375 115 12
Table 2: Tensioning Forces Table
8 Rev-2 (Dec 2010)

Inspection item
General conditions
Bolt tightness
Cleaning
Recoating
Balance adjustment
Water level
Water leak
Abnormal vibrations
Overheat unusual smell

Device
Fan M S R R D
Motor M S R R D D
Infill M M
Cold water basin Y M R D Q
Ball tap W
Water distribution W S Y Y
system
Valve S
Sump S M Q D
Strainer M M
Structural components S Y R Y
Casing Y
Louvers Y
Notes: D: Daily W: Weekly M: Monthly Q: Quarterly S: Six monthly Y:

Yearly R: As required
Table 3: Routine Inspection Schedule
9 Rev-2 (Dec 2010)

6.0 WATER REPLENISHMENT

In cooling towers, the amount of circulating water reduces due to the following three factors. It is
therefore necessary to replenish water by the reduced amount.
i.) Hot water is cooled down in the cooling water. Part of this cooling is by evaporation that
results a loss of circulating water.
ii.) The fan airflow carries away air-borne fine water droplets. This is referred to as carry-over
or drift loss.
iii.)Because of the evaporation loss, the concentration of the dissolved components and
impurities in the water increase. In order to prevent this, it is necessary to have a water
bleed (or blow-down). This bleed constantly carries out part of the circulating water.
6.1 EVAPORATION LOSS

Evaporation loss ( E ), can be estimated from the following:
E(kg/h) = Q/575 = CR.L/575
E(%) = 100.CR/575
where, Q : Amount of heat transferred from the water (Kcal/h).
CR : Cooling range (the difference between inlet and outlet water
temperatures).
L : Circulating water mass flow rate (kg/h).
It is noted that the latent heat of vaporization is 575 Kcal/kg. Therefore, for a 6°C
cooling range, the evaporation loss is about 1% of the cooling water flow rate.
6.2 CARRY-OVER LOSS

The drift or carry-over ( C ) depends on the type of the tower and drift eliminator.
Extensive measurements recorded on these towers indicated a drift loss as low as 0.02%
of the circulating water flow rate.
6.3 BLOW-DOWN
The blow-down ( D ) is carried out in any of the following manners.
i.) The drain valve is kept slightly open during the operation.
ii.) The water level is set somewhat higher to allow constant overflow from the overflow
pipe.
iii.) The whole circulating water is frequently replaced with fresh water at the time of
cleaning the cooling tower.
The blow-down amount depends on the quality and concentration of the dissolved
components in the water. It usually ranges from 0.2 to 2% of the circulating water flow
rate.
10 Rev-2 (Dec 2010)

6.4 MAKE-UP FLOW RATE

The amount of water to be replenished is determined from :
L=E+C+D
Let us take the following example :

Evaporation Loss : E = 1%
Drift Loss : C = 0.02%
Blow-down amount : D = 0.5%
Hence we obtain a make-up of 1.52%. It is desirable, however, to increase this by a

safety margin, in this case, say, a make-up of 2% of the circulating water flow should be
sufficient.
11 Rev-2 (Dec 2010)

7.0 TROUBLE SHOOTING

Some possible problems, their possible causes and remedies are given below.
TROUBLE POSSIBLE CAUSE REMEDY

Fan Blade tips & fan stack in Centre the fan shaft.
contact.
Unusual
Bolt loosened. Re-tighten the bolt.
sound and
Defective motor or bearing. Replace the motor or bearing.
vibration
Damaged fan. Replace the fan.
V-belt loosened. Tension the V-belt.
Voltage drop. Measure the voltage and contact the
electricity authority.
Over current Fan blades pitch angle changed. Readjust the blade angle.
Motor defective. Repair or replace the motor.
Overload by excessive airflow. Readjust the fan blade pitch angle.
Cold water basin water too low. Check and readjust the ball tap and
Circulating make-up water feed system.
water flow Strainer clogged. Clean off dirt from strainer.
reduction Circulating water pump defective Repair or replace the pump.
or short of capacity.
Circulating water flow is excessive. Readjust to the design flow rate.
Uneven water distribution. Clean up the spray nozzles.
Circulating
Fan airflow rates not enough. Check and readjust the fan blade pitch
water
angle and belts.
temperature
Exhaust air re-circulated. Improve the airflow conditions.
rises
Suction airflow deflected. Improve the airflow conditions.
Filling plugged. Clear up the plugged portion.
Circulating water flow is excessive. Readjust the valve for proper volume.
Excessive
Drift eliminator defective. Repair or replace drift eliminator.
Carry-over
Airflow rate excessive. Readjust the fan blade pitch angle.
Power not available at motor 1) Check power at starter. Correct any
terminals bad connections between the
control apparatus and the motor.
2) Check starter contacts and control
circuit. Reset the overloads, close
contacts, reset tripped switches or
replace failed control switches.
3) If power is not on all leads at
starter make sure overload and
Motor fails to short circuit devices are in proper
start condition.
Wrong connection Check motor and control connections
against wiring diagram.
Blown fuses Replace fuses with proper type and
rating
Overload trips Check and reset overload in starter.
Low voltage Check nameplate voltage against
power supply. Check voltage at motor
terminals.
12 Rev-2 (Dec 2010)

Open circuit in motor winding Check stator windings for open

circuits.
Short circuited stator Indicated by blown fuses. Motor must
Poor stator coil overloaded be rewound. Removed end bells,
locate with test lamp.
Motor or fan drive stuck Disconnect motor from load and
check motor and gear reducer for
cause of problem.
Rotor defective Look for broken bars and rings.
Motor runs Power failure Check for loose connections to line, to
and then dies fuses and to control.
down
Motor running single-phase Stop motor and attempt to start it.
Motor will not start if single-phased.
Check wiring, control and motor.
Motor leads connected incorrectly Check motor connections against
wiring diagram on motor
Ball bearings Check lubrication. Replace bad
Unusual
bearings.
motor noise
Electrical unbalance Check voltage and currents of all three
lines. Correct if required.
Air gap not uniform Check and correct bracket fits or
bearing.
Rotor unbalance Rebalance
Cooling fan hitting end bell guard Reinstall or replace fan.
Motor overload, wrong voltage or Check voltage and current of all three
unbalanced voltage lines against nameplate values.
Bearing over-greased Remove grease reliefs. Run motor up
to speed to purge excessive grease.
Wrong lubricant in bearings Change to proper lubricant. Refer
attached motor service manual.
One phase open Stop motor and attempt to start it.
Motor will not start if single phased.
Check wiring, controls and motor.
Poor ventilation Clean motor and check ventilation
openings. Allow ample ventilation
around motor.
Motor run
Winding fault Check with Ohmmeter
hot
Bent motor shaft Straighten or replace shaft
Insufficient grease Remove plugs and re-grease bearings.
Too frequent starting Limit accumulative starting time to a
total of 30 seconds each hour.
Deterioration of or foreign material Flush bearings and re-lubricate.
in grease
Bearings damaged Replace bearing.
Incorrect fan blade pitch Measure actual fan pitch and compare
to that recommended. Correct if
necessary.
Unbalanced terminal voltage Check for faulty leads, connections
and transformers.
13 Rev-2 (Dec 2010)

Voltage too low at motor terminals Check transformer and setting if taps.
because of line drop Use higher voltage on transformer
terminals or reduce loads. Increase
wire size or reduce inertia.
Motor does Starting load too high Check load motor is supposed to carry
not come up at start.
to speed Broken rotor bars Look for cracks near the rings. A new
rotor may be required. Have motor
service man check motor.
Open primary circuit Locate fault with testing device and
repair
Wrong Wrong sequence of phases Change any two of the three motor
rotation leads.
(motor)
Motor misaligned Realign.
Weak support Strengthen coupling.
Coupling out of balance Balance coupling.
Driven equipment unbalanced Rebalance driven equipment.
Defective bearings Replace bearings.
Bearing not in line Line up properly.
Motor
Balancing weights shifted Rebalance motor.
vibrates
Contradiction between balancing of Rebalance coupling or motor.
rotor and coupling (half key – full
key)
Polyphases motor running single Check for open circuit.
phase
Excessive end play Adjust bearing or add shim.
Bent or sprung shaft Straighten or replace shaft.
Excessive belt pull Decrease belt tension.
Pulleys too far away Move pulley closer to motor bearing.
Pulley diameter too small Use larger pulleys.
Misalignment Correct by realignment of drive.
Insufficient grease Maintain proper quantity of grease in
bearing.
Hot bearings
Deterioration of grease or lubricant Remove old grease, wash bearings
ball
contaminated thoroughly in kerosene and replace
with new grease.
Excess lubricant Reduce quantity of grease; bearing
should not be more than ½ filled.
Overloaded bearing Check alignment, side and end thrust.
Broken ball or rough races Replace bearing, first clean housing
thoroughly.
Blade rubbing inside of fan Adjust cylinder to provide blade tip
cylinder clearance.
Fan noise
Loose bolts in blade clamps Check and tighten if necessary. Check
fan blade pitch.
14 Rev-2 (Dec 2010)

SARAWAK (O&M)
3.6
PUMP
SINGLE STAGE CENTRIFUGAL END SUCTION PUMP
TO DIN 24255 DINFLOW
INSTALLATION, OPERATION
AND MAINTENANCE INSTRUCTIONS
Contents
Section Page
1. General Observations ……………………….2
2. Operation……………………………………….4
3. Control During Operation……………………5
4. Trouble Shooting……………………………...6
5. Maintenance……………………………………7
Please read these Operating instructions before installation and operation of the pump.
Should the pump respectively pumping set suffer damages because these instructions
have not been followed the guarantee will become void.
________________________________________________________________________________________________________________
Y:/regent/Instruction and products notes/Dinflow Instruction SS 06-Sept-07 Page 1
1. GENERAL OBSERVATIONS
1.1 Location of Unit
The installation location should provide enough room for inspection and maintenance
work. The room should be well aired. If the temperature of the pumped liquid is high
(80ºC to max 120ºC) the room temperature should not exceed 40ºC (otherwise use
special motors).
The pump-motor unit should be firmly fastened to its base in such a way that loosening
through vibration is avoided during operation.
Depending on the type of installation, horizontal and vertical installations are possible.
The appropriate type of electrical motor has to be selected. If vertically installed the
position of the motor underneath the pump should be avoided since leakage through
the mechanical seal may penetrate into the motor bearings.
The pipe work should be connected and supported in such a way that no stress is
introduced into the pump casing. After unfastening the flange bolts, both flanges
should spring apart by the thickness of the gasket and neither separate under an angle
nor stay together under force.
The preconditions are that:
(a) suction and discharge pipes are parallel and on centre;
(b) suction and discharge pipes are independently supported near the pump;
(c) Flexible connections are used if the temperature of the pumping liquid is high.
Flange gaskets should not protrude into the bore, which should be clean of weld
splatter, burrs, rust and other impurities.
1.2 Suction Piping
The suction line should:
(a) be as short and straight as possible and made one or two sizes larger than the
pump suction, so that the flow velocity does not exceed 1.5 – 2.0 m/sec;
(b) be equipped with eccentric reducers where

the excess diameter is located on the lower
side to avoid formation of an air pocket
(Fig 1)
________________________________________________________________________________________________________________
(c) be absolutely airtight and rise towards the pump or at least run horizontally;
(d) be equipped with a gate or foot value. These valves must not be used to control
the pump flow and must always remain fully open when the pump is running.
1.3 Discharge Piping
The discharge line should:
(a) have a diameter sufficiently large to limit the flow velocity to 2.5 – 3 m/sec;
(b) be fitted with a non-return valve between pump and discharge valve to prevent
reverse flow while the pump is stopped. This is particularly important when
pumps are operated in parallel. If reverse flow is allowed to occur, the pump will
‘turbine’ backwards and may be damaged when started under these conditions;
(c) be equipped with a discharge valve for start-up and flow regulation.
1.4 Piping in General
All bends should have large radii and their number should be limited to a minimum. If a
strainer is used in the suction line to prevent foreign matter from being drawn into the
pump the screen should have sufficient openings to keep the flow velocity through it
below 0.6 m/sec.
1.5 Shaft Sealing
This pump is equipped with a mechanical seal standardized according to DIN 24960.
Check if the pump shaft can be rotate easily by hand.
Do not start or rotate the pump without liquid nor rotate in the wrong direction since this
will seriously damage the mechanical seal.
1.6 Attention: Empty pump and piping if there is danger of frost!
________________________________________________________________________________________________________________
2. OPERATION
2.1 Control before Start-up
The pump is ready for start-up when:
 the motor-pump unit is firmly mounted;
 the sense of rotation of the motor is correct;
 the motor protection has been adjusted to maximum load as indicated on the motor
identification plate;
 the pump and suction line are primed;
If the pump operates under positive suction pressure, priming may be achieved by
venting the pump through the vent plug (057 in cross section).
If the pump operates in a suction mode with a foot valve, the pump may be primed
by filling pump and suction line through the vent plug.
If no foot valve is installed, the pump can be primed with a vacuum pump.
 the pump shaft rotates freely.
2.2 Start-up
Start the unit with closed discharge valve until pressure has built up in the discharge
line, then open discharge valve slowly. Do not operate unit for prolonged periods with
closed discharge valve to avoid over-heating of liquid and pump.
The pump set should be shut down at once and the trouble corrected if:
 little or no liquid is delivered;
 the pump does not build up enough pressure;
 the pump set vibrates or makes excessive noise (watch for cavitation ‘crackle’).
________________________________________________________________________________________________________________
3. CONTROL DURING OPERATION
The following items should be checked on a routine basis:
 shaft sealing
 A new mechanical seal can leak after start-up. After approx. 60 min. of run-in,
leaking should not exceed 1-2 drops per minute.
 leakage of entire installation
 the cleanliness of the suction strainer (a clogged strainer may cause cavitation!)
 the relative pressure in suction and discharge line
 the power absorbed by the electrical motor
 the speed of gyration
 noise and vibration level of the pump-motor unit
 the temperature of the motor bearings (max. 70ºC)
________________________________________________________________________________________________________________
4. TROUBLE SHOOTING
DEFECTS
liquid delivered
Motor runs hot

Loss of liquid
after starting
Not enough
Not enough
Cavitation
delivered
Vibration
pressure
No liquid
(Noise)
CAUSE
1 Pump not primed X
2 Speed too low X X X
3 Speed too high X X
4 Air leak on suction X X X X X
5 Air leak in seal X X
6 Air or gas in liquid X X X X
7 Discharge head too high (above rating) X X X X
8 Suction head too high X
9 Not enough suction head for hot liquid X
10 Inlet pipe not submerged enough X X X X X
11 Viscosity of liquid greater than rating X X X
12 Liquid heavier that rating X
13 Insufficient nett inlet head X X X X X
14 Impeller plugged up X X X
15 Wrong direction of rotation X X X
16 Excessive wear ring clearance X X
17 Damaged impeller X X X
18 Rotor binding X
19 Defects in motor X
20 Voltage and/or frequency lower than rating X
21 Foundation not rigid X
22 Misalignment of pump and driver X X
23 Bearing worn X
24 Rotor out of balance X
Pump shaft bent or improperly aligned with motor
25 X X
shaft
26 Impeller too small X X
________________________________________________________________________________________________________________
5. MAINTENANCE
This pump does not need any special maintenance. However, it should be examined at
regular intervals for vibration-free funning, power absorption and leakages.
Do not ‘service’ a well-operating mechanical seal since the seal rings have run in
together in a given position. If the seal is disassembled and reassembled the rings will
not touch exactly in the same position and as a consequence, the seal may leak.
5.1 Change of mechanical seal
If the seal leaks more than 1 – 2 drops per minute and if this amount of leakage cannot
be tolerated in the respective installation, the seal will have to be exchanged for a new
one since an adjustment is not possible.
 The pump casing can stay in the piping.
 Unscrew motor from baseplate (if motor is fastened separately), remove bolts
between supporting frame, casing cover and casing and disengage motor including
supporting frame, casing cover, stub shaft and impeller from the casing.
 Remove impeller nut, impeller and impeller key.
 Remove shaft sleeve, if fitted, and mechanical seal.
 Disengage casing cover.
 Before and after disassembly determine the cause of the seal failure. Frequently
the cause does not lie in the mechanical seal itself but in the condition of the pump
or its surrounding (i.e. dirt, temperature, excessive axial play, etc.).
 Examine the shaft sleeve and shaft (seat of sleeve gasket) for damage and replace
if necessary. Check proper running of shaft with dial gauge.
 Check if the axial and radial play of the motor bearings is within the specified limits.
Permissible axial play of the standard IEC motors depends on the location of the fixed
bearing – shaft side or ventilator side. Most of the manufacturers locate the fixed
bearing on the ventilator side and as a consequence the axial play on the shaft side can
vary between 0.9 – 1.2 mm when the motor is cold. If motors of this design are used
care has to be taken that the movable ring will slide easily on the sleeve (moisten shaft
sleeve with vegetable oil or liquid soap).
________________________________________________________________________________________________________________
 Complete units which are assembled at the factory are preferentially equipped with
motors whose fixed bearing is located on the shaft side, thereby reducing the axial
play when cold to 0 – 0.2 mm.
 Carefully clean seal chamber, sleeve and shaft before reassembly.
 Do not damage contact surfaces of seal rings.
 If O-rings from PTFE are used, heat these rings in water bath before assembling to
80ºC.
 Lubricate shaft sleeve slightly with vegetable oil or liquid soap.
 Mount seal cover, which supports the stationary ring of standardized seals,
perpendicular to shaft.
 It is recommended that casing gasket (005) be exchanged together with the

mechanical seal
Attention: When in doubt about the replacement seal or the elimination of the cause
of the defect, consult with a specialist.
5.2 Leakage Test
After assembly, fill pump with water and connect to pressure network (max. 10 bar) to
check for leakage.
________________________________________________________________________________________________________________
REGENT END SUCTION CENTRIFUGAL PUMP
ITEM NO. OFF NO. OFF FOR SPARES KIT

DESCRIPTION
NO PER UNIT 1 YEAR 2 YEARS 3 YEARS
2 IMPELLER 1 - - 1
20 GASKET 1 1 2 5
7 MECHANICAL SEAL COMPLETE 1 - - 1
17 CASE WEAR RING 1 - 1 2
19 BACK WEAR RING (If Fitted) 1 - - 2
8 SHAFT SLEEVE 1 - - 1
6 LANTERN RING 1 - 1 2
15 IMPELLER NUT 1 - - 1
93.0 LOCKING DEVICE 1 - 1 2
16 IMPELLER KEY 1 - - 1
________________________________________________________________________________________________________________
ROUTINE MAINTENANCE CHART

FOR END-SUCTION AND SPLIT CASING CENTRIFUGAL PUMP
Visually check for leaks

Check for vibration.
Every Week
Adjust gland as necessary to maintain slight leakage.
Hand test bearing housing for any sign of temperature rise
Every Month Check bearing temperature with thermometer
Every 3 Months Check grease lubricated bearings for saponification
Check the packing and replace if necessary

Check shaft or shaft sleeve for scoring.
Every 6 Months Check alignment of pump and motor.
Check holding down bolts for tightness.
Check coupling for wear.
Check rotating element for wear

Check wears ring clearances.
Every Year Clean and regrease bearings.
Measure total dynamics suction and discharge.
Heas as a test of pipe connection.
________________________________________________________________________________________________________________
Megaflow
SINGLE STAGE DOUBLE SUCTION
SPLIT CASING CENTRIFUGAL PUMP
Installation and operating

Instructions
Contents
O General .............................................................................................. 1
0.0 Safety ..................................................................................................... 1
0.1 Marking of instructions in the manual ................................................... 1
0.2 Personnel qualification and training ........................................................ 1
0.3 Non-compliance with safety instructions .............................................. 2
0.4 Safety awareness .................................................................................. 2
0.5 Safety instructions for the operator/user .............................................. 2
0.6 Safety instructions for maintenance, inspection and installation work ... 2
0.7 Unauthorized modification and manufacture of spare parts ..................... 2
0.8 Unauthorized modes of operation .......................................................... 2
1.0 Transport and interim storage ........................................................ 2

1.1 Safety instructions ................................................................................... 2
1.2 Transport .............................................................................................. 3
1.2.1 Lifting the pump unit by crane ............................................................... 3
2.0 Description of the product and accessories ................................ 4

2.1 Technical specification ............................................................................ 4
2.2 Designation ............................................................................................. 4
2.3 Design details ........................................................................................ 4
2.3.1 Pump casing .......................................................................................... 4
2.3.2 Impeller ................................................................................................ 4
2.3.3 Pump shaft ........................................................................................... 4
2.3.4 Shaft seal ............................................................................................. 4
2.3.5 Bearing and lubrication............................................................................ 4
2.4 Type of installation ............................................................................... 4
2.5 Attachment ............................................................................................. 4
2.6 Dimensions and weights ........................................................................ 4
3.0 Installation at site ............................................................................... 4

3.1 Safety regulations ................................................................................... 4
3.2 Checks to be carried out prior to installation ........................................... 4
3.3 Installing the pump/unit ......................................................................... 5
3.3.1 Removal of pump rotor securing device ................................................. 5
3.3.2 Aligning the pump/drive ......................................................................... 5
3.4 Connecting the piping ............................................................................ 5
3.4.1 Auxiliary connections ............................................................................. 5
3.4.2 Coupling guard ....................................................................................... 5
3.5 Final check.............................................................................................. 5
2
4.0 Commissioning, start -up/shutdown ................................................ 5
4.1 Commissioning ......................................................................................... 5
4.2 Shaft seal ................................................................................................. 5
4.3 Venting ..................................................................................................... 6
4.4 Commissioning ......................................................................................... 6
4.4.1 Checking the direction of rotation ............................................................... 6
4.4.2 Start-up .................................................................................................... 6
4.4.3 Pump operating range ............................................................................... 6
4.4.4 Shutdown .................................................................................................. 7
4. 5 Shutdown/storage/preservation ................................................................. 7
4.5.1 Storage of new pumps............................................................................... 7
4.5.2 Measures to be taken for prolonged shutdown ........................................... 7
4.6 Returning to service after storage .............................................................. 7
5.0 Maintenance / repair ............................................................................ 8

5.1 General instructions .................................................................................. 8
5.2 Maintenance/inspection ............................................................................ 8
5.2.1 Supervision of operation ........................................................................... 8
5.2.2 Maintenance of the shaft seal ................................................................... 8
5.2.3 Maintenance of the bearings ..................................................................... 8
5.3 Dismantling............................................................................................... 8
5.3.1 Fundamental instructions and recommendations ........................................ 9
5.3.2 Preparations for dismantling ..................................................................... 9
5.4 Reassembly .............................................................................................. 9
5.5 Note concerning replacement of assemblies/parts .................................... 11
5.5.1 Replacing the shaft seal............................................................................ 11
5.5.2 Replacing the casing wear rings and/or impeller wear rings ....................... 11
5.6 Spare parts............................................................................................... 12
5.6. 1 Purchasing of spares ................................................................................. 12
5. 6. 2 Proposal for spares .................................................................................. 12
5.6.2.1 Recommended spare parts ....................................................................... 12
6.0 Trouble-shooting .................................................................................. 13

6.1 General .................................................................................................... 13
6.2 Causes of faults and their remedies .......................................................... 14
7.0 Routine maintenance and inspections intervals............................ 16

