start-up, operation, and maintenance...

Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.PC 211 Catalog No. 531-614 Printed in U.S.A. Form 16JB-6SS Pg 1 901 12-97 Replaces: NewBook 2

Tab 5b

Start-Up, Operation, and Maintenance Instructions

SAFETY CONSIDERATIONSAbsorption liquid chillers provide safe and reliable service whenoperated within design specifications. When operating this equip-ment, use good judgment and safety precautions to avoid damageto equipment and property or injury to personnel.Be sure you understand and follow the procedures and safety pre-cautions contained in the chiller instructions as well as those listedin this guide.

DO NOT USE OXYGEN to purge lines, leak test, or pressurize achiller. Use dry nitrogen.NEVER EXCEED specified test pressures. For the 16JB chiller, themaximum pressure is 12 psig (83 kPa).WEAR goggles and suitable protective clothing when handling lith-ium bromide, octyl alcohol, inhibitor, lithium hydroxide, and hydro-bromic acid. IMMEDIATELY wash any spills from the skin withsoap and water. IMMEDIATELY FLUSH EYES with water and con-sult a physician.

DO NOT USE eyebolts or eyebolt holes to rig chiller sections or theentire assembly.DO NOT work on high-voltage equipment unless you are a qualifiedelectrician.DO NOT WORK ON electrical components, including control pan-els or switches, until you are sure ALL POWER IS OFF and no resid-ual voltage can leak from capacitors or solid-state components.LOCK OPEN AND TAG electrical circuits during servicing. IFWORK IS INTERRUPTED, confirm that all circuits are deenergizedbefore resuming work.NEVER DISCONNECT safety devices or bypass electric interlocksand operate the chiller. Also, never operate the chiller when any safetydevices are not adjusted and functioning normally.DO NOT syphon lithium bromide or any other chemical by mouth.BE SURE all hydrogen has been exhausted before cutting into purgechambers. Hydrogen mixed with air can explode when ignited.WHEN FLAMECUTTING OR WELDING on an absorption chiller,some noxious fumes may be produced. Ventilate the area thoroughlyto avoid breathing concentrated fumes.DO NOT perform any welding or flamecutting to a chiller while it isunder a vacuum or pressurized condition.NEVER APPLY an open flame or live steam to a refrigerant cyl-inder. Dangerous overpressure can result. When necessary to heat acylinder, use only warm (110 F [43 C]) water.DO NOT REUSE disposable (nonreturnable) cylinders or attempt torefill them. It is DANGEROUS AND ILLEGAL. When cylinder isemptied, evacuate remaining gas pressure, loosen the collar andunscrew and discard the valve stem. DO NOT INCINERATE.DO NOT ATTEMPT TO REMOVE fittings, covers, etc., whilechiller is running.

CONNECT THE ABSORPTION CHILLER to an emergency powersource to ensure that a constant power supply is maintained to the unitin the event that the main electrical power source is interrupted ortemporarily lost. Failure to provide an emergency power source to thechiller could result in crystallization of the lithium bromide solutioninside the machine, rendering it temporarily inoperative. A potentiallylengthy decrystallization process might be required to return thechiller to normal operation depending on the severity of the crystalli-zation and/or the length of time the machine was without power.PROVIDE AN EMERGENCY POWER SOURCE to the chilledwater and condenser water pumps to prevent the possibility of anevaporator freeze-up. Failure to provide emergency power to thesepumps could result in machine operation with no flow of waterthrough the tubeside of the evaporator, absorber and condenser sec-tions thereby allowing the water inside the evaporator tubes to freeze.Further, a frozen evaporator tube can burst causing contamination ofthe lithium bromide solution and the inside of the chiller. A freeze-upin the evaporator will also result in a long period of chiller down timedue to the extensive repairs required to bring the chiller and the lith-ium bromide solution back to its original condition.DO NOT climb over a chiller. Use platform, catwalk or staging. Fol-low safe practices when using ladders.DO NOT STEP ON chiller piping. It might break or bend and causepersonal injury.USE MECHANICAL EQUIPMENT (crane, hoist, etc.) to lift ormove inspection covers or other heavy components. Even if com-ponents are light, use such equipment when there is a risk of slippingor losing your balance.VALVE OFF AND TAG steam, water or brine lines before openingthem.DO NOT LOOSEN waterbox cover bolts until the water box has beencompletely drained.DO NOT VENT OR DRAIN waterboxes containing industrial brines,liquid, gases, or semisolids without permission of your process con-trol group.BE AWARE that certain automatic start arrangements can engagestarters. Open the disconnects ahead of the starters in addition to shut-ting off the chiller or pump.USE only repaired or replacement parts that meet the code require-ments of the original equipment.DO NOT ALLOW UNAUTHORIZED PERSONS to tamper withchiller safeties or to make major repairs.PERIODICALLY INSPECT all valves, fittings, piping, and reliefdevices for corrosion, rust, leaks, or damage.PROVIDE A DRAIN connection in the vent line near each pressurerelief device to prevent a build-up of condensate or rain water.IMMEDIATELY wipe or flush the floor if lithium bromide or octylalcohol is spilled on it.

16JB010-068Single-Effect Hermetic Absorption

Liquid Chillers With PIC Controls

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CONTENTS

Page

SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . 1

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4ABBREVIATIONS AND EXPLANATIONS . . . . . . . 4

CHILLER DESCRIPTION . . . . . . . . . . . . . . . . . . . . 4-12Chiller Information and Nameplate . . . . . . . . . . . . 4Basic Absorption Cycle . . . . . . . . . . . . . . . . . . . . . . 4Machine Construction . . . . . . . . . . . . . . . . . . . . . . . . 4Flow Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Equilibrium Diagram and Chiller

Solution Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5• PLOTTING THE SOLUTION CYCLEPurge System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-52Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12• ANALOG SIGNAL• DIGITAL SIGNALOverview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12PIC System Components . . . . . . . . . . . . . . . . . . . . 12• MASTER COMFORT CONTROLLER (PC6400)

MODULE• PROCESSOR/SENSOR INPUT/OUTPUT MODULE

(Slave PSIO-1)• SLAVE PSIO-2 MODULE• LOCAL INTERFACE DEVICE (LID)• SIX-PACK RELAY BOARDS• TEMPERATURE SENSORS• PRESSURE TRANSDUCERSLID Operation and Menus . . . . . . . . . . . . . . . . . . . 15• OVERVIEW• ALARMS AND ALERTS• LID MENU ITEMS• BASIC LID OPERATIONS (Using the Softkeys)• TO VIEW POINT STATUS• OVERRIDE OPERATIONS• TIME SCHEDULE OPERATION• TO VIEW AND CHANGE SET POINTS• TO ACCESS THE SERVICE MENU TABLES• LID DISPLAY SCREENSPIC System Functions . . . . . . . . . . . . . . . . . . . . . . . 22• CAPACITY CONTROL• ENTERING CHILLED WATER CONTROL• CONTROL POINT DEADBAND• PROPORTIONAL BANDS AND GAIN• SAMPLE RANGE• CHILLER TIMERS• OCCUPANCY SCHEDULEPIC Control Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . 30• AUTOMATED TEST• PC6400 INPUTS TEST• PC6400 OUTPUTS TEST• SLAVE PSIO-1 INPUTS TEST• SLAVE PSIO-1 OUTPUTS TEST• SLAVE PSIO-2 INPUTS TEST• CAPACITY VALVE ACTUATOR TESTRamp Loading Control . . . . . . . . . . . . . . . . . . . . . . 32Solution Concentration Control . . . . . . . . . . . . . . 33• FIRST STAGE• SECOND STAGE• THIRD STAGE• CAPACITY OVERRIDES• MANUAL CAPACITY VALVE CONTROL• PIC CONCENTRATION CONTROLS

(Solution High Concentration)Remote Start/Stop Controls . . . . . . . . . . . . . . . . . . 34Tower Fan Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Page

Control Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34Water/Brine Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . 47• RESET TYPE 1• RESET TYPE 2• RESET TYPE 3Spare Safety Inputs . . . . . . . . . . . . . . . . . . . . . . . . . 47• SPARE ALARM CONTACTSafety Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47Check Generator Temperature

Thermoswitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47Check High-Stage Generator Pressure

Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47Service Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 47• TO ACCESS THE SERVICE SCREENS• TO CHANGE THE PASSWORD• TO CHANGE THE LID DISPLAY FROM ENGLISH

TO METRIC UNITS• TO SCHEDULE HOLIDAYSCarrier Comfort Network (CCN) Interface . . . . . 51Attach to Network Device Control . . . . . . . . . . . . 51• ATTACHING OTHER CCN MODULES• LOG OUT OF NETWORK DEVICEPower-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52BEFORE INITIAL START-UP . . . . . . . . . . . . . . . . 52-56Job Data and Tools Required . . . . . . . . . . . . . . . . 52Inspect Field Piping . . . . . . . . . . . . . . . . . . . . . . . . . 52Inspect Field Wiring . . . . . . . . . . . . . . . . . . . . . . . . . 52Standing Vacuum Test . . . . . . . . . . . . . . . . . . . . . . 53• LONG INTERVAL TEST• SHORT INTERVAL TESTChiller Evacuation . . . . . . . . . . . . . . . . . . . . . . . . . . 54Set Up Chiller Control Configuration . . . . . . . . . 54Input the Design Set Points . . . . . . . . . . . . . . . . . . 54Input the Local Occupied Schedule

(OCCPC01S) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54Input the Service Configuration . . . . . . . . . . . . . . 54• PASSWORD• INPUT TIME AND DATE• CHANGE THE LID CONFIGURATION, IF

NECESSARY• MODIFY CONTROLLER IDENTIFICATION, IF

NECESSARY• INPUT EQUIPMENT SERVICE PARAMETERS, AS

NECESSARY• MODIFY EQUIPMENT CONFIGURATION, AS

NECESSARYCharge the Chiller With Solution and

Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55• HANDLING LITHIUM BROMIDE (LiBr) SOLUTION• CHARGING SOLUTION• CHARGING SOLUTION FOR CONDITIONS OTHER

THAN NOMINAL• INITIAL REFRIGERANT CHARGINGINITIAL CONTROL CHECKOUT AND

ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . 56,57Perform an Automated Control Test . . . . . . . . . . 56To Prevent Accidental Start-Up . . . . . . . . . . . . . . 56INITIAL START-UP . . . . . . . . . . . . . . . . . . . . . . . . . 58-65Preliminary Check . . . . . . . . . . . . . . . . . . . . . . . . . . 58• PREPARATIONFinal Adjustment of Capacity Controls . . . . . . . 58Final Refrigerant Charge Adjustment . . . . . . . . . 58Check Chiller Operating Conditions . . . . . . . . . . 59Check Chiller Shutdown . . . . . . . . . . . . . . . . . . . . . 59Check Low Refrigerant Level Operation . . . . . . 65

2

CONTENTS (cont)

Page

Determine NoncondensableAccumulation Rate . . . . . . . . . . . . . . . . . . . . . . . . 65

Instruct the Operator . . . . . . . . . . . . . . . . . . . . . . . . 65• PURGE OPERATION• CONTROL SYSTEM• AUXILIARY EQUIPMENT• CHILLER CYCLES• MAINTENANCE• SAFETY DEVICES AND PROCEDURES• OPERATIONS KNOWLEDGE• START-UP, OPERATION, AND MAINTENANCE

MANUALSSTART-UP/SHUTDOWN/RECYCLE

SEQUENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65-72Local Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65Pre-Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66Warm-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68• CONCENTRATION PROTECTION DURING START-

UP/PULLDOWN FAILURES (Check Method 1)• WARM-UP FAILURESRamp Loading Mode . . . . . . . . . . . . . . . . . . . . . . . . 68Normal Run Mode . . . . . . . . . . . . . . . . . . . . . . . . . . 68• CYCLE-GUARD™ CONCENTRATION CONTROL• CONTROL OVERRIDE AND FAULT PROTECTION

(Check Method 2)• REFRIGERATION PUMP CAVITATION

PROTECTION (Low Concentration Limit)Desolidification Mode (DESOLID) . . . . . . . . . . . . 70Shutdown Sequence . . . . . . . . . . . . . . . . . . . . . . . . 70Chilled Water Recycle Mode . . . . . . . . . . . . . . . . . 70Safety Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72Power Loss Dilution Cycle . . . . . . . . . . . . . . . . . . . 72OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . 72-74Operator Duties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72Before Starting the Chiller . . . . . . . . . . . . . . . . . . . 72Start the Chiller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72Stop the Chiller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72Start-Up After Limited Shutdown . . . . . . . . . . . . . 72Start-Up After Extended Shutdown . . . . . . . . . . . 73Start-Up After Below Freezing

Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73Chiller Shutdown — Normal Conditions . . . . . . 73Chiller Shutdown — Below Freezing

Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73Actions After Abnormal Shutdown . . . . . . . . . . . 73Actions After Power Interruption . . . . . . . . . . . . . 74PERIODIC SCHEDULED MAINTENANCE . . . . . . 74Every Day . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74Every Month . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74Every 2 Months . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74Every 6 Months . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74Every Year . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74Every 3 Years . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74Every 5 Years or 50,000 Hours

(Whichever Comes First) . . . . . . . . . . . . . . . . . . 74MAINTENANCE PROCEDURES . . . . . . . . . . . . . 74-85Service Ontime . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74Inspect the Control Center . . . . . . . . . . . . . . . . . . . 74Check Safety and Operating Controls

Monthly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74Log Sheets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74Inspect Rupture Disc and Piping

(Hot Water Units) . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Page

Inspect the Heat Exchanger Tubes . . . . . . . . . . 75• EVAPORATOR• ABSORBER/CONDENSERWater Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75Water Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . 75Purge Manual Exhaust Procedure . . . . . . . . . . . 75Absorber Loss Determination . . . . . . . . . . . . . . . 76Noncondensable Accumulation Rate . . . . . . . . 76Chiller Leak Test . . . . . . . . . . . . . . . . . . . . . . . . . . . 76• DRY NITROGEN• REFRIGERANT TRACERRepair the Chiller Leak, Retest, and Apply a

Standing Vacuum Test . . . . . . . . . . . . . . . . . . . 77Chiller Evacuation . . . . . . . . . . . . . . . . . . . . . . . . . 77Solution or Refrigerant Sampling . . . . . . . . . . . 77• SOLUTION SAMPLEInhibitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78Solution Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . 78Adding Octyl Alcohol . . . . . . . . . . . . . . . . . . . . . . . 78Removing Lithium Bromide from

Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78Refrigerant Charge Adjustment . . . . . . . . . . . . . 79Low Temperature Cutout Adjustment . . . . . . . . 79Cycle-Guard™ System Operation . . . . . . . . . . . 79Internal Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79Service Valve Diaphragm Replacement . . . . . . 79Hermetic Pump Inspection . . . . . . . . . . . . . . . . . . 82• DISASSEMBLY• INSPECTION• REASSEMBLY• COMPLETIONSolution Decrystallization . . . . . . . . . . . . . . . . . . 82• DECRYSTALLIZATION USING THE PIC

CONTROLS• SEVERE CRYSTALLIZATIONCondensing Water Tube Scale . . . . . . . . . . . . . . 85Water Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . 85Ordering Replacement Chiller Parts . . . . . . . . . 85TROUBLESHOOTING GUIDE . . . . . . . . . . . . . . 85-103Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85Checking the LID Display Messages . . . . . . . . 85Checking Temperature Sensors . . . . . . . . . . . . . 85• RESISTANCE CHECK• VOLTAGE DROP• CHECK TEMPERATURE ACCURACYPressure Transducers . . . . . . . . . . . . . . . . . . . . . . 94• CHECK PRESSURE TRANSDUCERS• REPLACING TRANSDUCERSControl Algorithm Checkout Procedure . . . . . . 94Control Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94Control Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . 94• RED LED• GREEN LEDSNotes on Module Operation . . . . . . . . . . . . . . . . . 95PC6400 Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95• INPUTS• OUTPUTSProcessor Module (Slave PSIO) . . . . . . . . . . . . . 95• INPUTS• OUTPUTSReplacing Defective Processor Modules . . . . . 96• INSTALLATIONPhysical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104-107START-UP CHECKLIST . . . . . . . . . . . . . CL-1 to CL-10

3

INTRODUCTIONEveryone involved in the start-up, operation, and main-

tenance of the 16JB chiller should be thoroughly familiarwith the following instructions and other necessary job databefore initial start-up and before operating the chiller and itscontrol system or performing chiller maintenance. Proce-dures are arranged in the sequence required for proper chillerstart-up and operation.

ABBREVIATIONS AND EXPLANATIONS

CCN — Carrier Comfort NetworkECW — Entering Chilled WaterGEN — GeneratorHX — Heat ExchangerLCD — Level Control DeviceLCW — Leaving Chilled WaterLID — Local Interface DevicePIC — Product Integrated ControlPSIO — Processor/Sensor Input/Output ModuleRLA — Rated Load AmpsSI — International System of Units (metric)

Words printed in all capital letters can be viewed on theLID (e.g., LOCAL, CCN, RUNNING, ALARM, etc).

Words printed both in all capital letters and italics can alsobe viewed on the LID and are parameters (CONTROL MODE,COOLING SETPOINT, TARGET CAPACITY VALVE, etc.)with associated values (e.g., modes, temperatures, percent-ages, pressures, on, off, etc.).

Words printed in all capital letters and in a box representsoftkeys on the LID control panel (e.g., ENTER , EXIT ).

Factory installed additional components are referred to asoptions in this manual; factory supplied but field installedadditional components are referred to as accessories.

CHILLER DESCRIPTION

Chiller Information and Nameplate — The chillernameplate includes model and serial number information(Fig. 1).

BasicAbsorption Cycle — The 16JB absorption chilleruses water as the refrigerant in vessels maintained under adeep vacuum. The chiller operates on the simple principlethat under low absolute pressure (vacuum), water takes upheat and vaporizes (boils) at a low temperature. (See Fig. 2.)For example, at the very deep vacuum of 0.3 in. (6.4 mm)of mercury absolute pressure, water boils at the relativelycool temperature of only 40 F (4 C). To obtain the energyrequired for this boiling, it takes heat from, and thereforechills, another fluid (usually water). The chilled fluid thencan be used for cooling purposes.

To make the cooling process continuous, the refrigerantvapor must be removed as it is produced. For this, a solutionof lithium bromide (LiBr) salt in water is used to absorb thewater vapor. Lithium bromide has a high affinity for water,and will absorb it in large quantities under the right condi-tions. The removal of the refrigerant vapor by absorption keepsthe chiller pressure low enough for the cooling vaporizationto continue. However, this process dilutes the solution andreduces its absorption capacity. Therefore the diluted lithiumbromide solution is pumped to separate vessels where it isheated to release (boil off) the previously absorbed water.Relatively cool condensing water from a cooling tower orother source removes enough heat from this vapor to con-dense it again into liquid for reuse in the cooling cycle. Thereconcentrated lithium bromide solution is returned to theoriginal vessel to continue the absorption process.

Machine Construction — An upper and a lowershell in Fig. 3 and 4 contain the 4 major sections of theabsorption machine: evaporator, absorber, generator andcondenser.

The lower shell contains the evaporator section and theabsorber section. In the evaporator, the refrigerant water va-porizes and in doing so, cools the fluid used in the air con-ditioning or cooling process. In the absorber section, the va-porized water is absorbed by lithium bromide solution.

The upper shell contains the generator section and the con-denser section. Diluted lithium bromide solution is heatedand reconcentrated in the generator. The water vapor re-leased in the reconcentration process is condensed to liquidin the condenser section.

The 16JB absorption chiller also has a solution heat ex-changer to improve operating economy; an external purgesystem to maintain machine vacuum by the removal of non-condensables; hermetic pumps to circulate the solution andthe refrigerant; and various operation, capacity and safetycontrols to provide reliable machine performance.

Flow Circuits — Figure 5 illustrates the basic flow cir-cuits of the 16JB absorption chiller.

The liquid to be chilled is passed through the evaporatortube bundle and is cooled by the evaporation of refrigerantwater sprayed over the outer surface of the tubes by the re-circulating refrigerant pump. The refrigerant vapors are drawninto the absorber section and are absorbed by the lithiumbromide-water solution sprayed over the absorber tubes. Theheat picked up from the chilled liquid is transferred from theabsorbed vapor to the cooling water flowing through the ab-sorber tubes.

The solution in the absorber becomes diluted as it absorbswater and loses its ability to continue the absorption pro-cess. It is then transferred by the solution pump to the gen-erator section to be reconcentrated. The weak (diluted) so-lution goes to the shell side of the generator where it is heatedby steam. This boils out its absorbed water.

The refrigerant water vapor boiled from the generatorsolution passes into the condenser section and condenses ontubes containing cooling water. This is the same cooling wa-ter which had just flowed through the absorber tubes. Thecondensed refrigerant water from the generator now flowsback to the evaporator to begin a new refrigerant cycle.

Fig. 1 — Model Nomenclature

4

The strong (reconcentrated) solution flows from the gen-erator back to the absorber spray headers to begin a new so-lution cycle. On the way, it passes through the solution heatexchanger where heat is transferred from the hot, strong so-lution to the cooler, weak solution being pumped to the gen-erator. This heat transfer improves solution cycle efficiencyby preheating the relatively cool, weak solution before it en-ters the generator and precooling the hotter, strong solutionbefore it enters the absorber.

During high load operation, some abnormal conditions cancause the lithium bromide concentration to increase abovenormal, with the strong solution concentration close to crys-tallization (see Fig. 6). If, for some reason, the chiller con-trols do not prevent strong solution crystallization duringabnormal operating conditions and flow blockage does oc-cur, the strong-solution overflow pipe will reverse or limitthe crystallization until the cause can be corrected. The over-flow pipe is located between the discharge box and the ab-sorber, bypassing the heat exchanger, as shown in Fig. 5.

If crystallization occurs, it generally takes place in the shellside of the heat exchanger, blocking the flow of strong so-lution from the generator. The strong solution then backs upin the discharge box and spills over into the overflow pipe,which returns it directly to the absorber sump. The solutionpump then returns the hot solution through the heat ex-changer tubes, automatically heating and decrystallizing theshell side.

Equilibrium Diagram and Chiller SolutionCycle — A sample solution cycle can be illustrated by plot-ting it on a basic equilibrium diagram for lithium bromide in

solution with water. The diagram is also used for perfor-mance analyses and troubleshooting. Figure 7 may be usedto plot the solution cycle for your chiller.

The left scale on the diagram indicates solution and watervapor pressures at equilibrium conditions. The right scaleindicates the corresponding saturation (boiling or condens-ing) temperatures for both the refrigerant (water) and thesolution.

The bottom scale represents solution concentration, ex-pressed as percentage of lithium bromide by weight in so-lution with water. For example, a lithium bromide concen-tration of 60% means 60% lithium bromide and 40% waterby weight.

The curved lines running diagonally left to right are so-lution temperature lines (not to be confused with the hori-zontal saturation temperature lines). The single curved lineat the lower right represents the crystallization line. The so-lution becomes saturated at any combination of temperatureand concentration to the right of this line, and it will beginto crystallize (solidify) and restrict flow.

The slightly sloped vertical lines extending from the bot-tom of the diagram are solution specific gravity lines. Theconcentration of a lithium bromide solution sample can bedetermined by measuring its specific gravity with a hydro-meter and measuring its temperature. Plotting the intersec-tion point for these 2 values and reading straight down to thepercent lithium bromide scale will give the concentration.The corresponding vapor pressure can also be determinedby reading the scale straight to the left of the point, and itssaturation temperature can be read on the scale straight tothe right.

Fig. 2 — 16JB Absorption Cooling Cycle

LEGEND

PIC — Product Integrated Control

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40 (4

.4)SPECIFIC GRAVITY

CRYSTALLIZATION LINE1.80

1.78

1.76

1.74

1.72

1.70

1.68

1.66

1.64

1.62

1.60

1.58

1.561.54

1.52

1.50

1.45

1.40

1.35

1.30

1.25

1.20

1.15

1.10

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(5.1

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20.0

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10.0

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(93.

3)

190

(87.

8)

180

(82.

2)

170

(76.

6)

160

(71.

1)

150

(65.

5)

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(60.

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(54.

4)

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(48.

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110

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80 (

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60 (

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20 (

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30 (

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40 (

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50 (

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WEAK LiBr SATURATION TEMPERATURE F (C)

6X

45

3

6

2 2'

1

7

88X

6X

Fig. 6 — Equilibrium Diagram for 16JB Solution Cycle

9

05

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5055

6065

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ITH

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BR

OM

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(154

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300

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(82.

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5)

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8)

140

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(78.

9)

110

(43.

3)

100

(37.

8)

90 (3

2.2)

80 (2

6.7)

70 (2

1.1)

60 (1

5.5)

50 (1

0.0)

40 (4

.4)SPECIFIC GRAVITY

CRYSTALLIZATION LINE1.80

1.78

1.76

1.74

1.72

1.70

1.68

1.66

1.64

1.62

1.60

1.58

1.561.54

1.52

1.50

1.45

1.40

1.35

1.30

1.25

1.20

1.15

1.10

1.05

0.2

(5.1

)

0.1

(2.5

)

0.5

(12.

7)

1.0

(25.

4)

2.0

(50.

6)

5.0

(126

.6)

25.0

(63

5)

20.0

(50

8)

15.0

(38

1)

10.0

(25

4)

200

(93.

3)

190

(87.

8)

180

(82.

2)

170

(76.

6)

160

(71.

1)

150

(65.

5)

140

(60.

0)

130

(54.

4)

120

(48.

9)

110

(43.

3)

100

(37.

8)

90 (

32.2

)

80 (

26.7

)

70 (

21.1

)

60 (

15.5

)

20 (

-6.7

)

30 (

-1.1

)

40 (

4.4)

50 (

10.0

)

WEAK LiBr SATURATION TEMPERATURE F (C)

Fig. 7 — Equilibrium Diagram for Plotting 16JB Solution Cycle

10

PLOTTING THE SOLUTION CYCLE — An absorption so-lution cycle at typical full load conditions is plotted inFig. 6 from Points 1 through 8X. The corresponding valuesfor these typical points are listed in Table 1. Note thatthese values will vary with different loads and operatingconditions.Point 1 represents the strong solution in the absorber as itbegins to absorb water vapor after being sprayed from theabsorber nozzles. This condition is internal and cannot bemeasured.Point 2 represents the diluted (weak) solution after it leavesthe absorber and before it enters the heat exchanger. Thisincludes the weak solution’s flow through the solution pump.Point 2 is used to calculate absorber loss.Point 2� represents the theoretical point calculated by refrig-erant temperature and the concentration measured by the re-frigerant level. Point 2� is used to calculate absorber lossand can be measured with a solution sample from the pumpdischarge. The Product Integrated Control (PIC) monitorsPoint 2� via the refrigerant temperature and calculates so-lution concentration based on the refrigerant level. For moreinformation on the PIC, see the Controls section, page 12.Point 3 represents the weak solution leaving the heat ex-changer. The solution is at the same concentration as atPoint 2, but at a higher temperature after gaining heat fromthe strong solution. This temperature is measured by the PICcontroller.Point 4 represents the weak solution in the generator afterbeing preheated to the boiling temperature. The solution willboil at temperatures and concentrations corresponding to thesaturation temperature established by the refrigerant vaporcondensing temperature in the condenser. The concentrationis the same as Point 3 but at a higher temperature; this tem-perature is measured by the PIC controller which measuresthe condensed refrigerant vapor leaving the condenser.Point 5 represents the strong solution leaving the generatorand entering the heat exchanger after being reconcentratedby boiling out refrigerant water. It can be plotted by mea-suring the temperatures of the leaving strong solution andthe condensed refrigerant vapor leaving the condenser (satu-ration temperature). These two temperatures are measuredby the PIC controller and used to calculate the strong solu-tion concentration.Point 6 represents the strong solution from the heat ex-changer. It is the same concentration as Point 5 but at a coolertemperature after giving up heat to the weak solution. Thetemperature is measured by the PIC controller.Point 6X represents the point on the crystallization line thatcorresponds to the conditions at Point 6 if the solution werecooled. This point is calculated by the PIC using the tem-perature and concentration at Point 6 as a reference.Point 7 represents the strong solution entering the absorberspray nozzles, after being mixed with some weak solutioninside the heat exchanger. The temperature is measured bythe PIC controller, but the concentration cannot be sampled.After leaving the spray nozzles, the solution is somewhatcooled and concentrated as it flashes to the lower pressure ofthe absorber, at Point 1.Point 8 represents a theoretical point calculated by using theconcentration at Point 6 and the solution saturation tempera-ture at Point 2. It is used to determine how close the chilleris to the crystallization line.Point 8X represents the point on the crystallization line thatcorresponds to the conditions at Point 8 if the solution werecooled. Point 8X is calculated by the PIC using the tempera-ture and concentration at Point 8 as a reference.

Table 1 — Equilibrium Cycle Data

POINTSOLUTION

TEMPVAPOR

PRESS HgPERCENTLITHIUM

BROMIDESOL

SATURATEDTEMP

F C (in.) mm) (F) (C)

1 115 46 0.27 6.9 63.3 43 62 101 38 0.27 6.9 59.5 42 63 165 74 1.65 41.9 59.5 95 354 192 89 3.00 76.2 59.5 115 465 215 102 3.00 76.2 64.0 115 466 146 63 0.60 15.2 64.0 64 18

6X 146 63 0.45 9 66.4 64 17.77 126 52 0.37 9.4 63.0 51 118 118 47.7 0.2 4 64 42 5.5

8X 118 47.7 0.2 4 65.5 36 2.2

Purge System — The basic components and flow cir-cuits of the 16JB motorless purge are shown in Fig. 8.

During machine operation, lithium bromide solution flowsfrom the solution pump through 2 transfer devices called educ-tors. In the absorber eductor (A1, Fig. 8), the solution drawsnoncondensables from the absorber by syphon effect and isthen discharged with its entrained noncondensables into thesecondary heat exchanger (B, Fig. 8). Here the noncondens-ables separate from the solution and pass into the condenser.

The noncondensables are drawn from the condenser bythe condenser eductor (A2) and are again entrained in so-lution. The mixture enters the purge separation pot (C) wherethe noncondensables collect in a storage chamber (D) andsolution flows back to the heat exchanger and absorber.

As the storage chamber fills with noncondensables, thesolution level is depressed to a predetermined level near thebottom of the storage chamber. At this point, an indicatorlight on the machine control panel signals the need to ex-haust the purge.

LEGEND

A1 — Abosrber EductorA2 — Condenser EductorB — Secondary Heat ExchangerC — Separation PotD — Storage ChamberE — Solution Return Valve

F — Level IndicatorG — Auxiliary Evacuation ValveH — Exhaust ValveJ — Exhaust BottleK — Hermetic Solution PumpL — Purge Valve

Fig. 8 — 16JB Purge System

11

Purge evacuation is begun by closing the solution returnvalve (E) and purge valve (L). Solution is forced into thechamber by the pump and the noncondensables are com-pressed to above atmospheric pressure. Exhaust valve (H) isnow opened to bleed the noncondensables into exhaust bottle(J) and is then reclosed.