0 General Not only must the general safety instructions
laid down in this chapter on ‖Safety" be
This pump/unit has been developed in
complied with, but also the safety
accordance with state-of-the-art
instructions outlined under specific
technology; it is manufactured with utmost
headings.
care and subject to continuous quality
control. 0.1 Marking of Instructions in the
These operating instructions are intended Manual
to facilitate familiarization with the pump The safety instructions contained in this
and its designated use. manual whose non - observance might
The manual contains important cause hazards to persons are specially
information for reliable, proper and efficient marked with the general hazard sign,
operation. Compliance with the operating namely
instructions is of vital importance to
ensure reliability and a long service life of
the pump and to avoid any risks. These
operating instructions do not take into
safety sign in accordance with DIN
account local regulations; the operator
4844-W9.The electrical danger warning
must ensure that such regulations are
sign is
strictly observed by all, including the
personnel called in for installation.
This pump/unit must not be operated
beyond the limit values specified in the
technical documentation for the medium safety sign in accordance with DIN 4844 -
handled, capacity, speed, density, W8. The word
pressure, temperature and motor rating.
Make sure that operation is in accordance
with the instructions laid down this is used to introduce safety instructions
manual or in the contract documentation. whose nonobservance may lead to damage
The name plate indicates the type to the machine and its functions.
series/size, main operating data and Instructions attached directly to the
works/serial number; please quote this machine, e.g. -arrows indicating the
information in all queried, repeat orders direction of rotation -markings for fluid
and particularly when ordering spare connections must always be complied with
part's. and be kept in perfectly legible condition at
If you need any additional information or all times.
instructions exceeding the scope of this 0.2 Personnel Qualification and
manual or in case of damage please Training
contact Regent Pumps' nearest customer
service centre. All personnel involved in the operation,
maintenance, inspection and installation of
0.0 Safety the machine must be fully qualified to carry
These operating instructions contain out the work involved.
fundamental information which must be Personnel responsibilities, competence and
complied with during installation, operation supervision must be clearly defined by the
and maintenance. Therefore this operating operator. If the personnel in question are
manual must be read and understood both not already in possession of the requisite
by the installing personnel and the know-how, appropriate training and
responsible trained personnel/operators instruction must be provided. If required,
prior to installation and commissioning, the operator may commission the
and it must always be kept close to the manufacturer/supplier to take care of
location of operation of the machine/unit such training. In addition, the operator is
for easy access. responsible for ensuring that the contents
of the operating instructions are fully
-1-
understood by the responsible person- 0.6 Safety Instructions for
nel. Maintenance, Inspection and
Installation Work
0.3 Non-compliance with Safety
Instructions The operator is responsible for ensuring
that all maintenance, inspection and
Non-compliance with safety instructions installation work be performed by
can jeopardize the safety of personnel, authorized, qualified specialist personnel
the environment and the machine who are thoroughly familiar with the
itself. Non-compliance with these manual.
safety instructions will also lead to
Work on the machine must be carried
forfeiture of any and all rights to
out only during standstill. The
claims for damages
shutdown procedure described in the
In particular, non - compliance can, for manual for taking the machine out of
example, result in: service must be adhered to without fail.
-failure of important machine/unit Pumps or pump units handling media
functions -failure of prescribed injurious to health must be
maintenance and servicing practices decontaminated. Immediately following
-hazard to persons by electrical, completion of the work, all safety -
mechanical and chemical effects relevant and protective devices must be
-hazard to the environment due to reinstalled and/or re - activated. Please
leakage of hazardous substances, observe all instructions set out in the
chapter on ―Commissioning" before
0. 4 Safety Awareness returning the machine to service.
It is imperative to comply with the 0.7 Unauthorized Modification and
safety instructions contained in this Manufacture of Spare Parts
manual, the relevant national health and
safety regulations and the operator's Modifications or alterations of the
own internal work, operation and machine are only permitted after
safety regulations. consultation with the manufacturer.
Original spare parts and accessories
0.5 Safety Instructions for the authorized by the manufacturer ensure
Operator/User safety. The use of other parts can
-Any hot or cold components that could invalidate any liability of the
pose a hazard must be equipped with a manufacturer for consequential damage.
guard by the operator, 0.8 Unauthorized Modes of
-Guards which are fitted to prevent Operation
accidental contact with moving parts
(e.g. coupling) must not be removed The warranty relating to the operating
whilst the machine is operating. reliability and safety of the pump/unit
supplied is only valid if the machine is
-Leakages (e.g. at the shaft seal) of
used in accordance with its designated
hazardous media handled (e.g.
use and if all operating instructions
explosive, toxic, hot) must be contained
described in chapter 1 have been
so as to avoid any danger to persons
followed. The limits stated in the data
and the environment. Pertinent legal
sheet must not be exceeded under any
provisions must be adhered to.
circumstances.
-Electrical hazards must be eliminated.
(In this respect refer to the relevant 1.0 Transport and interim storage
safety regulation applicable to different 1.1 Safety instructions
countries and/or the local energy
supply companies.) Transport of the unit requires
proper preparation and handling.
Observe the following
explanations and safety instructions.
-2-
1.2 Transport When lifting the unit by crane, observe the
directions of pull. Angles greater than 90°
Transport in horizontal position is are forbidden.
recommended in all cases, since this
Use separate belts on each side! The
ensures stable positioning of the unit
drawings opposite show correct lifting by
without any risk of accident, whatever the
crane.
method of transport, e. g., road, rail or
ship etc.
For transport purpose the unit should the
secured on suitable pallets or sleds. All
loose and movable parts must be
secured.
1.2.1 Lifting the pump unit by crane
The motor lifting lugs must
only be used for lifting the
motor alone and never for
lifting the complete unit.
-3-
2.0 Description of the product and and operating data. The fixed bearing at the
accessories internal bearing end is located on a bush to
permit rapid changing without removing the
2.1 Technical specification rotor or upper half.
The pump of the REGENT PUMPS series 2.4 Type of installation
is a horizontally installed, single-stage,
axially split volute casing pump with The pump is installed in horizontal position.
double - entry radial impeller. Connection See "Installation" operating instructions.
flanges are manufactured according to DIN,
ISO. BS of ANSI, as preferred. 2.5 Attachment
In waterworks, irrigation and drainage The accessories supplied with the pump
pumping plants, power stations, for are specified in the relevant individual
industrial water supply, in air conditioning operating instructions.
systems, dock installations, fire ex-
tinguishing systems and many other areas. 2.6 Dimensions and weights
2.2 Designation For dimensions and weights please refer to
the pump installation drawing.
T XXX–XXX–XXX
3.0 Installation at site
Type series
Suction DN in mm 3.1 Safety regulations
Discharge DN in mm
Electrical equipment operated
Nominal impeller dia. in mm
in hazardous locations must
2.3 Design details comply with the explosion
protection regulations. This is indicated on
2.3.1 Pump casing the motor rating plate. If the equipment is
Axially split volute casing with replaceable installed in hazardous locations. The
wear rings. Suction and discharge nozzles applicable local explosion protection
in lower half of casing are at the same regulations and the regulations of the test
level (inline version). certificate supplied with the equipment and
issued by the responsible approval
2.3.2 Impeller authorities must be observed and complied
with.
The double-entry radial impeller is
manufactured for the operating data The test certificate must be kept close to the
provided in each case. Also with wear location of operation for easy access (e.g.
rings, if requested. In double -entry radial foreman's office).
impellers the axial thrust is largely
balanced. 3.2 Checks to be carried out prior to
installation
2.3.3 Pump shaft
All structural work required must have
The shaft is fully sealed against the liquid been prepared in accordance with the
being pumped. Shaft - protecting sleeves dimensions stated in the dimension
are fitted in the seal area. table/installation plan. The concrete
foundations shall have sufficient strength
2.3.4 Shaft seal (min. BN 150) lo ensure safe and
functional installation in accordance with
The shaft seal at the drive end of internal
DIN 1045 or equivalent standards. Make
bearing end is designed as described in
sure that the concrete foundation has
the "Shaft seal" operating instructions.
set firmly before placing the unit on it. Its
2.3.5 Bearings and lubrication surface should be truly horizontal and
The pump is fitted with the bearing and even.
lubrication system stated in the design
-4-
3.3 Installing the pump/unit The flange covers on the pump suction and
discharge nozzles must be removed prior
See Operating Instructions ―installation". to installation in the piping.
Before setting up the pump,
check the operating data. 3.4.1 Auxiliary connections
Ensure that the data on the maker's plate The dimensions and locations of the
agrees with the data in the order and the auxiliary connections (cooling, heating,
system data, e. g. operating voltage, fre- sealing liquid, flushing liquid, etc.) are
quency, pumped liquid temperature etc. indicated on the installation plan or piping
layout.
3.3.1 Removal of pump rotor securing
device More detailed installation instructions are
given in the respective operating
This is not necessary for a horizontally instructions.
installed pump, since no securing device
is fitted. These connections are
required for proper functioning
3.3.2 Aligning the pump/drive of the pump and are therefore
To align the unit, refer to the sections, of vital importance!
"Coupling" and "Installation". 3.4.2 Coupling guard
Improper alignment of the unit In compliance with the accident
can cause damage to both the prevention regulations the pump
coupling and the unit itself! must not be operated without a
3.4 Connecting the piping coupling guard. If the customer specifically
Never use the pump itself as requests not to include a coupling guard in
an anchorage point for the our delivery, then the operator must supply
piping. Suction lift lines one.
should be laid with a rising slope towards 3.5 Final check
the pump and suction head lines with a Re - check the alignment as described in
downward slope towards the pump. The section 3.3.2.
pipelines should be anchored in close It must be easy to rotate the shaft by hand
proximity to the pump and should be at the coupling.
connected without transmitting any
Check the integrity and proper
stresses or strains. Their weight must not
functioning of all connections.
exert any load on the pump. With short
pipelines, the nominal diameters should be 4.0 Commissioning, start-up/
at least equal to the nominal diameters of shutdown
the pump nozzles. For long pipelines the
Compliance with the following
most economical nominal diameter has to
requirements is of paramount
be determined from case to case.
importance. Damage resulting
Any additional loads on the discharge and from non -compliance shall not be covered
suction nozzles, e.g. caused by: by the scope of warranty.
Weight of the water-filled pipes, changes
in the length of pipes owing to temperature 4.1 Commissioning
fluctuations, reactive forces due to Before starting up the pump make sure that
unbraced compensators must not exceed the following requirements have been
the stated values. checked and fulfilled.
An excessive, impermissible Has the pump been firmly bolted to the
increase in the pipeline forces base/foundation?
may cause leaks on the pump
where the medium handled can
escape into the atmosphere. Danger to life
when hot media are handled!
-5-
Have the coupling and pump unit been The direction of rotation must correspond to
aligned as specified? the direction indicated by the arrow on the
Are the pipes properly fitted? Has the pump. This can be verified by switching the
motor been installed according to its oper- pump on and then off again immediately.
ating instructions? Before checking the direction of
Can the unit be easily rotated by hand at rotation make sure that there is no
the coupling? (Carry out at least one full foreign matter in the pump casing.
rotation) Has the coupling guard been Never put your hands or any other objects
fitted? Have shaft been informed about into the pump!
sources of danger and measures taken to 4.4.2 Start - up
comply with the accident prevention
regulations? Dry-running will result in
increased wear and must be
Is the unit protected against overload
avoided
(appropriate safety valve)?
If a non - return valve is not fitted at the
Have the seals been fitted according to
discharge end, close the delivery gate
their operating instructions?
valve.
Have any additional devices been
If a shut - off valve is fitted at the suction
prepared and fitted according to their
end, open it fully.
operating instructions? Has lubrication
been provided for oil-lubricated bearings? All additional connections for cooling,
heating, lubrication, irrigation or sealing
Has the pump been vented as specified in
liquid etc, if fitted, must be opened fully or
section 4.3?
switched on and the flow must be checked.
4.2 Shaft seal Switch on the motor.
For putting the shaft into operation, refer As soon as the pump starts to deliver this
to Operating instruction "Shaft seal". If the can be recognized by the rising gauge
pump has been out of operation for a pro- pressure slowly open the delivery gate
longed period, the measures specified in valve fully.
section 4.6 must be carried out. The pump may operate against
4.3 Venting the closed gate valve only
during start – up and shutdown,
Before the pump is started up, it and the as otherwise inadmissible temperature rise
pipes must be vented and filled with the occurs resulting in damage.
liquid to be pumped. In the case of both
gravity feed and suction operation venting 4.4.3 Pump operating range
must be carried out via the hole on the up- The flow rate "Q" adjusts itself
per suction elbow. In the case of suction automatically to the delivery head
operation the pump must additionally be according to the Q - H characteristic. The
evacuated (a vacuum must be created). pumps permitted operating range is subject
4.4 Commissioning to limits, which have separate causes.
1. Partial load operating limit with low flow
4.4.1 Checking the direction of rate.
rotation This limit is indicated in the Q - H
For trouble-free operation of characteristic by Qmin or by the continuation
the pump, the correct of the characteristic which is
direction of rotation of the not depicted.
impeller is of paramount importance. If It is not permissible to operate
running in the wrong direction of rotation, the pump in the range from Q =0 t0 Qmin,
the pump cannot reach its duty point; prolonged operation in this range causes
vibrations and overheating will be the greatly increased mechanical loads which
consequence. The unit or the shaft seal the components cannot withstand. Brief
might be damaged. passage through the critical range is
Correct direction of rotation: permissible, e.g. during start - up.
-6-
2. NPSH -related limits in the partial load applicable the cooling chambers must be
and overload ranges drained or otherwise protected against
These two limits are determined by the freezing.
ratio of NPSHr to NPSHa. They are 4.5 Shutdown/storage/preservation
calculated as follows: The intersections of
NPSHr and NPSHa are projected onto the Each Regent Pumps pump leaves the
Q-H characteristic, where they give the factory carefully assembled. If
operating limits (refer to the diagram be- commissioning is to take place some time
low). Checking of the NPSHr operating after delivery, we recommend that the
limit is not necessary for operating the following measures be taken for pump
pump under design conditions. If system- storage.
related changes occur, an NPSH check 4.5.1 Storage of new pumps
must be carried out. If necessary, consult
New pumps are supplied by our factory duly
the nearest Regent Pumps after sales
prepared for storage.
service centre.
Maximum protection for up to 12 months,
if the pump is properly stored indoors.
Store the pump in a dry location.
Qmin 4.5.2 Measures to be taken for
prolonged shut down
NPSHr
1. The pump remains installed; periodic
check of operation.
NPSHa In order to make sure that the pump is
always ready for instant start-up and to
prevent the formation of deposits within the
pump and the pump intake area, start up the
pump set regularly once a month or once
4.4.4 Shutdown every 3 month for a short time (approx. 5
minutes) during prolonged shutdown
Close the shut-off element in the discharge periods. Prior to an operation check run
line. If the discharge line is equipped with a ensure that there is sufficient liquid available
check valve, the shut-off element may for operating the pump.
remain open, provided there is back 2. The pump is removed from the pipe and
pressure in the line. stored before putting the pump into storage
The shut-off element in the carry out all checks specified in sections
suction line must not be closed 5.1 to 5. 4: Spray - coat the inside wall of the
when switching off the pump, pump casing, and in particular the impeller
Switch off the motor, making clearance areas, with a preservative.
sure that the unit runs smoothly down to Spray the preservative through the suction
a standstill. Depending on- the system the and discharge nozzles. It is advisable to
pump should have an adequate after run close the nozzles (for ex. with plastic caps
period with the heat source switched off to or similar).
allow the medium handled to cool down
sufficiently to avoid any heat build-up within 4.6 Returning to service after
the pump. storage
In the case of prolonged shutdown, the Before returning the pump to service
shut-off element in the suction line has to carry out all checks and maintenance
be closed. Close the auxiliary connections. work specified in sections 5.1 and 5.2.
The shaft seal in pumps where the liquid is In addition, the instructions
fed in under vacuum must also be laid down in section 4.1
lubricated with sealing liquid during "Commissioning" and section
standstill. In the event of frost and/or 4.4.3 Operating limits must be
prolonged shutdowns, the pump and if observed.
-7-
Upon completion of the higher room temperatures, the bearing
work, all safety -related and temperature should be below 100°C
protective equipment must (212°F). If the pump features oil -
be properly refitted and/or lubricated bearings, the correct oil level
reactivated before starting the pump must be verified at regular,
set. intervals.
5.0 Maintenance/repair During pump operation the
shut-off element in the inlet line must not
5.1 General Instructions be closed. Any stand-by pumps installed
The operator is responsible for should be switched on and then
ensuring that all maintenance, immediately off again once a
inspection and installation work is week to keep them operational.
carried out by authorized, duly Attention should be paid to the
qualified staff that are thoroughly correct functioning of the
familiar with these operating in- auxiliary connections.
structions. If the flexible coupling elements begin to
show signs of wear, they should be
A regular maintenance schedule will
replaced in due time. See Operating
help avoid expensive repairs and
Instructions "Coupling".
contribute to trouble-free reliable
operation of the pump with a If the liquid for sealing, cooling and
minimum of maintenance expenditure lubricating is taken from an external
and work. source, the pressure must be 1.0 to 2.0
bar higher than at the suction nozzle.
Work on the unit must only
The gland packing (if the pump is fitted
be carried out with the
with one) should drip slightly during
electrical connections
operation. The gland should only be
disconnected. Make sure that the
gently tightened. See Operating In-
pump set cannot be switched on
structions "Shaft seal".
accidentally (danger to life!).
Pumps handling liquids 5.2.2 Maintenance of the shaft seal
posing health hazards must Maintenance is affected as described in
be decontaminated. When the "Shaft seal" Operating Instructions.
draining the medium, see to it that
there is no risk to persons or the 5.2.3 Maintenance of the bearings
environment. All relevant laws must The bearings are maintenance-free
be adhered to (danger to life!). and are greased for life. No lubrication
is required. Maintenance of oil -
5.2 Maintenance/inspection
lubricated bearings is to be effected as
5.2.1 Supervision of operation described in the "Oil -lubricated bear-
ings" Operating instructions.
The pump should run
quietly and free from 5.3 Dismantling
vibrations at all times. Before dismantling, secure the
The pump must never be allowed to pump so as to make sure it cannot be
run dry. switched on accidentally. The shut-off
Prolonged operation elements in the suction and discharge
against a closed shut -off lines must be closed. The pump must
element is not permitted in have cooled down to ambient temper-
order to prevent the medium ature, it must be drained and its pressure
handled from heating up. must be released.
At room temperatures of up to 30°C Dismantling and reassembly must
(86°F) the bearing temperature always be carried out in accordance with the
should not exceed 90°C (194°F). At relevant sectional drawing.
-8-
5.3.1 Fundamental instructions and bearing housing out of the recesses and lift
recommendations the rotor upwards out of the lower casing
Repair and maintenance work to the pump half. For further disassembly, place securely
must only be carried out by specially in horizontal position.
trained personnel, using original spare Pull of the bearing housing of the fixed
parts. bearing (opposite the drive end).
Observe the safety regulations laid down. Undo and twist off the grooved nut. Remove
And work on the motor shall be governed the deep groove ball bearing with bush from
by the specifications and regulations of the the shaft.
respective motor supplier. Remove bearing cover.
Dismantling and reassembly must always Remove V-Ring from shaft-protecting sleeve.
be carried out in accordance with the Remove shaft seal housing.
relevant general drawing. The general Pull off shaft protecting sleeve.
drawing and other relevant documents are The impeller is located with sliding fit on the
found in the annex. The dismantling se- shaft and can normally be removed easily.
quence can be derived from the general In case of difficulty, it can be loosened by
drawing. In case of damage you can gently tapping with a plastic hammer.
always contact our service departments.
Remove second shaft protection sleeve
5.3.2 Preparations for dismantling complete with the shaft seal housing, if fitted.
Remove coupling half.
Please observe the "Coupling" Operating
Instructions. Pull off bearing housing.
The pump is designed so that the Remove cir-clip and pull off deep groove ball
complete rotor can be removed in the bearing.
sequence described below without 5.4 Reassembly
removing the suction or discharge pipe or
disturbing the alignment of the pump unit: Reassembly is effected in reverse order to
Close the suction and delivery gate valves dismantling. For all work on the pump unit the
and drain the pump by opening the drain general diagram, in conjunction with the
plug and vent plug. individual parts list, serves as a guide.
Remove any pipes between additional The customary rules of mechanical
equipment and the pump. engineering and also the installation
Remove coupling guard. instructions for removal and installation of
shaft seal, bearing, impeller wear rings and
Detach the pump-side coupling half as
casing wear rings sections must be
described in the Operating instructions
observed. In the case of oil - lubricated
"Coupling". Loosen and push back the seal
cover. Undo flange screws and release the bearings, the Operating Instructions "Oil -
lubricated bearings" must be observed.
upper casing half from the lower casing
half with the aid of the forcing screws, For the required tightening torques please
remove with lifting gear and store in a safe refer to works standard ZN 192 unless
place. The interior of the pump is then free otherwise specified. It is essential to use the
(impeller with casing wear rings, shaft correct tightening torques and the required
seals) for inspection and further screw locking devices. The relevant parts are
disassembly. specially indicated in the general drawing.
In case of oil - lubricated pumps drain off The symbols for screw locking devices and
the oil. Remove the screw connection sealing elements are explained in BN 433. 0-
between bearing housing and bearing rings and V-rings must be replaced and
brackets. Also undo the nuts and bolts their seats on the shaft must be cleaned.
which secure the bearing cover. Press the
-9-
In addition, all the sealing elements must at the interior bearing end, proceed as
be fitted into the components provided for described above for the drive for the drive
this purpose before installation. motor side. Heat the deep groove ball bearing
For assembling the rotor, position the and fit it onto the sleeve.
pump shaft securely. All fits, threads and Push the sleeve with deep groove ball
sliding fits of the shaft must be cleaned bearing onto the pump shaft with key
and coated with assembly paste. inserted.
Insert the keys required for assembly into Tension the rotor parts elastically with groove
the pump shaft. nut and disc spring. For this purpose tension
Mount the impeller, which has a sliding fit. the disc spring to blocking point and then
When fitting the impeller, observe the undo the grooved nut again by half a turn.
direction of rotation (see diagram below). This measure is essential to
compensate for differences in
thermal expansion between pump shaft and
the components fitted on it.
Fitting of the rotor is then complete.
Insert the rotor into is the pump casing.
Apply liquid sealant (refer to the appended
list) to the surfaces of the casing wear
rings and the sealing faces of the casing.
Insert the rotor, observing the direction of
rotation. The diagram on the previous page
shows the correct method of installation.
Align the rotor and ensure that the fixing
pins are correctly seated in the casing.
The pins must be positioned as shown in the
For assembling the casing wear rings, diagram opposite.
observe item 7.4. 2 "Changing the casing The bearing housings must be fastened to
wear rings". the bearing brackets by means of the screw
Put the casing wear rings onto the running connections with the sealing cap inserted at
surfaces of the rotor. Ensure that the the interior bearing end. The seating
bezels of the rings are on the outside positions are determined by the recesses.
(towards the bearing). Insert the pins Fitting the bearing covers.
required for fixing the casing wear rings. Before fitting the casing cover, apply liquid
The remaining components are fitted first sealant to the joint surface of the lower
on the movable bearing side (i.e. the casing half (refer the appended list).
drive motor side) of the pump shaft. Tighten the flange screws diagonally from the
Push the shaft protecting sleeve onto the inside towards the outside.
pump shaft. Ensure that the groove Insert the keys for fitting the coupling into the
provided engages in the key of the pump shaft.
impeller. When fitting the coupling and accessories,
Push the complete housing shaft seal see refer to the individual operating instructions.
Operating Instructions "Shaft seals", V-
Ring over the pump shaft.
Push the bearing cover over the shaft.
Heat the deep grooved ball bearing and
fit it onto the pump shaft. It is essential to
avoid one sided pressure, e.g. hammer
blows, on the outer rings. The bearing is
secured by the disc and the securing ring.
To fit the shaft protecting sleeve, shaft
seal housing, V-Ring and bearing cover
- 10 -
5.5.1 Note concerning replacement of by split flows), the impeller neck must be
assemblies/parts. turned off on a lathe and the impeller wear
5.5.2 Replacing the shaft seal. ring fitted in addition (available as spare
parts).
Refer to Operating Instruction ―Shaft Alternatively, a new impeller can be supplied
seals‖. at short notice.
5.5.3 Replacing casing wear rings
and/or impeller wear rings.
The impeller clearance is given in the data
sheets ―Design and operating data‖.
To remove the impeller, proceed as
described in section 5.4 ―Reassembly‖.
After reassembly section 5.3.2, the casing
wear rings can be removed. When fitting
the rings, ensure that their bezels are on
the outside (towards the bearing).
The pins must be positioned as shown in
the following diagram.
If the impeller has not been fitted with a
wear ring at the factory, and changing the
casing wear ring alone does not achieve
anything close to the required impeller
clearance (the impeller neck is badly worn
- 11 -
5.6 Spare parts
5.6.1 Purchasing of spares
The following information is required for ordering (see manufacturers
nameplate of refer to the information given in the design and operating
data sheets):
Design series; serial number of pump: year of manufacture
The required parts should be specified as follows<see general drawing and
spares list).
Example:
Quantity Description Material Part No.