To return the purge to automatic operation, valve (E) isagain opened to allow solution flow to the absorber and valve(L) is reopened to resume noncondensable purging.

Purge operation is automatic, motorless and continuous.The noncondensables are trapped outside the machine andcannot re-enter even during shutdown.

For details of the actual purge exhaust procedure, refer tothe Maintenance Procedures section or to the instruction stickeron the machine.

CONTROLS

DefinitionsANALOG SIGNAL — An analog signal varies in propor-tion to the monitored source. It quantifies values betweenoperating limits. For example, a temperature sensor is an ana-log device because its resistance changes in proportion tothe temperature and it detects many values.

DIGITAL SIGNAL — A digital (discrete) signal is a two-position representation of the value of a monitored source.For example, a switch is a digital device because it only in-dicates whether a value is above or below a set point or bound-ary by generating an on/off, high/low, or open/closed signal.

Overview — The 16JB absorption liquid chiller containsa microprocessor-based control center that monitors and con-trols all operations of the chiller. The microprocessor con-trol system matches the cooling capacity of the chiller to thecooling load while providing state-of-the-art chiller protec-tion. The system controls cooling capacity within the set pointplus the deadband by sensing the leaving or entering chilledwater temperature and regulating the steam valve via a

mechanically-linked actuator. Movement of the valve causesthe steam rate to increase or decrease, thereby increasing ordecreasing the chiller’s capacity. The processor protects thechiller by monitoring the digital and analog inputs and ex-ecutes capacity overrides or safety shutdowns, if required.

PIC System Components — The Product IntegratedControl (PIC) is the chiller’s control system. The PIC con-trols the operation of the chiller by monitoring all operatingconditions. The PIC can also diagnose a problem with thechiller. It positions the steam valve to maintain leaving chilledwater temperature. The PIC can also interface with auxiliaryequipment such as pumps and cooling tower fans so that theyturn on only when required. The PIC checks all safeties toprevent any unsafe operating conditions.

The PIC can interface with the Carrier Comfort Network(CCN), if desired and can communicate with other PIC-equipped chillers and other CCN devices.

The PIC system consists of 3 modules housed inside thecontrol center (Fig. 9):• Master Comfort Controller (PC6400)• Slave PSIO-1 Module• Slave PSIO-2 Module

The PIC system also includes the following components:• LID• Six-Pack Relay Boards• Temperature Sensors• Pressure Transducers• Level Sensors• Temperature Switches

The control center is divided into two areas. The controlvoltages contained in each area of the control center are:• upper right side: all extra-low voltage wiring (24 v or less)• left side: 115 vac control voltage and chiller high power

wiringFigure 10 is a schematic representation of the PIC control

system.

12

PANELPART NUMBERS VOLTAGE

16JB010-758 230/3/6016JB010-768 460/3/6016JB010-778 575/3/6016JB010-788 380/3/50

NOTE: These drawings apply to panel part numbers listed in abovechart only. Panel part numbers are located inside control panel door.

LEGEND

CR — Control RelayFB — Fuse BlockFDC — Fused DisconnectGL — Ground LugLID — Local Interface DeviceLLC — Low Level ControlNEMA — National Electrical Manufacturer’s AssociationOL — OverloadPSIO — Processor/Sensor Input/OutputRB — Relay BoardRP — Refrigerant Pump ContactorTB — Terminal BlockTR — Transformer

Fig. 9 — Typical 16JB Chiller Control Center

13

PC6400

!LID

COMM 3

COMM 1

COMM 3

COMM 3

COMM 3SLAVE PSIO-2

SLAVE PSIO-1

LID (Local Interface Device)

1. Chilled Water Pumps2. Cooling Water Pumps3. Solution Pump4. Refrigerant Pump5. Capacity Control Valve6. Tower Fan Relay7. Alarm Relay8. LID Alarm Light

OUTPUTSINPUTS

1. Transducer Reference Voltage2. Solution Pump Pressure3. Low Refrigerant Level4. High Refrigerant Level5. Refrigerant Level Sensor6. Refrigerant Temperature7. Entering Chilled Water8. Leaving Chilled Water9. Weak LiBr Leaving Absorber

10. Weak LiBr Leaving HX11. Cooling Water Entering Absorber12. Cooling Water Leaving Absorber

PIC SYSTEMCONTROL CENTER

1. Cycle-Guard™ Auto/Manual Switch2. Generator Overflow Pipe3. Strong LiBr Leaving GEN4. Strong LiBr Lvg Hx5. LiBr Ent Absorb Spray6. Vapor Condensate Temp7. Cooling Water Lvg Condensor8. Stop Button on LID

1. Cycle-Guard Valve2. Chiller Run Relay3. LLC Valve

1. Chilled Water Flow2. Cooling Water Flow3. Purge Light4. Remote Contacts5. Refrigerant Pump Overload/High Temp6. Solution Pump Overload/High Temp7. Generator 1 High Temp8. Low Chilled Water Temp9. Temp Reset 4-20 mA10. Remote Reset Sensor11. Common Supply Sensor12. Common Return Sensor

LEGEND

COMM — Communications BusGEN — GeneratorHX — Heat ExchangerLCD — Level Control DeviceLiBr — Lithium BromideLLC — Low Level ControlPC6400 — Master Comfort ControllerPSIO — Processor/Sensor Input/OutputPIC — Product Integrated Controls

Fig. 10 — Schematic Representation of the 16JB PIC Control System

14

MASTER COMFORT CONTROLLER (PC6400) MOD-ULE — The PC6400 module contains all the operating soft-ware needed to control the chiller. To sense pressures andtemperatures, the 16JB uses:1 — Pressure transducer1 — Refrigerant level sensor2 — High-temperature thermistors

11 — Temperature thermistors3 — Level probesThe PC6400 module has inputs from the Cycle-Guard™

auto/manual switch, two 100K ohm, high-temperature ther-mistors, four 5K ohm temperature thermistors and the LIDstop switch. The 100K ohm thermistors measure the tem-perature of the Generator overflow pipe and the strong LiBrleaving the generator. The 5K ohm thermistors measure thetemperatures of the strong LiBr leaving the heat exchanger,the LiBr entering the absorber sprays, the vapor condensatetemperature, and the cooling water leaving the condenser.The module has outputs to the chilled water pump, the cool-ing water pump, the solution pump, the refrigerant pump,the capacity valve actuator, the tower fan relay, the alarmrelay, and the LID alarm light. The PC6400 communicateswith the slave PSIO and the 8-input modules through a sen-sor bus, Comm3. It also communicates wit the LID for userinterface and chiller control through the CCN bus, Comm1.

PROCESSOR/SENSOR INPUT/OUTPUT MODULE SLAVEPSIO-1 — This module operates as a slave to the PC6400module and has a total of 12 inputs, including inputs for thepressure transducer voltage reference, solution pump pres-sure, refrigerant level sensors, and the following 5K ohmthermistors:• refrigerant temperature• entering chilled water• leaving chilled water• weak LiBr leaving absorber,• weak LiBr leaving heat exchanger,• cooling water entering absorber• cooling water leaving absorberThe slave PSIO also has the following 3 outputs:• the cycle guard valve• the chiller run relay, and• the low level control valve

SLAVE PSIO-2 MODULE — This module has 12 inputs:chilled water flow, cooling water flow, purge light indicator,remote contacts, refrigerant pump overload/high temp, so-lution pump overload/high temp, generator high temp, lowchilled water temp, temp reset 4 to 20 mA, remote reset sen-sor, common supply sensor, and common return sensor.

LOCAL INTERFACE DEVICE (LID) — The LID is theprimary user interface. It is mounted in the control panel andcommunicates with the PC6400 module. The LID is the in-put center for all local chiller set points, schedule, setup func-tions, and options. It has a stop button, an alarm light, 4 but-tons (softkeys) for logic inputs, and a display screen.

SIX-PACK RELAY BOARDS — There are two 6-pack re-lay boards located in the control center. Each is a cluster of6 pilot relays energized by the PC6400 and the slave PSIO.One board is used for the chilled water pump relay, coolingwater pump relay, solution pump relay, refrigerant pump re-lay, and remote tower fan relay and remote alarm relay. Thesecond relay board is used for the Cycle-Guard™ valve, thechiller run relay and the LLC (Low Level Control) valve.

TEMPERATURE SENSORS (Fig. 11) — Located through-out the chiller, the temperature sensors sense the tempera-ture of LiBr, condensate, refrigerant, and water. Thetemperatures are read by the PIC. There are 2 temperaturesensor sizes:• The 5K ohm sensor has a range of −40 to 245 F (−40 to

118.3 C).• The 100K ohm sensor has a range of 77 to 442 F (25 to

228 C). The 100K ohm sensor is marked with a red band.

PRESSURE TRANSDUCERS (Fig. 12) — Also located atthe discharge pipe of the solution pump is a pressure trans-ducer used to detect solution pump pressure. The pressure isread by the PIC. The pressure ranges from −6.7 to 420 psig(−46.2 to 2896 kPa).

LEVEL PROBES — Located throughout the chiller, the levelprobes sense the liquid level in the evaporator.

LID Operation and Menus

OVERVIEW• The LID display automatically reverts to the default screen

(Fig. 13) after 15 minutes if no softkey activity takes place.If the LID is backlit, the backlighting turns off. The back-lit LID lights up again when a softkey is pressed.

• If a screen other than the default screen is displayed on theLID, the name of that screen is in the upper right corner(Fig. 14).

• The LID may be set to display either English or SI units.Use the LID configuration screen (accessed from the Serv-ice menu) to change the units. See the Service Operationsection, page 47.

• Local Operation — The PIC can be placed in Local Op-erating mode by pressing the LOCAL softkey. The PICwill accept commands from the LID only. The PIC willuse the local time schedule to determine start and stop times.

Fig. 11 — Control Sensors (5K ohm Thermistor)

Fig. 12 — Control Sensors(Pressure Transducer, Typical)

15

• CCN (Carrier Comfort Network) Operation — The PICcan be placed in CCN Operating mode by pressing theCCN softkey. The control will then accept modifications

from any CCN interface or module with the proper au-thority, as well as from the LID. The PIC will use the CCNtime schedule to determine start and stop times.

• The LID ‘‘freezes’’ when a shutdown alarm is sensed, al-lowing the operator to view conditions at the time of thealarm. The LID reverts to a display of current conditionsafter the alarm is cleared.Figures 15 and 16 show the LID menu structure.

ALARMS AND ALERTS — An alarm shuts down the chiller.An alert does not shut down the chiller, but it notifies theoperator that an unusual condition has occurred.

NOTE: When the chiller is in an alarm state, the remote alarmrelay is energized, and the alarm light on the control panel(Fig. 13) flashes on and off continually, indicating that thechiller has shut down because of the alarm. If an operatorturns off the chiller using the Stop button, the alarm light onthe control panel lights temporarily.

NOTE: When the chiller is in an alarm state, the default LIDdisplay ‘‘freezes,’’ that is, it stops updating. The first line ofthe LID default screen displays a primary alarm message;the second line displays a secondary alarm message.

The LID default screen freezes, enabling the operator tosee the conditions of the chiller at the time of the alarm. Ifthe value in alarm is one normally displayed on the defaultscreen, it flashes between normal and reverse print. The LIDdefault screen remains frozen until the condition that causedthe alarm is cleared by the operator.

Troubleshooting information is recorded in the alarm his-tory. Access the ALARM HISTORY screen from the Serv-ice Menu (Fig. 16). You may also access the status screenassociated with the value in alarm. The value will be high-lighted on the status screen by an asterisk in the far rightfield.

To determine what caused the alarm, the operator shouldread both the primary and secondary messages, as well asthe alarm history. The primary message indicates the mostrecent alarm condition. The secondary message gives moredetail on the alarm condition. Since there may be more thanone alarm condition, another alarm message may appear af-ter the first condition is cleared. Check the ALARM HIS-TORY screen for additional help in determining the reasonsfor the alarms. Once all the alarm conditions have been clearedand the LID RESET softkey has been pressed, the LIDscreen will return to normal and the chiller can be restarted.

When the chiller is in an alert state, the default LID screendoes not freeze. However, if the value in alert is on the de-fault screen, that value flashes on and off. For more infor-mation on the value in alert, access its associated status screen.The value will be highlighted on the status screen by an ex-clamation point in the far right field.

See the Troubleshooting Guide, page 85, for more detailson alarm messages.

LID MENU ITEMS — To perform any of the operationsdescribed below, the PIC must be powered up and have suc-cessfully completed its self test. The self test takes place au-tomatically, after power-up.

Press the MENU softkey to view the following fourmenu structures: STATUS, SCHEDULE, SETPOINT, andSERVICE.• The STATUS menu allows viewing and limited calibra-

tion or modification of control points and sensors, relaysand contacts.

• The SCHEDULE menu allows viewing and modificationof the Local and CCN time schedules.

• The SETPOINT menu allows set point adjustments, suchas the entering chilled water and leaving chilled water set-points.

• The SERVICE menu (Fig. 14) can be used to view or modifyinformation on the Alarm History, Control Test, ControlAlgorithm Status, Equipment Configuration, Equipment Serv-ice, Time and Date, Attach to Network Device, Log Out ofDevice, Controller Identification, and LID Configuration.For more information on the menu structures, refer to

Fig. 15 and 16.Press the softkey that corresponds to the menu structure

you want to view: STATUS , SCHEDULE , SETPOINT ,or SERVICE . To view or change parameters within any ofthese menu structures, use the NEXT and PREVIOUS soft-keys to scroll down to the desired item or table. Use theSELECT softkey to select that item. The softkey choices

that then appear depend on the table or menu you select. Thesoftkey choices and their functions are listed in Fig. 15.

RUNNING TEMP CONTROLLEAVING CHILLED WATER

01-01-97 11:48 28.8 HOURS

CHW-IN CHW-OUT EVAP-REF

ABS-IN ABS-OUT COND-OUT

G1SOL ABS-SOL G1-SAT

CCN LOCAL RESET MENU

00.0 00.0 00.0

00.0

00.0

00.0

00.0

00.0

SECONDARYSTATUSMESSAGE

ALARM LIGHT

STOP BUTTON

PRIMARY STATUSMESSAGE

CHILLERON TIME

DATE TIME

SOFT KEYS MENULINE

BLINKS CONTINUOUSLYON FOR AN ALARM

BLINKS ONCE TOCONFIRM A STOP

HOLD FOR ONESECOND TO STOP

EACH KEY'S FUNCTION ISDEFINED BY THE MENU DESCRIPTIONON MENU LINE ABOVE

00.0

Fig. 13 — LID Default Screen

ABS16JB SERVICE

ALARM HISTORYCONTROL TESTCONTROL ALGORITHM STATUSEQUIPMENT CONFIGURATIONEQUIPMENT SERVICETIME AND DATEATTACH TO NETWORK DEVICELOG OUT OF DEVICECONTROLLER IDENTIFICATIONLID CONFIGURATION

NEXT PREVIOUS SELECT EXIT

DEVICE NAME SCREEN NAME

Fig. 14 — LID Service Screen

16

CCN LOCAL RESET MENU

DEFAULT SCREEN

Start Chiller In CCN Control

Start Chiller In Local Control

Clear Alarms

STATUS SCHEDULE SETPOINT SERVICE

(SOFTKEYS)

Access Main Menu

List theStatus Tables

• MAINSTAT• PUMPSTAT• EVAPSTAT• ABSSTAT• CONDSTAT• GENSTAT

Display the Setpoint Table

(ENTER A 4-DIGIT PASSWORD)

List the Service Tables


START STOP RELEASE ENTER

(SELECT A TABLE)

(SELECT A POINTON THE TABLE)

(MODIFY ADISCRETE POINT) or

(MODIFY ANANALOG POINT) or(MODIFY CONTROLOPTIONS)

EXITNEXT PREVIOUS SELECT

ENTERENABLE DISABLE RELEASE

DECREASEINCREASE ENTERRELEASE

OCCPC01S (Local Control)OCCPC02S - 99S (CCN Control)

List the Schedules

1 2 3 4

Modify the SetpointDECREASEINCREASE QUIT ENTER

NEXT PREVIOUS SELECT EXITSelect the Setpoint

EXITSELECTPREVIOUSNEXT

Select a Schedule

12345678

Override

ENABLE DISABLE ENTER EXIT

Select a Time Period/OverrideEXITSELECTPREVIOUSNEXT

ENTER EXITDECREASEINCREASEModify a Schedule Time

Add/Eliminate a Day

(ANALOG VALUES)

(DISCRETE VALUES)

• ALARM HISTORY• CONTROL TEST• CONTROL ALGORITHM STATUS• EQUIPMENT CONFIGURATION• EQUIPMENT SERVICE• TIME AND DATE• ATTACH TO NETWORK DEVICE• LOG OUT OF DEVICE• CONTROLLER IDENTIFICATION• LID CONFIGURATION


SEE FIGURE 16

Select a Service Table

CCN — Carrier Comfort Network

Fig. 15 — 16JB LID Menu Structure

17


SERVICE TABLE

Display Alarm History(The table holds up to 25 alarmsand alerts with the last alarm atthe top of the screen.)

• Automated Test• PC6400 Inputs• PC6400 Outputs• Slave PSIO-1 Inputs• Slave PSIO-1 Outputs• Slave PSIO-2 Inputs• Capacity Valve Actuator

CONTINUEDON NEXT PAGE

CONTROL ALGORITHM STATUS

CONTROL TEST

ALARM HISTORY

List the Control Tests

NEXT PREVIOUS SELECT EXITSelect a Test

List the Control Algorithm Status Tables• COOLING — Capacity Control• APPROACH — Delta Ts and Approaches• OVERRIDE — Override/Alert Status• CONCENTR — Concentration Status• WSMDEFME — Water System Control/Information• OCCDEFCM — Time Schedule Status

NEXT PREVIOUS SELECT EXITSelect a Table

EQUIPMENT CONFIGURATION

Select CONFIG (Displays CONFIG Parameters)• Reset Type 1• Reset Type 2• Reset Type 3• Select/Enable Reset Type• Entering Chilled Water Control Option• Remote Contacts Option• Temperature Pulldown Rate• CCN Occupancy Configuration

List the Equipment Configuration Tables

• CONFIG• ALARM_CFG• BRODEF• OCCDEFCS• HOLIDAYS• CONSUME• RUNTIME• WSMALMDF

NEXT PREVIOUS SELECT EXITSelect a Table


ENTERENABLE DISABLE QUIT

DECREASEINCREASE ENTERQUIT (ANALOG VALUES)(DISCRETE VALUES)

Modify Configuration

Select a CONFIG Parameter

Select Any Other Equipment ConfigurationTable (BRODEF, HOLIDAYS, etc.)

Select a ParameterNEXT PREVIOUS SELECT EXIT

Modify a Parameter


DECREASEINCREASE ENTERQUIT

QUITYES NO ENTER

(ANALOG VALUES)(DISCRETE VALUES)(DISCRETE VALUES)

Fig. 16 — 16JB PIC Service Menu Structure

18


SERVICE MENU CONTINUEDFROM PREVIOUS PAGE

EQUIPMENT SERVICE (See Table 2, Examples 9, 10, and 11)

Service Tables:• SERVICE1• SERVICE2• SERVICE3

Select a Service Table

Select a Service Table ParameterNEXT PREVIOUS SELECT EXIT

Modify a Service Table Parameter

ENTERNO YES QUIT

(ANALOG VALUES)

(DISCRETE VALUES)

(DISCRETE VALUES)

TIME AND DATE

Display Time and Date Table:• To Modify — Time — Day of Week

— Date — Holiday TodayATTACH TO NETWORK DEVICEENTERDECREASEINCREASE EXIT

EXITINCREASE DECREASE ENTERLID Configuration Table

• To Modify — LID CCN Address— English or S.I. Metric Units— Password

• To View — LID Software Version (last 2 digits of part number

indicate software version)


DECREASEINCREASE ENTERQUIT

Select a DeviceATTACHNEXT PREVIOUS SELECT

Modify Device AddressEXITINCREASE DECREASE ENTER

• Use to attach LID to another CCN network or device• Attach to "LOCAL" to enter this machine• To upload new tables

Default ScreenMENURESETCCN LOCAL

LOG OUT OF DEVICE

EXITINCREASE DECREASE ENTER

CONTROLLER IDENTIFICATION

ABS16JB ControllerIdentification Table

• To modify — PC6400 CCN Address • To View — PC6400 Software Version (last 2 digits on part number indicate software version)

LID CONFIGURATION

List Network Devices• Local• Device 1• Device 2• Device 3• Device 4• Device 5

• Device 6• Device 7• Device 8• Device 9

LEGEND

CCN — Carrier Comfort NetworkLID — Local Interface Device

Fig. 16 — 16JB PIC Service Menu Structure (cont)

19

BASIC LID OPERATIONS (Using the Softkeys) — To per-form any of the operations described below, the PIC must bepowered up and have successfully completed its self test.

• Press NEXT to scroll the cursor bar down in order tohighlight a point or to view more points below the currentscreen.

• Press PREVIOUS to scroll the cursor bar up in order tohighlight a point or to view points above the current screen.

• Press SELECT to view the next screen level (high-lighted with the cursor bar) or to override (if allowable)the highlighted point value.

• Press INCREASE or DECREASE to change the high-lighted point value.

• Press ENTER to leave the selected decision or field andsave changes.

• Press QUIT to leave the selected decision or field with-out saving any changes.

• Press EXIT to return to the previous screen level.

TO VIEW POINT STATUS (Fig. 17) — Point status is theactual value of all of the temperatures, pressures, relays, andactuators sensed and controlled by the PIC.1. On the MENU screen, press STATUS to view the list of

Point Status tables.

2. Press NEXT or PREVIOUS to highlight the desiredstatus table. The list of tables includes:• MAINSTAT — Status of control points and sensors• PUMPSTAT — Status of pumps• EVAPSTAT — Status of evaporator• ABSSTAT — Status of the absorber• CONDSTAT — Status of the condenser• GENSTAT — Status of the generator

3. Press SELECT to view the desired Point Status table.

4. On the selected table, press NEXT orPREVIOUS until desired point is displayed on the screen.

OVERRIDE OPERATIONSTo Override a Value or Status1. From any STATUS screen, press NEXT or

PREVIOUS to highlight the desired point.

ABS16JB CHLR MAINSTAT POINT STATUS

CONTROL MODERUN STATUSOCCUPIED?ALARM STATECHILLER START/STOPREMOTE CONTACTSCOOLING SETPOINTCONTROL SETPOINTENTERING CHILLED WATERLEAVING CHILLED WATERTARGET CAPACITY VALVEACTUAL CAPACITY VALVE


OFFREADYYESNORMALSTOPOFF10.0° C10.0° C19.9° C14.4° C0.0%0.0%

Fig. 17 — Example of Point Status Screen(MAINSTAT)

20

2. Press SELECT to select the highlighted point.

For Discrete Points — Press START or STOP to se-lect the desired state.

For Analog Points — Press INCREASE orDECREASE to select the desired value.

3. Press ENTER to register new value.

NOTE: When overriding or changing metric values, it is nec-essary to hold the softkey down for a few seconds in orderto see a value change, especially on kilopascal values.To Remove an Override1. From any STATUS screen, press NEXT or

PREVIOUS to highlight the desired point.

2. Press SELECT to access the highlighted point.

3. Press RELEASE to remove the override and return thepoint to the PIC’s automatic control.

Override Indication — An override value is indicated bySUPVSR, SERVC, or BEST flashing next to the point valueon the STATUS table.

TIME SCHEDULE OPERATION (Fig. 18)

1. On the MENU screen, press SCHEDULE .

2. Press NEXT or PREVIOUS to highlight the de-sired schedule. When using PC6400 software, OCCPC01Sis the LOCAL Time Schedule and OCCPC02S is thefirst CCN Time Schedule. The actual CCN OccupiedSchedule number is defined on the CONFIG table. TheCCN schedule number can change to any value from 02to 99.

3. Press SELECT to access and view the time schedule.

4. Press NEXT or PREVIOUS to highlight the de-sired period or override that you wish to change.

NOTE: A schedule override is a temporary on period thatoverrides the current schedule.

5. Press SELECT to access the highlighted period oroverride.

6. a. Press INCREASE or DECREASE to change thetime values. Override values are in one-hour incre-ments, up to 4 hours.

b. Press ENABLE to select days in the day-of-week

fields. Press DISABLE to eliminate days from theperiod.

7. Press ENTER to register the values and to movehorizontally (left to right) within a period.

ABS16JB OCC PC01S

PERIOD ON OFF MTWTFSSH


TIME PERIOD SELECT

12345678

07000600000000000000000000000000

0 HOURSOVERRIDE

18001300030000000000000000000000

XXXXX XX XX

Fig. 18 — Example of Time ScheduleOperation Screen

21

8. Press EXIT to leave the period or override.

9. Either return to Step 4 to select another period or over-ride or press EXIT again to leave the current timeschedule screen and save the changes.

NOTE: Information on setting holiday designations may befound in the Service Operation section beginning onpage 51.

TO VIEW AND CHANGE SET POINTS (Table 2, Exam-ple 7, and Fig. 19)1. To view the SETPOINT screen, at the MENU screen press

SETPOINT .

2. Press SELECT to modify the highlighted set point.

3. Press INCREASE or DECREASE to change the se-lected set point value.

4. Press ENTER to save the changes and return to theprevious screen.

TO ACCESS THE SERVICE MENU TABLES — Informa-tion on accessing the SERVICE menu table may be found inthe Service Operation section, page 47.LID DISPLAY SCREENS — For more details on the in-formation available on the LID display screens, see Table 2.

PIC System FunctionsNOTE: Words not part of paragraph headings and printed inall capital letters can be viewed on the LID (e.g., LOCAL,CCN, RUNNING, ALARM, etc.). Words printed both in allcapital letters and italics can also be viewed on the LID andare parameters (CONTROL MODE, COOLING SETPOINT,TARGET CAPACITY VALVE, etc.) with associated values (e.g.,modes, temperatures, pressures, percentages, on, off, etc.).Words printed in all capital letters and in a box representsoftkeys on the LID control panel (e.g., ENTER andEXIT ). See Table 2 for examples of the information that

can appear on the LID screens. Figures 15-19 give an over-view of LID operation and menus.

CAPACITY CONTROL — The PIC controls the chiller ca-pacity by modulating the capacity valve in response to chillerwater temperature changes away from the CONTROL POINT.The CONTROL POINT may be changed by a CCN networkdevice or is determined when the PIC adds any active chilledwater reset to the COOLING SETPOINT. The PIC uses thePROPORTIONAL INC (Increase) BAND, PROPORTIONALDEC (Decrease) BAND, the PROPORTIONAL ECW (En-tering Chiller Water) GAIN, GEN SOLUTION TEMP BIASand SAMPLE range to determine how fast or slow to re-spond. CONTROL POINT may be viewed and/or overriddenfrom the STATUS table on the MAINSTAT screen. CON-TROL POINT may also be viewed from the CONTROL AL-GORITHM STATUS table on the COOLING screen. See thesection on Warm-Up, page 68, for more information on theseparameters.

ENTERING CHILLED WATER CONTROL — If this op-tion is enabled, the PIC uses the ENTERING CHILLED WA-TER temperature to modulate the capacity valve instead ofthe LEAVING CHILLED WATER temperature. ENTERINGCHILLER WATER control options may be viewed and/or modi-fied from the EQUIPMENT CONFIGURATION table shownon the CONFIG screen.

CONTROL POINT DEADBAND — This is the toleranceon the chilled water temperature CONTROL POINT. Ifthe water temperature goes outside the CONTROL POINTDEADBAND, the PIC opens or closes the capacity valve inresponse until it is within tolerance. The PIC may be con-figured with a 0.5 to 2 F (0.3 to 1.1 C) CONTROL POINTDEADBAND. CONTROL POINT DEADBAND may be viewedon the COOLING screen from the CONTROL ALGO-RITHM STATUS table; it may be viewed and/or modifiedon the SERVICE3 screen (SERVICE menu).

For example, a 1° F (0.6° C) deadband setting controlsthe water temperature within ±0.5 F (0.3 C) of the controlpoint. This may cause frequent capacity valve movement ifthe chilled water load fluctuates frequently. The default set-ting is 1° F (0.6 C).

PROPORTIONAL BANDS AND GAIN — Proportional bandis the rate at which the capacity valve position is correctedin proportion to how far the CHILLED WATER temperatureis from the control point. Proportional gain determines howquickly the capacity valve reacts to how quickly the tem-perature is moving from the CONTROL POINT. The pro-portional bands and gain may be viewed on the COOLINGscreen from the CONTROL ALGORITHM STATUS table;they may be viewed and/or modified on the SERVICE3 screen(SERVICE menu).

ABS16JB CHLR SETPOINT SETPOINT SELECT


50.0°FCOOLING Setpoint

Fig. 19 — Example of Set Point Screen

22

Table 2 — 16JB LID Display Data

IMPORTANT: The following notes apply to all Table 2examples.

1. Only 12 lines of information appear on the LID screen at any onetime. Press the NEXT or PREVIOUS softkey to highlight a pointor to view items below or above the current screen. If you have achiller with a backlit LID, press the NEXT softkey twice to pageforward; press the PREVIOUS softkey twice to page back.

2. To access the information shown in Examples 8 through 15, enteryour 4-digit password after pressing the SERVICE softkey. If no

softkeys are pressed for 15 minutes, the LID automatically logs off(to prevent unrestricted access to PIC controls) and reverts to thedefault screen. If this happens, you must reenter your passwordto access the tables shown in Examples 8 through 15.

3. Terms in the Description column of these tables are listed as theyappear on the LID screen.

4. The LID may be configured in English or Metric (SI) units usingthe LID CONFIGURATION screen. See the Service Operation sec-tion, page 47, for instructions on making this change.

5. The items in the Reference Point Name column do not appear onthe LID screen. They are data or variable names used in CCN orBuilding Supervisor (BS) software. They are listed in these tablesas a convenience to the operator if it is necessary to cross ref-erence CCN/BS documentation or use CCN/BS programs. For moreinformation, see the 16JB CCN Supplement.

6. Reference Point Names shown in these tables in all capital letterscan be read by CCN and BS software. Of these capitalized names,those preceded by an asterisk can also be changed (that is, writ-ten to) by the CCN, BS, and the LID. Capitalized Reference PointNames preceded by two asterisks can be changed only from theLID. Reference Point Names in lower case type can be viewed byCCN or BS only by viewing the whole table.

7. Alarms and Alerts: An asterisk in the far right field of a LID statusscreen indicates that the chiller is in an alarm state; an exclama-tion point in the far right field of the LID screen indicates an alertstate. The asterisk (or exclamation point) indicates that the valueon that line has exceeded (or is approaching) a limit. For moreinformation on alarms and alerts, see the Alarms and Alerts sec-tion, page 16.