1 Bearing ST 121
5.6.2 Proposal for spares

5.6.2.1 Recommended spare parts
Recommended spare parts stock for 2 years' operation to
VDMA24296 (also for continuous operation)
Part - No. Part description Number of pumps (incl. stand - by pumps)
2 3 4 5 6 8 10 and
more
Number of spare parts
117 impeller 1 1 1 2 2 3 30%
118 Casing wear ring 4 4 4 6 6 8 50%
117. 1 Impeller wear ring 4 4 4 6 G 8 50%
Shaft with keys and shaft nuts 1 1 2 2 2 3 30%
121 Anti — friction bearing 2 2 4 4 6 8 100%
119 Shaft protecting sleeve 4 4 4 6 6 8 50%
128 A Packing ring 32 32 48 46 48 64 40%
Set of seals 4 6 8 8 9 12 150%
Mechanical Rotating seal ring 4 6 8 8 8 12 90%
seal: 4 6 8 8 8 12 90%
Stationary seal ring 4 6 12 16 16 20 150%
0 – rings 4 6 12 16 16 20 150%
128B Seals on stationary seal rings 1 2 2 2 2 4 20%
Set of springs
These figures already include those components required twice for replacement
6.0 Trouble -shooting
- 12 -
NPSH
6.1 General
The diagram below is to facilitate
understanding of the causes of faults and
their remedies.
The cause of many operating faults on
pumps is often hydraulic. The hydraulic
behavior of a pump is illustrated by its
characteristic curves H, P, Eta and NPSH in
combination with the plant characteristic
curves HA and the pump curve H intersects.
The duty point B is where the system curves
HA and the pump curve H intersect. The duty
point B is where the system curves HA and
the characteristic curve H intersect. If it is not
possible to determine the cause of the
trouble, contact the Regent sole agent.
NPSH
Hgeo
Capacity
13
6.2 Causes of faults and their remedies Faults
Pump pressure too low
Pump pressure too high
Flow capacity too high
Flow capacity too low
Power consumption too high
Pump fails to pump liquid after being switched on
Pump ceases to pump liquid
Pump does not run smoothly (noise, vibrations)
Inadmissible temperature increase at pump/seal casing
Bearing temperature too high
Excessive leakage at the shaft seal
Drive machine overload
Leakage at pump
Cause Remedy
Duty point B does not lie at The
X X X X X X X X X calculated intersections of Q and - Re - adjust duty point
H
Pump or piping incompletely
X - Vent
vented or not primed
- Clean impeller check

Suction pipe or impeller - Check plan! for impurities
X X X X X X
blocked - Remove deposits in pump and /or piping
-Check strainer/suction aperture
Formation of air pockets in the
X X X - Correct suction conditions - Alter piping
piping
- Check mode of operation
- Correct suction conditions
Suction head too high
- Increase positive suction head
X X X X X (NPSH available too low)/ water
- Increase back pressure by throttling
level too low
- Install pump at a lower level
- Alter suction/intake pipe if resistances are too high
- Clean sealing liquid line, possibly introduce sealing liquid from an
external source or increase pressure
X X X X Air is drawn in at shaft seal
- Check level of liquid in lead tank - Renew shaft seal
- Renew shaft protecting sleeve
- Change over two phases of the power feed
X X X X X Wrong direction of rotation - Check electrical connections
- Check impeller position correct if necessary
- Increase speed
X X X Speed too low - Check switchgear
- Fit larger impeller 1)
- Check duty point/selection - Increase back pressure by throttling
- Check medium handled fot contamination by chemicals and The
X X X X internals worn
solid matter content
- Renew worn components
Pump pressure is lower than - Re -adjust duly point
X X
specified in the order - Increase back pressure by throttling
Higher density or viscosity of
- Reduce speed
X X medium handled than specified in
- II there is constant overloading possibly machine impeller 1)
The order
- Reduce speed
X X X X X Speed too high
- If there is constant overloading possibly machine impeller 1)
- Check
- Tighten lie bolts
X Tie bolts/seals - Renew gaskets
- Check pipe connections and pump mounting, if necessary
improve mounting of piping
- Check flushing/sealing liquid pressure
- Check sealing liquid line, possibly introduce sealing liquid from an
X Shall seal worn external source or increase pressure
- Renew shaft seal
- Alter piping
Unfavorable flow to suction to - If necessary, alter suction/intake pipe if resistances are too high
X X X X
suction noz2le of pump - Check whether pipe route has a twisted or irregular flow profile (e.
g. downstream of an elbow)
- 14 -
1) Consult Regent Pumps
Faults
Pump pressure too low
Pump pressure too high
Flow capacity too high
Flow capacity too low
Power consumption too high
Pump fails to pump liquid after being switched on
Pump ceases to pump liquid
Pump does not run smoothly (noise, vibrations)
Inadmissible temperature increase at pump/seal casing
Bearing temperature too high
Excessive leakage at the shaft seal
Drive machine overload
Leakage at pump
Cause Remedy
- Alter
Gland follower, seal cover (mech. - Renew
X X Seal) wrongly fitted, incorrect - Correct
packing material - Renew gland packing
- Check flushing / sealing liquid pressure
- Clean sealing liquid line, possibly introduce sealing liquid from an
Lack of cooling liquid or cooling external source or increase its pressure
X X liquid chamber contaminated
- Increase flow cooling liquid
- Clean cooling liquid
- Re-align pump / drive machines
Pump mis-aligned or there are - Check piping connections and pump mounting, if necessary
X X
resonance vibrations in the piping improve mounting of piping
- Apply vibration – damping measures
- Check duty point / layout
X Excessive axial thrust - Check mode of operation
- Check suction flow
- Clean bearing
Too little, too much or unsuitable
X - Renew lubricant
lubricant
- Top up reduce or change lubricant
- Renew detective fuses

X X X X Running on two phases - Check electrical connections
- Check switchgear
- Clean rotor
X X X Rotor imbalance - Check rotation re-align necessary
- Re-balance rotor
X X X Bearings damaged - Renew / change
- Re-adjust duty point
- Fully open shut-off valve in the suction / intake pipe
X X Flow capacity too low
- Fully open shut-off valve in the discharge pipe
- Recalculate or measure the hydraulic losses Hv
In star / delta operation motor - Check electrical connections
X X
sticks at star stage - Check switchgear
Inadmissible air or gas content in - Vent
X X X
liquid - Check integrity of suction pipe seal if necessary
- Reduce flow velocity at suction pipe entry
X X X X X Air drawn in at pump inlet - Increase suction head
- Check integrity of suction pipe and seal if necessary
- Renew defective pipes
- Check mode of operation
X Cavitation (ratting noise)
- Increase suction head
- Install pump at a lower level
- Check’
X X Foundation not rigid enough
- Alter
- Re-adjust duty point
X X X X X Inadmissible parallel operation
- Alter pump characteristicH1
X X Seal is out of true - Renew / change
- Check rotor
X X X X Impeller fouls casing components - Check impeller position
- Check that the piping is connected free of stress
- 15 -
1) Consult Regent Pumps
7.0 Routine maintenance and inspections intervals
Number of
Interval personnel Time (h) Maintenance job
required
- Check leakage on mechanical seal or leakage of

Daily 1 1/10 packed gland (see operating instructions "Shaft
seal")
- Check pump operation (positive suction pressure,

Weekly 1 1/4 total head, bearing temperature, noises and
vibrations)
- Check twist play of coupling (see operating

Monthly 1 1/4 instructions "Coupling") - If available, switch to stand-
by pump or carry out a test run (for 5 min.)
every 20,000 - Renew deep-groove ball bearings, (see operating

2 3
operating hours instruction)
- General inspection and overhaul of pump in

accordance with the operating instructions Check and
every 4 years or if renew, if required:
total head of pump 2 6
drops - wear parts such as: bearings, casing wear rings
(impeller wear rings, if provided), shaft sleeves
- impeller and shaft
- 16 -
SARAWAK (O&M)
3.7
EXHAUST FAN
INSTALLATION & MAINTENANCE GUIDEBOOK
Fan Series: CD / Direct Drive CABINET FAN
1. Purpose and Use of manual
The safety recommendations contained herein aim to support the installer, maintenance engineers and
other technicians who operate the ventilation equipment as listed above. These recommendations cannot
represent totally the methods or procedures required for safe operation. Care should always be taken
when working in close proximity to equipment or moving parts. Total safety depends on acquired skill,
experience and reasonable care in all operations
2. Technical Description and Characteristics of the CD Fan
The CD fan series construction consists of a Direct Drive Fan installed inside the fan cabinet. The cabinet
comes with a detachable access door at the base of the cabinet. This access door provides an access to the
direct driven fan (DD fan) for maintenance and troubleshoots purpose. The DD fan can also be
dismounted from the cabinet by removing the screw that secure the fan to the cabinet; if necessary.
The DD fan is suitable for handling non-toxic, non-flammable, non-corrosive air, without liquid, solid or
abrasive particles. Air temperature should not exceed 40°C. The fan should only be connected to an
electrical supply having the characteristics indicated on the label.
3. Installation
a) Check for any damaged or missing parts.

b) Check whether the impeller turns freely, that it is not unbalanced excessively, and there is no
play in the shaft.
c) The hangers on the cabinet fan provide the mean for ceiling mounting. The fan must be installed
with the motor shaft horizontal.
d) Connect the fan according to the wiring diagram illustrated on the fan label. Check that the
voltage of the electrical supply for testing is not higher than that shown on the fan label.
e) During testing the fan, make sure that the rotation of the fan is as shown by the arrow on the fan
housing, and that the electrical current input does not exceed that shown on the label.
f) Connect the ducting, if needed, to the inlet and outlet spigots provided on the cabinet.
4. Maintenance
Disconnect the electrical power supply before working on the fan unit.
Periodically check (at least once a year or more frequently if the characteristics of the air stream required)
that there are no obstructions and, if necessary, clean the passages and blades of the fan blower wheel.
Any dust particular/ foreign body deposits on the fan blower wheel can cause wheel imbalance and may
subsequent has negative effect on the fan motor bearing life and on vibration and noise levels.
In addition check that the fan does not show any sign of deformation or breakage and that the screws of
fixing nuts protection are tightly screwed.
The cleaning of the fan blower wheel can be done by access through the inspection door. If the
maintenance work is performed from a ladder or other support, ensure a firm footing. If the fan is
connected to duct, precautions should be taken to avoid duct from fallout.
BK-01/CD01-1
INSTALLATION & MAINTENANCE GUIDEBOOK
Fan Series: CD / Direct Drive CABINET FAN
5. Trouble Shooting
Use the following table to solve possible problems that you may encounter when using the fan. If further
assistance is necessary, refer to Nicotra for information on technical service.
Trouble Suggested Action
The fan does not work 1) Make sure that the wiring connection has been followed correctly,
all the wires are connected and that the circuit is live.
2) Make sure that the applied voltage is correct for the wiring
configuration of the motor.
3) Make sure that the power wiring is not earthed nor that any wire is
cut (in this case, replace motor or accessory wiring).
The fan rotates backwards 1) Make sure that the wiring diagram has been followed correctly.
2) Check that the rotation of the motor is the same as indicated on the
fan (if not, replace motor).
The fan draws more than the 1) Make sure that the wiring diagram has been followed correctly
rated current 2) Check that the pressure loss of the fan is not less than the design
value (if so, modify pressure loss).
The fan vibrates excessively 1) Make sure that all mechanical connections are tight and that the
or is too noisy blower wheel is mounted securely on the motor shaft, and is
positioned in the center of the fan housing (if not, tighten the
mechanical elements).
2) Check that the blower wheel is not deformed (if so, replace the
wheel).
3) Make sure that there is no accumulation of dust or grease on
impeller blades (if so, clean and rebalance the wheel).
4) Check whether the noise is due to fan vibrations or from the motor
(in the second case, replace the motor).
The fan does not give the 1) Make sure that the applied voltage is correct for the wiring
required performance configuration of the motor.
2) Make sure that the wheel orientation is correct (if not, replace the
wheel).
3) Verify that the fan is connected to the correct rotational speed
specified, for multi-speed motors.
4) Verify that the pressure loss of the fan is not greater than the design
value (if it is, modify the pressure loss).
NICOTRA reserves the right to improve or modify details/accessories without any obligation to update previous
production and manuals.
BK-01/CD01-2
I NSTALLATI ON, OPERATION
& M AINTENANGE M ANUAL
. ADT . ADTA . ADF . ADB . ABE . ARD.

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SARAWAK (O&M)
4.0
LIST OF EQUIPMENT INSTALLATION & SPARES
SARAWAK (O&M)
4.1
LIST OF EQUIPMENT INSTALLED
CADANGAN UNIVERSITI TEKNOLOGI MARA (UITM), KAMPUS MUKAH, DI ATAS SEBAHAGIAN LOT 35, BLOK 99, MUKAH LAND DISTRICT, MUKAH DIVISION, SARAWAK
SCHEDULE OF CHILLER – CENTRAL UTILITY PLANT
Description Brand Model Type Total Cooling Capacity (Tons) Refrigerant
Chiller No. 3 Carrier 19XR4647385KG52 Water Cooled Centrifugal Liquid Chiller (Standby) 550 R134a
Chiller No. 4 Carrier 30HXC260 Water Cooled Multiple Screw Compressor Liquid Chiller 250 R134a
SCHEDULE OF COOLING TOWER – CENTRAL UTILITY PLANT
Description Brand Model Type Total Cooling Capacity
SCHEDULE OF PUMPS – CENTRAL UTILITY PLANT
Description Brand Model Type Capacity
Fan Total
Total Fan Fluid
AHU Marking Model Cooling Motor Flow
w.g)
Block 1 Pentadbiran
B1-L1-AHU-1 39G0912 30 1767 2.3 3 2 1/2" 2 1/2" 1" 1.28 1450 1250 1050 258
B1-L1-AHU-2 39G1621 86 5590 2.5 7.5 3" 3" 1" 3.69 1950 2150 1750 813
B1-L2-AHU-1 39G1621 96 5910 2.6 11 3" 3" 1" 4.14 1950 2150 1750 873
B1-L2-AHU-2 39G1621 114 6717 3.1 11 3" 3" 1" 4.89 1950 2150 1750 883
B1-L2-AHU-3 39G1621 115 6669 2.8 11 3" 3" 1" 4.94 1950 2150 1750 900
Block 2 Perpustakaan
B2-L1-AHU-1 39G1822 174 7942 2.4 11 3" 3" 1" 7.47 2100 2250 1950 1080
B2-L2-AHU-1 39G2230 286 13686 2.9 30 3" 3" 1" 12.28 2400 3050 2350 1831
Block 3 Dewan Peperiksaan
B3-L1-AHU-1 39G1825 237 8870 2.7 15 3" 3" 1" 10.17 2100 2550 1950 1213
B3-L1-AHU-2 39G1825 237 8870 2.7 15 3" 3" 1" 10.17 2100 2550 1950 1213
Block 4a Fakulti Perladangan & Agroteknologi
B4a-L1-AHU-1 39G0914 237 2150 2.3 4 2 1/2” 2 1/2” 1" 2.33 1450 1450 1050 288
B4a-L1-AHU-2 39G0914 237 2150 2.2 4 2 1/2” 2 1/2” 1" 2.33 1450 1450 1050 288
B4a-L1-AHU-3 39G1015 54 2297 2.1 3 2 1/2” 2 1/2” 1" 2.72 1550 1550 1150 412
B4a-L1-AHU-4 39G1015 54 2297 2.0 3 2 1/2” 2 1/2” 1" 2.72 1550 1550 1150 412
B4a-L2-AHU-1 39G0914 63 2150 2.3 4 2 1/2” 2 1/2” 1" 2.33 1450 1450 1050 288
B4a-L2-AHU-2 39G0914 63 2150 2.2 4 2 1/2” 2 1/2” 1" 2.33 1450 1450 1050 288
B4a-L2-AHU-3 39G1015 54 2297 2.1 3 2 1/2” 2 1/2” 1" 2.72 1550 1550 1150 412
B4a-L2-AHU-4 39G1015 54 2297 2.0 3 2 1/2” 2 1/2” 1" 2.72 1550 1550 1150 412
B4a-L3-AHU-1 39G0914 63 2150 2.2 4 2 1/2” 2 1/2” 1" 2.33 1450 1450 1050 288
B4a-L3-AHU-2 39G0914 63 2150 2.3 4 2 1/2” 2 1/2” 1" 2.33 1450 1450 1050 288
Fan Total
Total Fan Fluid
AHU Marking Model Cooling Motor Flow
w.g)
B4a-L3-AHU-3 39G1015 54 2297 2.0 3 2 1/2” 2 1/2” 1" 2.81 1550 1550 1150 406
B4a-L3-AHU-4 39G1015 54 2297 2.0 3 2 1/2” 2 1/2” 1" 2.81 1550 1550 1150 406
Block 4b Fakulti Sains Gunaan
B4b-L1-AHU-1 39G1015 59 2,441 1.6 3 2 1/2” 2 1/2” 1" 2.56 1550 1550 1150 401
B4b-L1-AHU-2 39G0912 40 1,779 1.9 3 2 1/2” 2 1/2” 1" 1.72 1450 1250 1050 273
B4b-L1-AHU-3 39G0914 48 2,168 1.8 3 2 1/2” 2 1/2” 1" 2.06 1450 1450 1050 308
B4b-L1-AHU-4 39G0914 48 2,168 1.8 2.2 2 1/2” 2 1/2” 1" 2.06 1450 1450 1050 308
B4b-L2-AHU-1 39G0914 97 2,098 1.7 3 2 1/2” 2 1/2” 1" 4.17 1450 1450 1050 281
B4b-L2-AHU-2 3951015 58 2,266 1.5 2.2 2 1/2” 2 1/2” 1" 2.5 1550 1550 1150 401
B4b-L2-AHU-3 39G1015 67 2,450 1.8 3 2 1/2” 2 1/2” 1" 2.89 1550 1550 1150 417
B4b-L2-AHU-4 39G1015 65 2,282 1.7 3 2 1/2” 2 1/2” 1" 2.81 1550 1550 1150 417
B4b-L3-AHU-1 39G0914 55 2,139 2.0 4 2 1/2” 2 1/2” 1" 2.36 1450 1450 1050 288
B4b-L3-AHU-2 39G1015 55 2,421 1.8 3 2 1/2” 2 1/2” 1" 2.39 1550 1550 1150 406
B4b-L3-AHU-3 39G1015 68 2,519 2.1 4 2 1/2” 2 1/2” 1" 2.92 1550 1550 1150 424
B4b-L3-AHU-4 39G1015 61 2,207 1.8 3 2 1/2” 2 1/2” 1" 2.64 1550 1550 1150 412
Block 5 Dewan Kuliah
B5-L1-AHU-1 39G1418 108 4,607 2.5 7.5 3" 3" 1" 4.67 1750 1850 1550 710
B5-L1-AHU-2 39G1621 139 5,627 2.4 7.5 3" 3" 1" 5.97 1950 2150 1750 862
Block 7/8/9 Unit Keselamatan
B8-L1-AHU-1 39G1418 76 4,526 2.1 5.5 3" 3" 1" 3.25 1750 1850 1550 671
B9-L1-AHU-1 39G1317 68 3,856 2.2 5.5 3" 3" 1" 2.92 1750 1750 1450 615
Fan
Total
Total Fan Fluid
Cooling Airflow Water Water Drain Length Width Height Weight
FCU Marking Model Static Motor Flow
Cap (l/s) Inlet Outlet Pipe (mm) (mm) (mm) (Kg)
(Inch (kW) Rate, L/s
(kW)
w.g)
Block 1 Pentadbiran
B1-L1-FCU-1 42CET003 3.07 140 0.015 32W 3/4”FPT 3/4”FPT 3/4”MPT 0.13 770 557 242 21.5
B1-L2-FCU-1 42CET006 4.79 282 0.015 72W 3/4”FPT 3/4”FPT 3/4”MPT 0.2 1170 557 242 30
B2-L1-FCU-1 40LM070 21.6 900 0.6 0.9 1” 1” 3/4” 0.86 680 1200 480 95
B2-L2-FCU-1 42CET003 3.1 137 0.015 32W 3/4”FPT 3/4”FPT 3/4”MPT 0.13 770 557 242 21.5
B3-L1-FCU-1 42CET010 7.9 472 0.015 70wx2 3/4"FPT 3/4"FPT 3/4"MPT 0.34 1530 557 242 45
B3-L1-FCU-2 42CET003 3.1 111 0.015 32w 3/4"FPT 3/4"FPT 3/4"MPT 0.13 770 557 242 21.5
B4a-L1-FCU-1 42CET003 3.1 79 0.015 32w 3/4"FPT 3/4"FPT 3/4"MPT 0.13 770 557 242 21.5
B4a-L1-FCU-2 40LM060 18.4 737 0.5 0.82 1" 1" 3/4" 1.1 680 1000 480 72
B4a-L1-FCU-3 40LM060 18.4 565 0.5 0.82 1" 1" 3/4" 1.1 680 1000 480 72
B4a-L1-FCU-4 40LM060 18.4 677 0.5 0.82 1" 1" 3/4" 1.1 680 1000 480 72
B4a-L1-FCU-5 40LM070 21.6 957 0.6 0.9 1" 1" 3/4" 0.86 680 1200 480 95
B4a-L1-FCU-6 40LM070 21.6 957 0.6 0.9 1" 1" 3/4" 0.86 680 1200 480 95
B4a-L1-FCU-7 42CET004 4.0 152 0.015 45w 3/4"FPT 3/4"FPT 3/4"MPT 0.17 890 557 242 25
Fan
Total
Total Fan Fluid
(kW)
w.g)
B4a-L2-FCU-6 42CET010 7.9 371 0.015 70wx2 3/4"FPT 3/4"FPT 3/4"MPT 0.34 1530 557 242 45
B4a-L2-FCU-12 40LM050 14.2 428 0.5 0.55 1" 1" 3/4" 0.83 680 1000 480 70
B4a-L2-FCU-13 40LM060 18.4 677 0.5 0.82 1" 1" 3/4" 1.1 680 1000 480 72
B4a-L2-FCU-14 40LM090 29.1 949 0.6 1.43 1" 1" 3/4" 0.43 680 1200 480 100
B4a-L2-FCU-15 40LM090 29.1 949 0.6 1.43 1" 1" 3/4" 0.43 680 1200 480 100
Fan
Total
Total Fan Fluid
(kW)
w.g)
B4a-L3-FCU-12 40LM050 14.2 428 0.5 0.55 1" 1" 3/4" 0.83 680 1000 480 70
B4a-L3-FCU-13 40LM060 18.4 677 0.5 0.82 1" 1" 3/4" 1.1 680 1000 480 72
B4a-L3-FCU-14 40LM090 29.1 949 0.6 1.43 1" 1" 3/4" 0.43 680 1200 480 100
B4a-L3-FCU-15 40LM090 29.1 949 0.6 1.43 1" 1" 3/4" 0.43 680 1200 480 100
B4b-L1-FCU-1 40LM090 29.1 978 0.6 1.43 1" 1" 3/4" 0.43 680 1200 480 100
B4b-L1-FCU-2 40LM060 18.4 590 0.5 0.82 1" 1" 3/4" 1.1 680 1000 480 72
B4b-L1-FCU-3 40LM090 29.1 1,140 0.6 1.43 1" 1" 3/4" 0.43 680 1200 480 100
B4b-L1-FCU-4 40LM060 18.4 873 0.5 0.82 1" 1" 3/4" 1.1 680 1000 480 72
B4b-L2-FCU-1 42CET008 7.3 377 0.015 55wx2 3/4"FPT 3/4"FPT 3/4"MPT 0.31 1410 557 242 41
B4b-L2-FCU-2 42CET005 4.3 212 0.015 70w 3/4"FPT 3/4"FPT 3/4"MPT 0.19 970 557 242 25.6
Fan
Total
Total Fan Fluid
(kW)
w.g)
B4b-L2-FCU-12 40LM060 18.4 780 0.5 0.82 1" 1" 3/4" 1.1 680 1000 480 72
B4b-L2-FCU-13 40LM060 18.4 461 0.5 0.82 1" 1" 3/4" 1.1 680 1000 480 72
B4b-L2-FCU-14 40LM070 21.6 949 0.6 0.9 1" 1" 3/4" 0.86 680 1200 480 95
B4b-L2-FCU-15 40LM070 21.6 949 0.6 0.9 1" 1" 3/4" 0.86 680 1200 480 95
B4b-L3-FCU-12 40LM060 18.4 780 0.5 0.82 1" 1" 3/4" 1.1 680 1000 480 72
B4b-L3-FCU-13 40LM060 18.4 461 0.5 0.82 1" 1" 3/4" 1.1 680 1000 480 72
B4b-L3-FCU-14 40LM070 21.6 949 0.6 0.9 1" 1" 3/4" 0.86 680 1200 480 95
Fan
Total
Total Fan Fluid
(kW)
w.g)
B4b-L3-FCU-15 40LM070 21.6 949 0.6 0.9 1" 1" 3/4" 0.86 680 1200 480 95
Block 4c Fakulti Pengurusan Perniagaan
B4c-L1-FCU-1 42CET008 7.3 800 0.015 55wx2 3/4"FPT 3/4"FPT 3/4"MPT 0.31 1410 557 242 41
B4c-L1-FCU-5 42CET003 3.1 300 0.015 32w 3/4"FPT 3/4"FPT 3/4"MPT 0.13 770 557 242 21.5
B4c-L1-FCU-19 40LM060 18.4 1,758 0.5 0.82 1" 1" 3/4" 1.1 680 1000 480 72
B4c-L1-FCU-20 40LM060 18.4 1,758 0.5 0.82 1" 1" 3/4" 1.1 680 1000 480 72
B4c-L1-FCU-21 40LM090 29.1 2,712 0.6 1.43 1" 1" 3/4" 0.43 680 1200 480 100
Fan
Total
Total Fan Fluid
(kW)
w.g)
B4c-L1-FCU-22 40LM090 29.1 2,712 0.6 1.43 1" 1" 3/4" 0.43 680 1200 480 100
B4c-L1-FCU-23 40LM090 29.1 2,712 0.6 1.43 1" 1" 3/4" 0.43 680 1200 480 100
B4c-L1-FCU-24 40LM090 29.1 2,712 0.6 1.43 1" 1" 3/4" 0.43 680 1200 480 100
B4c-L1-FCU-25 40LM090 29.1 2,712 0.6 1.43 1" 1" 3/4" 0.43 680 1200 480 100
B4c-L1-FCU-26 40LM090 29.1 2,712 0.6 1.43 1" 1" 3/4" 0.43 680 1200 480 100
B4c-L1-FCU-27 40LM060 18.4 1,758 0.5 0.82 1" 1" 3/4" 1.1 680 1000 480 72
B4c-L1-FCU-28 40LM060 18.4 1,758 0.5 0.82 1" 1" 3/4" 1.1 680 1000 480 72
B4c-L1-FCU-29 40LM060 18.4 1,758 0.5 0.82 1" 1" 3/4" 1.1 680 1000 480 72
B4c-L1-FCU-30 40LM060 18.4 1,758 0.5 0.82 1" 1" 3/4" 1.1 680 1000 480 72
Fan
Total
Total Fan Fluid
(kW)
w.g)
18.05NP
B4c-L2-FCU-19 40LM120 35.2 3,475 0.7 1.83 25.4 0.43 0.43 680 1600 480 120
T (MPT)
B4c-L2-FCU-20 40LM090 29.1 2,712 0.6 1.43 1" 1" 3/4" 0.43 680 1200 480 100
B4c-L2-FCU-21 40LM090 29.1 2,712 0.6 1.43 1" 1" 3/4" 0.43 680 1200 480 100
B4c-L2-FCU-22 40LM090 29.1 2,712 0.6 1.43 1" 1" 3/4" 0.43 680 1200 480 100
B4c-L2-FCU-23 40LM090 29.1 2,712 0.6 1.43 1" 1" 3/4" 0.43 680 1200 480 100
B4c-L2-FCU-24 40LM090 29.1 2,712 0.6 1.43 1" 1" 3/4" 0.43 680 1200 480 100
B4c-L2-FCU-25 40LM090 29.1 2,712 0.6 1.43 1" 1" 3/4" 0.43 680 1200 480 100
B4c-L2-FCU-26 40LM060 18.4 1,758 0.5 0.82 1" 1" 3/4" 1.1 680 1000 480 72
B4c-L2-FCU-27 40LM060 18.4 1,758 0.5 0.82 1" 1" 3/4" 1.1 680 1000 480 72
B4c-L2-FCU-28 40LM060 18.4 1,758 0.5 0.82 1" 1" 3/4" 1.1 680 1000 480 72
B4c-L2-FCU-29 40LM060 18.4 1,758 0.5 0.82 1" 1" 3/4" 1.1 680 1000 480 72
B7-L2-FCU-1 40LM070 21.6 923 0.6 0.9 1" 1" 3/4" 0.86 680 1200 480 95
B7-L2-FCU-3 42CET004 4.0 179 0.015 45w 3/4"FPT 3/4"FPT 3/4"MPT 0.17 890 557 242 25
B7-L2-FCU-4 40LM040 11.6 603 0.4 0.57 1" 1" 3/4" 0.65 680 1000 480 68
Fan
Total
Total Fan Fluid
(kW)
w.g)
Block 20 Kafeteria
50.8 50.8 3/4"
B20-FCU-1 40LM200 58.3 7,203 0.8 3 2.25 784 1651 1541 230
MPT MPT MPT
50.8 50.8 3/4"
B20-FCU-2 40LM200 58.3 7,203 0.8 3 2.25 784 1651 1541 230
MPT MPT MPT

DESIGN
EXHAUST FAN SPEED EXTERNAL WATTAGE
TYPE AIRFLOW V/PH/Hz FAN DIA. BRAND MODEL
TAG NO. (RPM) STATIC (Pa) (w)
(l/s)
Block 1 Pentadbiran
B2-L1-EF-1 WALL MOUNTED 386 1301 FREE 18.3 240/1/50 200mm KDK 20 AQM8
B2-L1-EF-2 CABINET FAN 218 700 (L) 70 147 240/1/50 200mm NICOTRA CD 200
B2-L1-EF-3 CABINET FAN 178 1200 (H) 70 92 240/1/50 180mm NICOTRA CD 180
B2-L2-EF-1 CABINET FAN 178 1200 (H) 70 92 240/1/50 180mm NICOTRA CD 180
B2-L2-EF-2 CABINET FAN 218 700 (L) 70 147 240/1/50 200mm NICOTRA CD 200
B4a-L1-EF-1 IN LINE DUCT FAN 359 1120 (H) 80 147 240/1/50 200mm NICOTRA CD 200
DESIGN
(l/s)
DESIGN
(l/s)
Zone 3 – Pejabat Pusat Akuakultur & Unit Perladangan
Zone 3 – Pusat Hatcheri
B4a-b-EF-1 WALL MOUNTED 215 1109-1301 FREE 18.3 240/1/50 200mm KDK 20 AQM8
Zone 3 – Bengkel Kejuruteraan Akuatik & Depo
Zone 3 – Makmal Diagnostic
Zone 3 – Kemudahan Sokongan Akademik/ Penyelidikan – Pusat Jual Hasil & Stor
DESIGN
(l/s)
B4b-L1-EF-6 IN-LINE DUCT FAN 210 700 (H) 80 147 240/1/50 200mm NICOTRA CD 200
DESIGN
(l/s)
Block 4c Fakulti Pengurusan Perniagaan
Block 5 Dewan Kuliah
DESIGN
(l/s)
B9-L1-EF-1 IN LINE DUCT FAN 218 700 (L) 70 147 240/1/50 200mm NICOTRA CD 200
Block 13 Medan Selera
Block 15 Surau
Block 16 CITU
DESIGN
(l/s)
Block 17 Rumah Tetamu
Block 18 Pejabat Pengurusan Kolej
Block 20 Kafeteria
DESIGN
(l/s)
B20-GF-KEF-1 CENTRIFUGAL 4000 1183 400 4000 240/1/50 630mm NICOTRA RSH 630R c/w Drivepak
Central Utility Plant
CUP-EF-1 AXIAL FAN 3300 1440 130 1500 415/3/50 560mm NICOTRA ADT 560/160/10B/35/ALU
CUP-EF-2 AXIAL FAN 3300 1440 130 1500 415/3/50 560mm NICOTRA ADT 560/160/10B/35/ALU
Block G Pondok Pengawal
GH-EF-1 WALL MOUNTED 63 1109-1301 FREE 18.3 240/1/50 200mm KDK 20 AQM8
Substation
SCHEDULE OF SPLIT UNIT TYPE

Pipe Size
A/C Split Unit Tag No. Type Model Cooling Capacity (kW) CFM

B4a-A/C-1 WALL MOUNT 38KCV212/42KCV212 3.5 360 *1/4 *1/2 15.7mm
Zone 3 – Pejabat Pusat Akuakultur & Unit Perladangan
B4a-a-A/C-1 WALL MOUNT 38KCV209/42KCV209 2.6 295 *1/4 *3/8 15.7mm
B4a-a-A/C-3 CEILING 38VTA040/42XQ040 11.7 980 *3/8 *3/4 21mm
B4a-a-A/C-4 CEILING 38VTA040/42XQ040 11.7 980 *3/8 *3/4 21mm
B4a-a-A/C-10 CEILING 38CSR024/42XQ025 7.3 780 *3/8 *5/8 21mm
B4a-a-A/C-11 CASSETTE 38FN024/42TNC024 7 718 *3/8 *5/8 32mm
Zone 3 – Pusat Pemprosesan
B4a-c-A/C-1 WALL MOUNT 38KCV209/42KCV209 2.6 295 *1/4 *3/8 15.7mm
B4a-c-A/C-2 CEILING EXPOSED 38VTA060/42XQ060 17.6 1300 *3/8 *3/4 21mm
Pipe Size

Zone 3 – Bengkel Kejuruteraan Akuatik & Depo
B4a-d-A/C-1 WALL MOUNT 38KCV209/42KCV209 2.6 295 *1/4 *3/8 15.7mm
Zone 3 – Makmal Diagnostic
B4a-e-A/C-1 WALL MOUNT 38KCV209/42KCV209 2.6 295 *1/4 *3/8 15.7mm
B4a-e-A/C-4 CEILING 38VTA040/42XQ040 11.7 980 *3/8 *3/4 21mm
Zone – 3 Kemudahan Sokongan Akademik / Penyelidikan – Pusat Jual Hasil & Stor
B4a-g-A/C-1 WALL MOUNT 38KCV209/42KCV209 2.6 295 *1/4 *3/8 15.7mm
B4a-g-A/C-9 CEILING 38VTA040/42XQ040 11.7 980 *3/8 *3/4 21mm
Pipe Size
B4a-g-A/C-11 CEILING 38VTA040/42XQ040 11.7 980 *3/8 *3/4 21mm

B4b-A/C-1 CEILING 38VTA040/42XQ040 11.7 980 *3/8 *3/4 21mm
B4b-A/C-7 WALL MOUNT 38KCV212/42KCV212 3.5 360 *1/4 *1/2 15.7mm
B8-A/C-1 CEILING 38VTA040/42XQ040 11.7 980 *3/8 *3/4 21mm
B9-A/C-1 WALL MOUNT 38KCV209/42KCV209 2.6 295 *1/4 *3/8 15.7mm
Block 13 Medan Selera
B13-L1-A/C-1 WALL MOUNT 38KCV209/42KCV209 2.6 295 *1/4 *3/8 15.7mm
B13-L2-A/C-1 CEILING 38VTA040/42XQ040 11.7 980 *3/8 *3/4 21mm
B13-L2-A/C-5 CEILING 38CSR018/42XQ025 6.4 780 *1/4 *1/2 21mm
Pipe Size
Block 15 Surau
Block 16 CITU
B16-L1-A/C-4 CASSETTE 38FN033/42TNC033 9.7 971 *3/8 *3/4 32mm
Block 17 Rumah Tetamu
Pipe Size

Block 18 Pejabat Pengurusan Kolej
B18-L1-A/C-5 CASSETTE 38FN045/42TNC045 13.2 971 *3/8 *3/4 32mm
Block G Pondok Pengawal
GH-A/C-1 WALL MOUNT 38KCV212/42KCV212 3.5 360 *1/4 *1/2 15.7mm
SARAWAK (O&M)
4.2
SPARE PARTS
38KCD209
No. Part Name Quantity Remark
1 Rear net 1
2 Condenser assembly 1
3 Valve plate 1
10.1 Air outlet grille 1
10.2 Front panel 1
13 Axial flow fan 1
14 Asynchronous motor 1
18 Capacitor clip 1
19 Capacitor of compressor 1
22 Fan motor capacitor 1
23 Gas valve assembly 1
23.1 Gas valve 1
24 Liquid valve assembly 1
24.1 Liquid valve 1
25 Compressor 1
38KCD212
序号零部件名称数量备注
2 Condenser assembly 1
3 Valve plate 1
7 Water collector 1
10 Front panel assembly 1
10.1 Air outlet grille 1
10.2 Front panel 1
13 Axial flow fan 1
15 Supporter assembly of fan motor 1
18 Capacitor clip 1
19 Capacitor of compressor 1
21 Supporting board 1
22 Fan motor capacitor 1
23 Gas valve assembly 1
23.1 Gas valve 1
24 Liquid valve assembly 1
24.1 Liquid valve 1
25 Compressor 1
42KCD212
1 Panel assembly 1
2 Air filter 2
3.1 Display board assembly 1
4 Cover of indoor electronic control box 1
5 Panel frame assembly 1
9 Evaporator assembly 1
10 Fan motor cover 1
12 Bearing holder 1
13 Bearing base 1
14 Cross flow fan 1
15 Horizontal louver 1
16.1 Louver motor 1
17 Pipe clamp board 1
19.3 Main control board assembly 1
19.4 Ambient temperature sensor assembly 1
19.5 Pipe temperature sensor assembly 1
19.7 Transformer 1
21 Remote Controller 1
23 Drain joint 1
24 Air freshening filter 1

42KCD209808
1 Panel assembly 1
2 Air filter 2
3 Display box assembly 1
3.1 Display board assembly 1
5 Panel frame assembly 1
5.1 Screw cap 2
6 Drain hose 1
9 Evaporator assembly 1
10 Fan motor cover 1
12 Bearing holder 1
13 Bearing base 1
14 Cross flow fan 1
15 Horizontal louver 1
16 Chassis assembly 1
16.1 Louver motor 1
19 Electronic control box assembly 1
19.3 Main control board assembly 1
19.4 Ambient temperature sensor assembly 1
19.5 Pipe temperature sensor assembly 1
19.7 Transformer 1
21 Remote Controller 1
22 Seal 1
23 Drain joint 1
24 Air freshening filter 1

Carrier
International
42XQ/XQA
SPECIFIED 020 to 060 (50Hz)
PARTS
Sdn Bhd (3385-T) ---71125 SERIES
INTRODUCTION
This catalogue presents the most commonly used replacement parts for the standard
42XQ (Wireless remote control) / 42XQA (Wired remote control)
Underceiling/Console Fan Coil Unit and is not applicable to special units.
The illustration are for reference only and the actual parts for a particular unit may
look different from that shown in the illustrations.
ORDERING INSTRUCTIONS
A. All orders and inquiries should include the complete model and serial number
of the unit on which the parts are to be used, and the part number and
description of each part.
B. Dealers should forward orders to their Carrier distributor.
C. Distributor should forward orders to:
CARRIER INTERNATIONAL SDN BHD

Lot 4, Jalan P/6
43650 Bandar Baru Bangi
Selangor Darul Ehsan
Malaysia
Tel: 603-8925 8001
Fax: 603-8925 3578
GENERAL NOTES
1. Casing parts and panels are not normally stocked, but are available upon
request while in production. Requests for casing parts and panels for units
no longer in production must be cleared through Carrier International Sdn Bhd
for availability prior to submitting an order.
Certain parts are omitted in the interest of simplicity as orders for them are
infrequent that a simple description of parts, plus the model and serial
number of the unit will be acceptable.
2. The replacement parts listed in this catalogue are "Carrier Specified Parts"
and as a result of "standardization", may not be identical to the original part
furnished on the equipment.
SUPERCEDES
FORM: 42XQ-1-SPC FORM: 42XQ-2-SPC
DATE: 18 Aug 2006 DATE: 03 Mar 2009
PAGE: 1 of 5 PAGE : 1 of 5
Carrier
International
42XQ/XQA
PARTS Sdn Bhd (3385-T) ---71125 SERIES
Exploded view of a typical 42XQ/XQA unit
SUPERCEDES
Carrier
International
42XQ/XQA
Sdn Bhd (3385-T)
PARTS ---71125 SERIES
SPARE PARTS LIST
42XQ/XQA
Item Part Name Part No. 020 025 030 040 050 060
CASING GROUP - SHEET METAL PARTS
1 Fan Deck 38801392 1 1
38801394 1 1
38801395 1 1
2 Mounting Bracket 28801108 2 2 2 2 2 2
3 Panel Front 38801385 1 1
38801386 1 1
38801387 1 1
4 Panel Back 38801388 1 1
38801390 1 1
38801391 1 1
5 Structural Union 38801400 1 1 1 1 2 2
CASING GROUP - PLASTIC PARTS & FORM
6 Air Intake - Small 13704287 2 2 1 1
- Large 13704288 2 2 2 2
7 Air Filter - Small 13801115 2 2 1 1
- Large 13801116 2 2 2 2
8 Coil Insulation Right EPS 46618181 1 1 1 1 1 1
9 Coil Insulation Left EPS 46618190 1 1 1 1 1 1
10 Drain Hose 43170000 1 1 1 1 1 1
11 Drain Pan 06701074 1 1
06701075 1 1
06701076 1 1
12 End Cap Right 13704285 1 1 1 1 1 1
13 End Cap left 13704286 1 1 1 1 1 1
14 Horizontal Louver 09305061 1 1
09305062 1 1
15 Horizontal Louver Right 09305063 1 1
16 Horizontal Louver Left 09305064 1 1
17 Left Internal Side Assy 05859238 1 1 1 1 1 1
18 Right Internal Side Assy 05859239 1 1 1 1 1 1
19 Upper Closure Assy. 05821148 1 1
05821147 1 1
05821146 1 1
SUPERCEDES
Carrier
International
42XQ/XQA
Sdn Bhd (3385-T)
SPARE PARTS LIST (cont')
42XQ/XQA
BLOWER WHEEL AND MOTOR GROUP
20 Blower Wheel 42819023 2 2 3 3 4 4
21 Fan Housing Top 08401052 2 2 3 3 4 4
22 Fan Housing Bottom 08401053 2 2 3 3 4 4
23 Motor HC020045W9550-25 1
HC020068W9650-25 1
HC020076W9850-25 1
HC020082W9950-25 1
HC020075W0250A25 1
HC020104W0350A25 1
24 Capacitor HC91CA030D006-25 1
HC91CA035D007-25 1
HC91CA040D008-25 1 1 1
HC91CA050D009-25 1
25 Shaft 43125002 1 1
26 Shaft (Left) 43125001 1 1
27 Shaft (Right) 43125000 1 1
28 Coupling 05801028 1 1 2 2
29 Bearing Assy. 05821132 (Inc item 30 to 32) 1 1 2 2
30 Bearing 05801029 1 1 2 2
31 Bearing Bracket 38801397 1 1 2 2
32 Bearing Housing 38801398 1 1 2 2
33 Motor Fastener 33702005 2 2 2 2 2 2
34 Motor Bracket 38801396 1 1 1 1 1 1
COIL AND TUBING GROUP
35 Assy, Complete Coil 42XQA420-007 1
(Inclusive item 36 to 41)
42XQA420-008 1
(Inclusive item 36 to 41)
42XQA420-009 1
(Inclusive item 36 to 38 & 42 to 44)
42XQA420-010 1
42XQA420-011 1
42XQA420-012 1
36 Nut Flare 3/8" DD02CA101 1 1 1 2
37 Coupling 3/8" DD08DA101 1 1 1 1
38 Cap, Flare Seal 3/8" DD21FA101 1 1 1 1
39 Nut Flare 5/8" DD02CA301 1 1 1 1
40 Coupling 5/8" DE08DA301 1 1 1 1
41 Cap, Flare Seal 5/8" DD21FA301 1 1 1 1
42 Nut Flare 3/4" DD02CA401 1 1
43 Coupling 3/4" DE08DA401 1 1
44 Cap, Flare Seal 3/4" DD21FA401 1 1
45 Body, Coupling EA52PK001 1 1 1
46 Cap EA52PL001-A---25 1 1 1
47 Accurator EA52PJ076---A-25 1
EA52PJ080---A-25 1
EA52PJ090---A-25 1
SUPERCEDES
Carrier
International
42XQ/XQA
Sdn Bhd (3385-T)
SPARE PARTS LIST (cont')
42XQ/XQA
CONTROL GROUP
48 Receiver 17701061 1 1 1 1 1 1
49 Receiver Label 11702388 1 1 1 1 1 1
52 Control Panel Assy. 42XQA440-008 1 1 1 1 1 1
(42XQ - wireless) (Inclusive item 54 to 61)
53 Control Panel Assy. 42XQA440-010 1 1 1 1 1 1
(42XQA - wired) (Inclusive item 54 to 61)
54 Control Panel Base 38801380 1 1 1 1 1 1
55 Control Panel Cover 42201070 1 1 1 1 1 1
56 PCB Assy with Harness HK42ARXQ-003A-25 1 1 1 1 1 1
(42XQ - wireless)
PCB Assy with Harness HK42AWXQA004A-25 1 1 1 1 1 1
(42XQA - wired)
- Main control unit (IR cool) 42XQA440-012 1 1 1 1 1 1
with 6+3 core cable
- LED display receiver board 42XQA440-013 1 1 1 1 1 1
- Receiver + LED display cable 42XQA440-014 1 1 1 1 1 1
(960mm)
- Room air sensor (500mm) 42XQA440-015 1 1 1 1 1 1
- Freeze up sensor (500mm) 42XQA440-016 1 1 1 1 1 1
- IR remote controller (wireless) 42XQA440-017 1 1 1 1 1 1
- Wired remote controller 42XQA440-018 1 1 1 1 1 1
57 Transformer 42XQA440-009 1 1 1 1 1 1
58 Terminal Block 42731210 1 1 1 1 1 1
59 Terminal Block Cover 42XQA504-001 1 1 1 1 1 1
60 Wire for Control Box 42XQA440-007 1 1 1 1 1 1
61 Stepper Motor 25904100 1 1 1 1 1 1
62 Stepper Motor Joint 38801381 1 1 1 1 1 1
Revised part no.
SUPERCEDES
SARAWAK (O&M)
5.0
SERVICE & MAINTENANCE
SARAWAK (O&M)
5.1
MAINTENANCE SCHEDULE
MAINTENANCE SCHEDULE FOR AIR CONDITIONING AND VENTILATION SYSTEMS (ACMV)
ITEM TASK DESCRIPTION FREQUENCY M1 M2 M3 M4 M5 M6 M7 M8 M9 M10 M11 M12
1 FAN COIL UNIT
a) Check for abnormal noise and vibration Quarterly √ √ √ √
b) Check dust filter Quarterly √ √ √ √

Clean dirt and dust on grille or panel by wiping with soft
c) Quarterly √ √ √ √
cloth
d) Check Casing Cleanliness Quarterly √ √ √ √
e) Check and clean condensate drain pipe Quarterly √ √ √ √
f) Check operation of thermostat Quarterly √ √ √ √
g) Check electrical connection Quarterly √ √ √ √
2 AIR HANDLING UNIT
a) Check for abnormal noise and vibration Quarterly √ √ √ √
b) Check dust filter Quarterly √ √ √ √

Clean dirt and dust on grille or panel by wiping with soft
c) Quarterly √ √ √ √
cloth
d) Check Casing Cleanliness Quarterly √ √ √ √
e) Check and clean condensate drain pipe Quarterly √ √ √ √
f) Check operation of thermostat Quarterly √ √ √ √

3 AIR COOLED SPLIT UNITS
a) Check outdoor unit of obstructions blocking condenser coil Quarterly √ √ √ √

Observe operation of unit checking for excessive noise &
b) Quarterly √ √ √ √
vibration
c) Cleaning condenser coil Quarterly √ √ √ √
d) Check & Clean dust filter Quarterly √ √ √ √
e) Check Condensate drain for blockages and flow Quarterly √ √ √ √
f) Check unit operating gas pressure Quarterly √ √ √ √
4 VENTILATION FAN
a) Check unit of obstructions blocking the fan Monthly √ √ √ √ √ √ √ √ √ √ √ √

Observe operation of unit checking for excessive noise &
b) Quarterly √ √ √ √
vibration
c) Check & Clean fan Quarterly √ √ √ √
d) Check electrical connection Quarterly √ √ √ √

5 CHILLER
a) Check and record the chiller's operating data Monthly √ √ √ √ √ √

Check the chiller's safety and operating controls to ensure
b) Monthly √ √ √ √ √ √
machine protection
Inspect the unit mounted control center - general cleaning
c) Monthly √ √ √ √ √ √
and tightening of connections
d) Check the lubrication system and oil level Monthly √ √ √ √ √ √
Check guide vane linkage operational condition to ensure
e) Monthly √ √ √ √ √ √
opened and closed at the correct position
Conduct leak test on chiller system and report to the owner
f) Monthly √ √ √ √ √ √
for any repairs and additional refrigerant top up required
g) Check and tighten bolts and nuts as and when necessary Monthly √ √ √ √ √ √
h) Ensure chiller cleanliness by clean with clean cloth Monthly √ √ √ √ √ √

SARAWAK (O&M)
5.2
SERVICE REPORT AND RECORDS
SARAWAK (O&M)
5.3
BREAKDOWN & MAINTENANCE CALL
Contact Information
Air Conditioning Contractor Contact Address

Tan Kok Sia No. 8, Lot 8236, Ground
Tan Air Conditioning & Engineering Sdn Bhd. 082-331609 Floor, Jalan Pending, 93450
016-8886600 Kuching, Sarawak
Equipment Brand Contact Address

Chiller Plant
Carrier (Malaysia) Sdn. L112, S58, Ground Floor,
Air Handling Unit
Carrier Bhd. Central Road East, 93300
Fan Coil Unit
082-429221 Kuching, Sarawak
Air-Cool Split Unit
Executive Suite 702, Block
Truwater Cooling Towers B, Kelana Business Centre,
Cooling Tower Truwater Sdn Bhd No.97, Jalan SS7/2, Kelana
03-78048112 Jaya, 47301 Petaling Jaya,
Selangor
188, Jalan Kip 6, Taman
Orchid Dynamics Sdn Bhd
Pump Regent Perindustrian Kip, 52200
03-62733053
Kuala Lumpur
Lot 850, Jalan Subang 7,
Kruvent Industries (M)
Taman Perindustrian
KDK Sdn Bhd
Subang, 47500 Subang
03-80743399
Exhaust Fan Jaya, Selangor
True Aire Technologies 21, Jln TPP 6/4, Taman
Nicotra Sdn Bhd Perindustrian Puchong,
03-80513550 47100 Puchong, Selangor
SARAWAK (O&M)
6.0
MANUFACTURER LITERATURE & CATALOGUES
SARAWAK (O&M)
6.1
MANUFACTURER LITERATURE & CATALOGUES:
CHILLER PLANT
SARAWAK (O&M)
6.2
AIR HANDLING UNIT
SARAWAK (O&M)
6.3
FAN COIL UNIT
SARAWAK (O&M)
6.4
AIR-COOL SPLIT UNIT
SARAWAK (O&M)
6.5
COOLING TOWER
SERIES COOLING TOWER
TX-S MULTI-CELL 100-2000 HRT COOLING CAPACITY
Modular Design Crossflow Type
LOW NOISE • SUPER LOW NOISE • ENERGY SAVING SUPER LOW NOISE
TX-S Series is an induced draft cross-flow, film
filled, FRP multi-cell rectangular cooling
tower designed for the equipment cooling,
industrial process cooling and air
conditioning applications.
The TX-S Series Cooling Tower is designed in

accordance to CTI & JCI standards. Its
design saves space, light weight, blends
easily with architectural designs and offers
low operating costs.
The thermal performance of TX-S Series is :: Jusco Melaka, 5000HRT

backed by full written guarantee. Field
performance test to CTI standards can be
carried out and witnessed by the owners
appointed inspection engineer to ensure the
supplied cooling tower meets the thermal
performance.
Truwater TX-S Series Cooling Tower meets

most design criteria in terms of economy,
extra low noise and space saving.
:: CSF Data Center, Cyberjaya, 3000HRT