LEGEND

Abs — AbsorberAbsorb — AbsorberCCN — Carrier Comfort NetworkCHW — Chilled WaterCHWR — Chilled Water ReturnCHWS — Chilled Water SupplyConc — ConcentrationCond — CondenserDec — DecreaseEnt — EnteringGEN — GeneratorHX — Heat ExchangerInc — IncreaseLiBr — Lithium BromideLID — Local Interface DeviceLLC — Low Level ControlLvg — LeavingmA — MilliampsProt — ProtectiveRef — RefrigerantSol — SolutionTemp — Temperature

EXAMPLE 1 — MAINSTATSCREEN (STATUS TABLE)

To access this information from the LID default screen:

1. Press MENU .

2. Press STATUS (MAINSTAT will be highlighted).

3. Press SELECT .

DESCRIPTION STATUS/RANGE UNITS REFERENCE POINT NAMEControl Mode Reset, Off, Local, CCN MODE

Run Status Ready, Recycle, Startup, Warmup, Ramping, Running, CntrlTest, Override, Tripout, Abnormal, Desolid, Dilution STATUS

Occupied? 0/1 NO/YES OCCAlarm State 0/1 NORMAL/ALARM ALM*Chiller Start/Stop 0/1 STOP/START *CHIL_S_SRemote Contacts 0/1 OFF/ON *REMCONCooling Setpoint 41-65 (5-18.3) DEG F (DEG C) SP*Control Point 41-65 (5-18.3) DEG F (DEG C) *LCW_STPTEntering Chilled Water −40-245 (−40-118.3) DEG F (DEG C) CHW_INLeaving Chilled Water −40-245 (−40-118.3) DEG F (DEG C) CHW_OUT**Target Capacity Valve 0-100 % **CV_TRGActual Capacity Valve 0-100 % CV_ACTStartup Pulldown Failure 0/1 DSABLE/ENABLE PULLFAILChiller Run Relay 0/1 OFF/ON CHILLRUNSpare Prot Limit Input 0/1 ALARM/NORMAL SPR_PL*Temp Reset 4-20 mA 4 to 20 MA *RES_OPT*Remote Reset Sensor −40-245 (−40-118.3) DEG F (DEG C) *R_RESET*Common Supply Sensor −40-245 (−40-118.3) DEG F (DEG C) *CHWS*Common Return Sensor −40-245 (−40-118.3) DEG F (DEG C) *CHWR

NOTE: Values preceded by an asterisk (*) can be forced (changed byan operator) from the LID screen or from another control device (suchas a Carrier Comfort Network [CCN] terminal). Values preceded by

2 asterisks (**) can be forced (changed by an operator) only from theLID screen. Other devices, such as a CCN terminal, cannot changethe value.

23

Table 2 — 16JB LID Display Data (cont)

EXAMPLE 2 — PUMPSTAT SCREEN (STATUS TABLE)

DESCRIPTION RANGE/STATUS UNITS REFERENCE POINT NAMEDesolidification Mode 0/1 DSABLE/ENABLE DESOLMD

Time Left 15-240 MIN deso_tim**Chilled Water Pump 0/1 OFF/ON **CHWPChilled Water Flow 0/1 NO/YES CHWFLOW**Cooling Water Pump 0/1 OFF/ON **COOLPMPCooling Water Flow 0/1 NO/YES COOLFLOW**Refrigerant Pump 0/1 OFF/ON **REFPUMPRef Pump Overld/HiTemp 0/1 ALARM/NORMAL RFPMPFLT**Solution Pump 0/1 OFF/ON **SOLPUMPSolution Pump Pressure 8-434 (55.2-2992) PSI (kPa) SOLPRSSol Pump Overld/HiTemp 0/1 ALARM/NORMAL SPMPFLTSolution Pump Ontime 0-500,000 HOURS SP_HRS**Service Ontime 0-32,767 HOURS **S_HRSSolution Pump Starts 0-65,535 SP_STARTCycle Guard Auto/Manual 0/1 MAN/AUTO CGAUTOCycle Guard Valve 0/1 CLOSE/OPEN CGDVLVCycle Guard Counts 0-65,535 CG_COUNT

NOTE: Values preceded by an asterisk (*) can be forced (changed by an operator) from the LID screenor from another control device (such as a Carrier Comfort Network [CCN] terminal). Values precededby 2 asterisks (**) can be forced (changed by an operator) only from the LID screen. Other devices,such as a CCN terminal, cannot change the value.

EXAMPLE 3 − EVAPSTAT SCREEN (STATUS TABLE)

DESCRIPTION STATUS/RANGE UNITS REFERENCE POINT NAMEEntering Chilled Water −40-245 (−40-245) DEG F (DEG C) CHW_IN

CHW_IN Pulldown Deg/Min −10-10 (−5.6-5.6) ^ F (^ C) CHW_INPLeaving Chilled Water −40-245 (−40-118.3) DEG F (DEG C) CHW_OUT

CHW_OUT Pulldown Deg/Min −10-10 (−5.6-5.6) ^ F (^ C) CHW_OUTPRefrigerant Temp −40-245 (−40-118.3) DEG F (DEG C) EVAP_REF**Chilled Water Pump 0/1 OFF/ON **CHWPChilled Water Flow 0/1 NO/YES CHWFLOW**Refrigerant Pump 0/1 OFF/ON **REFPUMPRef Pump Overld/HiTemp 0/1 ALARM/NORMAL RFPMPFLTCycle Guard Auto/Manual 0/1 MANUAL/AUTO CGAUTO**Cycle Guard Valve 0/1 CLOSE/OPEN **CGDVLVRefrigerant Level Sensor 0-5 VOLTS CONLEV_VConcentration Level 40-70 % CONLEVRefrigerant Level:

Low Level Switch 0/1 OPEN/CLOSE REFLOWCycle Guard Level Adjust 0/1 OPEN/CLOSE REFCGHigh Level Switch 0/1 OPEN/CLOSE REFHIGH

Low Chilled Water Temp 0/1 ALARM/NORMAL LOWCHWTLLC Valve 0/1 OFF/ON LLCVLV

NOTE: Values preceded by 2 asterisks (**) can be forced (changed by an operator) only from the LIDscreen. Other devices, such as a CCN terminal, cannot change the value.

To access this display from the LID default screen:

1. Press MENU .

2. Press STATUS .

3. Scroll down to highlight PUMPSTAT.

4. Press SELECT .


1. Press MENU .

2. Press STATUS .

3. Scroll down to highlight EVAPSTAT.

4. Press SELECT .

24

Table 2 — 16JB LID Display Data (cont)EXAMPLE 4 — ABSSTAT SCREEN (STATUS TABLE)


1. Press MENU .

2. Press STATUS .

3. Scroll down to highlight ABSSTAT.

4. Press SELECT .

DESCRIPTION STATUS/RANGE UNITS REFERENCE POINT NAMESolution Pump Pressure 8.0-434 (55.2-2992) PSI (kPa) SOLPRS1Cooling Water Ent Absorb −40-245 (−40-118.3) DEG F (DEG C) ABS_IN

CLW Pulldown Deg/Min −10-10 (−5.6-5.6) ^ F (^ C) CLWPULLCooling Water Lvg Absorb −40-245 (−40-118.3) DEG F (DEG C) ABS_OUTLiBr Ent Absorb Sprays −40-245 (−40-118.3) DEG F (DEG C) RECRCLBWeak LiBr Lvg Absorb −40-245 (−40-118.3) DEG F (DEG C) ABS_SOLWeak LiBr Lvg HX −40-245 (−40-118.3) DEG F (DEG C) WLBLHIHXGEN LiBr Overflow Pipe 70-442 (25-228) DEG F (DEG C) GENOVFLOW**Solution Pump 0/1 OFF/ON **SOLPUMPSol Pump1 Overld/HiTemp 0/1 ALARM/NORMAL SPMP1FLTPurge Indicator Light 0/1 OFF/ON PURGELITE

NOTE: Values preceded by 2 asterisks (**) can be forced (changed by an operator) only from the LIDscreen. Other devices, such as a CCN terminal, cannot change the value.

EXAMPLE 5 — CONDSTAT SCREEN (STATUS TABLE)


1. Press MENU .

2. Press STATUS .

3. Scroll down to highlight CONDSTAT.

4. Press SELECT .

DESCRIPTION STATUS/RANGE UNITS REFERENCE POINT NAMECooling Water Lvg Absorb −40-245 (−40-118.3) DEG F (DEG C) ABS_OUTCooling Water Lvg Cond −40-245 (−40-118.3) DEG F (DEG C) COND_OUTVapor Condensate Temp −40-245 (−40-118.3) DEG F (DEG C) VAPORCD**Cooling Water Pump 0/1 OFF/ON **COOLPMPCooling Water Flow 0/1 NO/YES COOLFLOW**Tower Fan Relay 0/1 OFF/ON **TOWERFAN

NOTES:1. Values preceded by 2 asterisks (**) can be forced (changed by an operator) only from the LID

screen. Other devices, such as a CCN terminal, cannot change the value.2. All Reference Point Names on this screen and their associated values can be read by CCN and/or

Building Supervisor (BS) software.

EXAMPLE 6 − GENSTAT SCREEN (STATUS TABLE)


1. Press MENU .

2. Press STATUS .

3. Scroll down to highlight GENSTAT.

4. Press SELECT .

DESCRIPTION STATUS/RANGE UNITS REFERENCE POINT NAMEStrong LiBr Leaving GEN 77-442 (25-228) DEG F (DEG C) GEN_SOLStrong LiBr Lvg HX −40-245 (−40-1193) DEG F (DEG C) SLBLLOHXVapor Condensate Temp −40-245 (−40-118.3) DEG F (DEG C) GEN_SAT**Actual Capacity Valve 0-100 % **CV_ACTGenerator Hi Temp/Press 0/1 ALARM/NORMAL GENHITP

25

Table 2 — 16JB LID Display Data (cont)EXAMPLE 7 — SETPOINT DISPLAY SCREEN


1. Press MENU .

2. Press SETPOINT .

DESCRIPTION STATUS/RANGE UNITS REFERENCE POINT NAME DEFAULTCooling Setpoint 41-65 (5-18.3) DEG F (DEG C) cool_sp 50.0 (10.00)

EXAMPLE 8 — CONFIG DISPLAY SCREEN(EQUIPMENT CONFIGURATION TABLE)


1. Press MENU .

2. Press SERVICE .

3. Scroll down to highlight EQUIPMENT CONFIGURATION.

4. Press SELECT .

5. Scroll down to CONFIG.

6. Press SELECT .

DESCRIPTION STATUS/RANGE UNITS REFERENCE POINT NAME DEFAULTRESET TYPE 1Degrees Reset at 20 mA −15-15 (−8.3-8.3) DEG F (DEG C) deg_20ma 10 (5.6)RESET TYPE 2Remote Temp (No Reset) −40-245 (−40-118.3) DEG F (DEG C) res_rt1 65 (18.3)Remote Temp (Full Reset) −40-245 (−40-118.3) DEG F (DEG C) res_rt2 85 (29.4)Degrees Reset −15-15 (−8.3-8.3) DEG F (DEG C) deg_rt 10 (5.6)RESET TYPE 3CHW Delta T (No Reset) 0-15 (0-8.3) ^ F (^ C) restd_1 10 (5.6)CHW Delta T (Full Reset) 0-15 (0-8.3) ^ F (^ C) restd_2 0 (0)Degrees Reset −15-15 (−8.3-8.3) DEG F (DEG C) deg_chw 5 (2.8)

Select/Enable Reset Type 0-3 res_sel 0

CHW_IN CONTROL OPTION 0/1 DSABLE/ENABLE cwi_opt DSABLE

Remote Contacts Option 0/1 DSABLE/ENABLE r_contct DSABLE

Temp Pulldown Deg/Min 2-10 (1.1-5.6) DEG F (DEG C)/MIN tmp_ramp 3 (1.7)

CCN Occupancy Config:Schedule Number 2-99 occpcxxe 2Broadcast Option 0/1 DSABLE/ENABLE occbrcst DSABLE

EXAMPLE 9 — SERVICE1 DISPLAY SCREEN (EQUIPMENT SERVICE TABLE)

To access this display from the LID default screen:1. Press MENU .

2. Press SERVICE .

3. Scroll down to highlight EQUIPMENT SERVICE.

4. Press SELECT .

5. Scroll down to highlight SERVICE1.

6. Press SELECT .

DESCRIPTION STATUS/RANGE UNITS REFERENCE POINT NAME DEFAULTRefrigerant Trippoint 37-42 (2.8-5.5) DEG F (DEG C) reftrip 38 (3.3)Refrig Override Delta T 2-5 (1.1-2.8) ^ F (^ C) refdelta 2 (1.1)Water Flow Verify Time 0.5-5 MIN wflow_t 0.5Recycle Restart Delta T 2.0-10.0 (1.1-5.6) ^ F (^ C) rcyc_dt 5 (2.8)Recycle Stop Delta T 0.0-5.0 (0-2.8) DEG F (DEG C) rcyc_dt 2.5Sample Range 1-25 s_range 2Weak LiBr Lvg Abs Alert 100-150 (37.8-65.6) DEG F (DEG C) wlblabal 110 (43.3)Vapor Condensate Override 100-150 (37.8-65.6) DEG F (DEG C) condov 125 (51.6)GEN Strong LiBr Override 200-250 (93.3-121.1) DEG F (DEG C) g1slbov 225 (107.2)GEN Overflow Alarm 150-240 (65.5-15.5) DEG F (DEG C) g2ovalm 175 (79.4)Desolidification Time 15-240 MIN desoltim 60Concentration Sensor Cal:Conc at Low Level 50-60 % lowlev 55Volts at Low Level 0.0-5.0 VOLTS lowvolt 4.5Conc at High Level 50-60 % highlev 60Volts at High Level 0.0-5.0 VOLTS highvolt 3.0

Cycle Guard Level Adjust 50-60 % cgmidlev 55Line Frequency 0/1 freq 0Select: 0=60 Hz, 1=50 Hz

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EXAMPLE 10 — SERVICE2 DISPLAY SCREEN(EQUIPMENT SERVICE TABLE)


1. Press MENU .

2. Press SERVICE .


4. Press SELECT .


6. Press SELECT .

DESCRIPTION STATUS/RANGE UNITS REFERENCE POINT NAME DEFAULTSENSOR ALERT ENABLEDisable = 0, Low = 1, High = 2Temp = Alert Threshold

CHWS Temp Enable 0-2 chws_en 0CHWS Temp Alert −40, 245 (−40, 118.3) DEG F (DEG C) chws_al 245 (118.3)CHWR Temp Enable 0-2 chwr_en 0CHWR Temp Alert −40, 245 (−40, 118.3) DEG F (DEG C) chwr_al 245 (118.3)Reset Temp Enable 0-2 rres_en 0Reset Temp Alert −40, 245 (−40, 118.3) DEG F (DEG C) rres_al 245 (118.30

NOTE: CHWS Temp Alert, CHWR Temp Alert, and Reset Temp Alert are temperatures set by the operatorbased on local operating requirements.For each sensor (CHWS, CHWR, Reset Temp), the operator must set the temperature that activates thealert (Temp = Alert Threshold). In addition, for each sensor, the operator must also choose to disable thealert (Disable = 0), set the alert to activate when the actual temperature is lower than or equal to thethreshold temperature (Low = 1), or set the alert to activate when the actual temperature is higher thanor equal to the threshold temperature (High = 2).For example, if the operator wants the CHWS alert to activate when the CHWS temperature is at or below60 F (15.5 C), the CHWS Temp Alert is set to 60 F (15.5 C), and the CHWS Temp Enable is set to 1.

EXAMPLE 11 — SERVICE3 DISPLAY SCREEN (EQUIPMENT SERVICE TABLE)


1. Press MENU .

2. Press SERVICE .


4. Press SELECT .


6. Press SELECT .

DESCRIPTION STATUS/RANGE UNITS REFERENCE POINT NAME DEFAULTControl Point Deadband 0.5-2.0 (0.3-1.1) DEG F (DEG C) cp_db 1.0 (0.56)Proportional Inc Band 2-10 cv_inc 6.5Proportional Dec Band 2-10 cv_dec 6.0Proportional CHW_IN Gain 1-3 cv_cwi 2.0GEN Solution Temp Bias 1-10 g1_bias 5.0Capacity Valve Setup

Warmup Travel Limit 15-80 % warm_lim 65Running Travel Limit 15-100 % run_lim 100Linear Valve Type 0/1 NO/YES lin_cv NOPneumatic Valve type 0/1 NO/YES pn_cv NO

Solution Pump:Ontime 0-500000 Hours sol_time 0Starts 0-65534 sol_strt 0

27


EXAMPLE 12 — COOLING SCREEN (CONTROL ALGORITHM STATUS TABLE)

The data displayed on this screen is read-only data; that is, it cannot be changed from this screen. The chiller operatoror maintenance technician can view this data to determine what information is being used by the PIC to calculate thealgorithms that control the chiller operations.


1. Press MENU .

2. Press SERVICE .

3. Scroll down to highlight CONTROL ALGORITHM STATUS.

4. Press SELECT .

5. Scroll down to highlight COOLING.

6. Press SELECT .

DESCRIPTION STATUS/RANGE UNITS REFERENCE POINT NAMECAPACITY CONTROLControl Point 41-65 (5-18.3) DEG F (DEG C) ctrlptLeaving Chilled Water −40-245 (−40-118.3) DEG F (DEG C) CHW_OUTEntering Chilled Water −40-245 (−40-118.3) DEG F (DEG C) CHW_INControl Point Error −99-99 (72.8-37.2) DEG F (DEG C) cperrCHW_IN Delta T −99-99 (−55.0-55.5) ^F (^C) cwidtCHW_IN Reset −99-99 (−72.8-37.2) DEG F (DEG C) cwiresCHW_OUT Reset −99-99 (−72.8-37.2) DEG F (DEG C) cworesTotal Error + Resets −99-99 (−72.8-37.2) DEG F (DEG C) errorCapacity Valve Delta −2-2 % cvdTarget Capacity Valve 0-100 % CV_TRGActual Capacity Valve 0-100 % CV_ACTProportional Inc Band 2-10 cv_incProportional Dec Band 2-10 cv_decProportional CHW_IN Gain 1-3 cv_cwiControl Point Deadband 0.5-2 (0.3-1.1) DEG F (DEG C) cp_db

EXAMPLE 13 — CONTROL ALGORITHM STATUS (APPROACH) DISPLAY SCREEN

The data displayed on this screen is read-only data; that is, it cannot be changed from this screen. The chiller operatoror maintenance technician can view this data to determine what information is being used by the PIC to calculate thealgorithms that control the chiller operations. To access this display from the LID default screen:

1. Press MENU .

2. Press SERVICE .


4. Press SELECT .

5. Scroll down to highlight APPROACH.

6. Press SELECT .

DESCRIPTION STATUS/RANGE UNITS REFERENCE POINT NAMEChilled Water Delta T 0-50 (0-27.8) ^F (^C) CHWDTAbsorber Water Delta T 0-50 (0-27.8) ^F (^C) ABSWDTCondenser Water Delta T 0-50 (0-27.8) ^F (^C) CONDWDT

Absorber Approach 0-50 (0-27.8) ^F (^C) ABSAPPAbsorber Loss 0-50 (0-27.8) ^F (^C) ABSLOSSCondenser Approach 0-50 (0-27.8) ^F (^C) CONDAPPEvaporator Approach 0-50 (0-27.8) ^F (^C) EVAPAPP

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EXAMPLE 14 — OVERRIDE SCREEN (CONTROL ALGORITHM STATUS TABLE)

The data displayed on this screen is read-only data; that is, it cannot be changed from this screen. The chiller operatoror maintenance technician can view this data to determine what information is being used by the PIC to calculate thealgorithms that control the chiller operations.To access this display from the LID default screen:

1. Press MENU .

2. Press SERVICE .


4. Press SELECT .

5. Scroll down to highlight OVERRIDE.

6. Press SELECT .

DESCRIPTION STATUS/RANGE UNITS REFERENCE POINT NAMEOVERRIDE/ALERT STATUS:

Strong LiBr Leaving GEN 77-442 (25-228) DEG F (DEG C) GEN_SOLGEN Strong LiBr Override 311-320 (155-160) DEG F (DEG C) g1slbovVapor Condensate Temp −40-245 (−40-118.3) DEG F (DEG C) GEN_SATVapor Condensate Override 199-204 (92.8-95.5) DEG F (DEG C) condov

NOTES:1. None of the variables shown on this screen can be forced.2. An asterisk (or exclamation point) in the far right field of the LID screen indicates that the value is

in alarm (or alert) status.

EXAMPLE 15 − CONCENTR SCREEN (CONTROL ALGORITHM STATUS TABLE)

The data displayed on this screen is read-only data; that is, it cannot be changed from this screen. The chiller operatoror maintenance technician can view this data to determine what information is being used by the PIC to calculate thealgorithms that control the chiller operations.


1. Press MENU .

2. Press SERVICE .


4. Press SELECT .

5. Scroll down to highlight CONCENTR.

6. Press SELECT .

DESCRIPTION STATUS/RANGE UNITS REFERENCE POINT NAMEPoint 2:

Weak LiBr Leaving Absorb −40-245 (−40-118.3) DEG F (DEG C) ABS_SOLSaturation Temp 2 −40-245 (−40-118.3) DEG F (DEG C) TSAT_2LiBr Concentration 50-70 (10-21.1) % CONC_2

Point 5:Strong LiBr Leaving Gen 77-442(25-228) DEG F (DEG C) GEN_SOLVapor Condensate Temp −40-245 (−40-118.3) DEG F (DEG C) GEN_SATLiBr Concentration 50-70 (10-21.1) % CONC_5

Point 6:Strong LiBr Lvg HX 77-442 (25-228) DEG F (DEG C) SLBLHIHXLiBr Conc (Gen) 50-70 (10-21.1) % CONC_6Crystallization Conc 50-70 (10-21.1) % CONC_6XLiBr Temp at Crystal 0-245 (0-118.3) DEG F (DEG C) TSOL_6S

Point 8:Mixed Strong Conc 50-70 (10-21.1) % CONC_8Crystallization Conc 50-70 (10-21.1) % CONC_8XLiBr Temp at Crystal 0-245 (0-118.3) DEG F (DEG C) TSOL_7S

Point 3:Weak LiBr Lvg HX −40-245 (−40-118.3) DEG F (DEG C) WLBLLOHXLiBr Concentration 50-70 (10-21.1) % CONC_3

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Proportional Band — There are two response modes: onefor the temperature response above the control point; the otherfor response below the control point.

The temperature response above the control point is calledPROPORTIONAL INC BAND, and it can slow or quickencapacity valve response to chilled water temperature aboveDEADBAND. The PROPORTIONAL INC BAND can beadjusted from a setting of 2 to 10; the default setting is 6.5.

The response below the control point is called the PRO-PORTIONAL DEC BAND, and it can slow or quicken ca-pacity valve response to chilled water temperature below thecontrol point plus deadband. The PROPORTIONAL DECBAND can be adjusted on the LID from a setting of 2 to 10;the default setting is 6.0.

NOTE: Increasing either the PROPORTIONAL INC BANDor the PROPORTIONAL DEC BAND will cause the capac-ity valve to respond more slowly than it would at a lowersetting.PROPORTIONAL ECW GAIN — This parameter can be ad-justed at the LID for values of 1, 2, or 3; the default settingis 2. Increase this setting to increase capacity valve responseto a change in entering cooling water temperature.SAMPLE RANGE — This parameter can be adjusted at theLID between 2 and 25; the default setting is 2.

CHILLER TIMERS — The PIC maintains 2 runtime clocks,known as SOLUTION PUMP ONTIME and SERVICEONTIME. SOLUTION PUMP ONTIME indicates the totallifetime solution pump run hours. This timer can register upto 500,000 hours before the clock turns back to zero. TheSERVICE ONTIME is a resettable timer that can be used toindicate the hours since the last service visit or any otherdesignated reason. The time can be changed from the LID towhatever value is desired. This timer can register up to 32,767hours before it rolls over to zero.

OCCUPANCY SCHEDULE — The chiller schedule, de-scribed in the Time Schedule Operation section (page 21),determines when the chiller can run. Each schedule consistsof from 1 to 8 occupied/unoccupied time periods, set by theoperator. These time periods can be enabled (or not enabled)on each day of the week and for holidays. The day beginswith 0000 hours and ends with 2400 hours. The chiller is inan occupied state unless an unoccupied time period is ineffect.

NOTE: To determine whether or not the chiller is in an oc-cupied state and can be started, access the MAINSTAT screenand scroll to OCCUPIED ?. If the value in the right columnis YES, the chiller is in an occupied state and can be started.

Figure 18 shows a typical office building time schedulewith a 3-hour, off-peak cool down period from midnight to3 a.m., following a weekend shutdown. For example, holi-day periods are set to be unoccupied for 24 hours per day.The building operates Monday through Friday, 7:00 a.m. to6:00 p.m., with a Saturday schedule of 6:00 a.m. to 1:00 p.m.and includes the Monday midnight to 3:00 a.m. weekendcooldown schedule.

NOTE: This example is used only as an illustration and isnot intended as a recommendation for chiller operation.

The SCHEDULE function works in conjunction with theCCN OCCUPANCY CONFIG and SCHEDULE NUMBERconfigured by the operator on the CONFIG screen. SeeExample 8 of Table 3. The CCN schedule number can bechanged to any value from 02 to 99. If this number is changedfrom the CONFIG screen, the operator must use theATTACH TO NETWORK DEVICE table to upload the newnumber into the SCHEDULE screen.

The LOCAL schedule number (effective when the chilleris in the LOCAL mode) is 01 (PCOCC01S on the SCHED-ULE screen). The CCN schedule number, effective when thechiller is in the CCN mode, can be any number from 02 to99 (PCOCC02S-99S on the SCHEDULE screen).

The schedule can be bypassed by setting (‘‘forcing’’)CHILLER START/STOP to START on the MAINSTAT screen.For more information on forced starts, see Local Start-Up,page 65. The schedule can also be overridden to keep thechiller in an occupied state for up to 4 hours, on a one-timebasis.

PIC Control Tests — These instructions involve usingthe LID menu. See the LID Operation and Menus section,page 15 for information on using the LID.

The PIC has built-in control tests. Starting from the LIDdefault screen menu, press the MENU and SERVICE soft-keys. Use the NEXT softkey to highlight CONTROL TESTand press the SELECT softkey to access the CONTROLTEST menu. Choose the test you want to run by pressing theNEXT , PREVIOUS , SELECT , or EXIT softkeys. The

CONTROL TEST menu has the following options.• Automated Test• PC6400 Inputs• PC6400 Outputs• Slave PSIO-1 Inputs• Slave PSIO-1 Outputs• Slave PSIO-2 Inputs• Capacity Valve Actuator

Use the NEXT and PREVIOUS softkeys to scrollthrough the menu.

Use the SELECT softkey to activate the test.

Use the EXIT softkey to end either a manual or the au-tomated test and to exit the CONTROL TEST menu screenwhen the CONTROL TEST menu is displayed.

AUTOMATED TEST — Before running this test, be surethe manual steam shutoff valve is closed and the pump fusesare pulled, if the machine is not charged, or if you do notwant the pumps to run. When this test is selected, the PICstarts with the PC6400 Inputs test and proceeds through thetwo slave PSIO’s. As each test is executed, the LID displayshows which one is running as well as other pertinent data.At the end of each test, the user is asked whether to continuethe test. Appropriate responses are presented below, whereeach test is described in more detail.

When the entire automated test is complete, the LID dis-play reads, AUTOMATED TEST COMPLETE.

The tests described below can be run both as part of theautomated test sequence (automated mode) or manually (manualmode). To run them manually, use the selection procedureand softkeys described above. At the end of each test, pressthe EXIT softkey to return to the CONTROL TEST menu.

PC6400 INPUTS TESTManual Mode — When the PC6400 Inputs Test is selectedfrom the CONTROL TEST menu, the following 8 inputs aredisplayed on the LID.• Cycle-Guard™ Auto/Manual• GEN LiBr overflow Pipe• Strong LiBr Lvg GEN• Strong LiBr Lvg Hx• LiBr Ent Absorb Spray• Vapor condensate temp• Cooling water Lvg condenser• LID off switch

30

Each input is followed by an appropriate value. For ex-ample, GEN LiBr overflow pipe is followed by a tempera-ture. Any reading out of the valid range of −40 F to 245 F(−4 C to 118 C) for 5K ohm thermistors or 77 to 442 F(25 to 228 C) for 100K ohm thermistors will display the mini-mum or maximum temperature followed by an asterisk. Ifthis occurs, see the Troubleshooting Guide, page 85. If a com-munication failure occurs, a C displays after the input name.To exit the manual test, press the EXIT softkey at the endof any display.Automated Mode — While in automated mode, the LID dis-plays the following message, PC6400 THERMISTORTEST IN PROGRESS. If any thermistor fails, the name ofthe thermistor, along with the phrase, OUT OF RANGE, willdisplay on the LID.

When the test ends, the LID prompts, OK TO CON-TINUE? Pressing the YES softkey lets the automated testcontinue. Pressing the EXIT softkey terminates the auto-mated test, and the LID displays the CONTROL TEST menu.PC6400 OUTPUTS TEST — This test activates 7 outputs,not including the capacity valve actuator.Manual Mode — The LID first prompts with the message,PC6400 OUTPUTS TEST IN PROGRESS. As the outputsare activated, the following LID displays appear as listed be-low. To end the manual test, press the EXIT softkey afterany of the output checks.

ABS16JB — CONTROL TESTPC6400 OUTPUT TEST IN PROGRESSChilled Water Pump — ONChilled Water Flow — YESNEXT EXIT

ABS16JB — CONTROL TESTPC6400 OUTPUT TEST IN PROGRESSCooling Water Pump — ONCooling Water Flow — YESNEXT PREVIOUS EXIT

ABS16JB — CONTROL TESTPC6400 OUTPUT TEST IN PROGRESSSolution and Pump — ONSolution Pump 1 Pressure — 32.0 psia (220.6 kPa)NEXT PREVIOUS EXIT

ABS16JB — CONTROL TESTPC6400 OUTPUT TEST IN PROGRESSRefrigerant Pump — ONNEXT PREVIOUS EXIT

ABS16JB — CONTROL TESTPC6400 OUTPUT TEST IN PROGRESSTower Fan Relay — ONNEXT PREVIOUS EXIT

ABS16JB — CONTROL TESTPC6400 OUTPUT TEST IN PROGRESSAlarm Relay — ONNEXT PREVIOUS EXIT

ABS16JB — CONTROL TESTPC6400 OUTPUT TEST IN PROGRESSLID Alarm Light — ONNEXT PREVIOUS EXIT

Automated Mode — At the end of the automated test, theLID prompts, OK TO CONTINUE? Pressing the YES soft-key lets the automated test continue. Pressing the EXIT soft-key terminates the automated test, and the LID displays theCONTROL TEST menu.

SLAVE PSIO-1 INPUTS TESTManual Mode — This test displays 12 inputs. They are:

• Transducer Voltage Ref (reference)• Solution Pump Pressure• Low Refrigerant Level• High Refrigerant Level• Refrigerant Temperature• Entering Chilled Water• Leaving Chilled Water• Weak LiBr Leaving Absorber• Weak LiBr Lvg HX• Cooling Water Entering Absorber• Cooling Water Leaving Absorber

Each input is followed by an appropriate value. For ex-ample, Solution Pump Pressure is followed by a pressure read-ing. Any transducer or thermistor reading out of the validrange will display the maximum or minimum limit of thattransducer or thermistor, followed by an asterisk. If this oc-curs, refer to the Troubleshooting Guide, page 85. If a com-munication failure occurs, a C displays after the input name.Automated Mode — During the transducer part of the test,the LID displays the following message, PSIO-1 TRANS-DUCER TEST IN PROGRESS. If all transducers test OK,the LID displays, ALL TRANSDUCERS OK. If any trans-ducer fails, the name of the transducer, along with the mes-sage, OUT OF RANGE is displayed on the LID.

When the test ends, the LID prompts, OK TO CON-TINUE? Selecting EXIT terminates the automated test, andthe LID displays the CONTROL TEST menu. Pressing theYES softkey lets the automated test continue on to the ther-

mistor part of the Slave PSIO-1 inputs test.During the thermistor part of this test, the LID displays

the following message, PSIO-1 THERMISTOR TEST INPROGRESS. If all thermistors test OK, the LID displays,ALL THERMISTORS OK. If any thermistor fails, the nameof the thermistor, along with the phrase, OUT OF RANGE,displays on the LID.

When the test ends, the LID prompts, OK TO CON-TINUE? Pressing YES lets the automated test continue. Press-ing EXIT terminates the test, and the LID displays theCONTROL TEST menu.

SLAVE PSIO-1 OUTPUTS TEST — This test activates 3outputs: one for the Cycle Guard™ valve, one for the chillerrun relay, and one for the LLC valve.

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Manual Mode — During the Slave PSIO outputs test, the LIDdisplays the following messages:

ABS16JB — CONTROL TESTPSIO OUTPUTS TEST IN PROGRESSCycle Guard Valve — OPENNEXT EXIT

ABS16JB — CONTROL TESTPSIO OUTPUTS TEST IN PROGRESSChiller Run Relay — ONPREVIOUS EXIT

ABS16JB — CONTROL TESTPSIO OUTPUTS TEST IN PROGRESSDLLC Valve — ONPREVIOUS EXIT

Automated Mode — When in automated mode, the SlavePSIO-1 outputs test displays the same three outputs as inmanual mode. When the automated test is finished, the LIDprompts, OK TO CONTINUE? Pressing YES lets the au-tomated test continue. Pressing EXIT terminates the auto-mated test, and the LID displays the CONTROL TEST menu.SLAVE PSIO-2 INPUTS TESTSManual Mode — This test displays 12 inputs. They are:• Chilled Water Flow• Cooling Water Flow• Purge Light Indicator• Remote Contacts• Ref. Pump Overld/Hi Temp• Solution Pump Overld/Hi Temp• Generator High Temp• Low Chilled Water Flow• Temp Reset 4-20 mA• Remote Reset Sensor• Common Supply Sensor• Common Return Sensor

During the thermistor part of this test, the LID displaysthe following message, PSIO-2 THERMISTOR TEST INPROGRESS. If all thermistors test OK, the LID displays,ALL THERMISTORS OK. If any thermistor fails, the nameof the thermistor along with the phrase, OUT OF RANGE,displays on the LID.

When the test ends, the LID prompts, OK TO CON-

TINUE? Pressing YES lets the automated test continue. Press-

ing EXIT terminates the test, and the LID displays the

CONTROL TEST menu.

CAPACITY VALVE ACTUATOR TESTManual Mode — Close the manual steam valve for this test.When the capacity valve actuator test is selected from theCONTROL TEST menu, the LID displays the following:

ABS16JB — CONTROL TESTCAPACITY VALVE TEST IN PROGRESSCapacity Valve PositionHOLDING: XX.X%INCREASE DECREASE HOLD EXIT

Pressing the INCREASE softkey causes the valve to rampopen, pressing the DECREASE softkey causes the valve toramp closed, and pressing the HOLD softkey causes thevalve to stop moving. The ACTUAL CAPACITY VALVE willincrease to the capacity valve RUNNING TRAVEL LIMITuntil the DECREASE or EXIT softkey is pressed. If theEXIT softkey is pressed, the test returns to the CONTROL

TEST menu.Automated Mode — There is no automatic test for the ca-pacity valve actuator.

Ramp Loading Control — The ramp loading controlslows down the rate at which the chiller loads up. This con-trol can prevent the chiller from loading up during the shortperiod of time when the chilled water loop has to be broughtdown to normal design conditions and helps reduce steamdemand by slowly bringing the chiller water to the controlpoint. However, the total steam draw during this period re-mains almost unchanged.

Ramp loading is based on chilled water temperature.During the ramp loading mode, the LEAVING CHILLED WA-TER or ENTERING CHILLED WATER temperature changeis limited to the TEMP PULLDOWN DEG/MIN. This is therate that the controlled temperature is changed to reach theset point. The default rate is 3 F (1.7 C) degrees per minute.The control valve is allowed full travel to obtain this goalunless an inhibit or close signal is received by the PIC basedon another algorithm.

To set or change the temperature pulldown rate, press theMENU and SERVICE softkeys. Enter your 4-digit pass-

word. Access the EQUIPMENT CONFIGURATION screen.Press the SELECT softkey to view the CONFIG table.From there, scroll to TEMP PULLDOWN DEG/MIN andpress the SELECT softkey. Using the INCREASE andDECREASE softkeys, adjust the setting to the desired value.

To store the value, press the ENTER softkey. To exit thisscreen and keep the last value, press the QUIT softkey.

For more information on ramp loading, see the Ramp Load-ing Mode section on page 68.

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Solution Concentration Control — Capacity Over-rides can prevent premature safety shutdowns caused by so-lution crystallization which, in turn, can happen when thePIC determines that the solution is too concentrated or whentemperatures or pressures have exceeded safe limits of op-eration. The capacity override function allows the operatorto set one or more of the override values that determine wherethe capacity valve control occurs. The 3 possible stages ofcapacity valve control are:

FIRST STAGE — The PIC inhibits the capacity control valvefrom opening further. The status line on the LID displays areason for the override.

SECOND STAGE — The PIC closes the capacity controlvalve until the condition decreases below the override ter-mination temperature or concentration. The override termi-nation temperature or concentration is the point at which theoverride function is no longer in control and the chiller re-turns to normal run mode.

THIRD STAGE — When the solution temperature or con-centration is too high, the capacity valve is closed and thePIC switches to a STOP mode.

CAPACITY OVERRIDES (Table 3) — The operator can con-figure 3 capacity valve overrides from the LID:• Refrigerant Low Temperature Override (REFRIGERANT

TRIPPOINT and REFRIGERANT OVERRIDE DELTA T)• GEN Saturation Temperature Override (VAPOR CON-

DENSATE OVERRIDE)• GEN Solution Temperature Override (GEN STRONG

LiBr OVERRIDE)

The parameters in parentheses are accessed from theSERVICE1 screen. See Table 2, Example 9.

Refrigerant Low Temperature Override — The refrigerant lowtemperature override algorithm inhibits the capacity valvefrom opening or closes the capacity valve to prevent freez-ing. The operator can establish the setpoints at which thisoccurs by changing the values for the REFRIGERANTTRIPPOINT and REFRIGERANT OVERRIDE DELTA T.The PIC monitors the REFRIGERANT TEMP and comparesit to the REFRIGERANT TRIPPOINT plus the REFRIGER-ANT OVERRIDE DELTA T. The two override stages are:1. First stage — occurs if the REFRIGERANT TEMP is be-

low the REFRIGERANT TRIPPOINT plus the REFRIG-ERANT OVERRIDE DELTA T. The capacity valve is in-hibited from opening.

2. Second stage — occurs when the REFRIGERANT TEMPis less than the REFRIGERANT TRIPPOINT plus the RE-FRIGERANT OVERRIDE DELTA T minus 1 F (0.56 C).The capacity valve closes.

This capacity override ends (or returns to normal control)when the temperature increases to 2 F (1.1 C) above the trip-point plus override set point. When the capacity valve is in-hibited or closing, the LID displays, RUN CAPACITYLIMITED, LOW REFRIGERANT TEMP.GEN Saturation Temperature Override — When the chilleris in a RUN mode and the VAPOR CONDENSATE TEMPincreases above the override threshold, the capacity valve isinhibited or closed to prevent an increase in the heat input tothe generator. The two override stages are established whenthe operator changes the setpoint for VAPOR CONDEN-SATE TEMP OVERRIDE.1. First stage — occurs if the VAPOR CONDENSATE OVER-

RIDE is exceeded. The capacity valve is inhibited fromopening.

Table 3 — Capacity Overrides

CAPACITYOVERRIDE

LID TABLEACCESS

CONFIGURABLESETPOINT

SETPOINTDEFAULT

SETPOINTRANGE

FIRST STAGETRIPPOINT

(InhibitCapacity

Valve)

SECOND STAGETRIPPOINT

(Close CapacityValve)

THIRD STAGETRIPPOINT

(Non-RecyclableShutdown)

OVERRIDETERMINATION

(Return toNormal

Operation)

RefrigerantLowTemperatureOverride

EquipmentSERVICE1

RefrigerantTrippoint 38 F (3.3 C) 37 - 42 F

(2.8 - 55 C)<Trippoint+Override Delta T

<Trippoint+ Override Delta T− 1 F(0.56 C)

N/A>Tripppoint+ Override Delta T+ 2 F(1.1 C)

RefrigerantOverrideDelta T

2 F (1.1 C) 2 - 5 F(1.1 - 2.8 C)

GEN HighSaturationTemperatureOverride

EquipmentSERVICE1

VaporCondensateOverride

125 F(51.6 C)

100-150 F(37.7-65.5 C)

VaporCondensateOverride

VaporCondensateOverride+ 1 F (0.56 C)

N/A

VaporCondensateOverride− 2 F(1.1 C)

GEN HighSolutionTemperatureOverride

EquipmentSERVICE1

GEN StrongLiBr Override

225 F(107.2 C)

200-250 F(93.3-122 C)

GEN StrongLiBr Override

GEN StrongLiBr Override+ 8 F(4.4 C)

GEN StrongLiBr Override+ 10 F(5.5 C)

GEN StrongLiBr Override− 2 F(1.1 C)

ManualCapacity MAINSTAT

TargetCapacity

ValveN/A 0-100% N/A N/A N/A Release

HighConcentration

NotConfigurableby Operator

N/A N/A N/AConcentration:6X: 1.0% or8X: 1.0%

Concentration:6X: 0.6% or8X: 0.6%



33

2. Second stage — occurs if the VAPOR CONDENSATEOVERRIDE is exceeded by 1° F (0.56 C). The capacityvalve is closed.This capacity override ends when the VAPOR CONDEN-

SATE TEMP FROM G2 is 2 F (1.1 C) below the VAPORCONDENSATE OVERRIDE.GEN High Solution Temperature Override — When the chilleris in the RUN mode and the STRONG LiBr LEAVING GENincreases above the override threshold, the capacity valve isinhibited from opening or forced to close or the chiller isforced to the STOP mode to prevent an increase in the heatinput to the generator. The override set points are estab-lished when the operator changes the value for GEN STRONGLiBr OVERRIDE. There are three override stages.1. First stage occurs when the STRONG LiBr LEAVING GEN

is greater than the GEN STRONG LiBr OVERRIDE butless than the override plus 8 F (4.4 C). This level pro-hibits the capacity valve from opening.

2. Second stage occurs at the temperature between the GENSTRONG LiBr OVERRIDE plus 8 F (4.4 C) and GENSTRONG LiBr OVERRIDE plus 10 F (0.5 C). This levelcauses an ALERT condition and closes the capacity valve.

3. The third stage occurs when the temperature is greaterthan the override plus 10 F (5.5 C). This level causes anALARM condition, and the chiller controller initiates anon-recycle shutdown with dilution cycle. The capacityvalve is closed, the chiller is in a ‘‘high strong solutiontemperature’’ fault condition, and the LID display reads,PROTECTIVE LIMIT, STRONG LiBr LEAVING GEN.The condition will return to normal when the STRONGLiBr LEAVING GEN is 2 F (1.1 C) below the GEN STRONGLiBr OVERRIDE. Press the RESET softkey to restartthe chiller.

MANUAL CAPACITY VALVE CONTROL — When thechiller is under manual capacity valve control, the operatorhas full control of the capacity control valve and should con-tinuously monitor the chiller temperatures and concentra-tions. Based on these observations, the operator should takethe following actions:

NOTE: The refrigerant pump must be on.• Open the Cycle-Guard™ valve if the STRONG LVG HX

is less than 118 F (48 C) and the WEAK LiBr CONCEN-TRATION is above the CYCLE-GUARD LEVEL ADJUST.

• Open the Cycle-Guard valve if the STRONG LiBr LVGHX is greater than 118 F (48 C) and the refrigerant levelis below the high level switch.

The capacity control valve closes when any overrides re-quire it to. It will open only to the value entered.

PIC CONCENTRATION CONTROLS (Solution HighConcentration) — The PIC calculates and measures the con-centration at Points 6 and 8 of the chiller solution cycle. Italso calculates Points 6X and 8X, which are on the crystal-lization line. There are three thresholds between Points 6 and6X and another three thresholds between Points 8 and 8X.The thresholds are referred to as the:• Inhibit threshold — When the LiBr solution concentration

exceeds the inhibit threshold, the capacity valve is pro-hibited from opening. The solution concentration is 1%weaker than at Point 6X or 8X.

• Close threshold — When the LiBr solution concentrationexceeds the close threshold, the Capacity Valve is closed.The solution concentration is 0.6% weaker than at Points6X or 8X.

• Safety shutdown — If the LiBr solution concentration ex-ceeds the safety shutdown, then a non-recycle shutdownwith dilution cycle is initiated. The solution concentrationis 0.3% weaker than at Points 6X and 8X.

Points 6, 6X, 8, and 8X can be calculated by the operatorwith the help of Fig. 7 (Equilibrium Diagram for Plotting16JB Solution Cycle). Also, Points 6, 6X, 8, and 8X can beread from the CONCENTR screen on the LID as follows.Press the MENU and SERVICE softkeys. Scroll down tohighlight CONTROL ALGORITHM STATUS. Press theSELECT softkey. Scroll down to highlight CONCENTR.

Press the SELECT softkey.Scroll to the lists under POINT 6 and POINT 8. The vari-

able names for the points are as follows:

• Point 6 — STRONG LiBr LVG HX• Point 6X — CRYSTALLIZATION CONC• Point 8 — MIXED STRONG CONC, LiBr TEMP AT

CRYSTAL• Point 8X — CRYSTALLIZATION CONC

Each override stage is released when the calculated con-centration is 0.5% less than the corresponding threshold value.

Remote Start/Stop Controls — A remote device thatuses a set of contacts, such as a timeclock, may be used tostart and stop the chiller. However, the chiller should not beprogrammed, via a remote device or locally from the LID,to start and stop in excess of 2 or 3 times every 12 hours.

The contacts for the remote start are wired into the controlpanel at terminal strip TB1, terminals 514 and 515. See thecertified drawings for further details on contact ratings. Thecontacts must be dry (no power).

Disconnect all primary power when wiring electrical con-nections. Lock and tag all disconnect switches.

Tower Fan Relay — The chiller must be in the RUN-NING mode before the TOWER FAN RELAY algorithm isenabled. The following conditions must also be true:• The COOLING WATER PUMP is energized, COOLING

WATER FLOW is confirmed, and the WEAK LiBr LEAV-ING ABSORB is greater than 86 F (30 C).

• The TOWER FAN RELAY will be deenergized if any of thefollowing conditions occurs: the chiller is not in a run state,the COOLING WATER PUMP is deenergized, the COOL-ING WATER FLOW indication is lost, or WEAK LiBr LEAV-ING ABSORB is less than 77 F (25 C).

The tower fan relay control is not a substitute for a job-site condenser water temperature control. When used witha water temperature control system, the tower fan relaycontrol can be used to help prevent low cooling watertemperatures.

Control Wiring — See Fig. 20-30 for typical wiring sche-matics and component identification.

NOTE: These schematics do not show all the options or varia-tions that are available.

34

LEGEND AND NOTES FOR FIG. 20-30

LEGEND

51RP — Refrigerant Pump Overload51SP — Solution Pump88RP — Refrigerant Pump Contactor88SP — Solution Pump ContactorCB — Circuit BreakerCCN — Carrier Comfort NetworkCOMM — CommunicationsCR1 — Chilled Water Pump RelayCR2 — Cooling Water Pump RelayCR3 — Solution Pump RelayCR4 — Refrigerant Pump RelayCR5 — Tower Fan RelayCR6 — Cycle-Guard™ RelayCR7 — Alarm RelayCR8 — LLC ValveCR9 — Control Relay 9DEC — DecimalFB — Fuse BlockFB-2 — Refrigerant Pump Fuse BlockFB-6 — 115V Power Fuse BlockFDC — Fused DisconnectGEN — GeneratorHx — Heat ExchangerLiBr — Lithium BromideLID — Local Interface DeviceLLC — Low Level ControlM — MotormA — MilliampereNC — Normally ClosedNO — Normally OpenPC6400 — Master Comfort ControllerPL — Indicator LightPWR — PowerR — Identifies One Phase of a 3-Phase CircuitRB1, RB2 — 6-Pack Relay BoardRO — Return 115 VAC, Single-Phase, 60 Hz PowerRP — Refrigerant PumpS — A Switch or One Phase of a 3-Phase CircuitSLAVE PSIO — Processor/Sensor Input/OutputSO — Supply 115 VAC, Single-Phase, 60 Hz PowerSP — Solution PumpSS1 — Cycle-Guard Auto/Manual SwitchSW — A Switch or One Phase of a 3-Phase CircuitT — Terminalt* — ThermistorTB — Terminal BlockTR1, TR2, TR3 — 115 VAC to 21 VAC TransformerTR4 — 21 VAC to 5 VDC TransformerTR5 — 115 VAC to 24 VAC PC6400 Power

TransformerTR7 — 575/480/230 to 115 VAC Primary TransformerU — Identifies One Phase of a 3-Phase CircuitV — Identifies One Phase of a 3-Phase CircuitW — Identifies One Phase of a 3-Phase Circuit

NOTES:1. Channel number 1 is the pressure transducer reference voltage.2. Optional repeater module is field installed and wired.3. LID is door mounted.4. Float is normally open. Refrigerant level closes contact for nor-

mal run mode.5. All fuse blocks require 3 fuses except FB6 which requires 1 fuse.6. Three heater elements are required for each heater block.7. All fuses rated for 600 vac.8. Ground wire to door.9. A resistor is required to properly convert 4 to 20 mA signal to

4 to 10 volts. The 1K resistor is just a place holder to preventaccidental damage.

10. Refer to O&M manual before initializing 4 to 20 mA feature.11. CR1 and CR2 must be tied into any building automation system

in parallel so that either the chiller or the system can energize thepump. This is necessary to provide freeze protection.

CR — Control RelayM — Motor StarterCoil

Fuse

Push Button — Normally Open

Flow Switch — Normally Open

Level Switch — Normally Open

Push Button — Normally ClosedSelector Switch

Transformer

Pressure Transducer

Circuit Breaker

Disconnect SwitchTemperature Switch — Normally OpenHeld ClosedTemperature Switch — Normally ClosedOverloadsResistor/Thermistor

XXX

Terminal Block No. 1XXX

Terminal Block No. 2

Indicator Light

Factory WiringField Wiring

Contact — Normally OpenContact — Normally ClosedConnectors

Ground

35

Fig

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46

Water/Brine Reset — Three chilled water or brine tem-perature reset types are available and can be viewed or modi-fied on CONFIG screen under the EQUIPMENTCONFIGURATION menu on the PIC. (See Table 2,Example 8.) The default screen status message indicates whena chilled water reset is active. The CONTROL POINT on theMAINSTAT table (see Table 2, Example 1) indicates the chill-er’s reset temperature. The chilled water reset range is 41 to65 F (5 to 18 C).

To activate a reset type, input all configuration informa-tion for that reset type in the CONFIG screen under the EQUIP-MENT CONFIGURATION menu. Then, input the reset typenumber in the SELECT/ENABLE Reset Type input line.

RESET TYPE 1 — Reset Type 1 is an automatic chilled wa-ter temperature reset based on a 4 to 20 mA input signal. Thevalue for Reset Type 1 is user configurable; it is a tempera-ture that corresponds to a 20 mA signal. (4 mA correspondsto 0° F [0° C]; 20 mA corresponds to the temperature en-tered by the operator.)

Reset Type 1 permits up to ±15 F (±8.3 C) of automaticreset to the chilled water or brine temperature set point, basedon the input from a 4 to 20 mA signal. This signal is hard-wired into TB1 terminals, 701 (+) and 702 (−). The 4 to20 mA signal is externally powered; Reset Type 1 does notsupport an internally powered signal. The proper resistor mustbe installed between terminals 701 and 702 based on the sup-ply voltage of the 4 to 20 mA signal (typically 250 to500 ohms).

RESET TYPE 2 — Reset Type 2 is an automatic chilledwater temperature reset based on a remote temperature sen-sor input. Reset Type 2 permits ±15 F (±8.3 C) of automaticreset to the set point based on a temperature sensor wired tothe third 8-input module. The temperature sensor must bewired to TB1 terminals 703 and 704.

To configure Reset Type 2, enter the temperature of theremote sensor at the point where no temperature reset(REMOTE TEMP [NO RESET]) will occur. Next, enter thetemperature at which the full amount of reset will occur (RE-MOTE TEMP [FULL RESET]). Then, enter the maximumamount of reset required at the second temperature to op-erate the chiller (DEGREES RESET). Reset Type 2 can nowbe activated.

RESET TYPE 3 — Reset Type 3 is an automatic chilled wa-ter temperature reset based on cooler temperature differ-ence. This type of reset will add ±15 F (±8.3 C) based on thetemperature difference between entering and leaving chilledwater temperature. No wiring is required for this type of re-set, since it already uses the chilled water sensors.

To configure Reset Type 3, enter the chilled water tem-perature difference (the difference between entering and leav-ing chilled water) at which no temperature reset occurs(CHW DELTA T [NO RESET]). This chilled water tempera-ture difference is usually the full design load temperaturedifference. On the next input line, enter the difference in chilledwater temperature at which the full amount of reset will oc-cur (CHW DELTA T [FULL RESET]). Next, enter the amountof reset (DEGREES RESET). Reset Type 3 can now beactivated.

Spare Safety Inputs — Normally closed discrete in-puts for additional field-supplied safeties may be wired tothe spare protective limits input channel in place of the factory-installed jumper. (Wire multiple inputs in series.)


Wire these limits between 539 and 539A on TB1. The open-ing of any contact will result in a safety shutdown and theLID will display, SPARE SAFETY DEVICE.SPARE ALARM CONTACT — One spare set of alarm con-tacts is provided in the control panel. The contact ratings areprovided in the certified drawings. The contacts are locatedon terminal strip TB1, terminals 911 and 912. See Fig. 30.

Safety Controls — The PIC monitors all safety controlinputs and, if required, shuts down the chiller, limits the ca-pacity valve, or opens the Cycle-Guard™ valve to protectthe chiller from possible damage.

If the controller initiates a safety shutdown, it displays aprimary and a secondary alarm message on the LID. It alsoenergizes an alarm relay in the control box and blinks thealarm light on the control center. The alarm information isstored in memory and can be viewed on the LID from thePIC ALARM HISTORY table along with a troubleshootingmessage. To view the alarm information, press theMENU and SERVICE softkeys, and enter your 4-digit

password (to access the SERVICE table). ALARM HIS-TORY will be highlighted. Press the SELECT softkey.

To give a more specific operating condition warning, theoperator can also define alert limits on various monitoredinputs. Safety contact and alert limits are defined in Table 4.Also see Fig. 31 for information on the type of tool neededfor adjustment settings. Alarm and alert messages are listedin the Troubleshooting Guide section, page 85.

Check Generator Temperature Thermoswitch— The switch is factory set to open on a rise in temperatureabove 121 C (250 F) and close on a cooling below 114 C(237 F). Verify the approximate scale position setting(121 C [250 F]) and closed switch contacts. The switch rangeis 50 to 320 C (122 to 608 F).NOTE: The switch operation setting cannot be easily checkedin the field. It requires a precise scale adjustment so do notreposition if not necessary.

Check High-Stage Generator Pressure Switch— The switch is factory set to open on a rise in pressureabove −20 mm Hg G (−0.8 in. Hg) and close with a reduc-tion in pressure below −205 mm Hg G (−8 in. Hg).

Service Operation — Fig. 16 shows an overview ofthe service menus.TO ACCESS THE SERVICE SCREENS — You must entera password whenever you access the SERVICE screens.1. From the MENU screen, press the SERVICE softkey.

The softkeys now correspond to the numerals 1, 2, 3,and 4.

2. Press the four digits of your password, one at a time. Asyou enter each digit, an asterisk appears.NOTE: The initial factory-set password is 1 - 1 - 1 - 1.If the password is incorrect, an error message is dis-

played. If this occurs, return to Step 1 and try to access theSERVICE screens again. If the password is correct, the soft-key labels change to NEXT , PREVIOUS , SELECT , andEXIT , and the LID screen displays the following

SERVICE tables:• Alarm History• Control Test• Control Algorithm Status• Equipment Configuration• Equipment Service• Time and Date• Attach to Network Device• Log Out of Network Device• Controller Identification• LID Configuration

47

Table 4 — Safety Contacts and Alert Limits

MONITORED PARAMETER LIMIT APPLICABLE COMMENTSTEMPERATURE SENSORSOUT OF RANGE: 5K OHM −40-245 F ( −40-118.3 C) Must be outside range for 3 seconds.

TEMPERATURE SENSORSOUT OF RANGE: 100K OHM −77-422 F ( −25-216.7 C) Must be outside range for 3 seconds.

PRESSURE TRANSDUCERSOUT OF RANGE (HIGH)

Ratio = 0.060-0.98 Must be outside range for 3 seconds.Ratio = Input Voltage/Voltage Reference

TRANSDUCER VOLTAGE <4.5 vdc and >5.5 vdc Must be outside range for 3 seconds.Preset, Not Configurable.

GEN HIGH SOLUTION TEMP GEN Strong LiBr Override.Range 200-250 F (93.3-121.1 C)

Configurable on MAINTENANCE,OVERRIDE, or SERVICE1 screen. SeeTable 3 for more details.

GEN HIGH SATURATION TEMP Vapor Condensate Override.Range 100-150 F (37.7-65.5 C)

Configurable on MAINTENANCE,OVERRIDE, or SERVICE1 screen.See Table 3 for more details.

GEN OVERFLOW ALARM GEN Overflow Alarm,Range 150-240 F (66-115.6 C) Configurable on SERVICE1 screen.

(EVAPORATOR) LOWREFRIGERANT TEMP

Refrigerant Trippoint, Range 37-42 F (2.8-5.5 C)Override Delta T, Range 2-5 F (1.1-2.8 C)

Configurable on SERVICE1 screen.See Table 3 for more details.

WEAK LIBR LEAVINGABSORBER

Weak LiBr Lvg Abs Alert, Range 100-150 F(38-66 C) Configurable on SERVICE1 screen.

CYCLE GUARD Cycle Guard Level Adjust, Range 50-60%.Sets the refrigerant level so that theCycle-Guard™ valve opens when theweak LiBr is less than 60%.

CHWS SENSOR ALERT Disable, Low, or High. Configurable on SERVICE2 screen.Default is disabled.

CHWS TEMP ALERT SETTING −40-245 F (−40-118 C) Configurable on SERVICE2 screen.Default is 245 F (118 C).

CHWR SENSOR ALERT Disable, Low, or High. Configurable on SERVICE2 screen.Default is disabled.

CHWR TEMP ALERT SETTING −40-245 F (−40-118 C) Configurable on SERVICE2 screen.Default is 245 F (118 C).

RESET TEMP SENSOR ALERT Disable, Low, or High. Configurable on SERVICE2 screen.Default is disabled.

RESET TEMP ALERT SETTING −40-245 F (−4-118 C) Configurable on SERVICE2 screen.Default is 245 F (118 C).

LEAVING CHILLED WATER 9 F (5 C) below design set point;minimum of 36 F (2 C)

Manually set; see LID Operation andMenus section, page 15. Can be viewedon the LID display (EVAPSTAT screen).

Differential Water Flow Switch (Field Supplied)Operate water pumps with chiller off. Manually re-duce water flow and observe switch for proper cutout.Safety shutdown occurs when cutout time exceeds3 seconds.

CUT-OUTSETTINGADJUSTMENTSCREW

DIFFERENTIAL RANGESETSCREW (DEG C)

TEMPERATURERANGE SETSCREW (DEG C)

CAPILLARYTUBE

EXTERIOR VIEW INTERIOR VIEW

LEGEND

CHWR — Chilled Water ReturnCHWS — Chilled Water SupplyCOM — CommunicationN.C. — Normally ClosedN.O. — Normally Open

Leaving Chilled Water Cutout Switch

CONTACTS:

EXTERIOR INTERIORWIRING

48

See Fig. 15 for additional screens and tables available fromthe SERVICE screens listed above. Use the EXIT softkeyto return to the MENU screen.

NOTE: To prevent unauthorized persons from accessing theLID service screens, the LID automatically signs off andpassword-protects itself if a key has not been pressed for15 minutes. The sequence is as follows. Fifteen minutes

after the last key is pressed, the default screen displays, theLID screen light goes out (analogous to a screen-saver), theLID logs out of the password-protected SERVICE menu. Otherscreens and menus, such as the STATUS screen can be ac-cessed without the password by pressing the appropriatesoftkeys.

EXTERIOR VIEW

NOTE: This adjustment is factory set for a maximum 250 F (121 C) and should not be changed.If setting is incorrect, do not use a screwdriver to set adjustment. Use adjustment tool.

TEMPERATUREADJUSTMENTSCREW. SEE NOTE

INTERIOR VIEW

ADJUSTMENT TOOL

Fig. 31 — High Temperature Cutout Switch

49

TO CHANGE THE PASSWORD — The password may bechanged from the LID CONFIG screen.