Advantages
• Space Saving & Light Weight

Incorporating the high performance fill, the
installation space and operating weight are
greatly reduced.
• Energy Saving
The low speed, high efficiency fan and low
pressure drop fill design optimize the energy
consumption. :: Fuji Electric, Kulim, 6000HRT
• Low Noise level
The noise level is lowered by the specifically
designed low noise fan.
• Proven Corrosion Protection

Tower components are made of anti- corrosive
material suitable for cooling water application.
• Easy Hoisting or Crane Placement

The tower can be preassembled in the factory
for easy transport, lifting and site installation.
:: GB Building Singapore, 1140HRT
1
Features
:: Quill Interior Holding, PJ, 2100HRT
No Description Material / Specification

1 V-Belt and FRP Pulley Cover
Pulley System
2 Fan Assembly Aluminium Alloy
:: Kotra Pharma, Melaka, 1600HRT 3 Fan Stack FRP
4 Hot Water FRP

Distribution Box
5 Hot Water Basin FRP
6 High Performance Film Fill PVC

Pack and Drift Eliminator
7 Cold Water FRP

Basin Floor
8 Suction Sump FRP
9 Motor Weather Proof TEFC type
10 Ladder HDG Steel
11 Casing / Louver PVC

:: Tesco Tebrau, Johor, 1750HRT
12 Inspection Door FRP
13 Cold Water HDG Steel

Basin Frame
14 Internal Piping Optional
:: Sutera Mall, Johor, 2800HRT

2
Outline And Foundation Drawing (Single Cell)
TXS 100-1L TXS 125-1L TXS 150-1L TXS 175-1L

TXS 100-1S TXS 125-1S TXS 150-1S TXS 175-1S
TXS 200-1S TXS 225-1S TXS 250-1S TXS 300-1S
TXS 100-1E TXS 125-1E TXS 150-1E TXS 175-1E
TX-S SERIES LOW NOISE, SUPER LOW NOISE & ENERGY SAVING SUPER LOW NOISE RANGE
Tower
OVERALL DIMENSION MOTOR AXIAL FLOW FAN
Model
Rated
Output Rated Current Power Diameter Fan No of Drive
TXS - 1 L W H h kW (A 50/60Hz) Type Source (mm) Speed blades System
100-1L 3170 1680 2350 750 2.2 4.66 / 4.17 1400 450 4
100-1S 3170 1680 2350 750 2.2 4.66 / 4.17 1400 400 4
100-1E 3170 1680 2750 750 1.5 3.35 / 3.06 1400 397 4
125-1L 3370 1880 2350 750 3.7 7.35 / 6.95 1600 425 6
125-1S 3370 1880 2350 750 3.7 7.35 / 6.95 1600 380 4
TEFC, outdoor, 3 phase, induction motor, 4 pole
125-1E 3370 1880 2750 750 2.2 4.66 / 4.17 1600 360 6
3ph / 380V / 50Hz or 3ph / 415V / 50Hz
150-1L 3370 1880 2750 750 3.7 7.35 / 6.95 1600 425 6
150-1S 3370 1880 2750 750 3.7 7.35 / 6.95 1600 380 4
150-1E 3570 2080 2750 750 2.2 4.66 / 4.17 1830 360 6
175-1L 3370 1880 2750 750 5.5 11.0 / 9.93 1600 475 6
V Belt and Pulley
175-1S 3370 1880 2750 750 5.5 11.0 / 9.93 1600 430 4
175-1E 3770 2280 2750 750 3.7 7.35 / 6.95 2000 320 6
200-1L 3570 2080 2750 750 5.5 11.0 / 9.93 1830 450 5
200-1S 3570 2080 2750 750 5.5 11.0 / 9.93 1830 355 4
225-1L 3770 2280 2750 750 5.5 11.0 / 9.93 2000 450 6
225-1S 3770 2280 2750 750 5.5 11.0 / 9.93 2000 315 4
250-1L 3770 2280 2750 750 7.5 13.9 / 12.44 2000 450 6
250-1S 3770 2280 2750 750 7.5 13.9 / 12.44 2000 345 4
300-1L 3770 2280 3460 750 11.0
7.5 20.1
13.9 / 18.56
/ 12.44 2000 450 6
300-1S 3770 2280 3460 750 11.0
7.5 20.1
13.9 / 18.56
/ 12.44 2000 380 4
350-1L 4770 3030 3400 1000 11.0 20.1 / 18.56 2135 406 4
400-1L 4770 3030 3400 1000 15.0 26.8 / 24.05 2135 428 4
450-1L 5170 3430 3400 1000 11.0 20.1 / 18.56 2745 344 5
500-1L 5170 3430 3400 1000 15.0 26.8 / 24.05 2745 345 5
* We reserve the right to change data and specification without prior notice.
Outline And Foundation Drawing (Single Cell)
Tower
FOUNDATION DIMENSION PIPING DATA PIPING SIZE WEIGHT (KG)
Model
Make Up
External Internal Water Auto & Dry Oper.
TXS - 1 B C D E1 E2 F G J Piping Piping Outlet Overflow Drain Manual Weight Weight
100-1L 1580 3050 1680 1250 900 1135 840 - 100 x 2 100 x 1 100 x 1 50 x 1 50 x 1 25 x 1 790 1880
100-1S 1580 3050 1680 1250 900 1135 840 - 100 x 2 100 x 1 100 x 1 50 x 1 50 x 1 25 x 1 790 1880
100-1E 1580 3050 1680 1250 900 1135 840 - 100 x 2 100 x 1 100 x 1 50 x 1 50 x 1 25 x 1 900 1970
125-1L 1780 3250 1880 1450 900 1235 940 - 100 x 2 125 x 1 125 x 1 50 x 1 50 x 1 25 x 1 900 2110
125-1S 1780 3250 1880 1450 900 1235 940 - 100 x 2 125 x 1 125 x 1 50 x 1 50 x 1 25 x 1 900 2110
125-1E 1780 3250 1880 1450 900 1235 940 - 100 x 2 125 x 1 125 x 1 50 x 1 50 x 1 25 x 1 1010 2210
150-1L 1780 3250 1880 1450 900 1235 940 - 100 x 2 125 x 1 125 x 1 50 x 1 50 x 1 25 x 1 980 2370
150-1S 1780 3250 1880 1450 900 1235 940 - 100 x 2 125 x 1 125 x 1 50 x 1 50 x 1 25 x 1 980 2370
150-1E 1980 3450 2080 1450 1000 1335 1040 - 100 x 2 125 x 1 125 x 1 50 x 1 50 x 1 25 x 1 1010 2490
175-1L 1780 3250 1880 1450 900 1235 940 - 100 x 2 125 x 1 125 x 1 50 x 1 50 x 1 25 x 1 990 2500
175-1S 1780 3250 1880 1450 900 1235 940 - 100 x 2 125 x 1 125 x 1 50 x 1 50 x 1 25 x 1 990 2500
175-1E 2180 3650 2280 1650 1000 1435 1140 - 100 x 2 125 x 1 125 x 1 50 x 1 50 x 1 25 x 1 1220 2790
200-1L 1980 3450 2080 1450 1000 1335 1040 - 100 x 2 125 x 1 150 x 1 50 x 1 50 x 1 25 x 1 1113 2880
200-1S 1980 3450 2080 1450 1000 1335 1040 - 100 x 2 125 x 1 150 x 1 50 x 1 50 x 1 25 x 1 1113 2880
225-1L 2180 3650 2280 1650 1000 1435 1140 - 125 x 2 150 x 1 200 x 1 50 x 1 50 x 1 50 x 1 1180 3180
225-1S 2180 3650 2280 1650 1000 1435 1140 - 125 x 2 150 x 1 200 x 1 50 x 1 50 x 1 50 x 1 1180 3180
250-1L 2180 3650 2280 1650 1000 1435 1140 - 125 x 2 150 x 1 200 x 1 50 x 1 50 x 1 50 x 1 1190 3200
250-1S 2180 3650 2280 1650 1000 1435 1140 - 125 x 2 150 x 1 200 x 1 50 x 1 50 x 1 50 x 1 1190 3200
300-1L 2180 3650 2280 1650 1000 1435 1140 - 125 x 2 200 x 1 250 x 1 50 x 1 50 x 1 50 x 1 1785 3900
300-1S 2180 3650 2280 1650 1000 1435 1140 - 125 x 2 200 x 1 250 x 1 50 x 1 50 x 1 50 x 1 1785 3900
350-1L 2930 4650 3030 2090 1280 1790 1515 - 150 x 2 200 x 1 250 x 1 80 x 1 50 x 1 50 x 1 2150 5350
400-1L 2930 4650 3030 2090 1280 1790 1515 - 150 x 2 200 x 1 250 x 1 80 x 1 50 x 1 50 x 1 2280 5800
450-1L 3330 5050 3430 2490 1280 1990 1715 - 150 x 2 250 x 1 250 x 1 80 x 1 50 x 1 50 x 1 2970 6670
500-1L 3330 5050 3430 2490 1280 1990 1715 - 200 x 2 250 x 1 250 x 1 80 x 1 80 x 1 50 x 1 3130 7250
* Note: 1.) For Internal Piping Detail, Please Contact Truwater's Engineer. 2.) Balancing Pipe Connection Is Available Upon Request.
3.) External Piping to Open End. Internal Piping & Water Outlet to JIS10K FF Flange. 4.) Overflow, Drain, Make Up Auto & Manual to BSP Female Thread 4
Outline And Foundation Drawing (Two Cell)
TXS 200-2L TXS 250-2L TXS 300-2L

TXS 325-2L TXS 400-2L TXS 450-2L
TXS 500-2L TXS 200-2S TXS 250-2S
TXS 300-2S TXS 325-2S TXS 400-2S
TXS 450-2S TXS 500-2S TXS 200-2E
TXS 250-2E TXS 300-2E TXS 325-2E
Tower
Model
Rated
Rated Output Current Power Diameter Fan No of Drive
200-2L 3170 3360 2350 750 2.2 4.66 / 4.17 1400 450 4
200-2S 3170 3360 2350 750 2.2 4.66 / 4.17 1400 400 4
200-2E 3170 3360 2750 750 1.5 3.35 / 3.06 1400 397 4
250-2L 3370 3760 2350 750 3.7 7.35 / 6.95 1600 425 6
250-2S 3370 3760 2350 750 3.7 7.35 / 6.95 1600 380 4
250-2E 3370 3760 2750 750 2.2 4.66 / 4.17 1600 360 6
3ph / 380V / 50Hz or 3ph / 415V / 50Hz
300-2L 3370 3760 2750 750 3.7 7.35 / 6.95 1600 425 6
300-2S 3370 3760 2750 750 3.7 7.35 / 6.95 1600 380 4
300-2E 3570 4160 2750 750 2.2 4.66 / 4.17 1830 360 6
350-2L 3370 3760 2750 750 5.5 11.0 / 9.93 1600 475 6
V Belt and Pulley
350-2S 3370 3760 2750 750 5.5 11.0 / 9.93 1600 430 4
350-2E 3770 4560 2750 750 3.7 7.35 / 6.95 2000 320 6
400-2L 3570 4160 2750 750 5.5 11.0 / 9.93 1830 450 5
400-2S 3570 4160 2750 750 5.5 11.0 / 9.93 1830 355 4
450-2L 3770 4560 2750 750 5.5 11.0 / 9.93 2000 450 6
450-2S 3770 4560 2750 750 5.5 11.0 / 9.93 2000 315 4
500-2L 3770 4560 2750 750 7.5 13.9 / 12.44 2000 450 6
500-2S 3770 4560 2750 750 7.5 13.9 / 12.44 2000 345 4
600-2L 3770 4560 3460 750 11.0
7.5 20.1
13.9 / 18.56
/ 12.44 2000 450 6
600-2S 3770 4560 3460 750 11.0
7.5 20.1
13.9 / 18.56
/ 12.44 2000 380 4
700-2L 4770 6060 3400 1000 11.0 20.1 / 18.56 2135 406 4
800-2L 4770 6060 3400 1000 15.0 26.8 / 24.05 2135 428 4
900-2L 5170 6860 3400 1000 11.0 20.1 / 18.56 2745 344 5
1000-2L 5170 6860 3400 1000 15.0 26.8 / 24.05 2745 345 5
5
Outline And Foundation Drawing (Two Cell)
TXS 600-2L TXS 600-2S

TXS 700-2L TXS 800-2L
TXS 900-2L TXS 1000-2L
Tower
Model
Make Up
200-2L 1580 3050 1680 1250 900 1135 840 1680 100 x 4 100 x 2 150 x 1 50 x 1 50 x 1 25 x 1 1580 3760
200-2S 1580 3050 1680 1250 900 1135 840 1680 100 x 4 100 x 2 150 x 1 50 x 1 50 x 1 25 x 1 1580 3760
200-2E 1580 3050 1680 1250 900 1135 840 1680 100 x 4 100 x 2 150 x 1 50 x 1 50 x 1 25 x 1 1800 3940
250-2L 1780 3250 1880 1450 900 1235 940 1880 100 x 4 125 x 2 200 x 1 50 x 1 50 x 1 50 x 1 1800 4220
250-2S 1780 3250 1880 1450 900 1235 940 1880 100 x 4 125 x 2 200 x 1 50 x 1 50 x 1 50 x 1 1800 4220
250-2E 1780 3250 1880 1450 900 1235 940 1880 100 x 4 125 x 2 200 x 1 50 x 1 50 x 1 50 x 1 2020 4420
300-2L 1780 3250 1880 1450 900 1235 940 1880 100 x 4 125 x 2 250 x 1 50 x 1 50 x 1 50 x 1 1960 4740
300-2S 1780 3250 1880 1450 900 1235 940 1880 100 x 4 125 x 2 250 x 1 50 x 1 50 x 1 50 x 1 1960 4740
300-2E 1980 3450 2080 1450 1000 1335 1040 2080 100 x 4 125 x 2 250 x 1 50 x 1 50 x 1 50 x 1 2020 4980
350-2L 1780 3250 1880 1450 900 1235 940 1880 100 x 4 125 x 2 250 x 1 50 x 1 50 x 1 50 x 1 1980 5000
350-2S 1780 3250 1880 1450 900 1235 940 1880 100 x 4 125 x 2 250 x 1 50 x 1 50 x 1 50 x 1 1980 5000
350-2E 2180 3650 2280 1650 1000 1435 1140 2280 100 x 4 125 x 2 250 x 1 50 x 1 50 x 1 50 x 1 2440 5580
400-2L 1980 3450 2080 1450 1000 1335 1040 2080 100 x 4 125 x 2 250 x 1 50 x 1 50 x 1 50 x 1 2226 5760
400-2S 1980 3450 2080 1450 1000 1335 1040 2080 100 x 4 125 x 2 250 x 1 50 x 1 50 x 1 50 x 1 2226 5760
450-2L 2180 3650 2280 1650 1000 1435 1140 2280 125 x 4 150 x 2 250 x 1 50 x 1 50 x 1 50 x 1 2360 6360
450-2S 2180 3650 2280 1650 1000 1435 1140 2280 125 x 4 150 x 2 250 x 1 50 x 1 50 x 1 50 x 1 2360 6360
500-2L 2180 3650 2280 1650 1000 1435 1140 2280 125 x 4 150 x 2 250 x 1 50 x 1 50 x 1 50 x 1 2380 6400
500-2S 2180 3650 2280 1650 1000 1435 1140 2280 125 x 4 150 x 2 250 x 1 50 x 1 50 x 1 50 x 1 2380 6400
600-2L 2180 3650 2280 1650 1000 1435 1140 2280 125 x 4 200 x 2 250 x 2 50 x 2 50 x 2 50 x 2 3570 7800
600-2S 2180 3650 2280 1650 1000 1435 1140 2280 125 x 4 200 x 2 250 x 2 50 x 2 50 x 2 50 x 2 3570 7800
700-2L 2930 4650 3030 2090 1280 1790 1515 3030 150 x 4 200 x 2 250 x 2 80 x 2 50 x 2 50 x 2 4300 10700
800-2L 2930 4650 3030 2090 1280 1790 1515 3030 150 x 4 200 x 2 250 x 2 80 x 2 50 x 2 50 x 2 4560 11600
900-2L 3330 5050 3430 2490 1280 1990 1715 3430 200 x 4 250 x 2 250 x 2 80 x 2 50 x 2 50 x 2 5940 13340
1000-2L 3330 5050 3430 2490 1280 1990 1715 3430 200 x 4 250 x 2 250 x 2 80 x 2 80 x 2 50 x 2 6260 14500
Outline And Foundation Drawing (Three Cell)
TXS 300-3L TXS 375-3L TXS 450-3L

TXS 525-3L TXS 600-3L TXS 700-3L
TXS 750-3L TXS 300-3S TXS 375-3S
TXS 450-3S TXS 525-3S TXS 600-3S
TXS 700-3S TXS 750-3S TXS 300-3E
TXS 375-3E TXS 450-3E TXS 525-3E
Tower
Model
Rated
300-3L 3170 5040 2350 750 2.2 4.66 / 4.17 1400 450 4
300-3S 3170 5040 2350 750 2.2 4.66 / 4.17 1400 400 4
300-3E 3170 5040 2750 750 1.5 3.35 / 3.06 1400 397 4
375-3L 3370 5640 2350 750 3.7 7.35 / 6.95 1600 425 6
375-3S 3370 5640 2350 750 3.7 7.35 / 6.95 1600 380 4
375-3E 3370 5640 2750 750 2.2 4.66 / 4.17 1600 360 6
3ph / 380V / 50Hz or 3ph / 415V / 50Hz
450-3L 3370 5640 2750 750 3.7 7.35 / 6.95 1600 425 6
450-3S 3370 5640 2750 750 3.7 7.35 / 6.95 1600 380 4
450-3E 3570 6240 2750 750 2.2 4.66 / 4.17 1830 360 6
525-3L 3370 5640 2750 750 5.5 11.0 / 9.93 1600 475 6
V Belt and Pulley
525-3S 3370 5640 2750 750 5.5 11.0 / 9.93 1600 430 4
525-3E 3770 6840 2750 750 3.7 7.35 / 6.95 2000 320 6
600-3L 3570 6240 2750 750 5.5 11.0 / 9.93 1830 450 5
600-3S 3570 6240 2750 750 5.5 11.0 / 9.93 1830 355 4
700-3L 3770 6840 2750 750 7.5
5.5 11.0
13.9 / 9.93
/ 12.44 2000 450 6
700-3S 3770 6840 2750 750 5.5
7.5 11.0
13.9 / 9.93
/ 12.44 2000 315 4
750-3L 3770 6840 2750 750 7.5 13.9 / 12.44 2000 450 6
750-3S 3770 6840 2750 750 7.5 13.9 / 12.44 2000 345 4
900-3L 3770 6840 3460 750 7.5
11.0 20.1
13.9 / 18.56
/ 12.44 2000 450 6
900-3S 3770 6840 3460 750 7.5
11.0 20.1
13.9 / 18.56
/ 12.44 2000 380 4
1050-3L 4770 9090 3400 1000 11.0 20.1 / 18.56 2135 406 4
1200-3L 4770 9090 3400 1000 15.0 26.8 / 24.05 2135 428 4
1350-3L 5170 10290 3400 1000 11.0 20.1 / 18.56 2745 344 5
1500-3L 5170 10290 3400 1000 15.0 26.8 / 24.05 2745 345 5
7
Outline And Foundation Drawing (Three Cell)
TXS 900-3L
TXS 900-3S
TXS 1050-3L
TXS 1200-3L
TXS 1350-3L
TXS 1500-3L
Tower
Model
Make Up
300-3L 1580 3050 1680 1250 900 1135 840 1680 100 x 6 100 x 3 150 x 2 50 x 2 50 x 2 25 x 2 2370 5640
300-3S 1580 3050 1680 1250 900 1135 840 1680 100 x 6 100 x 3 150 x 2 50 x 2 50 x 2 25 x 2 2370 5640
300-3E 1580 3050 1680 1250 900 1135 840 1680 100 x 6 100 x 3 150 x 2 50 x 2 50 x 2 25 x 2 2700 5910
375-3L 1780 3250 1880 1450 900 1235 940 1880 100 x 6 125 x 3 150 x 2 50 x 2 50 x 2 25 x 2 2700 6330
375-3S 1780 3250 1880 1450 900 1235 940 1880 100 x 6 125 x 3 150 x 2 50 x 2 50 x 2 25 x 2 2700 6330
375-3E 1780 3250 1880 1450 900 1235 940 1880 100 x 6 125 x 3 150 x 2 50 x 2 50 x 2 25 x 2 3030 6630
450-3L 1780 3250 1880 1450 900 1235 940 1880 100 x 6 125 x 3 200 x 2 50 x 2 50 x 2 25 x 2 2940 7110
450-3S 1780 3250 1880 1450 900 1235 940 1880 100 x 6 125 x 3 200 x 2 50 x 2 50 x 2 25 x 2 2940 7110
450-3E 1980 3450 2080 1450 1000 1335 1040 2080 100 x 6 125 x 3 200 x 2 50 x 2 50 x 2 25 x 2 3030 7470
525-3L 1780 3250 1880 1450 900 1235 940 1880 100 x 6 125 x 3 200 x 2 50 x 2 50 x 2 50 x 2 2970 7500
525-3S 1780 3250 1880 1450 900 1235 940 1880 100 x 6 125 x 3 200 x 2 50 x 2 50 x 2 50 x 2 2970 7500
525-3E 2180 3650 2280 1650 1000 1435 1140 2280 100 x 6 125 x 3 200 x 2 50 x 2 50 x 2 50 x 2 3660 8370
600-3L 1980 3450 2080 1450 1000 1335 1040 2080 100 x 6 125 x 3 250 x 2 50 x 2 50 x 2 50 x 2 3339 8640
600-3S 1980 3450 2080 1450 1000 1335 1040 2080 100 x 6 125 x 3 250 x 2 50 x 2 50 x 2 50 x 2 3339 8640
700-3L 2180 3650 2280 1650 1000 1435 1140 2280 125 x 6 150 x 3 250 x 2 50 x 2 50 x 2 50 x 2 3540 9540
700-3S 2180 3650 2280 1650 1000 1435 1140 2280 125 x 6 150 x 3 250 x 2 50 x 2 50 x 2 50 x 2 3540 9540
750-3L 2180 3650 2280 1650 1000 1435 1140 2280 125 x 6 150 x 3 250 x 2 50 x 2 50 x 2 50 x 2 3570 9600
750-3S 2180 3650 2280 1650 1000 1435 1140 2280 125 x 6 150 x 3 250 x 2 50 x 2 50 x 2 50 x 2 3570 9600
900-3L 2180 3650 2280 1650 1000 1435 1140 2280 125 x 6 200 x 3 250 x 3 50 x 3 50 x 3 50 x 3 5355 11700
900-3S 2180 3650 2280 1650 1000 1435 1140 2280 125 x 6 200 x 3 250 x 3 50 x 3 50 x 3 50 x 3 5355 11700
1050-3L 2930 4650 3030 2090 1280 1790 1515 3030 150 x 6 200 x 3 250 x 3 80 x 3 50 x 3 50 x 3 6450 16050
1200-3L 2930 4650 3030 2090 1280 1790 1515 3030 150 x 6 200 x 3 250 x 3 80 x 3 50 x 3 50 x 3 6840 17400
1350-3L 3330 5050 3430 2490 1280 1990 1715 3430 200 x 6 250 x 3 250 x 3 80 x 3 50 x 3 50 x 3 8910 20010
1500-3L 3330 5050 3430 2490 1280 1990 1715 3430 200 x 6 250 x 3 250 x 3 80 x 3 80 x 3 50 x 3 9390 21750
Outline And Foundation Drawing (Four Cell)
TXS 400-4L TXS 500-4L