1. Press the MENU and SERVICE softkeys. Enter yourpassword and highlight LID CONFIGURATION. Pressthe SELECT softkey. Only the last 5 entries on the LIDCONFIGURATION screen can be changed: BUS #(number), ADDRESS #, BAUD RATE, US IMP/METRIC,and PASSWORD.

2. Use the ENTER softkey to scroll to PASSWORD. Thefirst digit of the password is highlighted on the LID screen.

3. To change the digit, press the INCREASE orDECREASE softkey. When you see the digit you want,

press the ENTER softkey.4. The next digit is highlighted. Change it and the third and

fourth digits in the same way you changed the first digit.5. After the last digit is changed, the LID goes to the BUS

variable. Press the EXIT softkey to leave that screen andreturn to the SERVICE menu.

TO CHANGE THE LID DISPLAY FROM ENGLISH TOMETRIC UNITS — By default, the LID displays informa-tion in English units. To change to metric units, access theLID CONFIG screen:

1. Press the MENU and SERVICE softkeys. Enter yourpassword and highlight LID CONFIGURATION. Pressthe SELECT softkey.

2. Use the ENTER softkey to scroll to US IMP/METRIC.3. Press the softkeys that corresponds to the units you want

displayed on the LID (e.g., US or METRIC ).

TO SCHEDULE HOLIDAYS (Fig. 32) — The time sched-ules may be configured for special operation during a holi-day period. When modifying a time period, an ‘‘H’’ at theend of the days of the week field signifies that the period isa holiday. (See Fig. 18.)

The CCN broadcast function must be activated for the holi-days configured in the HOLIDAY table to work properly.Access the BRODEF table from the EQUIPMENT CON-FIGURATION screen and press ENABLE to activate theholiday schedule. If the chiller is connected to a CCN net-work, only one chiller or CCN device can be configured asthe broadcast device. The device configured as the broad-caster is responsible for transmitting holiday, time, and daylight-savings dates throughout the network. For more informationon CCN operations, see the 16JB CCN supplement.

To view or change the holiday periods for up to 18 dif-ferent holidays, do the following:

1. At the MENU screen, press SERVICE to access theSERVICE menu.

2. If not logged on, follow the instructions for entering yourpassword. See the section, To Access the Service Screens,page 47. Once logged on, press NEXT until EQUIP-MENT CONFIGURATION is highlighted.

3. Press SELECT to access the EQUIPMENT CONFIGU-RATION screen.

4. Press NEXT until HOLIDAYS is highlighted. This isthe screen that allows you to define holidays.

5. Press SELECT to view a screen that lists 18 holidayperiods.

6. Press NEXT to highlight the holiday period you wishto view or change. Each period represents one holiday,starting on a specific date and lasting up to 99 days.

7. Press SELECT to access the holiday period. The screennow shows the holiday start month and day, and howmany days the holiday period will last.

8. Press NEXT or PREVIOUS to highlight themonth, day, or duration.

ABS16JB

Fig. 32 — Example of Holiday Period Screen

50

9. Press SELECT to select the month, day, orduration you wish to modify.

10. Press INCREASE or DECREASE to change the se-lected item.

11. Press ENTER to save the changes.

12. Press EXIT to return to the previous menu.

Carrier Comfort Network (CCN) Interface — TheCarrier Comfort Network (CCN) communication bus wiringis supplied and installed by the electrical contractor. It con-sists of shielded, 3-conductor cable with a drain wire. SeeFig. 29 and 30 for a typical wiring schematic.


The system elements are connected to the communicationbus in a daisy chain arrangement. The positive pin of eachsystem element communication connector must be wired tothe positive pin of the system element on either side of it;the negative pins must be wired to the negative pins; and thesignal ground pins must be wired to signal ground pins.

To attach the CCN communication bus wiring, refer tothe certified prints and wiring diagrams. The wire is insertedinto the CCN (COMM1) connections (terminals 304, 305,and 306) on terminal block TB1 in the control panel.

NOTE: Conductors and drain wire must be 20 AWG (Ameri-can Wire Gage) minimum stranded, tinned copper. Indi-vidual conductors must be insulated with PVC, PVC/nylon,vinyl, Teflon, or polyethylene. An aluminum/polyester 100%foil shield and an outer jacket of PVC, PVC/nylon, chromevinyl, or Teflon, with a minimum operating temperature rangeof −4 F to 140 F (−20 C to 60 C)is required. See the fol-lowing table for cables that meet the requirements.

MANUFACTURER CABLE NO.Alpha 2413 or 5463

American A22503Belden 8772

Columbia 02525

When connecting the CCN communication bus to a sys-tem element, a color code system for the entire network isrecommended to simplify installation and checkout. The fol-lowing color code is recommended:

SIGNAL TYPE CCN BUS CONDUCTORINSULATION COLOR

CCN (COMM1)CONNECTION

ON TB1+ RED Terminal 304

Ground WHITE Terminal 305− BLACK Terminal 306

Attach to Network Device Control — One of theselections on the Service menu is ATTACH TO NETWORKDEVICE. It serves the following purposes:• uploads the occupancy schedule number (if changed), as

defined on the CONFIG screen.• attaches the LID to any CCN device if the chiller has been

connected to a CCN network. This may include other PIC-controlled chillers.

• uploads changes from a new PC6400, LID module, or up-loads tables.Figure 32 illustrates the ATTACH TO NETWORK DE-

VICE LID screen. The LOCAL description is always thePC6400 module address of the chiller the LID is mountedon. Whenever the controller identification of the PC6400 ischanged, the change is automatically reflected on the bus andaddress for LOCAL device on the ATTACH TO NET-WORK DEVICE screen.

Whenever the ATTACH TO NETWORK DEVICE tableis accessed, no information can be read from the LID on anydevice until you attach one of the devices listed on the dis-play. The LID erases information about the module to whichit was attached to make room for information on another de-vice. Therefore, a CCN module must be attached when thisscreen is entered.

To attach to a device, highlight it using the SELECT soft-key and then press the ATTACH softkey. The message UP-LOADING TABLES, PLEASE WAIT flashes. The LID thenuploads the highlighted device or module. If the module ad-dress cannot be found, the message COMMUNICATION FAIL-URE appears. The LID then reverts to the ATTACH TONETWORK DEVICE screen. Try another device or checkthe address of the device that did not attach. The upload pro-cess time for each CCN module is different. In general, theuploading process takes 3 to 5 minutes.

NOTE: Before leaving the ATTACH TO NETWORKDEVICE screen, select the LOCAL device. Otherwise theLID will be unable to display information on the local chiller.

ATTACHING OTHER CCN MODULES — If the chillercontroller (PC6400) and LID have been connected to a CCNnetwork or other PIC-controlled chillers through CCN wir-ing, the LID can be used to view or change parameters onthe other controllers. If desired, another PIC-controlled ma-chine can be viewed and set points changed (if the other unitis in CCN control mode) from this particular LID module.

51

To view other devices, access the ATTACH TO NET-WORK DEVICE table. Highlight the desired device num-ber. Press the SELECT softkey to change the bus numberand address of the module to be viewed. Press the EXITsoftkey to move back to the ATTACH TO NETWORKDEVICE table. If the module number is not valid, the COM-MUNICATION FAILURE message will display. Enter a newaddress number or check the wiring. If the module is com-municating properly after the ATTACH softkey is pressed,the UPLOAD IN PROGRESS message will display, and in-formation on the new module can now be viewed.

Whenever there is a question regarding which module iscurrently being shown on the LID, check the device namedescriptor on the upper left corner of the LID screen. SeeFig. 33.

Once the CCN device has been viewed, use the ATTACHTO NETWORK DEVICE table to attach to the PIC that ison the chiller. Access the ATTACH TO NETWORKDEVICE table, scroll to LOCAL, and press theATTACH softkey to upload the LOCAL device. The PC6400

controller for the 16JB will now be uploaded.

NOTE: The LID will not automatically re-attach to thePC6400 controller module on the 16JB chiller. Access theATTACH TO NETWORK DEVICE screen. Press theATTACH softkey to attach the LOCAL device and view

information on the local chiller.

LOG OUT OF NETWORK DEVICE —To access this screenand log out of a network device, from the default LID screen,press the MENU and SERVICE softkeys. Scroll to high-light LOG OUT OF NETWORK DEVICE and press theSELECT softkey.

Power-Up — The LID goes through a self-diagnostic testand then displays the default screen. After the chiller isRESET, the PIC reads the ACTUAL CAPACITY VALVE andstarts driving it to the fully closed position by setting theTARGET CAPACITY VALVE to 0. Before starting the chiller,reset any alarms and return any fault conditions to a normalrange. The ALARM STATE must indicate NORMAL.

BEFORE INITIAL START-UP

Job Data and Tools Required1. Job specifications and job sheets, including a list of ap-

plicable design temperatures and pressures2. Chiller assembly and field layout drawings3. Controls and wiring drawings4. 16JB Installation Instructions5. Mechanic’s hand tools

6. Absolute pressure gage or water-filled wet-bulb vacuumindicator graduated with 0.1-in. (2 mm) of mercury in-crements. Do not use manometer or gage containingmercury.

7. Auxiliary evacuation pump, 5 cfm (2.5 l/s) or greater,with oil trap, flexible connecting hose, and connectionfittings

8. Compound pressure gage, 30-in. vacuum to 30 psig(75 cm vacuum to 200 kPa)

9. Digital volt-ohmmeter and clamp-on ammeter10. Liquid charging hose consisting of flexible 3⁄4-in.

(20-mm) hose connected to a 3-ft (1-m) long x 1⁄2-in.(15-mm) pipe trimmed at a 45-degree angle at one end,with a 1⁄2-in. MPT connector at the opposite end

11. Leak detector12. Hydrometer and insertion thermometer

Inspect Field Piping — Refer to the field piping dia-grams for your specific installation, and see the typical pip-ing schematic shown in Fig. 34. Inspect the chilled waterand cooling water piping.1. Verify that the location and flow direction of the water

lines are as specified on the drawings and as marked onthe chiller.

2. Check that all water lines are vented and properly sup-ported to prevent stress on waterbox covers or nozzles.

3. Make sure all waterbox drains are installed.4. Ensure that the water flow through the evaporator and con-

denser meet job requirements. Measure the pressure dropsacross both cooler and condenser.

5. Make sure the chilled water temperature sensors are in-stalled in the leaving chilled water piping. Also check thatappropriate thermometers or temperature wells and pres-sure gage taps have been installed in both entering andleaving sides of the evaporator, absorber, and condenserwater piping.

Inspect Field Wiring — Refer to the field and chillerwiring diagrams and inspect the wiring for both power sup-ply and connections to other system equipment (cooling tower,water supply pumps, auto. start if used, etc.)

Do not work on electrical components, including con-trol panels or switches, until you are sure that all poweris off and no residual voltage can leak from capacitorsor solid-state components.

Lock open and tag electrical circuits during servicing. Ifwork is interrupted, confirm that all circuits are deen-ergized before resuming work.

Do not apply power to hermetic pumps or attempt tostart the chiller until it has been charged with lithiumbromide solution and refrigerant. The pumps will be se-verely damaged if rotated without the full liquid charge.

1. Examine the wiring for conformance to job wiring dia-grams and applicable electrical codes.

2. Check the pump and motor nameplates and control panelfor agreement with supply voltage and frequency (Hz).

Fig. 33 — Example ofAttach to Network Device Screen

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3. Verify the correct overload and fuse sizes for all motors.Refer to the 16JB Product Data and Installation Instruc-tions manuals for current draw and motor sizes.

4. Check that electrical equipment and controls are properlygrounded in accordance with applicable electrical codes.

5. Make sure the customer/contractor has verified proper op-eration of water pumps, cooling tower fan, and associ-ated auxiliary equipment. This includes ensuring that motorsare properly lubricated and have proper electrical supplyand proper rotation.

Standing Vacuum Test — Before the chiller is ener-gized or placed in operation, check for air leaks with a stand-ing vacuum test. Examine the 2 test procedures describedbelow and select the one that applies to your job application.

LONG INTERVAL TEST — Use this test procedure if anabsolute pressure reading has been recorded at least 4 weekspreviously and the reading was not more than 1 in.(25 mm) of mercury.1. Connect an absolute pressure gage to the auxiliary evacu-

ation valve and record the pressure reading. The originalreading is listed on a tag that comes with the chiller. (Donot use a mercury gage.)

2. If the pressure has increased by more than 0.1 in.(2.5 mm) of mercury since the initial reading, an air leakis indicated. Leak test the chiller as described in the Main-tenance Procedures section, page 74, then perform the shortinterval test which follows.

SHORT INTERVAL TEST — Use this test procedure if:1. No previous absolute pressure readings have been re-

corded, OR2. The previous absolute pressure reading was made less than

4 weeks ago, OR3. The reading indicated a chiller pressure of more than

1 in. (25 mm) of mercury, OR4. The chiller had to be leak tested after the long interval

test.Procedure1. Connect the absolute pressure gage to the auxiliary evacu-

ation valve and record the pressure reading.2. If the reading is more than 1 in. (25 mm) of mercury ab-

solute, evacuate the chiller as described in the Mainte-nance Procedures section, page 74.

3. Record the absolute pressure reading and the ambienttemperature.

4. Let chiller stand for at least 24 hours.5. Note the absolute pressure reading when the ambient tem-

perature is within 15° F (8° C) of the ambient tempera-ture recorded in Step 3.

6. If there is any noticeable increase in pressure, an air leakis indicated. Leak test the chiller as described in the Main-tenance Procedures section, then repeat the short intervalvacuum test to ensure leak free results.

Fig. 34 — Typical Piping and Wiring

Field PipingControl WiringPower Wiring

53

Chiller Evacuation — When the chiller’s absolute pres-sure is greater than 1 in. (25 mm) of mercury absolute, thechiller must be evacuated as described in MaintenanceProcedures section, page 74.

Set Up Chiller Control Configuration

Do not operate the chiller before the control configu-rations have been checked and a control test has beensatisfactorily completed. Protection by safety controlscannot be assumed until all control configurations havebeen confirmed.

While you are configuring the 16JB chiller, write downall configuration settings. A log, such as the one shown onpages CL-1 to CL-10, is a convenient way to list configu-ration values.

Input the Design Set Points — To modify the setpoints, access the SETPOINT menu. (Press the MENU andSETPOINT softkeys.) The PIC can control a set point ac-

cording to either the leaving or entering chilled water tem-perature. To change the type of control, access the CONFIGtable on the LID. Scroll down to highlight CHW_IN CON-TROL OPTION. To control the set point according to theleaving chilled water, press the DISABLE softkey; to con-trol the set point according to the entering chilled water, pressthe ENABLE softkey.

Input the Local Occupied Schedule (OCCPC01S)— To set up the occupied time schedule according to thesite requirements, access the SCHEDULE screen on the LID.If no schedule is available, set it for 24 hours occupied perday, 7 days per week including holidays. This is the defaultsetting. For more information on how to set up a time sched-ule see the section on Time Schedule Operation, page 21.

If a CCN system is being installed or if a secondary timeschedule is required, configure the CCN occupancy sched-ule (OCCPC02S - OCCPC99S). This task is normally doneusing a CCN Building Supervisor terminal, but it can alsobe done at the LID. For more information on CCN func-tions, see the 16JB CCN Supplement. Also, see the sectionon Occupancy Schedule, page 30.

NOTE: When the chiller is under CCN control, it should notbe allowed to start until the initial start-up procedures havebeen completed. Refer to Initial Start-Up, Preliminary Check,on page 58.

Input the Service Configuration — The followingconfigurations are done from the SERVICE menu on the LID:• password• equipment configuration• equipment service (service parameters)• time and date• attach to network device• log out of device• controller identification• LID configuration

PASSWORD — You must enter a password whenever youaccess the SERVICE screens. The default, factory-set pass-word is 1 - 1 - 1- 1. The password may be changed from theLID CONFIGURATION screen. See the Service Operationsection, page 47, for instructions on how to change thepassword.

INPUT TIME AND DATE — Access the TIME AND DATEscreen from the SERVICE menu. Input the present time ofday, date, and day of the week. HOLIDAY TODAY shouldbe set to YES only if the present day is a holiday.

CHANGE THE LID CONFIGURATION, IF NECESSARY— From the LID CONFIGURATION screen, the LID CCNaddress, units (English or metric), and password can be changed.For instructions on changing the password and units, see theService Operation section, page 47. For more informationon the CCN address, refer to the 16JB CCN Supplement.The default CCN address is Bus 0, Address 250.

MODIFY CONTROLLER IDENTIFICATION, IF NECES-SARY — From the CONTROLLER IDENTIFICATIONscreen, you can change the PC6400 module address. If thereis more than one chiller at the site, change the controller ad-dress for each chiller. Write the new address on the PC6400module for future reference. The default address is Bus 0,Address 1.

If there is more than one chiller at the site, change theLID CCN address, as well. The LID address is changed fromthe LID CONFIGURATION screen.

INPUT THE EQUIPMENT SERVICE PARAMETERS, ASNECESSARY — The EQUIPMENT SERVICE menu has 3tables: SERVICE1, SERVICE2, and SERVICE3.

Access the SERVICE1 table to modify or view the fol-lowing site parameters.

RefrigerantTrip Point

Usually 3 F (1.7 C) belowdesign refrigerant temperature

Line Frequency 50 or 60 HzRefrigerant OverrideDelta T Usually 2 F (1.8 C)

Water FlowVerify Time

Used for chiller pumps andsystem pumps

ConcentrationSensor Calculation

Set after charge is trimmed

NOTE: Other values are left at the default settings. These may bechanged by the operator as required. The SERVICE2 and SERV-ICE3 tables can be modified by the owner or operator as needed.

MODIFY EQUIPMENT CONFIGURATION, AS NECES-SARY — The EQUIPMENT CONFIGURATION screen in-cludes the CONFIG table. Carrier provides certified draw-ings with the configuration values required for the site. Modifythese tables only if requested to do so. Possible modifica-tions include• chilled water reset (types 1, 2, and 3)• entering chilled water control (enable or disable)• remote contact option (enable or disable)• temperature pulldown (degrees per minute)• CCN occupancy configuration (schedule number and broad-

cast option)NOTE: The following section is included for reference only.For detailed information on CCN operations, consult the 16JBCCN Supplement.

In addition to the CONFIG table, the EQUIPMENT CON-FIGURATION screen includes the CCN screens and tablesdescribed below.OCCDEFCS — The OCCDEFCS tables contain the local andCCN time schedules.HOLIDAYS — From the HOLIDAYS tables, you can con-figure the days of the year that holidays are in effect. See theLID Operation and Menus section that begins on page 15 formore details on this function.

54

BRODEF — From the BRODEF screen, you can:• Configure the outside air temperature and humidity sen-

sors, if installed.• Define the start and end of daylight savings time. Enter

the dates for the start and end of daylight savings, if re-quired for your location.

• Activate the CCN broadcast function which allows the holi-day periods defined in the HOLIDAYS table to take effect.

Other Tables — The ALRM_CFG, CONSUME, RUN-TIME, and WSMALMDF tables are used only in a CCNnetworked system. These tables can only be modified usingCCN Building Supervisor (BS) software.

Charge the Chiller with Solution andRefrigerantHANDLING LITHIUM BROMIDE (LiBr) SOLUTION

Lithium bromide and its lithium chromate or lithiumblend inhibitor can irritate the skin and eyes. Wash offany solution with soap and water. If any solution entersthe eye, wash the eye with fresh water and consult aphysician immediately. Lithium bromide is a strong saltsolution; do not syphon by mouth.

Liquid materials that are added to lithium bromidesolution such as lithium hydroxide, hydrobromic acid,octyl alcohol, and inhibitors are classified as hazardousmaterials. These materials, and any lithium bromide so-lution they are in, must be handled in accordance withcurrent Occupational Safety and Health Administration(OSHA) and Environmental Protection Agency (EPA)regulations.

Solutions of lithium bromide and water are nontoxic, non-flammable, nonexplosive, and can be handled easily in opencontainers. The solution is chemically stable and does notundergo any appreciable change in properties even after yearsof use in the absorption chiller. Its general chemical prop-erties are similar to those of table salt.

Because lithium bromide salt can corrode metal in the pres-ence of air, wipe off any solution spilled on metal parts ortools and rinse the part with fresh water as soon as possible.After rinsing, coat the tools with a light film of oil to preventrust. After emptying metal containers of solution, rinse thecontainer with fresh water to prevent corrosion. Immedi-ately wipe or flush the floor if lithium bromide or octyl al-cohol is spilled on it. Refer to the appropriate Material SafetyData Sheet (MSDS) for information on leak or spilldisposal.

Lithium bromide should be stored only in the original con-tainer or in a completely clean container. Used lithium bro-mide solution should be disposed of by a reputable chemicaldisposal company.CHARGING SOLUTION — Solution is drawn into the ab-sorber through the solution pump service valve while thepump is off. To minimize the chance of air entering the chiller,the solution should not be drawn in directly from a smallcontainer. A vacuum pump should be in operation while thesolution is being charged into the chiller to remove en-trained noncondensables.1. Connect a flexible hose to a 1⁄2-in. MPT adapter and

a 1⁄2-in. (15-mm) pipe. Fill both pipe and hose withdeionized water to minimize any air entry into the chiller.

2. Insert the 1⁄2-in. (15-mm) pipe into the container (be sureit goes to the bottom), and connect the flexible hose tothe solution pump service valve (Fig. 35). The lithiumbromide container must be marked with the name of theinhibitor being used for your chiller. A 55% concentra-tion solution must be used.

3. Open the service valve. Continue charging until the so-lution level is near the bottom of the container. Do notallow air to be drawn into chiller.

4. Either transfer the rest of the solution from a full con-tainer to this container or repeat the procedure fromStep 1 until the amount specified in Table 5 has been chargedinto the chiller.

CHARGING SOLUTION FOR CONDITIONS OTHERTHAN NOMINAL — The solution quantity can be adjustedto compensate for other than nominal values for the designchilled water temperature, cooling water temperature, or flows.

The solution should not be added to the chiller morethan 24 hours before the chiller is ready to start. If thechiller is charged prematurely, the corrosion inhibitorslose their effectiveness, since they need heat to form theinitial layer of corrosion protection.

The solution quantity can be increased or decreased byup to 10% of the nominal charge listed in Table 5. Adjust thequantity as follows:1. Increase (or decrease) the nominal solution charge by 1%

for each degree F (0.56° C) that the design chilled watertemperature is below (or above) 44 F (7 C).

2. Increase (or decrease) the nominal solution charge by 1%for each 2° F (1.1° C) that the design cooling water tem-perature is above (or below) 85 F (29 C).

3. Increase the nominal solution charge by 1% for each 10%reduction in design cooling water flow below nominal 100%.

4. Do not adjust nominal charge for changes in steampressure.

Fig. 35 — Charging Solution and Refrigerant

55

INITIAL REFRIGERANT CHARGING — The refrigerantcharge must be de-ionized water that meets Carrier Speci-fication No. RW01-19. Do not use tap water. Use CarrierPart No. PV30DB021, de-ionized water, which may be pur-chased from approved Carrier vendors. See Service BulletinNo. A9503 for additional information on refrigerant for the16JB chiller.

Charge the water through the refrigerant pump servicevalve, following the appropriate steps in the ChargingSolution section, page 55.

Charge at least the amount listed in Table 5 under InitialRefrigerant amount. This charge must be adjusted after start-upto achieve optimal Cycle-Guard™ control conditions to limitthe maximum solution concentration (which prevents solu-tion crystallization). However, any extra refrigerant shouldbe limited because the normal refrigerant pump dischargepressure is below atmospheric pressure, and a vacuum bottleis required to remove refrigerant (see Final Refrigerant ChargeAdjustment section, page 58).

Table 5 — Machine Nominal Charges*

UNIT16JB

LiBrSOLUTION

INITIALREFRIG

Gal. L Gal. L010,012,014 110 417 40 152

018,021 160 606 50 190024,028 200 758 65 246032,036 260 985 70 265041,047 320 1213 90 341054,057 360 1365 175 663061,068 390 1477 265 1004

*Based on solution at 53° concentration, 44 F (7 C) leaving chilledwater, 85 F (29 C) entering condensing water and 12 psig (83 kPa)steam (or equivalent hot water temperature).

INITIAL CONTROL CHECKOUT ANDADJUSTMENT

Perform an Automated Control Test — The pro-cedures in this section check the PIC control systems. Thepurpose of this checkout is to ensure that control circuits havenot been affected by shipping or installation damage or al-tered in the process of making field wiring connections.

Follow the checkout sequence in detail. The chiller mustbe charged with solution and refrigerant before startingthe checkout. Chilled water and condensing water cir-cuits must be filled and operative, but the manual steamor hot water valve must remain closed.

Do not rotate hermetic pumps until the chiller is chargedwith lithium bromide-water solution and refrigerant.

Remove and pull the fuses to determine which contactorsare energized without actually running a motor, pump, orother device. The PIC checks most devices to verify theiroperation. Pulling the fuses may generate an alarm.

Check the safety controls status by performing an auto-mated control test. The automated control test also checkswhether all outputs and inputs are functioning, including:• PC6400 inputs• PC6400 outputs• slave PSIO-1 inputs• slave PSIO-1 outputs• slave PSIO-2 inputs• capacity valve actuator

The chiller must be in the OFF mode in order to performthe automated control test. To place the chiller in OFF mode,press the STOP button located to the left of the LID soft-keys. Close the manual steam supply valve before runningthe capacity valve actuator.

For information on how to access the CONTROL TESTmenu and perform the test, refer to the PIC Control Testssection on page 30. The PIC Control Tests section also hasa detailed description of the each of the functions checkedby the automated controls test. Table 6 summarizes the de-vices and functions checked by the control tests.

Once the automated control test begins, the LID will askthe operator to confirm that each specific function or opera-tion is occurring and whether or not to continue the test. Ifan error occurs, the operator has the choice of attempting toaddress the problem while the test is being run or to note theproblem and proceed to the next part of the test.

When the automated control test is complete or if theEXIT softkey is pressed, the test will stop and the

CONTROL TEST table will display on the LID. If a specificautomated test procedure has not completed, access that pro-cedure to test the function when you are ready to proceedwith the Control Test process.

To Prevent Accidental Start-Up — The PIC can beconfigured so that chiller start-up is more difficult than justpressing the LOCAL or CCN softkeys during chillerservice or other times when necessary. Access the MAIN-STAT screen and highlight CHILLER START/STOP. Over-ride the current START value by pressing the SELECT softkeyand then the STOP and ENTER softkeys. The wordSUPVSR will display on the LID.

Now, when attempting to restart the chiller, remember toremove the STOP override setting. Access the MAINSTATscreen and highlight CHILLER START/STOP. The 3 soft-keys represent 3 choices:• START − forces the chiller ON• STOP − forces the chiller OFF• RELEASE − puts the chiller under remote or schedule

control

To return the chiller to normal control, press theRELEASE softkey; then, press the ENTER softkey. For

additional information, see Local Start-Up, page 65.The default LID screen message line indicates which com-

mand is in effect.

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Table 6 — 16JB Functions and Devices Tested by the PIC Control Test

TEST FUNCTION/DEVICE TESTED1) Automated Control Test Performs tests 2 through 7

2) PC6400 Inputs

Cycle-Guard™ auto/manualOverflow pipeStrong LiBr leaving GENStrong LiBr leaving HXLiBr ent abosrber sprayVapor condensate tempCooling water leaving condLID off switch

3} PC6400 Outputs

Chilled water pumpCooling water pumpSolution pumpRefrigerant pumpTower fan relayAlarm relayLID alarm light

4) Slave PSIO-1 Inputs

Transducer voltage referenceSolution pump pressureLow refrigerant levelHigh refrigerant levelRefrigerant level sensorRefrigerant tempEntering chiller waterLeaving chilled waterWeak LiBr leaving absorberWeak LiBr leaving HXCooling water ent absorbCooling water leaving absorb

5) Slave PSIO-1 OutputsCycle-Guard valveChiller run relayLLC valve

6) Slave PSIO-2 Inputs

Chilled water flowCooling water flowPurge light indicatorRemote contactsRet pump overld/high tempSol pump overld/high tempGenerator high tempLow chilled water tempTemp reset 4-20 mARemote reset sensorCommon supply sensorCommon return sensor

7) Capacity Valve Actuator Capacity valve position(a PC6400 output)

LEGEND

GEN — GeneratorHX — Heat ExchangeLiBr — Lithium BromideLID — Local Interface DeviceLLC — Low Level Control

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INITIAL START-UPThe following start-up procedures are used for absorption

chillers with PIC control systems. During initial start-up, thereis a period of time when initial inhibiting occurs in absorp-tion chillers and large amounts of gas are generated. Thisbreak-in period may take up to 400 hours of run time tocomplete.

Preliminary Check — Check the operation of the aux-iliary equipment and the status of the system before startingthe 16JB chiller. Set up the chiller configuration and per-form the control tests as described in the Set Up Chiller Con-trol Configuration beginning on page 54 and Perform an Au-tomated Control Test, page 56.

PREPARATION1. Supply power to the control panel, chilled water, and cool-

ing water pumps. Open the manual steam supply valves,chilled water valves, and cooling water valves.

2. Make sure the pumps are rotating in the proper direction.To do this, place a 30-in. (762 mm), 30 psi (207 kPa)gage on the discharge of each pump. Access the PUMP-STAT screen on the LID and turn on each pump from theLID. Read the pressure on each pump gage. The solutionpump should read 28 psi (193 kPa). If a pump pressureis 30 in., the pump is rotating in the wrong direction. Therefrigerant pump pressure should read from 5 to 11 in.(127 mm to 279 mm). If it is less than 5 in., the pump isrotating in the wrong direction. If a pump is rotating inthe wrong direction, it must be corrected. To correct ro-tation, switch any 2 wires on the pump overload blocks(Fig. 9).

Do not work on electrical components, including con-trol panels or switches, until you are sure that allpower is off and no residual voltage can leak fromcapacitors or solid-state circuits. Lock open and tagelectrical circuits during servicing. If work is inter-rupted, confirm that all circuits are deenergized be-fore resuming work.

3. Access the MAINSTAT screen to disable the STARTUPPULLDOWN FAILURE by pressing the DISABLE andthen the ENTER softkeys.

NOTE: When the following 2 conditions are met: the GENsolution temperature is greater than 160 F (71 C) and theleaving chilled water temperature is decreasing, then theSTARTUP PULLDOWN FAILURE is automatically set toENABLE.

4. Place the Cycle-Guard™ switch in the AUTO. position.Depress the LOCAL softkey. The chiller will begin thestart-up procedure.

5. When the chiller has reached the RAMPING mode inthe start-up cycle (as indicated in the primary and sec-ondary messages on the LID) and the solution is warm,press the MENU , STATUS , MAINSTAT , andSELECT softkeys on the LID. Scroll down to TARGET

CAPACITY VALVE. Press the SELECT softkey; then pressthe ENTER softkey. This puts a supervisory hold on thecapacity valve and limits its opening to the current value.

6. Determine the chiller absorber loss as described in Main-tenance Procedures, Absorber Loss Determination sec-tion, page 76.

If the absorber loss is greater than 12° F (4.4° C), evacu-ate the chiller (see Maintenance Procedures, Chiller Evacu-ation section, page 77) to remove any noncondensablesthat might prevent normal operation. As an alternate pro-cedure, limit steam pressure to keep the strong solutiontemperature under 140 F (60 C) and allow the purge toremove the noncondensables.Once the absorber loss has been reduced to below 12 F(6.7 C) by either of the above procedures, the purge willevacuate the chiller to the normal absorber loss of 8 F(4.4 C) or less.

7. Add the amount of octyl alcohol specified in Table 7 throughthe solution pump service valve. (Refer to MaintenanceProcedures, Adding Octyl Alcohol section, page 78.) Donot allow air to be drawn into chiller. The addition of oc-tyl alcohol should be postponed until most of this break-inperiod has elapsed or the accumulation rate of non-condensables has decreased.

After the absorber loss has been reduced to below 12° F(6.7° C) by either of the above procedures (Step 6), place thechiller in automatic operation, with the capacity control re-leased and steam pressure normal. The purge will evacuatethe chiller to the normal absorber loss of 8° F (4.4° C) orless.

Table 7 — Octyl Alcohol Initial Charge

16JBOCTYL ALCOHOL

Gal. L010,012,014 1 4

018,021 1 4024,028 2 8032,036 3 12041,047 3 12054,057 3 12061,068 3 12

Final Adjustment of Capacity Controls — Al-low the chiller to operate long enough with a fairly stableload for the system to reach equilibrium. Verify that the chilledwater temperature is close to the set point and the systemis stable (with little capacity control valve cycling orsearching).

The controller tuning parameters have been factory-configured for control stability with typical applications. How-ever, if necessary, the parameters can be adjusted from theLID by accessing the SERVICE3 display screen, selectingthe parameter that needs fine tuning, and making the appro-priate changes. See Capacity Overrides section, page 33, andPIC System Functions, page 22.

Final Refrigerant Charge Adjustment — The ad-justment should be made after:1. Chiller is operating with stable temperatures at 40 to 100%

of full load.2. Absorber loss is 12° F (6.6° C) or less.3. Refrigerant specific gravity is 1.02 or less.

The refrigerant charge is adjusted so that the Cycle-Guard™ system can limit maximum solution concentrationand avoid solution crystallization. Proceed as follows:1. Place Cycle-Guard Switch on the control panel in the AUTO.

position. Then, if the Cycle-Guard valve remains off atleast 10 minutes, proceed to Step 2. If not, gradually re-duce the load on the chiller (to reduce the solution con-centration) until the Cycle-Guard valve remains off. Cali-brate the analog float for point 1 or 2, as appropriate, inStep 7. The valve will be energized when the refrigerantHIGH LEVEL SWITCH, or CYCLE GUARD LEVEL AD-JUST is closed (CLOSE on the EVAPSTAT display screen).

58

2. Remove a solution sample from the solution pumpservice valve and measure the specific gravity andtemperature.

3. Locate the intersection point of the specific gravity andtemperature values on the equilibrium diagram (Fig. 36or 37). Read down from this point to the solution con-centration scale to determine the percent lithium bromideby weight in the weak solution.

4. Determine the approximate percent of full load on the chillerby comparing the chilled water temperature spread andflow in relation to design. Refer to this percent load inTable 8 and find the corresponding weak solution con-centrations required to make the refrigerant chargeadjustment. The refrigerant level charge can be adjustedat either of the 2 refrigerant levels.

Table 8 — Weak Solution Concentrations forAdjusting Refrigerant Charge

REFRIGERANTLEVEL

PERCENT LOAD ON CHILLER100 90 80 70 60 50 40

Weak Solution Concentration (%)High 60.0 60.4 60.8 61.2 61.6 61.9 62.2

Cycle-Guard™Level Adjust 58.5 58.9 59.2 59.6 59.9 60.3 60.6

NOTE: Concentrations listed in Table 8 are for nominaldesign conditions. For special design conditions, obtainthe special concentration settings from the factory.Reference field experience report No. 75-4 for furtherinformation.

5. Adjust chiller operating conditions until the chiller op-erates with stable temperatures at either one of the 2 weaksolution concentrations (±0.1%) listed in Table 8 underthe selected percent load.To increase the concentration:a. Increase the load.b. Lower chilled water temperature (set point adjuster

setting).c. Raise condensing water temperature (or throttle con-

densing water flow).After adjusting conditions, repeat Steps 2 and 3 to verifysolution concentration.

6. The refrigerant charge can be adjusted at any one of 2refrigerant levels described below. Use the refrigerant levelin Table 8 that corresponds tot he weak solution concen-tration at the percent load determined in Step 4. Proceedas follows, at the appropriate refrigerant level:

7. Calibrate the refrigerant level device in the refrigerant cham-ber to ensure proper control of the solution concentra-tions. The refrigerant level device must be calibrated atthe 2 points described below.Calibration Point 1: The chiller is operating at high loadand the solution concentration is taken at high refrigerantlevel. The chiller should be running close to its maxi-mum capacity, and the condenser water temperature shouldbe between 80 and 90 F (27 and 32 C). Take a solutionsample at the solution pump service valve. Determine andrecord its concentration. From the LID, press MENUand STATUS . Scroll to EVAPSTAT. From the EVAP-STAT table, scroll to REFRIGERANT LEVEL SENSOR

and record the voltage; it should be between 0 and 5 vac.Next, adjust the solution concentration and voltage. Atthe LID, press MENU and SERVICE . After enteringyour password, scroll to and select the EQUIPMENT SERV-ICE table. Select the SERVICE1 table and scroll toCONC AT HIGH LEVEL. Press the INCREASE orDECREASE softkeys to adjust to the concentration

(XX.X%) recorded above. Press ENTER . Scroll to VOLTSAT HIGH LEVEL and press the INCREASE orDECREASE softkeys to adjust the voltage (X.X) to match

the voltage recorded above. Press ENTER .Calibration Point 2: The chiller is operating at low loadand the solution concentration is taken at low refrigerantlevel. The chiller should be running around 50% load andallowed to stabilize at this load for at least one hour. Takea solution sample and voltage reading as described forCalibration Point 1. Record the solution concentration andvoltage readings as described for Calibration Point 1. Ac-cess the SERVICE1 table as described above and adjustthe CONC AT LOW LEVEL and VOLTS AT LOW LEVELto match the recorded data.

8. Check the status of the Cycle-Guard valve. If it is open,gradually remove refrigerant water from the refrigerantservice valve until the Cycle-Guard valve closes. (SeeSolution or Refrigerant Sampling section, page 77.) If theCycle-Guard valve is closed, add small quantities of wa-ter to the chiller until the Cycle-Guard valve opens. Addor remove refrigerant water to change the level in the re-frigerant chamber as needed. When adding or removingrefrigerant water, allow approximately 10 minutes for thetemperatures and concentrations to stabilize. Periodicallycheck the weak solution concentration while adjusting therefrigerant charge. Re-adjust chiller conditions, if neces-sary, to maintain controlled concentration. Recalibrate thelevel switch per Step 7.

9. If the solution charge has been increased (or decreased)for design conditions other than nominal, decrease (or in-crease) the refrigerant charge by an equal amount. (Referto the Charge Chiller with Solution and Refrigerant, Charg-ing for Conditions Other than Nominal, page 55.)

Check Chiller Operating Conditions — Check tobe sure that the chiller temperatures, pressures, water flows,and solution and refrigerant levels indicate that the system isfunctioning properly. Keep a log of the chiller’s operatingparameters using the LID status and maintenance screens asa source of data and a log sheet, such as the sample log sheetshown in Fig. 38 (see also Table 9).

Check Chiller Shutdown — Depress the Stop but-ton. The capacity control valve closes and the Cycle-Guardvalve opens to dilute the solution. When the solution has beensufficiently diluted, the chiller shuts down.

Depending on the solution concentration before shut-down, the shutdown can take up to 20 minutes. If the chillerdoes not shut down correctly, check the operation of capac-ity controls, refrigerant level switches, Cycle-Guard valve,and chiller wiring.

59

1.35

1.30

1.25

1.20

1.15

1.10

1.05


% O

F L

ITH

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BR

OM

IDE

BY

WE

IGH

T IN

SO

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4035

3025

2015

105

0

SATURATION TEMPERATURE IN DEGREES F (DEGREES C)

0.9

(22.

9)

0.8

(20.

3)

0.7(

17.8

)

0.6

(15.

2)

0.5

(12.

7)

0.4

(10.

1)

0.3

(7.6

)

0.2

(5.1

)

0.1

(2.5

)

0.08

(2.

0)

70 (

21.1

)

60 (

15.5

)

50 (

10)

40 (

4.4)

30 (

-1.1

)

20 (

-6.7

)

10 (

-12.

2)

SO

LUTI

ON

TE

MP

ER

ATU

RE

90 (

32.2

)

155

(68.

3)

63 (

17.2

)

55 (

12.8

)

45 (

7.2)

SPECIFIC GRAVITY

Fig

.36

—P

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qu

ilib

riu

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ram

LiB

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60

1.66

1.64

1.62

1.60

1.58

1.56

1.54

1.52

1.80

1.78

1.76

1.74

1.72

1.70

1.68

6560

5550

% L

ITH

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BR

OM

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SATURATION TEMPERATURE IN DEG F (DEG C)


SPECIFIC GRAVITY

SO

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ON

TE

MP

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ATU

RE

CRYSTALLIZATION LINE

120

(48.

9)

110

(43.

3)

100

(37.

8)

90 (3

2.2)

90 (3

2.2)

80 (2

6.7)

70 (2

1.1)

60 (1

5.6)

140

(60.

0)

130

(54.

4)

150

(65.

5)

20 (

-6.7

)

70 (

21.1

)

60 (

15.5

)

50 (

10)

40 (

4.4)

30 (

-1.1

)

0.8

(22.

9)

0.7

(17.

8)

0.6

(15.

2)

0.5

(12.

7)

0.4

(10.

1)

0.3

(7.6

)

0.2

(5.1

)

0.1

(2.

5)

0.08

(2.

0)

Fig

.37

—P

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of

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61

JOB NAME: LOCATION:

CHILLER MODEL NO: S/N:

OPERATION HOURS: TAKEN BY:

DATE: JOB NO.:

ITEMNO.

DATAITEM*

RECORD1

RECORD2

RECORD3

RECORD4

REOORD5

RECORD6

RECORD7

RECORD8

EVAPORATOR:

1 Entering ChilledWater Temperature

2 Leaving ChilledWater Temperature

3 RefrigerantTemperature

4 Specific Gravity ofRefrigerant Sample

5 Cycle-Guard™ ValveStatus

6 Chilled Water PD

7 Refrigerant PumpPressure

8 Refrigerant LevelSensor

ABSORBER:

9 Cooling Water InTemperature

10 Cooling Water OutTemperature

11 Weak LiBr LeavingAbsorber Temperature

12 Specific Gravity ofWeak LiBr Sample

13 Weak LiBr SampleTemperature

14 Weak LiBr LeavingHX Temperature

15 Solution to Sprays Temperature(Recirc LiBr Entering Sprays)

16 Cooling Water PD

17 Pump Pressure

CONDENSER:

18 Cooling Water OutTemperature

19 Vapor CondensateTemperature

20 Cooling Water PD

Fig. 38 — Sample Log for 16JB Chiller

62

ITEMNO.

DATAITEM*

RECORD1

RECORD2

RECORD3

RECORD4

REOORD5

RECORD6

RECORD7

RECORD8

GENERATOR:

21 Strong LiBr LeavingGEN Temperature

22 Strong LiBrLeaving HX1

23 GEN InternalPressure

24 Steam SupplyPressure

25 Steam Pressureto Chiller

26 Actual Capacity Valve% of Opening

ADDITIONAL DATA ITEMS:

27 Chilled WaterGPM

28 Absorber WaterGPM

29 Refrigerant SaturationTemperature

30 Weak LiBrConcentration

31 Weak LiBr SaturationTemperature

32 Strong LiBrConcentration, GEN

33 Absorber Loss

34 Evaporator Approach

35 Absorber Approach

36 Condenser Approach

LEGEND

GEN — GeneratorGPM — Gallons Per MinuteHX — Heat ExchangerLiBr — Lithium BromidePD — Pressure DifferentialSG — Specific Gravity*See Table 9 for information on how to obtain data for this log.

Fig. 38 — Sample Log for 16JB Chiller (cont)

63

Table 9 — How to Obtain Data for Log (Fig. 38)

ITEM NO. HOW OBTAINED UNITS1 Default screen (CHW_IN) or EVAPSTAT screen DEG F (DEG C)2 Default screen (CHW_OUT) or EVAPSTAT screen DEG F (DEG C)3 Default screen (EVAP_REF) or EVAPSTAT screen DEG F (DEG C)4 Measured by operator SG (Specific Gravity)5 Light on control box or read on EVAPSTAT screen ON/OFFMANUAL/AUTO6 Gage reading by operator psid (kPad)7 Measured by Operator psig (kPa)8 EVAPSTAT screen Volts9 Default screen (ABS_IN) or or ABSSTAT screen DEG F (DEG C)

10 Default screen (ABS_OUT) or ABSSTAT screen DEG F (DEG C)11 Default (ABS_SOL) screen or ABSSTAT screen DEG F (DEG C)12 Measured by operator SG13 Measured by operator DEG F (DEG C)14 ABSSTAT screen DEG G (DEG C)15 ABSSTAT screen psig (kPa)16 Gage reading psig (kPa)17 Default or CONDSTAT screen (COND_OUT) DEG F (DEG C)18 CONDSTAT screen DEG F (DEG C)19 Measured by operator psid (kPad)20 Default or GENSTAT screen (GEN_SOL) DEG F (DEG C)21 Default screen or GENSTAT (GEN_SAT) screen DEG F (DEG C)22 GENSTAT screen psi (kPa)23 Measured by operator psig (kPa)24 Measured by operator psig (kPa)25 GENSTAT screen %26 Chilled Water PD [6] X (2.31) ± (dh)* ft H2O (mH2O)27 Cooling Water PD [20] X (2.31) ± (dh)* ft H2O (mH2O)

28 Use equilibrium chart, (Fig. 36): Refrigerant Temperature [3],and Refrigerant Sample specific gravity (SG) [4]. DEG F (DEG C)

29 Use equilibrium chart (Fig. 36), Weak LiBr Sample Temperature [13],and Weak LiBr Sample SG [12]. %

30 Use equilibrium chart (Fig. 36), Weak Solution concentration [30], andWeak LiBr Leaving Absorb [11]. DEG F (DEG C)

31 Use equilibrium chart (Fig. 36), Strong LiBr Leaving GEN [21], andVapor Condensate Temperature [19].

32[33] = [3] − [29], where 0 to 8 is normal; 8 to 12 requires action; andmore than 12 is out of range. Or, see ABSORBER LOSS on theAPPROACH screen.

DEG F (DEG C)

33[34] = [2] − [3], where 0 to 3 is normal; 4 to 5 requires action; and morethan 5 is out of range. Or, see EVAPORATOR APPROACH on theAPPROACH sereen.

DEG F (DEG C)

34[35] = [11] − [10], where 4 to 8 is normal; 8 to 12 requires action; andmore than 12 is out of range. Or, see ABSORBER APPROACH on theAPPROACH screen.

DEG F (DEG C)

35[36] = [19] − [18], where 4 to 8 is normal; 8 to 12 requires action; andmore than 12 is out of range. Or, see CONDENSER APPROACH on theAPPROACH screen.

DEG F (DEG C)

*d/h is the difference in height (ft) between 2 pressure gages. If the inlet pressure gage is higher than the outletpressure gage, use +dh; if the inlet pressure gage is lower than the outlet pressure gage, use −dh.

NOTE: Numbers in [ ] refer to item numbers in Fig. 38.

Consult the PD tables for PD at 6 GPM. Data is in the 16JB Product Data manual. Use:

PD2.55

GPM2 = GPM1 ( )PD1

where 1 is the design condition.

64

Check Low Refrigerant Level Operation — Af-ter the chiller has completed a normal shutdown:1. From the LID, access the PUMPSTAT display screen by

pressing the MENU and STATUS softkeys. From thePUMPSTAT screen, select REFRIGERANT PUMP, andpress the ON softkey to turn it on. Next, select SOLU-

ONTION PUMP and press the softkey to turn it on.2. From the PUMPSTAT screen, scroll to CYCLE GUARD

AUTO/MANUAL and press the MANUAL softkey to setit to manual, or set the Cycle-Guard™ Auto/Manual switchon the front of the control box to manual. This transfersrefrigerant from the evaporator and lowers the refrigerantlevel until it reaches the low-level switch. LOW LEVELSWITCH on the EVAPSTAT screen should read OPENand the LLC valve should come on. The LLC valve willtransfer solution from the discharge of the solution pumpto the evaporator pump to protect the refrigerant pump.

3. Release the Cycle-Guard switch and the refrigerant pump(if not already released in Step 2) for normal operation.To release the Cycle-Guard switch, set the Cycle-Guardon the control panel to AUTO. Or, access the PUMP-STAT screen on the LID and release the Cycle-Guard switchby scrolling to REFRIGERANT PUMP, SOLUTION PUMP,and pressing the RELEASE softkey. Then scroll toCYCLE GUARD AUTO/MANUAL and press theAUTO softkey.

4. Release the Refrigerant Pump and the Solution Pump fornormal operation.When enough refrigerant has been recovered from the so-lution to raise the evaporation level above the low-levelswitch, the refrigerant pump will run.

Determine Noncondensable Accumulation Rate— After approximately 400 hours of chiller operation, therate of noncondensable accumulation in the purge should bemeasured to be sure that the chiller does not have an air leak.If a leak is indicated, it must be corrected as soon as possibleto minimize internal corrosion damage. Refer to Mainte-nance Procedures, Noncondensable Accumulation Rate sec-tion on page 76 for checking procedures.

Instruct the Operator — Check to be sure that the op-erator(s) understands all operating and maintenance proce-dures. Point out the various chiller parts and explain theirfunctions as part of the complete system:• evaporator• absorber• generator• heat exchangers• condenser• relief devices• refrigerant and solution charging valve• temperature sensor locations• pressure transducer locations• Schrader fittings• waterboxes• tubes• vents• drains

In addition, review the following systems and equipment.

PURGE SYSTEM — Closing and opening the valves as wellas the purge rate.

CONTROL SYSTEM — CCN and LOCAL start, reset, menus,softkey functions, LID operation, occupancy schedule, setpoints, safety controls, and auxiliary and optional controls.

AUXILIARY EQUIPMENT — Starts and disconnects, sepa-rate electrical sources, pumps, and the cooling tower.

CHILLER CYCLES — Describe solution concentration andpurge cycles.

MAINTENANCE — Review scheduled, routine, and ex-tended shutdowns; the importance of maintaining log sheets,solution analysis, water treatment, tube cleaning; and the im-portance of maintaining a leak-free chiller.

SAFETY DEVICES AND PROCEDURES — Electrical dis-connects, relief device inspection, and solution handling.

OPERATIONS KNOWLEDGE — Check the operator’s un-derstanding of the following: start, stop, and shutdown pro-cedures; safety and operating controls; solution sampling;and job safety.

START-UP, OPERATION, AND MAINTENANCE MANU-ALS — Review these documents with the operator(s).

START-UP/SHUTDOWN/RECYCLE SEQUENCE(Fig. 39)

Figure 39 summarizes the start-up/shutdown/recyclesequence.

Local Start-Up — Local start-up (or a manual start-up)is initiated by pressing the LOCAL softkey, which is on thedefault LID screen. Local start-up can proceed if the chillerschedule indicates that the current time and date has beenestablished as a run time and date. This condition is referredto as ‘‘occupied.’’ See the sections on Time ScheduleOperation (page 21), Occupancy Schedule (page 30), ToPrevent Accidental Start-Up (page 56) and Fig. 18.

If the current time and date is not established as a run time,the chiller can be forced to start as follows. From the defaultLID screen, press the MENU and STATUS softkeys. Scroll

to highlight MAINSTAT. Press the SELECT softkey. Scrollto highlight CHILLER START/STOP. Press the START soft-key to override the schedule and start the chiller.

NOTE: The chiller will continue to run until this forced startis released, regardless of the programmed schedule. To re-lease the forced start, highlight CHILLER START/STOP fromthe MAINSTAT screen and press the RELEASE softkey.This action returns the chiller to the start and stop times es-tablished by the schedule.

NOTE: The chiller may also be started by overriding the timeschedule. From the default screen, press the MENU andSCHEDULE softkeys. Scroll down and select the current

schedule. Select OVERRIDE, and set the desired overridetime.

Another condition for local start-up must be met for chill-ers that have the REMOTE CONTACTS OPTION on theEQUIPMENT CONFIGURATION screen set to ENABLE.For these chillers, the REMOTE CONTACTS parameter onthe MAINSTAT screen must be ON. From the LID defaultscreen, press the MENU and STATUS softkeys. Scroll tohighlight MAINSTAT and press the SELECT softkey. Scrolldown the MAINSTAT screen to highlight REMOTE CON-TACTS and press the SELECT softkey. Then, press theON softkey. To end the override, select REMOTE CON-

TACTS and press the RELEASE softkey.

65

Pre-Start — Once these conditions are met, the PIC thenperforms a series of pre-start checks to verify that all pre-start alerts and safeties are within the limits shown inTable 4 (Safety Contacts andAlert Limits). The pre-start checksinclude:• STRONG LiBr LEAVING G1 <180 F (82.2 C)• REFRIGERANT TEMP is greater than REFRIGERANT

TRIPPOINT + REFRIGERANT OVERRIDE DELTA T• WEAK LiBr LVG ABSORB is less than WEAK LiBr

LVG ABS ALERT

The run status line on the LID reads PRESTART. SeeFig. 40, a flowchart of the start-up procedure. If the checksare successful, the chilled water/pump relay will beenergized.

Twenty seconds later, the PIC begins to monitor severalchiller functions which, if they fail, will abort the start-upsequence. These functions are listed below and are shown inthe flow chart in Fig. 40.1. CHILLED WATER FLOW not confirmed within the

WATER FLOW VERIFY TIME period (operator config-urable; default time, 5 minutes)

2. COOLING WATER FLOW not confirmed within theWATER FLOW VERIFY TIME period

3. SOLUTION PUMP is OFF, SOLUTION PUMP PRES-SURE < 10 psia (172 kPa)

4. SOLUTION PUMP is ON5. SOLUTION PUMP PRESSURE > 10 psia (172 kPa)

AB/C H I J K L MF/GD/E

0A PRESTART CHECKS & START CHILLED WATER PUMP

B CHILLED WATER FLOW VERIFY

C CHILLED WATER TEMPERATURE & COOLING WATER PUMP

D COOLING WATER FLOW VERIFY TIME

E TOWER FAN ALGORITHM & SOLUTION PUMP START

F SOLUTION PUMP VERIFY

G REFRIGERANT PUMP START

H CAPACITY VALVE 50%

I WARM-UP MODE

J RAMPING MODE

K RUNNING MODE

L NORMAL DILUTION

M SHUTDOWN MODE

A. Prestart Checks and Chilled Water Pump. After the start-up com-mand, the chiller performs PRESTART checks and starts the chilledwater pumps.

B. Chilled Water Flow. Twenty seconds after the CHILLED WATERPUMP is set to ON, the PIC checks to see that CHILLED WATERFLOW is verified. It continues to check the CHILLED WATER FLOWup to the WATER FLOW VERIFY TIME.

C. Chilled Water Temperature and Cooling Water Pump. The chilledwater temperature is measured. If it is above the CONTROL POINTplus the CONTROL POINT DEADBAND, then the cooling waterpump is energized.

D. Cooling Water Flow Verification. Twenty seconds after the cool-ing water pump is energized, the PIC checks that COOLING WA-TER FLOW is verified. It continues to check cooling water flow upto the WATER FLOW VERIFY TIME.

E. Tower Fan Algorithm and Solution Pump. The PIC starts thetower fan algorithm and the SOLUTION PUMP is energized (ON).

F. Solution Pump Verification. Twenty seconds after the SOLU-TION PUMP is energized, their discharge pressure is measuredto verify that the pump is on.

G. Refrigerant Pump. Five seconds after the solution pump is veri-fied the REFRIGERANT PUMP is energized (ON).

H. Capacity Valve. The PIC sets the ACTUAL CAPACITY VALVE to50% open.

I. Warm-Up Mode. The chiller is now in the WARMUP mode. Thecapacity valve is opened 1/3 of the way (from 50% to the capacityvalve WARMUP TRAVEL LIMIT) every 5 minutes.

J. Ramping Mode. When the WARMUP mode is complete, RAMP-ING mode begins, and the chilled water temperature is brought tothe set point within the ramping parameters.

K. Running Mode. The chiller is in normal RUN mode. Schedulesand overrides are in effect.

L. Normal Shutdown With Dilution. If there is chilled water flow andthere is no low chilled water temperature fault and if SOL PUMPOVERLD/HITEMP is NORMAL, then a dilution cycle is com-pleted. In the dilution cycle, the SOLUTION PUMP and REFRIG-ERANT PUMP are energized (ON), and the CYCLE GUARD VALVEis OPENed for 15 minutes or until the DILUTION LEVEL SWITCHis OPENed.

M. Shutdown Mode. The capacity valve is closed, refrigerant pumpis deenergized, Cycle-Guard™ valve is closed, cooling water pumpand tower fan are deenergized, and solution pump is deener-gized. If it is a RECYCLE shutdown, the chilled water pump re-mains energized; otherwise, it is deenergized.

Fig. 39 — Start-Up/Shutdown/Recycle Sequence

66

NOPrestart Checks Passed ?

YES

Start ChilledWater Pump

YES

NO

Enunciate Alert Condition

NO

YES

A

Enable Tower Fan Algorithm

Start Solution Pump

Solution PumpPressure > 10 PSIA?

NO

YES WATER FLOW VERIFYTimer Elapsed ?

YES

Solution PumpPressure Fault

(State 83)

YES

NO

StartRequest

Start WATER FLOW VERIFY Timer

Delay 20 Seconds

WATER FLOW VERIFYTimer Elapsed ?

Chilled WaterFlow Failure(State 80)

Chilled WaterFLOW = YES?

Solution PumpPressure

Transducer Fault(State 82)

NOSolution PumpPressure < 10 PSIA?

Delay 20 Seconds


Startup Complete:Run Status = Warmup

Start Refrigerant Pump

Drive Capacity Valve to 50%


Chilled Water Temp >Control Point + Deadband?

NO

A

Monitor Chilled Water Tempfor Recycle Startup

YES

Start CoolingWater Pump

Delay 20 Seconds

Cooling WaterFLOW = YES?

YES

NO

WATER FLOW VERIFYTimer Elapsed ?

NO

YES

Cooling WaterFlow Failure(State 81)

Fig. 40 — 16JB Chiller Start-Up Flowchart

67

If a function fails, an alarm displays on the LID with amessage specific to the type of failure. To re-start the start-upsequence, find the cause of the alarm, remedy the problem,press the RESET softkey on the control panel, and re-initiate the start-up sequence.

After the CHILLED WATER FLOW is verified, the PICcompares the chilled water temperature to CONTROL POINTplus CONTROL POINT DEADBAND. If the chilled watertemperature is less than or equal to the CONTROL POINTplus CONTROL POINT DEADBAND, the PIC goes into theRECYCLE mode.

If the temperature is greater than the CONTROL POINTplus CONTROL POINT DEADBAND, then the COOLINGWATER PUMP is energized.

After 20 seconds, the PIC verifies the COOLING WATERFLOW. The PIC waits up to the WATER FLOW VERIFY TIMEto confirm flow.

After the COOLING WATER FLOW has been verified, theTOWER FAN CONTROL algorithm is enabled. Then, the PICmonitors the SOLUTION PUMP PRESSURE. If the pres-sure is less than 10 psia (172 kPa), the PIC energizes theSOLUTION PUMP.

Twenty seconds later, the PIC monitors the SOLUTIONPUMP PRESSURE to be sure greater than 10 psia (172 kPa).

The REFRIGERANT PUMP is energized, and the PIC con-trol starts the warm-up mode. At this point, the capacity con-trol valve is set to 50%.

Warm-Up — At the start of the warm-up period, the ca-pacity valve is set to 50% of its fully open position. Duringwarm-up, for a period of 20 minutes, the capacity valve con-tinues to open to its WARMUP TRAVEL LIMIT (an operator-configurable value) in three 5-minute stages. At each 5-minuteinterval, the valve opens 1/3 of the way between its initial50% and the WARMUP TRAVEL LIMIT.

CONCENTRATION PROTECTION DURING START-UP/PULLDOWN FAILURES (Check Method 1) —During thewarm-up period, the PIC checks the STRONG LiBr LEAV-ING temperature to see that it is increasing. The PIC alsomonitors the LEAVING CHILLED WATER temperature tosee that it is decreasing. If both these conditions are met,then the override and fault protection is enabled.

After five minutes, if the LEAVING CHILLED WATER tem-perature is decreasing, the warm-up period continues. Afteran additional 5 minutes, if the LEAVING CHILLED WATERtemperature is still decreasing, the start-up is complete andthe ramp loading sequence begins. If a non-recycle shut-down is begun, the LID displays, PROTECTIVE LIMIT,SLOW PULLDOWN: LCHW.

Fifteen minutes after start-up is complete, the PIC moni-tors the STRONG LiBr LEAVING GEN. If it is less than158 F (70 C), then a non-recycle shutdown is initiated. TheLID displays, PROTECTIVE LIMIT, STRONG LIBR LEAV-ING G1. The LEAVING CHILLED WATER temperature isalso monitored.

WARM-UP FAILURES —Afailure occurs during the warm-upperiod under the following conditions:

If the REFRIGERANT PUMP has been ON for 15 min-utes and the STARTUP PULLDOWN FAILURE isENABLED (see the MAINSTAT screen on the LID), and1. The CHW_OUT PULLDOWN DEG/MIN is less than or

equal to 0, and CHW_OUT is not decreasing.2. The STRONG LIBr LEAVING GENis less than 158 F

(70 C).

Ramp Loading Mode — Ramp loading slows downthe rate at which the chiller loads up. This feature can pre-vent the chiller from loading up during the short period oftime when the chilled water loop has to be brought down tonormal design conditions and helps to reduce steam demandby slowly bringing the chiller water to the control point. How-ever, the total steam draw during ramp loading remains al-most unchanged.