TXS 600-4L TXS 700-4L
TXS 800-4L TXS 900-4L
TXS 1000-4L TXS 400-4S
TXS 500-4S TXS 600-4S
TXS 700-4S TXS 800-4S
TXS 900-4S TXS 1000-4S
TXS 400-4E TXS 500-4E
TXS 600-4E TXS 700-4E
Tower
Model
Rated
400-4L 3170 6720 2350 750 2.2 4.66 / 4.17 1400 450 4
400-4S 3170 6720 2350 750 2.2 4.66 / 4.17 1400 400 4
400-4E 3170 6720 2750 750 1.5 3.35 / 3.06 1400 397 4
500-4L 3370 7520 2350 750 3.7 7.35 / 6.95 1600 425 6
500-4S 3370 7520 2350 750 3.7 7.35 / 6.95 1600 380 4
500-4E 3370 7520 2750 750 2.2 4.66 / 4.17 1600 360 6
3ph / 380V / 50Hz or 3ph / 415V / 50Hz
600-4L 3370 7520 2750 750 3.7 7.35 / 6.95 1600 425 6
600-4S 3370 7520 2750 750 3.7 7.35 / 6.95 1600 380 4
600-4E 3570 8320 2750 750 2.2 4.66 / 4.17 1830 360 6
700-4L 3370 7520 2750 750 5.5 11.0 / 9.93 1600 475 6
V Belt and Pulley
700-4S 3370 7520 2750 750 5.5 11.0 / 9.93 1600 430 4
700-4E 3770 9120 2750 750 3.7 7.35 / 6.95 2000 320 6
800-4L 3570 8320 2750 750 5.5 11.0 / 9.93 1830 450 5
800-4S 3570 8320 2750 750 5.5 11.0 / 9.93 1830 355 4
900-4L 3770 9120 2750 750 5.5 11.0 / 9.93 2000 450 6
900-4S 3770 9120 2750 750 5.5 11.0 / 9.93 2000 315 4
1000-4L 3770 9120 2750 750 7.5 13.9 / 12.44 2000 450 6
1000-4S 3770 9120 2750 750 7.5 13.9 / 12.44 2000 345 4
1200-4L 3770 9120 3460 750 11.0
7.5 20.1
13.9 / 18.56
/ 12.44 2000 450 6
1200-4S 3770 9120 3460 750 11.0
7.5 20.1
13.9 / 18.56
/ 12.44 2000 380 4
1400-4L 4770 12120 3400 1000 11.0 20.1 / 18.56 2135 406 4
1600-4L 4770 12120 3400 1000 15.0 26.8 / 24.05 2135 428 4
1800-4L 5170 13720 3400 1000 11.0 20.1 / 18.56 2745 344 5
2000-4L 5170 13720 3400 1000 15.0 26.8 / 24.05 2745 345 5
9
Outline And Foundation Drawing (Four Cell)
TXS 1200-4L
TXS 1200-4S
TXS 1400-4L
TXS 1600-4L
TXS 1800-4L
TXS 2000-4L
Tower
Model
Make Up
400-4L 1580 3050 1680 1250 900 1135 840 1680 100 x 8 100 x 4 150 x 2 50 x 2 50 x 2 25 x 2 3160 7520
400-4S 1580 3050 1680 1250 900 1135 840 1680 100 x 8 100 x 4 150 x 2 50 x 2 50 x 2 25 x 2 3160 7520
400-4E 1580 3050 1680 1250 900 1135 840 1680 100 x 8 100 x 4 150 x 2 50 x 2 50 x 2 25 x 2 3600 7880
500-4L 1780 3250 1880 1450 900 1235 940 1880 100 x 8 125 x 4 200 x 2 50 x 2 50 x 2 50 x 2 3600 8440
500-4S 1780 3250 1880 1450 900 1235 940 1880 100 x 8 125 x 4 200 x 2 50 x 2 50 x 2 50 x 2 3600 8440
500-4E 1780 3250 1880 1450 900 1235 940 1880 100 x 8 125 x 4 200 x 2 50 x 2 50 x 2 50 x 2 4040 8840
600-4L 1780 3250 1880 1450 900 1235 940 1880 100 x 8 125 x 4 250 x 2 50 x 2 50 x 2 50 x 2 3920 9480
600-4S 1780 3250 1880 1450 900 1235 940 1880 100 x 8 125 x 4 250 x 2 50 x 2 50 x 2 50 x 2 3920 9480
600-4E 1980 3450 2080 1450 1000 1335 1040 2080 100 x 8 125 x 4 250 x 2 50 x 2 50 x 2 50 x 2 4040 9960
700-4L 1780 3250 1880 1450 900 1235 940 1880 100 x 8 125 x 4 250 x 2 50 x 2 50 x 2 50 x 2 3960 10000
700-4S 1780 3250 1880 1450 900 1235 940 1880 100 x 8 125 x 4 250 x 2 50 x 2 50 x 2 50 x 2 3960 10000
700-4E 2180 3650 2280 1650 1000 1435 1140 2280 100 x 8 125 x 4 250 x 2 50 x 2 50 x 2 50 x 2 4880 11160
800-4L 1980 3450 2080 1450 1000 1335 1040 2080 100 x 8 125 x 4 250 x 2 50 x 2 50 x 2 50 x 2 4452 11520
800-4S 1980 3450 2080 1450 1000 1335 1040 2080 100 x 8 125 x 4 250 x 2 50 x 2 50 x 2 50 x 2 4452 11520
900-4L 2180 3650 2280 1650 1000 1435 1140 2280 125 x 8 150 x 4 250 x 2 50 x 2 50 x 2 50 x 2 4720 12720
900-4S 2180 3650 2280 1650 1000 1435 1140 2280 125 x 8 150 x 4 250 x 2 50 x 2 50 x 2 50 x 2 4720 12720
1000-4L 2180 3650 2280 1650 1000 1435 1140 2280 125 x 8 150 x 4 250 x 2 50 x 2 50 x 2 50 x 2 4760 12800
1000-4S 2180 3650 2280 1650 1000 1435 1140 2280 125 x 8 150 x 4 250 x 2 50 x 2 50 x 2 50 x 2 4760 12800
1200-4L 2180 3650 2280 1650 1000 1435 1140 2280 125 x 8 200 x 4 250 x 4 50 x 4 50 x 4 50 x 4 7140 15600
1200-4S 2180 3650 2280 1650 1000 1435 1140 2280 125 x 8 200 x 4 250 x 4 50 x 4 50 x 4 50 x 4 7140 15600
1400-4L 2930 4650 3030 2090 1280 1790 1515 3030 150 x 8 200 x 4 250 x 4 80 x 4 50 x 4 50 x 4 8600 21400
1600-4L 2930 4650 3030 2090 1280 1790 1515 3030 150 x 8 200 x 4 250 x 4 80 x 4 50 x 4 50 x 4 9120 23200
1800-4L 3330 5050 3430 2490 1280 1990 1715 3430 200 x 8 250 x 4 250 x 4 80 x 4 50 x 4 50 x 4 11880 26680
2000-4L 3330 5050 3430 2490 1280 1990 1715 3430 200 x 8 250 x 4 250 x 4 80 x 4 80 x 4 50 x 4 12520 2900
TX-S Series Quick Selection Table
The diagrams below show the common combinations of various cold water, hot water, wet bulb temperature.
However, if there is a difference in temperature combination, please contact the company for a selection
of the cooling tower by our computer software
In 95 98.6 95 97 98 98.6 97 100 98.6 100 100

Deg F Out 85.1 89.6 86 87 88 89.6 87 90 89.6 90 90
WB 80.6 80.6 81 81 82 81.5 82 82 82.4 83 84
In 35 37 35 36.1 36.7 37 36.1 37.8 37 37.8 37.8

Deg C Out 29.5 32 30 30.5 31.1 32 30.6 32.2 32 32.2 32.2
WB 27 27 27.2 27.2 27.8 27.5 27.8 27.8 28 28.3 28.3
Model Motor
TXS HRT kW m3/hr
100 100 2.2x1 42 78 50 54 55 74 48 67 69 63 58

125 125 3.7x1 53 98 60 68 69 93 60 84 86 78 73
150 150 3.7x1 63 117 72 81 83 111 72 101 104 94 88
175 175 5.5x1 75 137 87 95 97 130 85 118 120 109 102
200 200 5.5x1 86 156 100 108 110 148 97 135 138 125 116
225 225 5.5x1 95 176 110 122 125 167 108 152 155 141 130
250 250 7.5x1 107 195 122 135 138 185 120 168 172 157 146
300 300 11x1 126 234 150 162 166 222 145 202 208 188 176
350 350 11x1 150 273 174 189 194 260 168 236 240 220 204
375 375 3.7x3 159 294 180 205 207 279 180 252 258 234 217
400 400 15x1 173 314 200 216 220 296 193 270 276 251 232
450 450 11x1 190 353 220 243 250 334 217 304 310 282 260
500 500 15x1 214 390 250 270 276 370 241 337 345 314 292
525 525 5.5x3 225 411 261 285 291 390 255 354 360 327 306
600 600 11x2 252 468 300 324 330 444 290 405 414 377 350
700 700 11x2 300 546 350 378 385 518 338 473 480 439 408
750 750 7.5x3 321 585 366 410 414 555 360 504 516 471 438
800 800 15x2 345 624 400 432 440 592 386 540 552 502 464
900 900 11x2 385 702 450 486 495 668 434 608 620 565 520
1000 1000 15x2 428 780 500 540 550 740 482 675 690 628 584
1050 1050 11x3 450 819 510 567 582 780 504 708 720 660 612
1200 1200 15x3 504 936 600 648 660 888 580 810 828 753 700
1350 1350 11x3 575 1059 660 729 748 1002 651 912 930 846 780
1400 1400 11x4 604 1092 695 756 770 1036 676 946 960 878 816
1500 1500 15x3 642 1170 732 810 828 1110 720 1008 1032 942 876
1600 1600 15x4 672 1248 800 864 880 1184 772 1080 1104 1004 928
1800 1800 11x4 690 1404 900 972 990 1336 868 1216 1240 1130 1040
2000 2000 15x4 856 1560 1000 1080 1100 1480 964 1350 1380 1256 1168
11
SOUND LEVEL CHART (FROM 100~2000 TON)
The measuring point at 45 degrees is diagonally above the top edge of the fan stack, opposite of motor driver side. If
fan diameter is less than 1.5m, the measuring distance should be limited to 1.5m standard.
SOUND LEVEL dB(A) - SINGLE CELL (100~500 TON) SOUND LEVEL dB(A) - 2 CELLS (200~1000 TON)
Louver Panel Fan Louver Panel Fan
2m 10m 2m 10m 45 deg 2m 10m 2m 10m 45 deg
100-1L 63.5 55.0 57.5 53.0 68.0 200-2L 66.0 57.0 61.0 55.0 70.0
100-1S 58.5 51.0 55.0 49.5 66.0 200-2S 61.5 53.0 57.0 51.0 68.0
100-1E 56.0 49.0 53.0 46.0 63.0 200-2E 59.0 52.0 55.0 49.0 66.0
125-1L 65.0 57.0 61.0 54.5 70.0 250-2L 68.0 58.0 62.0 56.0 72.0
125-1S 60.5 52.5 57.0 51.0 68.0 250-2S 64.0 54.0 59.0 51.0 70.0
125-1E 57.0 50.0 54.0 47.0 65.0 250-2E 61.0 52.0 56.0 51.0 68.0
150-1L 66.0 57.0 62.0 54.5 70.0 300-2L 69.0 60.0 64.0 56.0 72.0
150-1S 60.5 52.5 57.0 50.5 68.0 300-2S 64.0 54.0 59.0 53.0 70.0
150-1E 59.0 51.0 56.0 49.0 65.0 300-2E 62.0 53.0 57.0 52.0 68.0
175-1L 67.0 58.0 63.0 56.0 71.5 350-2L 70.0 60.0 65.0 58.0 73.0
175-1S 62.0 53.0 58.5 52.0 69.0 350-2S 65.0 56.0 60.0 54.0 71.0
175-1E 61.0 52.0 58.0 51.0 68.0 350-2E 64.0 54.0 59.0 53.0 69.0
200-1L 67.0 58.0 62.0 55.5 71.0 400-2L 70.0 60.0 65.0 58.0 73.0
200-1S 62.0 53.0 58.0 52.0 69.0 400-2S 65.0 56.0 60.0 54.0 71.0
225-1L 67.0 58.0 62.0 54.0 71.0 450-2L 70.0 60.0 65.0 58.0 73.0
225-1S 63.0 54.0 57.5 52.0 69.0 450-2S 66.0 56.0 60.0 54.0 71.0
250-1L 68.0 59.0 62.5 56.5 72.0 500-2L 70.0 60.0 65.0 58.5 74.0
250-1S 63.0 54.0 60.0 53.5 70.0 500-2S 67.0 57.0 61.0 55.0 73.0
300-1L 68.0 59.0 64.0 57.0 72.0 600-2L 71.0 61.0 67.0 60.0 73.0
300-1S 65.0 56.0 60.0 54.0 71.0 600-2S 68.0 58.0 62.0 56.0 73.0
350-1L 69.0 60.0 65.0 58.0 73.0 700-2L 72.0 62.0 68.0 61.0 74.0
400-1L 71.0 62.0 67.0 59.0 73.5 800-2L 74.0 64.0 69.0 62.0 75.0
450-1L 69.0 60.0 65.0 58.0 73.0 900-2L 72.0 62.0 68.0 61.0 74.0
500-1L 71.0 62.0 67.0 59.0 73.5 1000-2L 74.0 62.0 69.0 62.0 75.0
SOUND LEVEL dB(A) - 3 CELLS (300~1500 TON) SOUND LEVEL dB(A) - 4 CELLS (400-2000 TON)
Louver Panel Fan Louver Panel Fan
2m 10m 2m 10m 45 deg 2m 10m 2m 10m 45 deg
300-3L 69.0 60.0 64.0 56.0 72.0 400-4L 70.0 61.0 65.0 58.0 73.0
300-3S 64.0 54.0 59.0 51.0 70.0 400-4S 65.0 56.0 60.0 54.0 71.0
300-3E 62.0 53.0 57.0 52.0 68.0 400-4E 63.0 54.0 58.0 53.0 69.0
375-3L 70.0 61.0 65.0 58.0 73.0 500-4L 70.0 61.0 65.0 58.0 73.0
375-3S 64.0 54.0 59.0 51.0 70.0 500-4S 65.0 56.0 60.0 54.0 71.0
375-3E 62.0 53.0 57.0 52.0 68.0 500-4E 63.0 54.0 58.0 53.0 69.0
450-3L 70.0 61.0 65.0 58.0 73.0 600-4L 71.0 62.0 66.0 59.0 73.5
450-3S 66.0 56.0 60.0 54.0 71.0 600-4S 67.0 57.0 61.0 55.0 73.0
450-3E 63.0 54.0 58.0 53.0 69.0 600-4E 65.0 55.0 60.0 54.0 71.0
525-3L 70.0 61.0 65.0 58.0 73.0 700-4L 71.0 62.0 66.0 59.0 73.5
525-3S 66.0 56.0 60.0 54.0 72.0 700-4S 67.0 57.0 61.0 55.0 73.0
525-3E 63.0 54.0 58.0 53.0 69.0 700-4E 65.0 55.0 60.0 54.0 71.0
600-3L 72.0 62.0 67.0 60.0 74.0 800-4L 72.0 62.0 66.0 59.0 74.0
600-3S 66.0 56.0 60.0 54.0 72.0 800-4S 68.0 58.0 62.0 56.0 73.0
700-3L 72.5 62.5 68.0 62.0 74.0 900-4L 72.0 62.0 67.0 60.0 75.0
700-3S 68.0 57.0 61.0 55.0 72.0 900-4S 69.0 59.0 66.0 59.0 73.0
750-3L 72.5 62.5 68.0 62.0 74.0 1000-4L 73.0 63.0 69.0 62.0 75.0
750-3S 68.0 57.0 61.0 55.0 72.0 1000-4S 71.0 61.0 67.0 60.0 74.0
900-3L 74.0 64.0 69.0 62.0 75.0 1200-4L 75.0 65.0 70.0 63.0 76.0
900-3S 71.0 61.0 67.0 60.0 73.0 1200-4S 73.0 63.0 69.0 62.0 74.0
1050-3L 75.0 65.0 70.0 63.0 76.0 1400-4L 76.0 67.0 72.0 64.0 77.0
1200-3L 76.0 67.0 72.0 64.0 78.0 1600-4L 77.0 69.0 73.0 66.0 79.0
1350-3L 75.0 65.0 70.0 63.0 76.0 1800-4L 76.0 67.0 72.0 64.0 77.0
1500-3L 76.0 67.0 72.0 64.0 78.0 2000-4L 77.0 69.0 73.0 66.0 79.0
12
RECOMMENDED UNIT LAYOUT
It is advisable to select and design the best layout or location to avoid air recirculation. Recirculation occurs when some of
the hot moist discharge air leaving the cooling tower flows back into the fresh air inlet.
The following guidelines will provide the best location or layout which will minimize recirculation, maximize fresh air flow and
allow adequate maintenance accessibility.
A. SINGLE UNIT INSTALLATIONS

The best place for TX-S Series Cooling Tower is in an open space. However, when this is not possible, correct layout
guidelines must be followed to provide satisfactory installation.
Ensure that the top of the cooling tower is higher than any adjacent walls, buildings or other structures.
Figure 1(a) and 1(b) are examples of incorrect installation. These conditions can be corrected by elevating the unit on
structural steel/concrete plinths so that the top is higher that the wall as shown in Figure 1(c).
INCORRECT : Wind effect with top of unit lower than top of wall CORRECT : Installation elevated so that top of unit is
higher than top of wall
FIGURE: 1(a) FIGURE: 1(b) FIGURE: 1(c)
When a cooling tower is located near a wall,

consideration must be given to the clearance distance
between the air inlets of the tower and the wall
structure(s). See Figure 2, Recommended Dimensions D1
and D2. FIGURE 2 :
Installation next
The minimum dimensions, D1 and D2, as shown in Table to a wall.
1 must be maintained to ensure that the unit is provided
adequate air flow. In some installation, consideration
must also be given to access to the unit for
maintenance. Room must be provided for piping,
TABLE 2
removals of access panels, etc. Tower Model End Wall Minimum Dimension, mm
TXS Length, L mm D3 (End-to-End)
Sometimes other pieces of equipment such as pumps, All models All sizes 1000
filters, piping etc are placed in front of the air inlets. Tower Model Louver Width, Minimum Dimension, mm
These obstructions should not be located any closer TXS W mm D4 (Side-by-Side)
than the minimum dimensions in Table 1.
200-2L ~ 600-2L Below 4500 3000
700-2L ~ 1000-2L Below 7000 3500

TABLE 1
400-3E ~ 550-3E
Tower Model Minimum Dimension (mm)
600-3L ~ 700-3L
TXS D1 (At Louver Side) D2 (At Panel Side)
600-3S ~ 700-3S
100-1,125-1, 1500 1500
150-1,175-1 1050-3L ~ 1200-3L Below 10000 5000
600-4E ~ 700-4E
200-1,225-1, 2000 1500 800-4L ~ 1000-4L
250-1,300-1 800-4S ~ 1000-4S
350-1,400-1, 2500 1500 1350-3L ~ 1500-3L Below 14000 6000

450-1,500-1 1400-4L ~ 2000-4L
The minimum dimensions are as listed in Table 2
13
B. MULTIPLE UNIT INSTALLATIONS
When more than one cooling tower is installed at the same TABLE 3
location, recirculation becomes a bigger problem.
Tower Model End Wall Minimum Dimension, mm
TXS Length, L mm D5 (End Wall Panel Side)
With the installations of two cooling towers, they should be
All models All sizes 1000
placed end to end with the narrows ends adjacent as
shown in Figure 3. Another method is to locate the units Tower Model Louver Width, Minimum Dimension, mm
TXS W mm D6 (Louver Side to Solid wall)
side-by-side with the longer sides parallel to each other as
shown in Figure 4. In either configuration, the distance 200-2L ~ 600-2L Below 4500 3500
between the units must provide adequate airflow as well
as room for piping to the unit and access for maintenance.
700-2L ~ 1000-2L Below 7000 4000
400-3E ~ 550-3E
600-3L ~ 700-3L
600-3S ~ 700-3S
1050-3L ~ 1200-3L Below 10000 6000

600-4E ~ 700-4E
800-4L ~ 1000-4L
800-4S ~ 1000-4S
FIGURE 3: MULTIPLE UNITS PLACED END TO END
1350-3L ~ 1500-3L Below 14000 6000
1400-4L ~ 2000-4L
Louvered Wall Enclosures

TX-S Series Cooling Tower can also be installed in enclosures
with louvered or slotted walls and an open top (Figure 6)
with this type of enclosure, the air flow patterns will be a
mixture of the open type and well installation. The inlet air
will be drawn from the top as well as through the louvers or
slots.
When considering a multiple-cell unit located in a louvered
FIGURE 4: MULTIPLE UNITS PLACED SIDE-BY-SIDE
wall enclosures, the D7 and D8 dimensions, found in Table
4, must be used as absolute minimums.
SPECIAL ENCLOSURE INSTALLATION
1) Solid Wall Enclosures or Wells
FIGURE 6: LOUVERED WALL ENCLOSURE
Figure 5 shown a cooling tower is installed in a well. When
considering a multiple-cell unit located in a well, the D5
and D6 dimensions, found in Table 3, must be used as
absolute minimums.
Tower Model End Wall Minimum Dimension, mm

TXS Length, L mm D7 (End Wall Panel Side)
FIGURE 4: MULTIPLE UNITS PLACED SIDE-BY-SIDE All models All sizes 1000
Tower Model Louver Width, Minimum Dimension, mm
The unit should be oriented so that the air flow uniformly to TXS W mm D8 (Louver Side to Louvered wall)
the air inlets on all louver sides of the unit. The air discharge All models All sizes 2500
of the unit must be level with or higher than surrounding
walls.
14
TX-S SERIES CROSSFLOW COOLING TOWER SPECIFICATION
1.0 GENERAL 6.0 INFILL
The cooling tower shall be 6.1 Infill shall be Vacuum-formed
induced-draft, crossflow, rectangular, film-type, rigid, corrugated PVC sheets.
film filled, FRP Cooling Tower. Cooling The infill shall be bonded with specially
tower shall be Truwater TX-S Series or formulated glue in blocks. The infill
approved equivalent. modules shall be resistant to rot, fungi,
bacteria and organic/inorganic acids
and alkali as commonly found in
2.0 CAPACITY cooling towers. The design shall meet
Cooling Tower shall be capable of 0.02% drift loss of the circulation water
providing the thermal performance flow.
scheduled.
PVC Casing
7.0 HOT WATER DISTRIBUTION
3.0 PERFORMANCE WARRANTY SYSTEM
The cooling tower manufacturer shall The hot water distribution shall be of
guarantee that the tower supplied will open gravity type basin. It shall be
meet the specified performance made of FRP material. It shall be light
conditions when the tower is installed weight and non-corrosive to maintain
according to plans. stable water sprinkling effect.
4.0 CONSTRUCTION 8.0 COLD WATER BASIN

The cooling tower main frame structure The cold water basin shall be of FRP and
shall be hot dip galvanized steel (HDG). supported on HDG steel framework. The
The casing shall be made of PVC. basin shall be designed with sufficient
HDG Steel Structure water capacity to avoid air
5.0 MECHANICAL EQUIPMENT entrainment in the outlet during
operating conditions. The basin shall be
5.1 Fan(s) shall be propeller-type,
equipped with suction strainer,
incorporating heavy-duty blades of
make-up ball valve, overflow and drain.
aluminum alloy. Blades shall be
For multiple tower arrangement,
individually adjustable. Fan blades shall
equalizing pipes between basins shall
be factory balanced and assembled.
be provided to maintain the same level
Pitch angle should be variable to allow
of water in each basin.
flexibility.
5.2 The V-belts shall be of rubber with 9.0 ACCESS AND SAFETY
fabric impregnated able to withstand Ladder shall be provided for inspection
the adverse ambient conditions of 50°C & maintenance purposes. HDG steel
Mechanical Equipment
and 100% R.H. The pulleys shall be cast fan guard shall be provided over each
iron with the grooves of standard fan cylinder.
dimensions. The entire V-belt & pulley
set must be fully enclosed in a FRP
molded case to protect the v-belts from
in contact with the humid discharge air.
5.3 Motor(s) shall be TEFC,

weatherproof sq. caged induction type
suitable for 3ph /50Hz/415V power
supply and with 1450 rpm. Motor shall
be installed outside the discharge air
stream.
Hot Water Basin
TCT/B/003
Truwater Cooling Towers Sdn Bhd (188113-A)