After start-up and warm-up, the PIC switches to the ramploading mode (RAMPING on the MAINSTAT screen).During the ramp loading mode, the LEAVING CHILLEDWATER or ENTERING CHILLED WATER temperature changeis limited to the TEMP PULLDOWN DEG/MIN. This is therate that the controlled temperature is changed to reach theset point. The default rate is 3 F (1.7 C) per minute. Thecontrol valve is allowed full travel to obtain this goal unlessan inhibit or close signal is received by the PIC based onanother algorithm.

To set or change the temperature pulldown rate, refer tothe Ramp Loading Control section, page 32.

Normal Run Mode — Under normal run mode, the PICcontrols the capacity valve position in response to the moni-tored chilled water temperature with resets. The controlalgorithm uses the CONTROL POINT DEADBAND,PROPORTIONAL INCR BAND, PROPORTIONAL DECBAND, PROPORTIONAL CHW_IN GAIN, SAMPLE RATEand GEN SOLUTION TEMP BIAS to position the valve. Thesevariables are found on the SERVICE3 screen. There may beother overrides limiting the capacity valve’s position, such athe RUNNING TRAVEL LIMIT.

CONTROL POINT DEADBAND is a defined tolerancearound the CONTROL POINT. PROPORTIONAL INC BANDis the divisor used when the chilled water temperature is abovethe CONTROL POINT. PROPORTIONAL DEC BAND is thedivisor used when the chilled water temperature is below theCONTROL POINT. PROPORTIONAL CHW-IN GAIN is amultiplier used on the rate of change of the entering chilledwater. It is a way to react to the building load. GEN SO-LUTION TEMP BIAS limits the valve opening based on therate of change of the strong solution leaving the generator.A high value such as 10 has the maximum effect of speedingthe response and a low value such as 1 has the slowest re-sponse time.

The sample rate adds extra time to the control algorithm.The PIC takes reading of all data points every 5 seconds,however, the PIC does not adjust the capacity valve every 5seconds. The sample rate is a multiplier for the reaction timeof the valve. For example: a sample rate of 2 causes the ca-pacity control valve to correct every 10 seconds. A samplerate of 6 causes the valve to correct every 30 seconds.

68

Is Reflev>Mid-level +0.25%

(See Note)

CYCLE-GUARD™VALVE

Con_lev< cgmidlev?YES

refcg = CLOSErefcg = OPEN

In Controls Test?YES

RefrigerantPump is OFF?

Close CycleGuard Valve

In DilutionCycle?

YES

NO

Cycle-GuardAuto/Manual

Switch in AutoPosition?

YES

EXIT

Stron LiBr Lvg Hx > 118?

Open Cycle-Guard Valve



NO

NO

NO Is RefcgClosed?

Is Ref HighClosed?

Save_level =reflow +0.25%

Is Reflev>

(See Note)NO



EXIT

YES

YES

YES

YES

NO

NO

YES

NO

NO

YESNO

Save_level

NOTE: The Refrigerant Level sensor input provides a decreasing 0 to 5 volt input signal con-verted to a percentage for an increasing level in the evaporator. The Cycle Guard Level adjustinput provides an adjustment to the percentage value that represents Mid-Level.

Fig. 41 — Cycle-Guard Valve Operation Flowchart

69

CYCLE-GUARD™ CONCENTRATION CONTROL —During high-load operation, some abnormal conditions cancause the concentration of the lithium bromide solution toincrease above normal. When this happens, the Cycle-Guardvalve opens to transfer a small amount of refrigerant into thesolution circuit to limit the concentration. This keeps the strongsolution from crystallizing. For more information on con-trolling the Cycle-Guard valve, see the section, Capacity Over-rides, page 33. See Fig. 41 for a flowchart of the Cycle-Guard valve operation.

The Cycle-Guard Auto/Manual switch on the control panel(Fig. 9) can be set to MANUAL to operate the Cycle-Guardvalve manually. When the Cycle-Guard Auto/Manual switchis set to AUTO. the PIC controls the Cycle-Guard™ valve.The REFRIGERANT PUMP must be ON in order for theCYCLE GUARD VALVE to be OPEN. To view the status ofthe refrigerant pump and Cycle-Guard valve, access the PUMP-STAT screen on the LID.

CONTROL OVERRIDEAND FAULT PROTECTION (CheckMethod 2) — The REFRIGERANT LEVEL SENSOR volt-age should be calibrated the first time the chiller is startedup. Failure to do so causes inaccuracies between the refrig-erant level and the concentration of the LiBr solution.

The REFRIGERANT LEVEL SENSOR is calibrated by tak-ing a solution concentration reading at low and high con-centration levels and entering these readings and their asso-ciated voltages in the SERVICE1 screen (Concentration SensorCal).

If the STRONG LiBr LVG HX temperature is greater than118 F (47.8 C) and the HIGH LEVEL SWITCH is closed, theCYCLE GUARD VALVE opens. See Fig. 40. It closes whenthe HIGH LEVEL SWITCH is opened and after the RE-FRIGERANT LEVEL SENSOR has been reduced by an ad-ditional .25% vdc.

The CYCLE GUARD LEVEL ADJUST (see the SERV-ICE1 screen on the LID.) has a default value of 55%, whichrepresents the equivalent of 2.5 vdc from the REFRIGER-ANT LEVEL SENSOR. The voltage is inversely proportionalto the refrigerant level. This value sets the level that the PICuses for opening and closing the Cycle-Guard valve.

REFRIGERATION PUMP CAVITATION PROTECTION(Low Concentration Limit) — During low-load operation withlow condensing water temperature, the normal dilution ofthe solution lowers the refrigerant level in the evaporator.Before the level becomes low enough to cause pump cavi-tation and damage to the hermetic pump motor, the LOWLEVEL SWITCH opens and the LLC valve is energized. TheLLC valve transfers weak solution from the absorber pumpto the evaporator pump to protect the refrigerant pump fromcavitation. Once the low level switch is closed the LLC valvewill be turned off.

Desolidification Mode (DESOLID) — TheDESOLID (desolidification) mode is not a normal run modebut is a mode of operation initiated by the operator to de-solidify LiBr that has crystallized. To put the chiller in DE-SOLID mode, do the following:1. Be sure the chiller CONTROL MODE is set to OFF by

checking the MAINSTAT screen on the LID (see Table 2,Example 1).

2. From the SERVICE1 screen (see Table 2, Example 9),set the DESOLIDIFICATION TIME to a maximum of4 hours.

3. From the PUMPSTAT screen (see Table 2, Example 2),ENABLE the DESOLIDIFICATION MODE.

4. Manually control the pumps and the capacity control valve.

For more information on the DESOLID mode, see the sec-tion in Maintenance Procedures on Solution Decrystalliza-tion, page 82.

Shutdown Sequence (Fig. 42) — The chiller willshut down if any of the following occurs:• the STOP button on the control panel is pressed for at least

one second (the alarm light will blink once to confirm thestop command)

• a recycle condition is present (see Chilled Water RecycleMode section)

• the OCCUPIED parameter on the MAINSTAT screen in-dicates NO; that is, the chiller is not scheduled to run atthe current time and date.

• the chiller’s protective limits have been reached and thechiller is in an alarm state

• the start/stop status has been overridden to STOP from theCCN network or the LIDNormal shutdown begins by setting the TARGET CAPAC-

ITY VALVE to 0% (CLOSE) and starting a 15 minute solu-tion pump timer. The PIC checks the following conditions toverify a dilution cycle shutdown: CHILLED WATER FLOWis verified; the LOW CHILLED WATER TEMP has not beenexceeded; and SOL PUMP OVERLD/HITEMP is not tripped.

The PIC control monitors the DILUTION LEVEL SWITCH(Cycle-Guard Level Adjust). The CYCLE GUARD VALVEis set to OPEN until the DILUTION LEVEL SWITCH (Cycle-Guard Level Adjust) is opened or the solution pump timerreaches 15 minutes. Then, the CYCLE GUARD VALVE isclosed and the REFRIGERANT PUMP, COOLING WATERPUMP, SOLUTION PUMP, and the TOWER FAN RELAYare all deenergized. If the shutdown is a non-recycle shut-down (not due to low CHILLED WATER temperature ini-tiated by the RECYCLE CONTROL MODE), the CHILLEDWATER PUMP is deenergized. If the chiller is in a recycleshutdown CONTROL MODE, the CHILLED WATER PUMPremains energized and the CONTROL MODE stays inRECYCLE.

Chilled Water Recycle Mode — When the chiller isrunning in a lightly loaded condition, it may cycle off andwait until the load increases before restarting. This cyclingis normal and is known as a recycle shutdown. A recycleshutdown is initiated when any of the following conditionsoccur:• when the chiller is operating under the control of leaving

chilled water temperature (that is, when the CHW_IN CON-TROL OPTION on the CONFIGURATION display screenis disabled) and the LEAVING CHILLED WATER tem-perature is more than RECYCLE STOP DELTA T belowthe CONTROL POINT for 3 seconds, and the CONTROLPOINT has not increased by 1° F (0.56° C) in the last5 minutes. Both LEAVING CHILLED WATER and CON-TROL POINT values may be read from the MAINSTATdisplay screen on the LID.

• when the chiller is operating under the control of enteringchilled water temperature (that is, when the CHW_IN CON-TROL OPTION on the CONFIG display screen is en-abled) and the ENTERING CHILLED WATER temperatureis RECYCLE STOP DELTA T below the CONTROL POINT,and the CONTROL POINT has not increased in the last10 minutes. The ENTERING CHILLED WATER tempera-ture may be read from the MAINSTAT display screen onthe LID.

• when the LEAVING CHILLED WATER temperature iswithin RECYCLE STOP DELTA T of the REFRIGERANTTRIPPOINT for 5 seconds. The REFRIGERANT TRIP-POINT may be viewed from the SERVICE1 screen.

70

SHUTDOWN

CLOSE:Capacity Control

Valve

NO

YES

YES

Chilled Water Flow = YES?

YES

Low Chilled Water Temp = YES?

NO

Solution Pump Overload?

NO

YES

Refrigerant Pump Overload?

NO

YESSolution Pump Timer Started?

NO

Start 15 MinuteSolution Pump Timer

YESNOSolution Pump Timer Elapsed?

NOYES

Cycle Guard Level Adjust = OPEN?

Cycle-Guard Valve = OPENSTOP:

Refrigerant Pump

Cycle-Guard Valve = CLOSED

STOP:Refrigerant Pump

Cycle-Guard™ Valve = CLOSED

STOP:Cooling Water PumpCooling Tower Fan

STOP:Solution Pump

YESRecycle Shutdown?

NO

STOP:Chilled Water Pump

NORMAL Shutdown Complete

NO

YES

YES

NO

Low Chilled WaterTemp = YES?

Chilled WaterFlow = YES?

Fig. 42 — 16JB Chiller Shutdown Sequence Flowchart

71

When the chiller is in RECYCLE mode, the chilled waterpump relay stays energized so that the chilled water tem-perature can be monitored for increasing load. The recyclecontrol uses RECYCLE RESTART DELTA T to check whenthe chiller should be restarted. RECYCLE RESTARTDELTA T is an operator-configured function that defaults to5 F (2.8 C). This value is viewed and/or modified on theSERVICE1 screen. The chiller will restart when:• the chiller is operating in leaving chilled water control and

the LEAVING CHILLED WATER temperature is greaterthan the CONTROL POINT plus the RECYCLE RESTARTDELTA T for 5 seconds; or

• the chiller is operating in entering chilled water controland the ENTERING CHILLED WATER temperature is greaterthan the CONTROL POINT plus the RECYCLE RESTARTDELTA T for 5 seconds.Once these conditions are met, the chiller will begin a start-up

with a normal start-up sequence.

Safety Shutdown — A safety shutdown is identical toa manual shutdown with the exception that the LID will dis-play the reason for the shutdown, the alarm light will blinkcontinuously, the default screen display will freeze, and thespare alarm contacts will be energized. A safety shutdownrequires that the RESET softkey be pressed to clear the alarm.Before pressing the RESET softkey, record the default screenvalues. If the alarm is still present, the alarm light will con-tinue to blink. Once the alarm is cleared (by fixing the prob-lem and pressing the RESET softkey), the operator mustpress the CCN or LOCAL softkey to restart the chiller.

Power Loss Dilution Cycle — While the chiller isrunning, the PIC control records the concentration and tem-peratures at Points 6 and 8. See the Equilibrium Diagramand Chiller Solution Cycle section on page 5. At power-up,the chiller checks these points and compares them to the cur-rent conditions and the crystallization line. If the current con-ditions are less than the saved values plus a buffer, the LIDdisplays MACHINE CRYSTALLIZATION and RUN DE-SOLIDIFICATION. If the current conditions are close to thecrystallization line, the chiller enters a dilution cycle andthe LID displays, DILUTION MODE XX MIN TILCOMPLETION. If Dilution is not needed the chiller willrestart.

OPERATING INSTRUCTIONS

Operator Duties1. Become familiar with the absorption chiller and related

equipment before operating. See Introduction and ChillerDescription sections, pages 4-12.

2. Start and stop the chiller as required.3. Inspect equipment; make routine adjustments; maintain

chiller vacuum and proper refrigerant level; exhaust purgeas required.

4. Keep a log of operating conditions and recognize abnor-mal readings.

5. Protect the system against damage during shutdown.

Before Starting the Chiller — Be sure that:1. Power is on to the cooling water and the chilled water

pump starters, the cooling tower fan, and the absorptionchiller control panel.

2. Cooling tower has proper water level.3. Chilled and condensing water circuits are full and valves

are open.4. Correct steam or hot water supply is available.5. Air supply for pneumatic controls is adequate.6. Alarm indicator lights are off.

Start the Chiller — If the chiller has manual auxiliarystart, first energize the auxiliaries.

To release the control circuit after a safety shutdown, fromthe LID, press the RESET and then the LOCAL orCCN softkeys. This starts the chiller.

Now follow one of the 2 procedures described below asit applies to your chiller:• Start-Up After Limited Shutdown — If chiller has been

shut down for less than 3 weeks• Start-Up After Extended Shutdown — If chiller has been

shut down for 3 weeks or more

Stop the Chiller1. The occupancy schedule starts and stops the chiller au-

tomatically once the time schedule has been set up.2. Pressing the Stop button on the control panel for one sec-

ond causes the alarm light to blink once to confirm thatthe Stop button has been pressed. Then, the chiller fol-lows the normal shutdown sequence described in theControls section, page 12. The chiller will not restart un-til the CCN or LOCAL softkey is pressed. The chilleris now in the OFF mode.

If the chiller fails to stop, in addition to action the PICinitiates, the operator should close the manual steam valveand then open the main disconnect.

Start-Up After Limited Shutdown1. Place the Cycle-Guard™ switch on the control panel door

(Fig. 9) in the AUTO position.2. Press the LOCAL or CCN softkey to start the chiller.

The chiller should start in the normal manner. The pri-mary and secondary locations on the LID default screenshould display a series of messages reflecting the run sta-tus of the chiller. See Table 2, Example 1 (MAINSTATscreen) for the list of possible RUN STATUS displays. Thesolution typically heats up to normal operating condi-tions within 20 to 30 minutes.If, however, the chiller does not lower the leaving chilledwater temperature to the design level, noncondensablesmay be present. In this case, take an absorber loss read-ing (see Maintenance Procedures, Absorber Loss Deter-mination section, page 76).If absorber loss is 12° F (6.7° C) or less, the chilled watertemperature should drop to the design level within a shortperiod as the automatic purge evacuates the chiller. A com-pletely evacuated chiller normally has an absorber loss of8° F (4.4° C) or less. Purge the chiller.If absorber loss is greater than 12° F (6.7° C), follow theprocedure for Start-Up After Extended Shutdown.

3. Empty the purge chamber periodically to allow the purgesystem to operate optimally. See Purge Manual ExhaustProcedure, page 75.

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Start-Up After Extended Shutdown1. Place the Cycle-Guard™ switch on the control panel door

(Fig. 9) in the AUTO position.

2. Press the LOCAL or CCN softkey to start the chiller.When the refrigerant pump starts and the solution is warm(strong solution approximately 100 to 130 F [38 to55 C]), override the normal capacity valve position.Access the MAINSTAT screen., scroll to TARGETCAPACITY VALVE, and press the INCREASE orDECREASE softkeys until the capacity reaches 50%.

Press the SELECT and ENTER softkeys.3. Let the chiller run until there is a temperature drop across

the evaporator. To determine this, access the LID de-fault screen and read the temperatures for CHW_IN andCHW_OUT. The CHW_OUT temperature should be lowerthan the CHW_IN temperature.

4. Empty the purge storage chamber. See Purge ManualExhaust Procedure, page 75.

5. Check the noncondensables accumulation rate. See Non-condensable Accumulation Rate section, page 76.

6. If the noncondensable accumulation rates are within ac-ceptable limits, slowly increase the TARGET CAPAC-ITY VALVE (from the MAINSTAT screen) to 100%. Takeat least 1 hour to do this step.

7. Determine the chiller absorber loss (see MaintenanceProcedures, Absorber Loss Determination section,page 80). If absorber loss is 12° F (6.7° C) or less, openthe capacity control valve by selecting TARGETCAPACITY VALVE from the MAINSTAT screen and press-ing the RELEASE softkey to allow the chiller to op-erate. The purge will evacuate the chiller to the normalabsorber loss of 8° F (4.4° C) or less. Purge the chiller.If absorber loss is more than 12° F (6.7° C), evacuatethe chiller to remove noncondensables that can preventnormal operation (see Maintenance Procedures, ChillerEvacuation section, page 77). An alternative procedureis to limit steam pressure so that the low-stage generatorstrong solution temperature remains below 140 F (60 C)while the chiller purge removes the noncondensables.

8. When absorber loss is reduced to 12° F (6.7° C) or less,return steam pressure to normal and allow the purge toestablish the normal 8° F (4.4° C) or less absorber lossrate.

9. After evacuation, check the noncondensable accumula-tion rate to determine chiller tightness (see Noncon-densable Accumulation Rate section, page 76).

10. Empty the purge chamber periodically to allow the purgesystem to operate optimally. See Purge Manual ExhaustProcedure, page 75.

Start-Up After Below-Freezing Conditions —Refill all water circuits if previously drained. Then followthe procedure for Start-Up After Extended Shutdown.

Remove the solution from the refrigerant circuit by fol-lowing the procedure, Removing Lithium Bromide fromRefrigerant, page 78.

Chiller Shutdown — Normal Conditions1. From the LID, press the STOP softkey. The chiller goes

through automatic dilution for about 15 minutes and shutsdown.

2. Close the main steam valve and stop the system pumps.Leave the chiller in this condition until the next start-up.

Chiller Shutdown — Below FreezingConditions1. From the LID, press the STOP softkey. Wait until au-

tomatic dilution is complete (about 15 minutes) and allchiller pumps stop.

2. Close the main steam valve and stop the system pumps.3. The refrigerant circuit requires special treatment.

a. Fill a hose with water (to avoid letting air into the chiller)and connect the hose between the solution pump andrefrigerant pump service valves.

b. Start the solution pumps by accessing the PUMP-STAT screen from the LID, selecting SOLUTION PUMP,and pressing the ON softkey. Open both service valves.Keep the steam valve closed. If the chiller has a re-frigerant pump with above-atmospheric discharge pres-sure, it must be stopped for this procedure.

c. Allow the solution pump to run for 10 minutes. Thistransfers lithium bromide solution into the refrigerantand lowers the refrigerant’s freezing point. Close theservice valves and remove the hose.

d. Start both the solution and the refrigerant pumps, andoperate them for about one minute to be sure lithiumbromide has been mixed throughout the refrigerantcircuit.

e. Release the solution pumps and the refrigerant pumpby accessing the PUMPSTAT screen from the LID, se-lecting SOLUTION PUMP and REFRIGERANT PUMP,and pressing the RELEASE softkey.

4. Completely drain all tube bundles and flush all tubes withan antifreeze chemical such as glycol.

Actions After Abnormal Shutdown — Abnormalstop occurs automatically when any of the safety devices sensea condition which might be potentially damaging to the chiller.When this happens the steam valve closes completely, thealarm relay closes, and the type of problem is indicated inthe primary and secondary messages on the LID default screen.The messages on the LID inform the operator of the mostrecent alarm condition. Record the default screen values, sincethey indicate the chiller’s state before the alarm occurred.This information is lost after the alarm is cleared.

There may be multiple alarms and/or alerts stored in thealarm history. To view the alarm history, Press theMENU softkey, the SERVICE softkey, enter your 4-digit

password, and then use the SELECT softkey to view theALARM HISTORY screen.

To clear any alarms, the condition that caused the alarmmust be corrected. Then press the RESET softkey. The alarmlight will stop flashing and the alarm relay will open. Thechiller is now ready for a dilution cycle or a restart.

If the condition that caused the alarm or alert is a one thatdoes not allow shutdown dilution, the condition should becorrected and the chiller should be either restarted or be putinto a normal dilution cycle. Put the chiller into a normaldilution cycle by following the instructions under Desolidi-fication Mode (DESOLID), page 70.

73

Actions After Power Interruption — If the controlpower is interrupted during operation, the chiller stops im-mediately without the normal shutdown sequence and dilu-tion cycle. If the capacity control valve is open, close thesteam supply valve immediately.

Solution crystallization can occur if the concentration ishigh (e.g., chiller was operating with a relatively large load).If so, press the LOCAL or CCN softkey to restart thechiller as soon as possible after the power is restored. Thechiller will restart automatically when power is recoveredonly if conditions allow. For more information see PowerLoss Dilution Cycle on page 72. If the chiller cannot be op-erated because of crystallization, follow the decrystalliza-tion instructions in the Maintenance Procedures section,page 74.

To change the DESOLIDIFICATION TIME, press theMENU and then the SERVICE softkeys. Scroll to the

EQUIPMENT SERVICE screen. Use the SELECT softkeyto view the SERVICE1 screen. Scroll to DESOLIDIFICA-TION TIME, press the SELECT softkey, and then press theINCREASE or DECREASE softkey to change the

desolidification time. Press the ENTER softkey to recordyour change.

PERIODIC SCHEDULED MAINTENANCENormal preventive maintenance for 16JB absorption chill-

ers requires periodic, scheduled inspection and service. Eachitem in the list below is detailed in the Maintenance Proce-dures section.

Every Day1. Log the chiller and system readings. To obtain the read-

ings, access the Maintenance screens by pressing theMENU and SERVICE softkeys. Enter your 4-digit

password, and then scroll to CONTROL ALGORITHMSTATUS. Use the SELECT softkey to view the ControlAlgorithm Status screen. From this screen, you can usethe SELECT softkey to view the COOLING,APPROACH, OVERRIDE, and CONCENTR tables fromwhich you can access chiller and system readings.

2. Exhaust purge.

Every Month1. Determine absorber loss.2. Determine noncondensable accumulation rate.3. Check the cooling fan on the control panel to be sure it

is running properly.4. Clean the chiller as needed.5. Check safety and operating controls.

Every 2 Months1. Check low-temperature cutout.2. Check Cycle-Guard™ valve operation.

Every 6 Months1. Check refrigerant charge.2. Check octyl alcohol.

Every Year — Check tubes for scale and fouling.

Every 3 Years — Replace service valve diaphragms.

Every 5 Years or 50,000 Hours (WhicheverComes First)1. Inspect hermetic pumps.2. Filter or regenerate the solution if necessary.

MAINTENANCE PROCEDURESEstablish a regular maintenance schedule based on the ac-

tual chiller requirements, such as chiller load, run hours, andwater quality. The time intervals listed in this section are of-fered only as guides to service.

Service Ontime — The LID displays a SERVICE ON-TIME value on the PUMPSTAT screen. This value shouldbe reset to zero by the service person or the operator eachtime major service work is completed so that the time be-tween service can be seen.

Inspect the Control Center — Maintenance is gen-erally limited to general cleaning and tightening of connec-tions. Vacuum the cabinet to eliminate dust build-up. If thechiller controls malfunction, refer to the Troubleshooting Guide,page 85 for control checks and adjustments.

Be sure that power to the control center is off when clean-ing and tightening connections inside the controlcenter.

Check Safety and Operating Controls Monthly— To ensure chiller protection, the Automated Control Testshould be done at least once a month. On the LID, press theMENU and SERVICE softkeys. Scroll to CONTROL TEST

and press the SELECT softkey. See the PIC Control Testssection, page 30, for more details on these tests.

Log Sheets — Readings of chiller and system pressure-temperature conditions should be recorded daily to aid theoperator in recognizing both normal and abnormal chillerconditions. The record also aids in planning a preventive main-tenance schedule and in diagnosing chiller problems. A typi-cal log sheet is shown in Fig. 38. Table 9 briefly explainshow to obtain the data for log sheets.

Inspect Rupture Disc and Piping (Hot WaterUnits) — The rupture disc on this chiller protects the sys-tem against the potentially dangerous effects of overpres-sure. To ensure against damage to the equipment and pos-sible injury to personnel, this device must be kept in peakoperating condition. At a minimum, the following mainte-nance is required.1. At least once a year, disconnect the vent piping at the

disc outlet and carefully inspect the holder and disc forany evidence of internal corrosion or rust, dirt, scale, leak-age, etc.

2. If corrosion or foreign material is found, do not attemptto repair or recondition the disc. Replace the rupture disc.

3. If the chiller is installed in a corrosive atmosphere, con-duct rupture disc inspections more frequently.

74

Inspect the Heat Exchanger TubesEVAPORATOR — Inspect and clean the evaporator tubes atthe end of the first operating season. The tube condition de-termines the scheduled frequency for cleaning and indicateswhether water treatment is adequate in the chilled water/brine circuit. Inspect the entering and leaving chilled watertemperature sensors for signs of corrosion or scale. Replacethe sensor if it is corroded or remove any scale if found.

ABSORBER/CONDENSER — Since this water circuit isusually an open system, the tubes may be subject to con-tamination and scale. Clean the tubes with a tube cleaningsystem at least once per year and more often if the water iscontaminated. Inspect the entering and leaving absorber andcondenser water sensors for signs of corrosion or scale. Re-place the sensors if corroded or remove any scale if found.

Higher than normal condenser and absorber approaches,together with the inability to reach full refrigeration load,usually indicate dirty tubes or air in the chiller. If the re-frigeration log indicates a rise above normal approaches, checkthe absorber/condenser loss against the leaving absorber/condenser water temperatures. If these readings are more thanwhat the design difference is supposed to be, then the ab-sorber or condenser tubes may be dirty or water flow may beincorrect. Check the absorber loss to verify that no non-condensables are in the chiller.

During the tube cleaning process, use brushes especiallydesigned to avoid scraping and scratching the tube walls. Con-tact your Carrier representative to obtain these brushes. Donot use wire brushes.

Hard scale may require chemical treatment for its pre-vention or removal. Consult a water treatment specialistfor proper treatment procedures.

Water Leaks — Water can infiltrate from the evapora-tor, absorber, or condenser circuits. Water accumulation isindicated during chiller operation when the refrigerant levelincreases and the Cycle-Guard™ valve operates too soon.

Water Treatment — Untreated or improperly treated wa-ter may result in corrosion, scaling, erosion, or algae. Theservices of a qualified water treatment specialist should beobtained to develop and monitor a treatment program.

Water must be within design flow limits, clean, and treatedto ensure proper chiller performance and to reduce thepotential of tube damage due to corrosion, scaling, ero-sion, and algae. Carrier assumes no responsibility forchiller damage that results from untreated or improp-erly treated water.

Purge Manual Exhaust Procedure (Fig. 43) —See also Chiller Description section, pages 4-12, for an ex-planation of the purge operation, component identification,and illustrations.

NEVER LEAVE the chiller during the purge operation.A failure to close the exhaust valve will disable the chillerand could cause the solution to crystallize.OPERATE THE VALVES in the correct sequence.NEVER LET AIR leak into the chiller.MAKE SURE that the tip of the vinyl tube is at the bot-tom of the plastic bottle at all times.NEVER SPILL any solution from the plastic bottle.If spilled on personnel or the floor, follow the warningpertaining to Handling Lithium Bromide (LiBr) Solu-tion, page 55.

1. Exhaust purge only when the chiller and solution pumpare operating, because the exhaust pressure is suppliedby the solution pump.

2. Keep the end of the plastic tube below the liquid level inthe plastic bottle.

3. Close the solution return valve (Fig. 8, Item E).4. Wait approximately 5 minutes for the storage chamber

pressure to rise above atmospheric pressure.5. Slowly open the exhaust valve. (Fig. 8, Item H). If the

liquid level in the exhaust bottle drops, close the valveand wait approximately 2 minutes.

6. Slowly reopen the exhaust valve. If bubbles appear in theexhaust bottle, leave the exhaust valve open until bubblesstop and the solution level in the bottle begins to rise.Close the valve; the purge is now exhausted. If bubblesare still present and the exhaust bottle is full, the proce-dure must be repeated (Steps 3 through 6).

7. Open the solution return valve to resume the purgeoperation.

8. Slowly open the exhaust valve and allow the solution inthe bottle to be drawn into the purge tube. Lower the so-lution level until the bottle is one-third to one-half full.Close the exhaust valve before the solution level in thebottle nears the tube end. Do not allow air to be drawninto the purge tube.

9. Log the date and time of the purge evacuation to providean indication of changes in the rate of noncondensableaccumulation.

Fig. 43 — Purge Exhaust Assembly

75

Absorber Loss Determination — Take absorberloss readings when the chiller is operating with a stabletemperature.1. Make sure that the Cycle-Guard™ valve or LLC valve is

closed and has not operated for at least 10 minutes beforetaking readings.

2. Fill thermometer wells on the discharge lines of the so-lution and refrigerant pumps with oil or heat-conductivecompound and insert the thermometers.

3. Take refrigerant and solution samples (see Solution or Re-frigerant Sampling, page 77), and determine the specificgravity and temperature of each sample. The samples canbe returned to the chiller through the purge exhaust bottle.

4. Using the equilibrium diagram (Fig. 36 or 37), plot theintersection point of the specific gravity and temperatureof the solution sample. Extend this point horizontally tothe right and read the saturation temperature. Repeat withthe refrigerant sample, using Fig. 36 and 37 and readingto the right for the saturation temperature.

5. Subtract the solution saturation temperature from the re-frigerant saturation temperature. The difference is the ab-sorber loss. Repeat the readings with a second sample toverify steady state conditions. If the absorber loss is greaterthan 12° F (6.7° C), chiller evacuation is necessary be-cause excessive noncondensables may interfere with nor-mal operation before they can be removed by the purge(see Chiller Evacuation section, page 77).The absorber loss is calculated by the PIC and can be read

on the LID. Press the MENU and then the SERVICE soft-keys. Enter your 4-digit password. Scroll to the Control Al-gorithm Status screen. Select the APPROACH table. Readthe value for ABSORBER LOSS. This value is much largerthan those used on earlier chillers, because we are measur-ing the values corresponding to the conditions existing in-side the absorber.

For probable causes and suggested remedies for high ab-sorber loss, refer to the Troubleshooting Guide, beginningon page 85.