Executive Suite 702, Block B, Kelana Business Centre, No. 97, Jalan SS7/2, Kelana Jaya, 47301 Petaling Jaya, Selangor, Malaysia.
Tel. : +603 7880 8800 Fax : +603 7804 5519
E-mail : Tw.Cooling@truwater.com.my Website : www.truwater.com.my
SARAWAK (O&M)
6.6
PUMP
D-Series
Design Featuresl
1'10 '130 180 650 850 11OO US.G.P,M Operating Temperatures
600 With standard packed gland - minus 10'C to 105"C.
500
Maximum with cooled stuffing box - 160 " C. With
mechanical seal - maximum depends upon seal fitted.
400
100
90 300
80
250
70
€oo 200 g
o F
u
s50 u
- 40
1so -
30 100
90
80
20 70
20 25 30 40 50 60 70 80 100 L/S
20 25 30 40 50 60 70 80- 100 150 200 250 300 m3/h
D-Series
180 240 350 500 650 9oO11oO 1750 2650 45OO US,G.PM
100
300
80
7o 250
60 200
'150
49
:30 100
;25
E soa
a,
<:::'
20 70:
U 60 $i
-.,15 so. '
40
10
:9 30,
, ,,' .8 25
, ,,7 .'
,.:,,:,,.6 20-, ,:
:..::,:...5
.,,,, .4
3':.:.4..:.::5::9.:7:8,,9:::1,fi:::::,:.15.:...?.c,..:25.3O:::40 50.60.,,]:30]'10{t 150 2O0 300 400
,11s,
',1:5:,,.,',24,,.25:39..,'r40r.'506017080 100,,.rr150 200250300:400.500.600,800:1000,.r.1500 mqn
Materialsl Megaflow Series
Standard Parts All Bronze
Casing No,8 Bronze
Casing Nuts Bronze
Casing Studs Stainless Steel
Casirtg.Wearing Rings No.5 Bronze .
rclandCiips, Type 316 St. Steel
45 60 90 120 150 180 240 300 450 600 900 1200 1500 1800 24oo 30oo 4000 o[ff/hl
9 12151A 24 3A 60 90 1io 50 r80 240 i00 i80 4?0 6b0 lbo 9b0td00r)00 .QIl/s]
Selection charts of Regent Megaflow'T'series pump (50H2)
Megaflow Series
Q IUS-ooml
l?000 15000 20000 '
Vertical lnstallation
Paft No. Paft Designation
116 Volute Casing
103
ffi 101
Cover
Foot
123 Pump Shaft
117 lmpeller
121 Bearing
102 Motot Stool
125 Bearing Housing
126 Bearing Cover
112 Spring
115 0-Ring
120 Radial Shaft Seal Ring
114 Shaft Seal Housing
107 Valve
1284 Gland Packing
131 Stufiing Box lnsert
127 Neck Ring
129 Lantern Ring
118 Casing Wear Ring
Vertical Split
119 Shaft Protecting Sleeve
Casing Pump 104 Spacer Sleeve
105 BEaring Bush
1'13 Washer
106 Flexible Tube
111 Nut
122 Circlip
Other Latest Model Regent Megaflow Configurations Available

Suitable For - Application Green Building and Space Saving
Full Bronze Cast - Side Fire Pump - Bottom Fire Pump - Side
Suction Top discharge Suction Top discharge Suction Top discharge
Available From
R$encprtrrtps found since 7948
1-7 Redwood Drive
Dingley, Victoria 3172
Australia
Tel: +51 (0) 3 9551 5111
D i n f l o w
Bare
centrifugal
P u mshaft
p s
Bare
P u mshaft
ps
Dinflow
The Regent Dinflow is a single stage end
suction centrifugal pump. It provides high
performance at an economical cost and is
particularly suited to mechanical and fire
services as well as being suitable for use
in a variety of other applications.
The volute casing is fitted with a

replaceable wear ring and is designed
to provide a smooth flow into the double
shrouded hydraulically balanced impeller.
The Dinflow pumps can be fitted with a

range of mechanical seals or a simple
packed gland depending on the liquid you
are pumping. These pumps feature back
I.G.P.M. pull-out design for easy maintenance and
15 30 40 60 80 100 150 200 300 400 600 800 1200 1600 2200 3000 4000 are available in a variety of materials.
160
400
100
Refer to individual curves The Regent Dinflow has been engineered
for final selection 300
80 200-500
to the stringent International Standard DIN
150-500 250
60
-500
200
24255.
50
80-400 300 150
100 125-400 150-400 -400
40 200-400 250
-400
-400
30 40-320 80-320 100 100
50-320 150
METRES
65-320 -320 125-320

FEET
-320 200 250 80

-320
20 32-260 50-260 -320
100 60
40-260 65-260 -260 125
80-260 -260 50
Design Features:
150-260
32-200 50-160 65-200 40
40-200 80-200 100 200
10 -200 150-200
125-200 -260 30
8 50-160
32-160 65-160 80-160
6
40-160
20 Operating Temperatures
TOTAL HEAD
65 100
5 50-130 -130 -160
32-130
40-130 15 With standard packed gland - minus 10˚C
4
to 105˚C. Maximum with cooled stuffing
3 10
box - 160˚C. With mechanical seal -
2 3 4 5 6 8 10 20 30 40 50 60 80 100 150 200 300 450
maximum depends upon seal fitted.
FLOW RATE LITRES/SECOND
Operating Pressures
Maximum operating pressure 1600kPa.
Maximum test pressure up to 2100kPa.
(Maximum pressure will vary depending
on particular pump model - higher ratings
I.G.P.M.
available on application).
15 30 40 60 80 100 150 200 300 400 600 800 1200 1600 2200 3000 4000
160
100
40-320H 50-320H 65
-320H 80-320H
400 Maximum Speed
32-260
300 Maximum direct coupled speeds for
80 50-260
40-260 65-260 80-260 100-260 Dinflow pumps vary between 3600 RPM
60 200
50 32-200 and 1800 RPM, depending upon pump size.
40-200 50-200 65-200 150
40 80-200
100-200
50-160 125-200
30 32-160 40-160 100
METRES
65-160 80-160
Back Pull-Out Design
FEET
80
20 50 100-160 60
40-130
-130
65-130 50
The Dinflow pump is of “Back Pull-Out”
32-130
40 design, and when a suitable spacer
10
30 coupling is fitted to a direct coupled unit,
8
the casing and motor can remain in
6 20
TOTAL HEAD
5
position while all other pump parts can be
15
4
Refer to individual curves
for final selection
removed for simple and quick maintenance.
3 10
2 3 4 5 6 8 10 20 30 40 50 60 80 100 150 200 300 450

Material Options:
Most combinations of: Cast Iron, Bronze, Zinc-free Bronze and Stainless Steel are available
for casings and impellers. Other materials and special coatings available upon request.
Cast Iron Bronze Z.F. Bronze Stainless Steel
Casing ✔ ✔ ✔ ✔
Impeller ✔ ✔ ✔ ✔
Shaft 앶 앶 앶 ✔
Shaft Sleeve 앶 ✔ 앶 ✔
Wear Ring ✔ ✔ ✔ ✔
Applications:
* Airconditioning I.G.P.M.
* Heating and Ventilation 15 30 40 60 80 100 150 200 300 400 600 800 1200 1600 2200 3000 4000
160
* Refrigeration 400
* Fire Protection 100
300
* Plumbing 80
80-400
* Circulating 60
50
200
* Transfer 40 40-320
50-320
65
-320 80-320 100 150-320
150
-320 125-320
* Irrigation 30
50-260
100
METRES
32-260 40 65
* Drainage
FEET
-260 80-260 80
-260 100-260 125
20 -260
* Water Pressure Boosting 32-200 40 50
-200 65-200 60
-200 80-200 100-200 50
* Process Industry 50 40
40-160 -160 80
* Petroleum Products 10 32-160 65-160
-160
30
8 65
* General Industry 50 -130
-130
6 40-130 20
TOTAL HEAD
32-130
* Food and Drink Manufacture 5
15
* Water Treatment and Supply 4
Refer to individual curves
for final selection
* Cooling Towers 3 10
2 3 4 5 6 8 10 20 30 40 50 60 80 100 150 200 300 450

I.G.P.M.
15 30 40 60 80 100 150 200 300 400 600 800 1200 1600 2200 3000 4000
160
50-200
400
100
300
80 32-260 50
40-260 65-260 80-260 100-260
-260
60 200
50 32-200
40-200 65-200
80-200 100 150
40 50-160 -200
32-160
40-160 80-160
65-160
30 150 100
METRES
50-13 -400
50-130 0
FEET
65-130 1150 RPM 80

20 32-130 40-130 60
150-320
1150 RPM 50
125-260 40
10 1150 RPM
30
8
6 20
TOTAL HEAD
5 100-320
1150 RPM Refer to individual curves 15
4 for final selection
3 10
2 3 4 5 6 8 10 20 30 40 50 60 80 100 150 200 300 450

Shaft sleeve Flanges
Stuffing Box Fully machined hook type 9 Flange dimensions and drilling
shaft sleeve prevents shaft are according to ISO 2084-16BAR
damage under the gland (BS4504-1969 Table 16/11)
packing which substantially
reduces maintenance costs.
Wear rings
Replaceable wear rings
Standard pump is fitted with a
7 are fitted as standard
packed gland. Mechanical seal to all casings and also
options available. 10 to back covers on larger
4 pumps which reduces
maintenance time and
cost.
Bearings 6 3
All models have Casing
grease lubricated, The volute casing is
sealed for life of robust design with
bearings as integrally cast feet,
standard with vertical top centreline
the option of discharge with axial
oil bath or suction incorporating
greaseable cast inlet vane to
bearings give best flow to
available. impeller eye.
8
Support Foot Shaft 2 1
Each pump has Bearing Housing 5 Shafts are stainless steel and
Impeller
Rugged cast iron construction with Double shrouded type is
a removable only 5 sizes are needed to cover
only five bearing housings covering hydraulically balanced,
support foot fitted all 46 pump models. A domed lock
complete range of pumps which positively driven by shaft
at the drive end nut secures the impeller.
give many common interchangeable key & axially locked between
for greater rigidity. sleeve and impeller nut.
parts.
Export Brochure 6/98
Available From: Regent Pumps:

A.C.N. 006 936 527
59-63 Redwood Dve, Dingley Victoria 3172 Australia
Phone: (03) 9551 5111 Fax: (03) 9551 7217
Int. Ph: (613) 9551 5111 Int. Fax: (613) 9551 7217
All specifications are subject to change without notice.

SARAWAK (O&M)
6.7
EXHAUST FAN
Wall Mounted Ventilating Fans
15AAQ1 15cm/6" Dimension
Excellent For Small Room G B
C
ØA
E sq.
C D
H F I 4 - Ø6 Hole
• High efficiency motor Specifications

• Automatic Shutter Noise Nett
Model RPM CFM Motor Rating Motor W Motor Type Level (dB) Weight (kg)
15AAQ1 1480 170 220-240V 15 Condenser 31 1.40

50Hz
Dimensions (mm)
Model A B C D E F G H I
15AAQ1 155 240 195 254 170 75 55 54 52
20AQM8 20cm/8" Dimension

25AQM7 25cm/10" Installation Hole
30 J B
F
30AQM8 30cm/12"
Suitable For General Indoor Ventilation
E
G sq.
F
C
D
40
17
10
H 90 I K
Specifications
Motor Motor W Motor Noise Nett
Motor
Model RPM CFM Level Weight
Rating Low High HP Type(dB) (kg)
20AQM8 1109 ~ 1301 318 14.9 ~ 18.3 0.02 37 2.30
240V 4 Pole
25AQM7 999 ~ 1221 530 50Hz 25.2 ~ 30.8 0.03 Condenser 39 2.60
30AQM8 925 ~ 1085 727 31.8 ~ 38.8 0.05 45 3.00
• Q-blade for perfect balance and quiet operation Dimensions (mm)

• High efficient motor for energy saving
Model A B C D E F G H I J K
• Ball bearing motor for smooth rotation and 20AQM8 200 dia. 300 310 160 150 260 240 83 45 68 140
excellent durability 25AQM7 250 dia. 350 360 185 175 310 290 65 150
40 48
• Automatic Shutter 30AQM8 300 dia. 400 410 210 200 360 340 81 160
13
Ceiling Mounted Ventilating Fans
20CQT1 20cm/8" Dimension
Suitable For Home & Small Room A sq.
C
H D
B sq.
C
F dia.
E sq.
• Q-Blade design for perfect balance, Specifications
quiet operation Noise Nett
Model RPM CFM Motor Rating Motor W Motor Type
• High efficiency of air flow Level (dB) Weight (kg)
• Durable and long lasting operation 20CQT1 1207 265 220-240V 25.7 Condenser 41 1.80
50Hz
• Quiet and energy efficient
Dimensions (mm)
Model A B C D E F G H
20CQT1 315 305 286 128 260 223 200 18
25TGQ7 25cm/10" Dimension

Suitable For Commercial & Residential Use Louver D Name Plate
Space
A F
Ø For
C B Locking
E H
Blade Power Cord

Spinner
• New louver design for better outlook Specifications

• Q-blade design for perfect balance and Motor Noise Nett
quiet operation Model Motor W Motor Motor
RPM CFM Level Weight
Rating HP Type
Low High (dB) (kg)
• High efficiency motor for energy saving
240V 4 Pole
• Ball bearing motor for smoother and more 25TGQ7 959 ~ 1172 367
50Hz 24.8 ~ 30.3 0.03
Condenser
45 1.90
durable operation
Dimensions (mm)
Model A B C D E F G H
25TGQ7 250 355 336 177.5 365 272 310 117.5
12
AXIAL FAN SERIES
ADT O ADF O ADBO ARD
NICOTRAllGebhardt
NlcoTRAl\Gebh
1. AxialFanlntroduction
Gebhardt
Nicotra "'-"--"'
2. ADTSeries.",-",
3. A D FS e r i e s - , , - . - " I
4. ADTA Series t
- Air Performance
- SoundPowerLevel
5. -'
ADT,ADFGeneralDimension a
6. View
ADT,ADF ExPloded o
7. ADBSeries.--.-, o
8. --.
ADBGeneralDimensi.on. o
9. ADB Explo d.V,iew- o
10. A R DS e r i e s. - - " " I
--,
1 1 . ARDGeneralDimension I
12. ARD ExplodedView I
13. ProductsRange
14. -
Nomenclature
15. Appendix
NlCOTRAllGebhardt
lntroduction
The NicotraGebhardtaxialfan providewide rangeof air volumefrom 360 t3/hr to
216,000r3/hr, at staticpressureup to 10OOPa of completefan systemwith most
Remarkably
application.
diversified are the directresultof rigor-
highfan efficiencies
ouslydevelopedaerodynamicallyprofiled bladesandadvanced
impeller manufacturing
technique.
FEATURES
x l
'l ,
', 'i h ' ;
\
{
uh.,
\ \
. ' / .
1t \\ : ''-/'
F. r/
I\ 'l
I
\,
HighEfficiency
Blade
FullyAdjustable
Versatile
HighQualityMaterial
ComPonents
Interchangeable
ln Linel
. TheAxiallmpellerls Balanced G2.5
. Anti-static
GRN for Anti SparkApplic :
, T -
On BS7346part2#
. ThirdPartyCertification ForQmokeSpillAPP|ication
. SeriesADTAis AMCACertified
ForPe;formances
':,ji€ & $ounds
: j
NlCOTRAliGebhardt
Test Standard
to
The performances shownare for standardunits.Fansare testedin accordance
to
test resultsare corrected
Method1, BS 848 Part 1: 1980.Underthis standard,
standard of 1.2kglm3'
air densitY
dueto manufacturing
fan performance fallswith
variations
Anyvariationin individuar Perfor-
class B torerances of the Britishstandard.Fan soundlevelsare givenon
on in-ductmethodas
manceCurvestogetherwith OctaveBandspectrum,based
specifiedin BS 848 Parl2.
lmpeller
They are Glass Reinforced
Aerofoilbladesare availablein Threetypesof material.
Nylon(GRN),Aluminium GRN(ASrAr).
(AL)andAnti-static
GRN,GlassReinforcedNYlon
high temperaturecapability
GrassreinforcedNyron66 has greaterstrengthand for standard
heat).Higherspeedsare acceptable
(-40'Cto +150"Coi non-radiant
whenGRNbladesarefitted.i".ott"nded maximum Tip Speedfor GRNis
impeller
11Sm/sec.
AL
Aluminium,
in emergencysmokeand fume
Bladesare availablein AluminiumLM6.Provenfor use -40"c to
up to 400"c. rt is arso suitabrefor continuousoperation
extractapprications
+200"C.MaximumTipSpeedforALbladesislo0m/sec.
Anti-staticBlades
to provideanti-static properties The
are available.
GRN Bradesspeciailyformurated as "potentially
principle
application whichis categorised
forthesebladesis for installation
a
explosiveatmosphere" and wherethe riskof ignitionof gas or dustvapoursthrough
sparkincidentis a PossibilitY.
havea
Theseanti_static bradeswhichare madewith20% grassfilring(as standard)
percentage of carbonblackaddedto controlthe surfaceresistivity'
normalGRN
bladeshavea slightlylowertensilestrengththan the
The anti-static
however that
we are recommending
blades,thisshouldnotconcernmostapplications,
the maxcontinuous temperature
operating in limitedto -30degOto 110 degC'
NlGOTRAllcebhardt
Balancing
axialimpellers
All NicotraGebhardt to ISOStdNo 1940,Edi-
andfansarebalanced
Amplitude= 2'5 mm/s)in our
tion usingbalancinggradeof G2.5 (Displacement
factory.
HubSystem
6 hubssystems
bladesandtherearebasically
Ourrangeof axialfan is fullyadjustable
as shownbelow:
Hub Size Numberof Blades
110 5 Blades
160 5 & 10Blades
23O 3, 6 & 12 Blades
25O 3, 6 & 12 Blades
400 4 , 8 , 1 2& 1 6 B l a d e s
550 4,7 & 11Blades
for AxialFan
HubCombination
T h e c o mp l e teh u b syste mfo r i mpeller1400 and 1600 consistsof side plate m etal ,
c e n t e rh u b ,a l u m i n i u mb l a d e ,b l a d eh o l d e ra n d t a p e rl o c kb u s h .
O u r 2 5 0 a n d 4 0 0 h u b a re d e signedto be mountedwith taper - lockbush 25 17 of
4 2 m m , 48 mm,5 5 mm a n d 6 0 mm diameteras optionalfeatur e.
BladesDesign/TYPes
we havethe followingdesignof impellers:
Basically,
DesignType Material Hubsystem

S GRN
GRN/Anti- Static 110,160'230
B ALU 110,160,230
A GRN
GRN/ALU/Anti-Static 110, 160' 230
T ALU 25O
C ALU 4OO
Casing
-
A l l s t a n da rd a xi a lfa n tu b e ca si ng' ssur facear e appliedwith paint RAL 7030 b y
p o w d e rc o a ti n g me th o d .C o a ti ngthicknessis 60pm'
T h u s ,b y th i s me th o d ,tu b e ca si ngsur faceappear edto be wr inkleand pr ovidebetter
a g a i n stch e mi ca al n d wear '
p r o c t e c ti o n
NICOTRA\\Gebhardt
Longcaseaxialcasingsare rolled.from 2.0 mm to 5'Omm mildsteel'The standard
{ootmountedsupportcan be provided
doubleflangedI Jractietmountingis provided,
Tube.uring comewitfrsianOard view port,and the accessdoor can be
as optional.
requestedas oPtion.
ElectricMotor
TEFC,foot mountedinsulationin
NicotraGebhardtuse standardthreephrasemotoll C|ass
insu|ation
1P55,
accordance EN ooog+or BS 4999,Enc|osure
withIECstandard
protectionclasses'two speedmotor(polesswitCh)
"F".Othermediumtemperatures,
and etc as oPtional.
ComPuterselection
model
softwareallowsyou to selectthe mostsuitable
fan selection
our user-friendly by the stateof art
dataand fan .u,ue wil| be generated
to yourneeds.Performance
software.
Reversalof Air Flow

three-phasedmotorsby simply
Air flow directioncan be reversedon fans fittedwith
in reverserotationis
the directionof rotation.Butthe impacton performance
reversing
approximatelY;
Airflow/ volume: -40%
Pressure reduction:-50%
Powerreduction: -35"/"
Trulyreversible
axialfan,everyotherblademustbe set in the oppositedirectionof
Fora trulyreversible
flow.The bladesmustbe the samehanding. The impacton performancein reverserota-
for up to maxpitchangleof 30 deg)'
(applicable
tionis approximately:
Airflow/ volume: -20%
Pressure reduction:-35%
Powerreduction: -30%
Contra-rotating
as optional'A two
Multi-stageaxial fans with contra-rotatingimpellerscan be supplied
the pressuredevel-
stage contra-rotatingassemblydevelopJapproximately2.5 times
fanandincreases
opiObya singlesta'ge soundlevelby8-10dB'
theoverall
N|COTRAllcebhardt
To selecta contra-rotating axial,dividethe staticpressureby 2.5 and selectAS
thoughit was a singlestageunit.The kW figureis for onestageonlyand shouldbe
multiplyby two to the system.
CasingOverviewDimension
0315-0560 0630-1
600(<FS200) 1120-1600(>FS200)
StandardArrangement
A = Fromthemotorto theimpeller
B = Fromtheimpeller
to themotor
AU= Fromthemotorto theimpeller,
up position.
NlCOTRAllGebhardt
ADT Series
APPLICATION
NicotraGebhardtADT are particularly suit-
of staleair,for general
ableforthe extraction
drying processand all those
ventilation,
applicationswhich require moving large
volumesof air.
CONSTRUCTION
The housingis madeof heavy-gauge mild
steel casing,seamlessdoubleflangesat
both end. Powder coated bake enamel
finishing(60 micron)or galvanizedsteel'
Highefficiency impellermadeof adjustable
pitchaerofoilblade;ALU type or GRN type'
Footmounting& Hot dip galvanized casing
as an oPtion.
is available
WORKING TEMPERATURE
- 4 0 ' Ct o 1 5 0 ' C: G R N
- 4 0 " Ct o 2 0 0 ' C: A L U
MOTOR
withtypeof "TotallyEnclosedFancooled'(TEFC),horizontalfootmounted
Three-phase
Cagelnduction
Squirrel Motor,featured systemwithClassB tem-
withclassF insulation
peraturerise (80"c).Voltagesupplyincludes400v/50H2,4O0Vl60Hz or 44OYl6OHz'
upon
Motorstandardsare comprywith lEc 60034or BS 4ggg.other requirements
demandbasis.
or steelflexible
Motorare wiredto an externalterminalboxwithcableandthroughPVC
Pleasereferto page17 Appendix
conduit. forwireconnectiondiagram'
NF T H EA I R
D I R E C T I OO
The standard to the motor(B),on demandthe fanscan be
air flowfromthe impeller
supplied withthe direction (A).
fromthe motorto the impeller
NlCOTRAIlGebhardt
ADI ADFGeneralDimension
ADT/FwithHanger
N x O
ADT/Fwith MountingFeet(optional)
ADT/F-hanger ADT/F- Mounting

Feet(optional)
ADT/F Dimensios
General MtrFrame Size
G H I J pxl
MODEL gA 0BPCD) AC D Nx0 E F M x A
355 8 X1 0 211 365 4X16 395 2775 265 315 2x10 90
315 315 355 395
355 I X 10 211 405 4x16 39s 2975 305 355 2x10 90
355 355 395 435
400 I x 10 256 405 4x16 440 2975 305 355 2x'10 100
355 355 395 435
355 12X 10 211 450 4x16 395 320 350 400 2x10 90
400 400 440 480
12X 10 291 450 4X16 475 320 350 400 2x10 112
400 400 440 480 435
12X 10 256 500 4x16 440 345 400 450 2x10 100
450 450 490 530 400
475 12X 10 331 500 4x16 515 345 400 450 2x10 112
450 450 490 530
12X 10 356 550 4x16 538 370 450 500 2x14 132
500 500 540 580 s00
12X 10 356 611 4x16 538 4025 460 560 2t14 132
560 560 605 660 500
12X 10 326 691 4x20 538 4375 530 630 2x14 112
OJU 630 675 730 500
730 700 12X 10 526 691 4X20 738 4375 530 630 2x14 tou
630 630 675
18X 1 2 324 774 4X20 536 477.5 610 710 2x16 112
710 710 755 810 500
1 8X1 2 534 774 4x20 746 4775 610 710 2x16 160
710 710 755 810 710
',18
X 12 384 864 4x20 596 5225 700 800 2x16 132
800 800 845 900 560
18X 12 584 864 4X20 796 522.5 700 800 2 x1 6 180
800 800 845 900 760
18X 12 454 964 4x20 666 592,5 800 900 2x16 132
900 900 945 1000 630
'1000 18X 12 644 964 4X20 856 592,5 800 900 2x16 200
900 900 945 820
'1000 454 1065 4x20 666 6725 900 1000 2x16 160
1000 1045 1100 630 24X12
624 1065 4x20 836 6725 900 1000 2x16 200
1000 1000 1045 1'100 800 24X12
24X12 724 1185 4X20 936 742.5 1020 1120 2x16 225
1120 1120 1185 1250 900
24X12 974 1185 4X20 1186 742.5 1020 1120 2x'16 280
11 2 0 1120 1185 1250 1150
24x12 794 1324 4X25 1084 8075 1050 1250 3x20 250
1250 1250 1315 1380 1000
944 1324 4x25 1234 807,5 1050 1250 3x20 280
1250 1250 1315 1380 1150 24X12
912 1476 4X25 1202 8825 1200 1400 3x20 280
1400 1400 1465 1530 1120 32X14
1250 32X 14 1042 1676 4X25 1332 981,5 1400 1600 3x20 315
1600 1600 1663 1730
Dueto a policyof continuous development andimprovement to supplyproductwhichmaydifferfromthose

the rightis reserved
anddescribed
illustrated in thispublications.
dimensions
Certified willbe suppliedon receiptof order
NICOTRA\lGebhardt
ADT,ADF ExPlodedView
Part List, Specification,Arrangement
Part DescriPtion Specification
etc
1 Tube Casing Painted (RAL 7030), Hot Dipped, Stainless Steel'
Terminal Box PVC, Cast lron, etc
2
3 ViewPort Cover Depend on Vcasing material
4 Mouting Feet (OPtional) Depend on Vcasing material
5 Counter Flange (OPtional) Deoend on Vcasing material
6 Electrical Motor Soecification as Per requested
7 lmpeller ALU, GRN, GRN-antistatic
8 Fan Guard P a i n t e do r H o t D i P P e d
(OPTIONAL)
FLANGE
AXIALCOUNTER
MODEL @A 68 (PCD) @c D NxZ
315 3 15 355 395 40 BX 1 0
355 355 395 435 40 BX 1 0
400 400 440 480 40 1 2X 1 0
450 450 490 530 40 1 2X 1 0
500 500 540 580 40 12X10
560 560 605 660 40 1 2X 1 0
630 630 675 730 40 1 2X 1 0
710 710 755 810 40 18X12
800 800 845 900 40 1 Bx 1 2
900 900 945 1000 60 18X12
1000 1000 1045 11 0 0 60 24X12
1120 1120 1185 1250 60 24X12
1250 1250 1315 1380 60 24X12
1400 1400 1465 1530 60 32X14
1600 1600 1663 1730 60 32X14
NlCOTRAliGebhardt
ProductRange
Aerodynamic Performance
The Emergency withBS
Fumeand SmokeExtractFanrangeis testedin accordance
as a
undernormalambientconditions
848 Part1, andthe datashownis determined
standardbasisfor unitselection.
Pa
FanPerformanceCurves l n sw g
2000 80
60
400 - 1250@ 960 rpm 85848:ft'l:1980
TYPED lnstallation 0
1000 630-125O@72Orpm
800 3 0
600
20
400
u 1 0
) 08
3
u
2oo
06
I
< lnn 04
2 8 0 0,3
60
40
20
0 1 02 03 04 30 40 60 80 100m7s
VOLUIVlE {t3/mrn
025 0 5 6 8 12 16 20 80 I 20 160 (xl'ci00)
," Fan Performance Curves

2000
fl 31s - 630 @ 2800 rpm

1000 n : t s - 1 2 5 0@ 1 4 o or p m
800
600
400
u 1 0
08
u
L 06
U
F
4
100
z 80 3
s 60
0 1 03 04 06 081 60 80'100m3/s
VOLUME
, ft3lmin
025 05 1 5 Z 6 8 12 16 20 80 t20 too lil(js[i
Dimensionsandperformance is
graphsdetailedin thisleafletareto be usedonlyas a guide.Certifiedinformation
our SalesOffice.Note:Dataabove1250mmshallbe providedon request.
on requestfrom
available
NlCOTRAilGebhardt
Nomenclature
in the
your requirements
when orderingNicotraGebhardtAxialfans,pleasespecify
sequenceto avoidconfusion'
followings
Data
1. FanTYPeand Performance
- FanTYPe: ADT,ADF,ADB or ARD
- CaPacitY
- StaticPressure
2. ElectricMotorDetails
50 Hz or 60 Hz type
- Power,mainsupply,voltage,frequency'
- MotorSPeed,PolaritY
(ClassF,ClassH, etc)
- Insulation
Material
3. lmPeller
- GlassReinforced GRN
NYlon,
- Aluminium A,L U
- AntiStaticGRN
No of Bladesand BladeT
(SamPle)
Description
I ALU- 18.5/4P
ADF1000/400/08c 120.0
ADT LongCaseDrive
1000 = 1000mm
FanDiameter
4007 H u bS i z e
8C BladetYPe"C",QtY= 3
20" BladeAngle20 Deg
ALU ALUMaterial
NlCOTRAllGebhardt
WiringDiagram
ForVarious
Application
LI L2
StarConnection L2r L22 L23
Star-Delta
Connection
n
Multi-speedmotoniin Dahlander
Connection(tappedwinding)
IU lw
t o.-
2U 2W
o +
LI L2
Low Speed
Multi-speedwith 2 separateWindingds
n
lu lv lw
t-H
Low ed High Speed

99
099
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SARAWAK (O&M)
7.0
TEST CERTIFICATES
CADANGAN UNIVERSITI TEKNOLOGI MARA (UiTM) KAMPUS MUKAH DI ATAS
SARAWAK.
AS-BUILT DRAWINGS AND OPERATION AND MAINTENANCE MANUAL FOR

AIR-CONDITIONING & MECHANICAL VENTILATION SYSTEM
AS-BUILT DRAWINGS (VOL 2 OF 2)
CONCESSIONAIRE
KP Mukah Development Sdn. Bhd.

Level 3A, Wisma Bukit Mata Kuching,
Jalan Tunku Abdul Rahman,
93100 Kuching, Sarawak
Arkitek: Jurutera Sivil & Struktur:

Jurubina Unireka Jurutera Perunding Wahba Sdn Bhd
Suite 19.11 Kueh Hock Kui Commercial Centre, S/L No. 4, Lot 12155,
Lot 3007 Jalan Tun Ahmad Zaidi Adruce, Ground Floor, Song Plaza,
93150 Kuching, Jalan Tun Jugah / Jalan Song,
Sarawak 93350 Kuching,
Sarawak
Jurutera Mekanikal & Elektrikal: Jurukur Bahan:

Perunding CHL Sdn. Bhd. PUBM Quantity Surveyors Sdn Bhd
No. 15A, 1st & 2nd Floor, Lot 248, 1st Floor,
Lot 511, Section 6, KTLD, Lorong 3, Jalan Ang Cheng Ho,
Jalan Kulas, 93100 Kuching,
PO Box 1114, Sarawak
93722 Kuching,
Sarawak
SARAWAK (O&M)
8.0
AS BUILT DRAWING
CADANGAN UNIVERSITI TEKNOLOGI MARA (UiTM) KAMPUS MUKAH DI ATAS SEBAHAGIAN
LOT 35, BLOK 99, MUKAH LAND DISTRICT, MUKAH DIVISION, SARAWAK
AS-BUILT DRAWING LIST
DRAWING NO. DESCRIPTION DRAWING NO. DESCRIPTION
UITM/TA/BP/ACV/01 BANGUNAN PENTADBIRAN - LEVEL 1 UITM/TA/DP/CW/01 DEWAN PEPERIKSAAN - LEVEL 1 FLOOR PLAN
AIR-CONDITION AND VENTILATION LAYOUT CHILLED WATER PIPE LAYOUT
UITM/TA/BP/ACV/01a AIR-CONDITION AND VENTILATION SERVICES UITM/TA/FPA/ACV/01 FAKULTI PERLADANGAN & AGROTEKNOLOGI
LEVEL 1 PLAN
UITM/TA/BP/ACV/01b AIR-CONDITIONING AND VENTILATION SERVICES AIR-CONDITIONING AND VENTILATION LAYOUT
AIR-CONDITIONING CONTROL PANEL
UITM/TA/FPA/ACV/01a AIR-CONDITION AND VENTILATION SERVICES
UITM/TA/BP/ACV/01c AIR-CONDITIONING AND VENTILATION SERVICES
AIR-CONDITIONING CONTROL PANEL UITM/TA/FPA/ACV/01b AIR-CONDITIONING AND VENTILATION SERVICES
UITM/TA/BP/ACV/01d BANGUNAN PENTADBIRAN
FCU CONTROL PANEL UITM/TA/FPA/ACV/01c AIR-CONDITIONING AND VENTILATION SERVICES
UITM/TA/BP/ACV/02 BANGUNAN PENTADBIRAN - LEVEL 2
AIR-CONDITION AND VENTILATION LAYOUT UITM/TA/FPA/ACV/01d AIR-CONDITIONING AND VENTILATION SERVICES
UITM/TA/BP/ACV/03 BANGUNAN PENTADBIRAN - UPPER LEVEL 2
AIR-CONDITION AND VENTILATION LAYOUT UITM/TA/FPA/ACV/01e AIR-CONDITIONING AND VENTILATION SERVICES
UITM/TA/BP/ACV/04 BANGUNAN PENTADBIRAN
AIR-CONDITION AND VENTILATION UITM/TA/FPA/ACV/02 FAKULTI PERLADANGAN & AGROTEKNOLOGI
SCHEDULE OF AHU, FCU AND EXHAUST FAN LEVEL 2 PLAN
AIR-CONDITIONING AND VENTILATION LAYOUT
UITM/TA/BP/CW/01 BANGUNAN PENTADBIRAN
LEVEL 1 FLOOR PLAN UITM/TA/FPA/ACV/03 FAKULTI PERLADANGAN & AGROTEKNOLOGI
CHILLED WATER PIPE LAYOUT LEVEL 3 PLAN
AIR-CONDITIONING AND VENTILATION LAYOUT
UITM/TA/BP/CW/02 BANGUNAN PENTADBIRAN
LEVEL 2 FLOOR PLAN UITM/TA/FPA/ACV/04 FAKULTI PERLADANGAN & AGROTEKNOLOGI
CHILLED WATER PIPE LAYOUT SCHEDULE OF AHU, FCU AND EXHAUST FAN
UITM/TA/P/ACV/01 PERPUSTAKAAN - LEVEL 1 FLOOR PLAN UITM/TA/FPA/CW/01 FAKULTI PERLADANGAN & AGROTEKNOLOGI
AIR-CONDITION AND VENTILATION LAYOUT LEVEL 1 FLOOR PLAN
CHILLED WATER PIPE LAYOUT
UITM/TA/P/ACV/01a AIR-CONDITION AND VENTILATION SERVICES
UITM/TA/FPA/CW/02 FAKULTI PERLADANGAN & AGROTEKNOLOGI
UITM/TA/P/ACV/01b AIR-CONDITIONING AND VENTILATION SERVICES LEVEL 2 FLOOR PLAN
AIR-CONDITIONING CONTROL PANEL CHILLED WATER PIPE LAYOUT
UITM/TA/P/ACV/02 PERPUSTAKAAN - LEVEL 2 FLOOR PLAN UITM/TA/FPA/CW/03 FAKULTI PERLADANGAN & AGROTEKNOLOGI
UITM/TA/BP/ACV/03 PERPUSTAKAAN
AIR-CONDITION AND VENTILATION UITM/TA/PPAUP/ACV/01 PEJABAT PUSAT AKUAKULTUR & UNIT PERLADANGAN
SCHEDULE OF AHU, FCU AND EXHAUST FAN GROUND FLOOR AND FIRST FLOOR PLAN
AIR-CONDITION AND VENTILATION LAYOUT
UITM/TA/P/CW/01 PERPUSTAKAAN - LEVEL 1 FLOOR PLAN
CHILLED WATER PIPE LAYOUT UITM/TA/PH/ACV/01 PUSAT HATCHERI - FLOOR PLAN
UITM/TA/P/CW/01 PERPUSTAKAAN - LEVEL 2 FLOOR PLAN
CHILLED WATER PIPE LAYOUT UITM/TA/PP/ACV/01 PUSAT PEMPROSESAN - GROUND FLOOR PLAN
UITM/TA/DP/ACV/01 DEWAN PEPERIKSAAN - LEVEL 1 FLOOR PLAN
AIR-CONDITION AND VENTILATION LAYOUT UITM/TA/BKAD/ACV/01 BENGKEL KEJURUTERAAN AKUATIK DAN DEPO
GROUND FLOOR PLAN
UITM/TA/DP/ACV/01a AIR-CONDITION AND VENTILATION SERVICES AIR-CONDITION AND VENTILATION LAYOUT
UITM/TA/DP/ACV/01b AIR-CONDITIONING AND VENTILATION SERVICES UITM/TA/MD/ACV/01 MAKMAL DIAGNOSTIC - GROUND FLOOR PLAN
AIR-CONDITIONING CONTROL PANEL AIR-CONDITION AND VENTILATION LAYOUT
UITM/TA/DP/ACV/02 DEWAN PEPERIKSAAN UITM/TA/MD/ACV/01a MAKMAL DIAGNOSTIC

AIR-CONDITION AND VENTILATION AIRCOND CONTROL PANEL DRAWING
SCHEDULE OF AHU, FCU AND EXHAUST FAN
DRAWING NO. DESCRIPTION DRAWING NO. DESCRIPTION
UITM/TA/KSAP/ACV/01 KEMUDAHAN SOKONGAN AKADEMIK / PENYELIDIKAN UITM/TA/DK/CW/01 DEWAN KULIAH - PELAN TINGKAT BAWAH
- PUSAT JUAL HASIL & STOR - GROUND FLOOR PLAN CHILLED WATER PIPE LAYOUT
AIR-COND AND VENTILATION LAYOUT
UITM/TA/KKPD/ACV/01 BANGUNAN UNIT KESELAMATAN / KESIHATAN /
UITM/TA/FSG/ACV/01 FAKULTI SAINS GUNAAN - LEVEL 1 PLAN PENYELENGGARAAN / DEPO KENDERAAN
UITM/TA/FSG/ACV/01a AIR-CONDITION AND VENTILATION SERVICES
UITM/TA/KKPD/ACV/01a AIR-CONDITION AND VENTILATION SERVICES
UITM/TA/FSG/ACV/01b AIR-CONDITIONING AND VENTILATION SERVICES
AIR-CONDITIONING CONTROL PANEL UITM/TA/KKPD/ACV/01b AIR-CONDITIONING AND VENTILATION SERVICES
UITM/TA/FSG/ACV/01c AIR-CONDITIONING AND VENTILATION SERVICES
AIR-CONDITIONING CONTROL PANEL UITM/TA/KKPD/ACV/01c BANGUNAN UNIT KESELAMATAN / KESIHATAN /
PENYELENGGARAAN / DEPO KENDERAAN
UITM/TA/FSG/ACV/01d AIR-CONDITIONING AND VENTILATION SERVICES FCU CONTROL PANEL
UITM/TA/KKPD/ACV/02 BANGUNAN UNIT KESELAMATAN / KESIHATAN /
UITM/TA/FSG/ACV/01e AIR-CONDITIONING AND VENTILATION SERVICES PENYELENGGARAAN / DEPO KENDERAAN
AIR-CONDITIONING CONTROL PANEL LEVEL 2 FLOOR PLAN
UITM/TA/FSG/ACV/02 FAKULTI SAINS GUNAAN - LEVEL 2 PLAN
AIR-CONDITION AND VENTILATION LAYOUT UITM/TA/KKPD/ACV/03 BANGUNAN UNIT KESELAMATAN / KESIHATAN /
UITM/TA/FSG/ACV/03 FAKULTI SAINS GUNAAN - LEVEL 3 PLAN AIR-CONDITION AND VENTILATION
AIR-CONDITION AND VENTILATION LAYOUT SCHEDULE OF AHU, FCU AND EXHAUST FAN
UITM/TA/FSG/ACV/04 FAKULTI SAINS GUNAAN UITM/TA/KKPD/CW/01 BANGUNAN UNIT KESELAMATAN / KESIHATAN /

AIR-CONDITION AND VENTILATION PENYELENGGARAAN / DEPO KENDERAAN
SCHEDULE OF AHU, FCU AND EXHAUST FAN LEVEL 1 FLOOR PLAN
UITM/TA/FSG/CW/01 FAKULTI SAINS GUNAAN - LEVEL 1 FLOOR PLAN
CHILLED WATER PIPE LAYOUT UITM/TA/KKPD/CW/02 BANGUNAN UNIT KESELAMATAN / KESIHATAN /
UITM/TA/FSG/CW/02 FAKULTI SAINS GUNAAN - LEVEL 2 FLOOR PLAN LEVEL 2 FLOOR PLAN
CHILLED WATER PIPE LAYOUT CHILLED WATER PIPE LAYOUT
UITM/TA/FSG/CW/03 FAKULTI SAINS GUNAAN - LEVEL 3 FLOOR PLAN UITM/TA/MSB/ACV/01 MECHANICAL SERVICES
CHILLED WATER PIPE LAYOUT MSB ROOM SUBSTATION 2 AND 3
FLOOR PLAN VENTILATION LAYOUT
UITM/TA/FSG/CW/04 FAKULTI SAINS GUNAAN - LEVEL LOWER ROOF PLAN
CHILLED WATER PIPE LAYOUT UITM/TA/MSPP/ACV/01 MEDAN SELERA & PUSAT PELAJAR - LEVEL 1 PLAN
UITM/TA/FPP/ACV/01 FAKULTI PENGURUSAN PERNIAGAAN
LEVEL 1 FLOOR PLAN UITM/TA/MSPP/ACV/01a MEDAN SELERA & PUSAT PELAJAR
AIR-CONDITION AND VENTILATION LAYOUT KITCHEN HOOD AND EXHAUST FAN CONTROL PANEL
UITM/TA/FPP/ACV/01a AIR-CONDITION AND VENTILATION SERVICES UITM/TA/MSPP/ACV/02 MEDAN SELERA & PUSAT PELAJAR - LEVEL 2 PLAN
UITM/TA/FPP/ACV/02 FAKULTI PENGURUSAN PERNIAGAAN
LEVEL 2 FLOOR PLAN UITM/TA/S/ACV/01 SURAU - LEVEL 1 FLOOR PLAN
AIR-CONDITION AND VENTILATION LAYOUT AIR-CONDITION AND VENTILATION LAYOUT
UITM/TA/FPP/ACV/03 FAKULTI PENGURUSAN PERNIAGAAN UITM/TA/C/ACV/01 CITU - LEVEL 1 FLOOR PLAN

AIR-CONDITION AND VENTILATION AIR-CONDITION AND VENTILATION LAYOUT
SCHEDULE OF AHU, FCU AND EXHAUST FAN
UITM/TA/C/ACV/02 CITU - LEVEL 2 FLOOR PLAN
UITM/TA/FPP/CW/01 FAKULTI PENGURUSAN PERNIAGAAN AIR-CONDITION AND VENTILATION LAYOUT
LEVEL 1 FLOOR PLAN
CHILLED WATER PIPE LAYOUT UITM/TA/RT/ACV/01 RUMAH TETAMU - LEVEL 1 & LEVEL 2 FLOOR PLAN
UITM/TA/FPP/CW/02 FAKULTI PENGURUSAN PERNIAGAAN
LEVEL 2 FLOOR PLAN UITM/TA/RT/ACV/02 RUMAH TETAMU - LEVEL 3 & LEVEL 4 FLOOR PLAN
CHILLED WATER PIPE LAYOUT AIR-CONDITION AND VENTILATION LAYOUT
UITM/TA/DK/ACV/01 DEWAN KULIAH - PELAN TINGKAT BAWAH UITM/TA/RT/ACV/03 RUMAH TETAMU - LEVEL 5 FLOOR PLAN
AIR-CONDITION AND VENTILATION LAYOUT AIR-CONDITION AND VENTILATION LAYOUT
UITM/TA/DK/ACV/01a AIR-CONDITION AND VENTILATION SERVICES UITM/TA/PPK/ACV/01 PEJABAT PENGURUSAN KOLEJ

LEVEL 1 FLOOR PLAN
UITM/TA/DK/ACV/01b AIR-CONDITIONING AND VENTILATION SERVICES AIR-CONDITION AND VENTILATION LAYOUT
UITM/TA/K/ACV/01 KAFETERIA - GROUND FLOOR
UITM/TA/DK/ACV/02 DEWAN KULIAH - PELAN TINGKAT 1 AIR-CONDITION AND VENTILATION LAYOUT
DRAWING NO. DESCRIPTION
UITM/TA/K/ACV/01a AIR-CONDITION AND VENTILATION SERVICES
UITM/TA/K/CW/01 KAFETERIA - GROUND FLOOR PLAN

UITM/TA/GH/ACV/01 PONDOK PENGAWAL KESELAMATAN

GROUND FLOOR PLAN
UITM/TA/CUP/ACV/01 CENTRAL UTILITY PLANT – LEVEL 1 FLOOR PLAN

(PROPOSED FOR CONTROL PANEL RELOCATE)
UITM/TA/CUP/CW/01 CENTRAL UTILITY PLANT – LEVEL 1 FLOOR PLAN

UITM/TA/CUP/CW/CWP/01 CHILLER AND WATER PUMP RC PLINTH
UITM/TA/CUP/CW/CWP/01 CHILLER CONTROL PANEL
UITM/TA/CUP/CW/DWHS/01 DUCT WORK HANGER SUPPORT DETAIL

(UNDER THE ROOF) &
CHILLED WATER PIPE SUPPORT
UITM/TA/SCH/CW/01 AIR-CONDITIONING SERVICES

CHILLED WATER SYSTEM SINGLE LINE DIAGRAM
UITM/TA/SCH/CW/02 CENTRAL UTILITY PLANT

CHILLED WATER SYSTEM DIAGRAM

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CADANGAN UNIVERSITI TEKNOLOGI MARA (UiTM) KAMPUS MUKAH DI ATAS

AS-BUILT DRAWINGS AND OPERATION AND MAINTENANCE MANUAL FOR

OPERATION AND MAINTENANCE MANUAL (VOL 1 OF 2)

KP Mukah Development Sdn. Bhd.

Arkitek: Jurutera Sivil & Struktur:

Jurutera Mekanikal & Elektrikal: Jurukur Bahan:

2.0 DESCRIPTION OF THE INSTALLATIONS

3.0 SYSTEM OPERATING PROCEDURE/INSTRUCTION

3.1 Chiller Plant

4.0 LIST OF EQUIPMENT INSTALLATION & SPARES

4.1 List of Equipment Installed

5.0 SERVICE & MAINTENANCE

5.1 Maintenance Schedule

6.0 MANUFACTURER LITERATURE & CATALOGUES

6.1 Chiller Plant

7.0 TEST CERTIFICATES

8.0 AS BUILT DRAWING

SCHEDULE OF FAN COIL UNIT

SCHEDULE OF EXHAUST FAN

B1-L1-EF-3 CEILING MOUNTED 34 1207 60 25.7 240/1/50 200mm KDK 20 CQT1

B1-L2-EF-3 CEILING MOUNTED 48 1207 60 25.7 240/1/50 200mm KDK 20 CQT1

B1-L2-EF-4 CEILING MOUNTED 35 1207 60 25.7 240/1/50 200mm KDK 20 CQT1

B1-L2-EF-5 CEILING MOUNTED 35 1207 60 25.7 240/1/50 200mm KDK 20 CQT1

SCHEDULE OF AIR HANDLING UNIT

SCHEDULE OF FAN COIL UNIT

Total Fan Total Fan Fluid

SCHEDULE OF EXHAUST FAN

B1-L1-EF-3 CEILING MOUNTED 34 1207 60 25.7 240/1/50 200mm KDK 20 CQT1

SCHEDULE OF AIR HANDLING UNIT

SCHEDULE OF FAN COIL UNIT

Total Fan Total Fan Fluid

SCHEDULE OF EXHAUST FAN

B3-L1-EF-5 CEILING MOUNTED 35 1207 60 18.3 240/1/50 200mm KDK 20 CQT1

SCHEDULE OF AIR HANDLING UNIT

SCHEDULE OF FAN COIL UNIT

Total Fan Total Fan Fluid

SCHEDULE OF A/C SPLIT UNIT

B4a-L1-EF-3 CEILING MOUNTED 80 1207 70 25.7 240/1/50 200mm KDK 20 CQT1

B4a-L1-EF-14 CEILING MOUNTED 80 1207 70 25.7 240/1/50 200mm KDK 20 CQT1

B4a-L2-EF-2 CEILING MOUNTED 50 1207 70 25.7 240/1/50 200mm KDK 20 CQT1

B4a-L2-EF-3 CEILING MOUNTED 50 1207 70 25.7 240/1/50 200mm KDK 20 CQT1

B4a-L2-EF-5 CEILING MOUNTED 80 1207 70 25.7 240/1/50 200mm KDK 20 CQT1

B4a-L2-EF-16 CEILING MOUNTED 80 1207 70 25.7 240/1/50 200mm KDK 20 CQT1

B4a-L3-EF-2 CEILING MOUNTED 50 1207 70 25.7 240/1/50 200mm KDK 20 CQT1

B4a-L3-EF-3 CEILING MOUNTED 50 1207 70 25.7 240/1/50 200mm KDK 20 CQT1

B4a-L3-EF-5 CEILING MOUNTED 80 1207 70 25.7 240/1/50 200mm KDK 20 CQT1

B4a-L3-EF-16 CEILING MOUNTED 80 1207 70 25.7 240/1/50 200mm KDK 20 CQT1

SCHEDULE OF A/C SPLIT UNIT

SCHEDULE OF EXHAUST FAN

SCHEDULE OF A/C SPLIT UNIT

BENGKEL KEJURUTERAAN AKUATIK & DEPO

SCHEDULE OF A/C SPLIT UNIT

SCHEDULE OF EXHAUST FAN

SCHEDULE OF A/C SPLIT UNIT

SCHEDULE OF EXHAUST FAN

SCHEDULE OF A/C SPLIT UNIT

SCHEDULE OF EXHAUST FAN

SCHEDULE OF AIR HANDLING UNIT

SCHEDULE OF FAN COIL UNIT

Total Fan Total Fan Fluid

SCHEDULE OF A/C SPLIT UNIT

B4b-A/C-1 CEILING Carrier 38VTA040/42XQ040 11.7 980 *3/8 *3/4 21mm

SCHEDULE OF EXHAUST FAN

B4b-L2-EF-8 CEILING MOUNTED 42 1207 70 25.7 240/1/50 200mm KDK 20 CQT1

B4b-A/C-1 CEILING Carrier 38VTA040/42XQ040 11.7 980 3/8 3/4 21mm

B8-A/C-1 CEILING Carrier 38VTA040/42XQ040 11.7 980 3/8 3/4 21mm