Noncondensable Accumulation Rate — The mostimportant maintenance item on the 16JB absorption chilleris to maintain chiller vacuum within acceptable limits. Chillervacuum tightness can be checked by determining the rate atwhich noncondensables accumulate. Some noncondens-ables are normally generated within the chiller; however, anair leak or the need for additional inhibitor is indicated if theaccumulation rate increases.

After chiller evacuation or other service, operate the chillerfor at least 200 hours before determining the noncondens-able accumulation rate. Then proceed as follows (Fig. 44):1. Fill a length of flexible hose with water and connect it to

the purge exhaust connection. Insert the free end of thehose into a container of water. Exhaust the purge com-pletely (see Purge Manual Exhaust Procedure section, onpage 75).

2. Operate the chiller for 24 hours with the purge operatingnormally.

3. Fill a 2-pint (1000 cm3) bottle with water and invert it ina clean container filled with water.

4. Insert the free end of a water-filled hose into the bottle.5. Follow the purge exhaust procedure. Noncondensables dis-

place water in the inverted bottle. Continue until bub-bling in the bottle ceases and only solution flows fromthe exhaust tubing.

6. Close the exhaust valve and mark the liquid level on theinverted bottle. Remove the bottle from the container.

7. Return the purge to normal operation. Replace the ex-haust bottle (Fig. 8, Item J). Open the solution return valve(Fig. 8, Item E).

8. Measure the amount of noncondensables removed. If agraduated bottle was used to collect the noncondens-ables, the amount (volume) of noncondensables removedis indicated on the bottle. If a nongraduated bottle wasused, mark the exhaust level, take the bottle out of thewater container emptying any liquid that may be left inthe bottle, and then fill the bottle with liquid to the ex-haust mark. Pour the liquid into a graduated container tomeasure the volume displaced.

9. If the operating accumulation rate has increased substan-tially from previous rates (see Table 10), the chiller hasan air leak or requires additional inhibitor. Have a solu-tion sample analyzed (see Solution Analysis section,page 78, to determine the proper corrective action). If aleak is indicated, it must be found and repaired as soonas possible to minimize internal corrosion damage.

Table 10 — Maximum AllowableNoncondensable Accumulation Rate*

UNIT16JB

MAX. ALLOW.RATE (per 24) UNIT

16JB

MAX ALLOW.RATE (per 24 hr)

fl oz cc fl oz cc010,012,014 3.99 118.0 041,047 13.29 393.3

018,021 5.98 177.0 054,057 11.97 353.9024,028 7.98 235.9 061,068 15.95 471.9032,036 10.25 302.8

*During operation.

Chiller Leak Test — All joints welded at the time ofchiller installation must be leak tested before initial start-upof the chiller. If the chiller has been opened for service, thechiller or the affected vessels must be pressurized and leaktested. Joints must also be leak tested after repair. If there isany indication of air leakage, leak test the entire chiller. Thereare 2 ways to leak test the chiller: pressurizing with dry ni-trogen or introducing a refrigerant tracer.

Fig. 44 — Collecting Noncondensables

76

DRY NITROGEN1. Be sure the auxiliary evacuation valve, purge exhaust valve,

and all pump service valves are closed.2. Connect a copper tube from the pressure regulator on the

cylinder to the auxiliary evacuation valve. Never applyfull cylinder pressure to the pressurizing line.

3. Open the charging valve fully.4. Slowly open the cylinder regulating valve. See Table 11.5. Observe the pressure gage on the chiller and close the

cylinder regulating valve when pressure reaches test level.Do not exceed 8 psig (55 kPa).

6. Test all joints with an ultrasonic leak detector or soap bubblesolution. Mark the leaks.

7. Release chiller pressure, correct all leaks, and retest toensure a proper repair.

8. Perform a chiller evacuation.

Table 11 — Quantity of Refrigerant and NitrogenRequired for Leak Testing

UNIT16JB

HFC-134a NITROGEN(No. of cylinders)

lb kg300 cu ft vol

8.5 cu m010-014 4 1.5 1.5018,021 5 2.0 2.5024,028 10 4.5 4.5032,036 11 5.0 5.0041,047 14 6.5 6.5054,057 17 8.0 8.0061,068 22 10.0 10.0

REFRIGERANT TRACER — Use an environmentally ac-ceptable refrigerant as a tracer for leak test procedures suchas HFC-134a or HCFC-22. Because HCF-134a and HCFC-22are above atmospheric pressure at room temperature, leaktesting can be performed with these refrigerants in the chiller.

HCFC-22 and HFC-134a will dissolve oil and some non-metallic materials, dry the skin, and, in heavy concen-trations, may displace enough oxygen to cause asphyxi-ation. When handling these refrigerants, protect the handsand eyes and avoid breathing fumes.

HFC-134a should not be mixed with air or oxygen andpressurized for leak testing. In general, HFC-134a shouldnot be present with high concentrations of air or oxygenabove atmospheric pressure, because the mixture canundergo combustion.

Use an electronic leak detector, halide leak detector, soapbubble solution, or ultra-sonic leak detector. Be sure that theroom is well ventilated and free from concentration of re-frigerant tracer to keep false readings to a minimum. Beforemaking any necessary repairs to a leak, release the pressurein the chiller vessels.

Repair the Chiller Leak, Retest, and Apply aStanding Vacuum Test — After pressurizing the chiller,test it for leaks with a soap bubble solution, an electronicleak detector, a halide torch, or an ultrasonic leak detector.Bring the chiller back to atmospheric pressure, repair anyleaks found, and retest.

After retesting and finding no leaks, apply a standing vacuumtest. Refer to the Standing Vacuum Test section on page 53.

Chiller Evacuation — The chiller must be evacuatedin order to remove excessive noncondensables. In addition,the chiller must be evacuated after air has entered it duringservice work or when absorber loss is greater than 12° F(6.7° C) during operation.1. Connect an auxiliary evacuation device to the auxiliary

evacuation valve (Fig. 45). Use a line size at least equalto the connection size on the auxiliary device and keepthe line as short as possible. A check valve must be usedon the suction lines. Be sure all connections are vacuumtight.A vacuum pump oil trap can also serve as a cold trap ifit has a center well to hold dry ice or a mixture of salt andice. Any water vapor that can contaminate the oil in thevacuum pump is condensed and removed by the cold trap.The cold trap reduces the time required for evacuationand eliminates the need for frequent replacement of thepump oil charge.

2. Start the evacuation device. After one minute, open theauxiliary evacuation valve. If the chiller is not operating,reduce chiller absolute pressure to the pressure equiva-lent to the saturation temperature of the refrigerant. (Todetermine the saturation temperature, determine the cur-rent chiller temperature. Then, read the corresponding satu-ration temperature from Fig. 36 or 37.) If the chiller isoperating, evacuate it until absorber loss is 12° F (6.7° C)or less.

3. Close the auxiliary evacuation valve and turn off the aux-iliary evacuation device.

4. Chiller evacuation can remove octyl alcohol. Check a so-lution sample for the presence of octyl alcohol and addmore if necessary (see Adding Octyl Alcohol, page 78).

Solution or Refrigerant Sampling — (See precau-tions pertaining to handling lithium bromide solution asdescribed in Charge Chiller with Solution and Refrigerantsection, page 55.)

Take solution or refrigerant samples from the pump serv-ice valve while the pump is operating.

Before taking a sample for analysis or absorber loss de-termination, be sure the chiller is operating with a steadyload and that the Cycle-Guard™ valve has not been ener-gized within 10 minutes prior to sampling.

Attach a hose adapter to the pump service valve. Do notuse copper or brass fittings when taking samples for analy-sis; copper oxide can form and contaminate the samples.

The solution pump normally discharges at above atmo-spheric pressure, but the refrigerant pump discharges at avacuum, so the respective sampling procedures aredifferent.

Fig. 45 — Chiller Evacuation Device

77

SOLUTION SAMPLE1. Fill a length of flexible tubing with water and connect

one end to the hose adapter. Place the free end in a con-tainer of water. Be sure the end is submerged (Fig. 46).

2. Open the valve slightly. When the container water levelrises, wait several seconds to purge the water from thetube. Then remove the tube end from the water and fillthe sample container.

3. Turn off the service valve and remove the hose and adapter.

Inhibitor — The initial charge of lithium bromide in-cludes a lithium chromate or lithium blend for the inhibitor.The inhibitor is used in conjunction with alkalinity controlto minimize the amount of hydrogen normally generated withinthe chiller. Excessive hydrogen generation interferes with chillerperformance.

The inhibitor is gradually depleted during chiller opera-tion and occasional replenishment is necessary. Solution al-kalinity also changes over a period of time and must be ad-justed (see Solution Analysis, below).

IMPORTANT: Altering the inhibitor or using solutionand internal surface treatments not specified by the equip-ment manufacturer may result in performance deterio-ration and damage to the absorption chiller.

Solution Analysis — Laboratory analysis of a solutionsample gives an indication of change in solution alkalinityand depletion of inhibitor and may indicate the degree ofchiller leak tightness.

The lithium bromide solution must be analyzed regularly.The frequency depends on the type of inhibitor in the chiller.If the chiller is lithium chromate inhibited the following sam-pling frequency is required:1. Once a year at the start of the cooling season or2. Every 3000 hours of operation

If the chiller is blend inhibited, the following samplingfrequency is required:1. One sample at the start of the cooling season, one sample

mid season (approximately 1500 operation hours), andone sample prior to seasonal shutdown or

2. Every 1500 hours of operationNOTE: The above sampling frequency is for normal ma-chine operation.

In addition, have the solution analyzed if there is an in-dication of a noncondensable problem. Take the sample fromthe solution pump service valve while the chiller is running(see Solution or Refrigerant Sampling section page 77). Thesample concentration should be between 58% and 62% byweight for best results.

Solution analysis should be done by an approved lab-oratory. The analysis interpretation and the adjustment rec-ommendations should be made by a trained absorptionspecialist.

Solution adjustment procedures are not the same for chro-mate and lithium blend for the inhibitor solution inhibitors.Call your Carrier service representative for instructions onhow to make this adjustment.

Adding Octyl Alcohol — Octyl alcohol may be re-quired when the leaving chilled water temperature starts torise above the design temperature without alteration of thecontrol set point. Since the rise in temperature can also becaused by fouled tubes or other problems, use the followingprocedure to determine whether a lack of octyl alcohol is thecause.1. Remove a sample of solution from the solution pump serv-

ice valve (see Solution or Refrigerant Sampling section,page 77). If the solution has no odor of alcohol (very pun-gent), add about 1⁄2 gal. (2 L) of octyl alcohol.The addition of octyl alcohol also may be required afterthe chiller has been evacuated or after an extended periodof operation.

Use only specified octyl alcohol. Other types of al-cohol have a detrimental effect on chiller perfor-mance. Use Carrier Part No. 16B4−1551.

2. Fill a length of flexible tubing with water and connectone end to the solution pump service valve (seeFig. 46). Insert the other end in a container of octyl al-cohol. Stop the chiller. Then open the service valve toallow alcohol to be drawn into the chiller. Close the valvebefore drawing air into the hose. Restart the chiller.

Removing Lithium Bromide from Refrigerant —During normal operation, some lithium bromide may be car-ried over into the refrigerant. Lithium bromide in the refrig-erant is automatically transferred back to the absorber by theCycle-Guard™ valve when it is needed. The refrigerant flowsthrough the Cycle-Guard valve into the solution circuit, andseparation is made in the generator in the normal manner.

Lithium bromide recovery can also be initiated by placingthe Cycle-Guard switch in the manual position while the chilleris running and the capacity control valve is open. When therefrigerant specific gravity drops below 1.02, return the Cycle-Guard switch to AUTO. to close the Cycle-Guard valve.

Fig. 46 — Adding or Removing Fluid

78

Refrigerant ChargeAdjustment — Check the evapo-rator refrigerant (water) charge after every 6 months of op-eration. An increase in the amount of water in the chillerindicates tube leakage. Furthermore, the correct refrigerantcharge must be maintained for accurate operation of the Cycle-Guard™ system.

For charge adjustment, refer to the Initial Start-Up, FinalRefrigerant Charge Adjustment section, page 58.

Low Temperature CutoutAdjustment — This chillersafety serves to prevent freeze-up damage to the evaporatortubes. Check the cutout periodically to confirm that it tripsat the selected setting. See Item TA1 on Fig. 3 and the figureof the leaving chilled water cutout switch that accompaniesTable 4. Also refer to the sensor locations in Fig. 47.NOTE: If the cutout sensor has been exposed to tempera-tures above 120 F (49 C), the control must be recalibrated.See the figure below Table 4, page 48.1. Remove the control sensing element from its well in the

chilled water pipe. Immerse the element in a container ofcool water. Slowly stir crushed ice into the water so thatthe temperature goes down at a rate not exceeding 1° F(0.5° C) per minute.

2. Observe the cutout temperature. It should be 9° F (5° C)below the design leaving chilled water temperature or aminimum of 36 F (2 C). If the control fails to cut out by36 F(2 C), stop the chiller immediately and replace theswitch with a new calibration switch.

3. When the control cuts out, the chiller shuts down imme-diately without going through the dilution cycle. The con-trol cuts in when the sensing element warms up 7.2° F(4° C).If necessary, reset the cutout adjustment screw (Table 4)and recalibrate. Restart the chiller by pressing theRESET softkey and then the LOCAL or CCN soft-

key. Replace the sensing elements in their wells.

Cycle-Guard System Operation — To check theCycle-Guard operation, place the Cycle-Guard switch in themanual position. The Cycle-Guard transfer valve energizes.The flow of refrigerant will cause the transfer line betweenthe valve and the solution pump inlet to feel cold to the touch.This line should not feel cold when the transfer valve is closed(not energized). If the line is cold when the valve is deen-ergized, the valve is leaking and must be repaired. Returnthe Cycle-Guard switch to the AUTO. position.

During normal operation, the PC6400 controller controlsthe Cycle-Guard valve. The controller senses the strong so-lution concentration.

A Cycle-Guard system malfunction makes the chiller sus-ceptible to solution crystallization. See the TroubleshootingGuide, pages 85-103 (Additional Problems/Symptoms and

Their Probable Causes and Remedies, ‘‘Solution Crystalliza-tion During Operation’’). Also, refer to the section,Normal Run Mode, page 68.

Internal Service — To prevent corrosion from air in-side the chiller, break the vacuum by introducing nitrogenwhenever the chiller is opened for maintenance or repair.

While the chiller is open, it is good practice to minimizethe amount of air entering it by continuously feeding nitro-gen into the chiller at approximately 1 psig (7 kPa) pressure.

Perform service work promptly and efficiently and closethe chiller as soon as possible. Do not rely on the inhibitorfor corrosion protection unless all lithium bromide and re-frigerant have been removed and the chiller has been com-pletely flooded with a lithium inhibitor-water solution priorto chiller opening.

Leak test the chiller thoroughly after the chiller has beenclosed up.

When flamecutting or welding on an absorption chiller,some noxious fumes may be produced. Ventilate the areathoroughly to avoid breathing concentrated fumes.

Never cut into the purge chamber to remove any hy-drogen gas that might be present in the chamber unlessthe purge has been exhausted. Hydrogen can form anexplosive mixture in the air.

Service Valve Diaphragm Replacement — To re-place valve diaphragms:1. Break the chiller vacuum by introducing nitrogen. Solu-

tion and refrigerant can be transferred to opposite sumpswithin the chiller or removed from the chiller. If they areremoved from the chiller, store them in clean containersfor recharging.

2. Remove and replace old valve diaphragms. Clean the mat-ing surfaces before replacing the valves and diaphragms.Torque the valve bolts to approximately 3 lb-ft(0.4 kg-m).

3. Test all affected connections for leakage (see Chiller LeakTest section, page 76).

4. Re-evacuate the chiller after servicing (see Chiller Evacu-ation section, page 77).

5. Replace solution and refrigerant in the chiller (the samequantity that was removed).

79

P1

P

T16 T10 T9

T6

T12

V3 T7 V2 T15 V1 T14 T11T6

L1

L3

L2

2 AND 4 PASS EVAPORATOR ARRANGEMENT

2 PASS ABSORBER/1 PASS CONDENSER ARRANGEMENT

T17T2

T1

T5

VIEW C-C

C

C

T4

T3

T17

1 AND 3 PASS EVAPORATOR ARRANGEMENT

T2

T1

Fig. 47 — 16JB Sensor Location and Installation

80

LOCATION DESCRIPTION SENSOR TYPE WIRE/TERMINALNUMBER

T1 Entering Chilled Water 5K Thermistor WHT TB2-208, BLK, TB2-209T2 Leaving Chilled Water 5K Thermistor WHT TB2-210, BLK TB2-211T3 Cooling Water Entering Absorber 5K Thermistor WHT TB2-216, BLK, TB2-217T4 Cooling Water Leaving Absorber 5K Thermistor WHT TB2-218, BLK TB2-219T5 Cooling Water Leaving Condenser 5K Thermistor WHT TB2-413, BLK TB2-414T6 Refrigerant Temperature 5K Thermistor WHT TB2-206, BLK TB2-207T7 Weak LiBr Leaving Absorber 5K Thermistor WHT TB2-212, BLK TB2-213T8 Weak LiBr Leaving HX 5K Thermistor WHT TB2-214, BLK TB2-215T9 Generator Overflow Pipe 100K Thermistor WHT TB2-403, BLK TB2-404T10 Strong LiBr Leaving Generator 100K Thermistor WHT TB2-405, BLK TB2-406T11 Strong LiBr Leaving HX 5K Thermistor WHT TB2-407, BLK TB2-408T12 LiBr Entering Absorber 5K Thermistor WHT TB2-409, BLK TB2-410T13 Condensate Temp from Condenser 5K Thermistor WHT TB2-411, BLK TB2-412

P1 Solution Pump Pressure Pressure Transducer−6.7 to 420

RED TB2-143, BLK TB2-144,CLR TB2-202

L1 Refrigerant Level Sensor Analog Float Switch WHT/RED TB2-344, GRN TB2-204C,RED/BLU TB2-204B

L2 Low Refrigerant Level Discrete Float Switch TB2-711, TB2-712L3 High Refrigerant Level Discrete Float Switch TB2-713, TB2-714

T14 Refrigrant Pump Overload Klixon TB2-527, TB2-528T15 Solution Pump Overload Klixon TB2-531, TB2-532T16 High Temperature Cutout Temperature Switch TB2-535, TB2-536T17 Low Chilled Water Temperature Temperature Switch TB2-539, TB2-540V1 Cycle Guard Valve Solenoid TB1-S0, TB1-903V2 LLC Valve Solenoid TB1-S0, TB1-915V3 Purge Indicator Discrete Float Switch TB1-R0, TB1-918

LEGEND

GEN — GeneratorHX — Heat ExchangerLiBr — Lithium BromideLLC — Low Level Control

*Size dependent.

NOTE: T13 (Condensate Temperature from Condenser) is not depicted on this figure. It is located onthe back of the machine.

Fig. 47 — 16JB Sensor Location and Installation (cont)

81

Hermetic Pump Inspection — The pumps used onCarrier absorption chillers are hermetic and do not requireseals. Pump motors are cooled by the fluids being pumped.

Never run a hermetic pump motor dry. Even momen-tary operation without the chiller filled with liquid willdamage bearings and overheat the motor. Use only thecurrent value specified in the control circuit diagram whensetting the pump starter overloads.

The pumps are a stamped design and are either 3 or 5 horse-power range, 3 and 5 HP, Frame P66K/R. See Fig. 48.

Disassemble, inspect, and reassemble the pumps asfollows.

DISASSEMBLY — Items in ( ) refer to Fig. 48.

Disconnect all primary power to the pumps; lock andtag all disconnect switches.

1. Break the chiller vacuum with dry nitrogen if not al-ready done.

2. Remove the solution and refrigerant from the chiller. Storethe solution in clean containers until ready to rechargethe chiller.

3. Disconnect the motor power leads at the stator junctionbox (Item 23). Mark the leads to ensure properreassembly.

4. Remove cap screws (Fig. 48).

NOTE: Use blocking to support the weight of the motor sta-tor (Item 19) when removing bolts.5. Pull the motor stator and adapter flange (Item 17) straight

back from the pump casing. If the flange is frozen to thecasing by paint, gently pry between the adapter flangeand the pump discharge pipe (Item 6) to break the paintseal.

6. Remove and discard the gasket (Fig. 48, Item 16).7. Remove the impeller (Item 8) by straightening the lock-

ing tabs on the impeller locking washer (Item 10). Keepthe impeller from rotating while removing the impellerlocking bolt (Item 11). Remove the impeller key(Item 12). Remove the motor side wearing ring(Item 13).

8. Remove the stud nuts (Item 14). Tap and slightly twistthe motor wearing ring housing (Item 15). Loosen andremove the housing.

9. Slide out the rotor (Item 3) to avoid damage to the statorcan (Item 1), rotor liner (Item 2), and motor end bearing(Item 21).

10. Remove the motor end bearing and the motor end bear-ing spring (Item 20).

INSPECTION1. Check for front end and motor end bearing (Items 18 and

21) wear by measuring the depth from the large end ofthe cone to the start of the cone as indicated in Fig. 56.If wear exceeds 3/16 in. (5 mm), replace the bearing.

2. Check the recirculation passages (Item 4). Clean ifnecessary.

3. Examine the impeller, stator can, rotor liner, casing wear-ing ring (Item 9), and motor wearing ring (Item 13) forwear. Clean or replace during reassembly if necessary.

NOTE: The original wearing rings (Items 9 and 13) are heldin place with Loctite™ adhesive. If it becomes necessary toreplace them, break the old ring with a chisel.4. Check the bearing spring (Item 20) for free movement

within the bearing housing.

REASSEMBLY — Refer to Fig. 48.

1. Clean all parts.2. Install the bearing spring in the motor end bearing hous-

ing (Item 22).3. Insert the motor end bearing in the motor end housing.

The fit should be free, sliding without excessive radialplay.

4. Guide the rotor into position carefully to avoid damageto the rotor liner, stator can, and motor end bearing.

5. Install the front end bearing (Item 18) in the wearingring housing (Item 15).

6. Install the bearing and wearing ring housing onto theadapter flange (Item 17). Tighten the stud nuts.

7. Replace both wearing rings (Items 9 and 13), if neces-sary. Before replacing them, thoroughly clean the sur-face of the wearing ring housings. Use hand pressure toposition the new rings. Do not use Loctite adhesive.

8. Install the impeller with the impeller key, lock washer,and locking bolt. Bend the washer tabs over the flats ofthe locking bolt heads.

9. Install a new 1/32-in. (0.8 mm) thick EPR (Ethylene Pro-pylene Rubber) gasket (Fig. 48, Item 16) on the 3 or5 HP, Frame P66K/R motor.

10. Be sure the casing wearing ring (Item 9) is in place.11. Slide the motor stator housing and adapter flange as-

sembly into the pump casing. Use blocking to supportthe motor stator. Oil, install, and tighten bolts and wash-ers to approximately 18 lb-ft (2.4 kg-m) torque. Re-move the blocking.

COMPLETION1. Leak test the affected joints to be sure that all pump con-

nections are tight. See Chiller Leak Test, page 76.2. Evacuate the chiller. See Chiller Evacuation, page 77.3. Recharge the chiller with the same amount of solution

and refrigerant as removed. See Charge the Chiller withSolution and Refrigerant, page 55.

4. Reconnect the motor power leads to the proper motor wiresand replace the stator junction box.

5. Resupply power to the pump.6. Record the inspection date and results in your chiller log.

Solution Decrystallization — Crystallization (solid-ifcation) occurs when the strong solution concentration andtemperature cross over to the right of the crystallation lineon the equilibrium diagram (Fig. 6, 7, and 38). It should notoccur if the chiller controls are correctly adjusted and thechiller is properly operated. Refer to the Troubleshooting Guide,beginning on page 85, for probable causes and remedies.

82

LEGEND

1 — Stator Can2 — Rotor Liner3 — Rotor Core4 — Recirculation Passage5 — Cap Screw6 — Pump Discharge Pipe7 — Pump Casing8 — Impeller9 — Casing Wearing Ring

10 — Impeller Locking Washer11 — Impeller Locking Bolt12 — Impeller Key

13 — Motor Side Wearing Ring14 — Stud Nuts15 — Motor Wearing Ring Housing16 — Casing Gasket17 — Adapter Flange18 — Front End Bearing19 — Stator20 — Motor End Bearing Spring21 — Motor End Bearing22 — Motor End Bearing Housing23 — Stator Junction Box

NOTE: See disassembly and reassembly procedures foritem references.

Fig. 48 — Hermetic Pump (3 and 5 HP, Frame P66K/R)

83

DECRYSTALLIZATION USING THE PIC CONTROLS —If crystallization occurs, it generally takes place in the shellside of the heat exchanger and blocks the flow of strong so-lution from the generator. The strong solution then over-flows into a pipe that returns it directly to the absorber sump.The solution pump then returns the hot solution through theheat exchanger tubes, automatically heating and decrystal-lizing the shell side. The PIC controls indicate an alarm con-dition if the temperature of the overflow pipe exceeds thevalue of GEN OVERFLOW ALARM. GEN OVERFLOWALARM can be adjusted by accessing the SERVICE1 screenon the LID. Adjust the alarm temperature by pressing theINCREASE or DECREASE softkey until the desired tem-

perature is reached. Then press the ENTER softkey to recordyour change.

Before the chiller can be put in DESOLID mode, it mustbe OFF. After the chiller is OFF, set the DESOLIDIFICA-TION TIMER as follows.1. Access the SERVICE1 screen.2. Scroll to DESOLIDIFICATION TIME and press the

SELECT softkey.

3. Press the INCREASE or DECREASE softkey until therequired time is reached.

4. Press the ENTER softkey to record your selected time.

NOTE: The usual time to completely desolidify is 4 hours or240 minutes, which is also the maximum time configurablefrom the SERVICE1 screen.

Now, the chiller can be put in DESOLID mode, asfollows.1. Access the PUMPSTAT screen on the LID. Scroll to

DESOLIDIFICATION MODE; then, press the followingsoftkeys: SELECT , ENABLE , and ENTER .

2. Scroll to SOLUTION PUMP then, press SELECT ,ON , and ENTER softkeys.

3. Scroll to REFRIGERANT PUMP. Then, press theSELECT , ON , and ENTER softkeys.

4. Scroll to CYCLE GUARD AUTO/MANUAL and press theMANUAL and ENTER softkeys.

5. Press the EXIT softkey. Access the MAINSTAT screen.Scroll to TARGET CAPACITY VALVE and pressthe SELECT softkey. Press the INCREASE orDECREASE softkey to adjust to a value that will open

the capacity valve and add heat. Press the ENTER soft-key when the desired value is shown on the LID.At this point the chiller is in manual control. Monitor thesolution temperature to maintain 140 F (60 C). The re-frigeration pump and Cycle-Guard™ valve will pumpthe refrigerant into the solution to dilute it to aid indesolidification.

When the chiller is in desolidification mode, the op-erator has sole control over heat input to the chiller.The operator must attend the chiller and monitor itcontinuously during this time.

When heating the chiller in this manner, remove the low-temperature cutout (LTCO) sensing bulbs from their wellsand insulate them to prevent overheating. When the chillertemperatures return to normal, recalibrate the LTCO (seeLow Temperature Cutout Adjustment, page 79).

When the DESOLID mode has ended, release the targetcapacity valve as follows.1. Access the STATUS screens on the LID.2. Scroll to TARGET CAPACITY VALVE; then, press the

SELECT and RELEASE softkeys.

3. Press the EXIT softkey to return to the STATUS screen.

4. Scroll the SOLUTION PUMP then press the SELECTand RELEASE softkeys.

5. Scroll to REFRIGERANT PUMP; then, press theSELECT and RELEASE softkeys.

6. Scroll to CYCLE GUARD AUTO/MANUAL; then, pressthe SELECT and RELEASE softkeys.

SEVERE CRYSTALLIZATION — If crystallization (solidi-fication) results from a long, unscheduled shutdown (such asfrom a power failure) without proper dilution, the solutionpump(s) may become bound and fail to rotate. This causesthe overloads to trip out. In such a case, the chiller is se-verely crystallized and the solution pump will not start.

If the chiller is severely crystallized and the solution pumpwill not start, add heat to the outside of the solution pumpas follows.1. Heat the solution pump casing and adjacent lines with

steam.

Under no circumstances apply heat directly to pumpmotor or controls when warming the casing. Do notapply direct heat to any flange connections; high tem-perature can deteriorate the gasket material.

2. Since rotation of a hermetic pump cannot be viewed di-rectly, check the solution pump rotation by installing acompound gage on the pump service valve and readingthe discharge pressure. Reset the pump overloads in thecontrol panel if they are tripped.If the pump is rotating normally, the gage will show areading above atmospheric pressure. If the pump casingand discharge line are completely blocked, the gage willshow zero atmospheric pressure. If the pump interior isonly partially blocked, a deep vacuum will indicate thatthe pump is not rotating.

3. Continue heating the casing until the gage pressure showsabove atmospheric pressure with pump overloads reset.Do not reset pump overloads more than once in any 7-minuteperiod.If the heat exchanger is also blocked, the decrystalliza-tion process will begin as soon as the solution pump startsrotating and the adjacent weak solution lines have de-crystallized. If the heat exchanger or adjacent piping doesnot decrystallize automatically, heat the blocked area ex-ternally with steam or a soft torch flame. Crystallizationin purge piping can be broken up by applying heat in thesame manner.

4. If the strong solution line from heat exchanger to ab-sorber spray nozzles is blocked, operate the chiller inDESOLID mode.

When the chiller is in DESOLID mode, all alarmsand safeties may not protect the chiller. The opera-tor must attend to the chiller and monitor the solu-tion leaving absorber temperature (which must notexceed 140 F [60 C]) to avoid overheating the chiller.

84

Condensing Water Tube Scale — Condensing wa-ter tube scale is indicated if the temperature difference be-tween the condensing water leaving the condenser and therefrigerant condensate from the condenser is greater than thenormal 4 to 7° F (2 to 4° C) difference at full load (capacitycontrol valve fully open). Scale reduces heat transfer, in-creases steam consumption, and limits chiller capacity. Scalecan also cause serious corrosion damage to the tubes.

Soft scale can be removed from tubes with cleaning brushes,specially designed to avoid scraping or scratching the tubewalls. The brushes are available through your Carrier rep-resentative. Do not use wire brushes.

Hard scale may require chemical treatment for its pre-vention or removal. Consult a water treatment specialistfor proper treatment.

Water Treatment — Untreated or improperly treated wa-ter may result in corrosion, scaling, erosion, or algae. Theservices of a qualified water treatment specialist should beobtained to develop and monitor a treatment program.

Water must be within design flow limits, clean, and treatedto ensure proper chiller performance and reduce the po-tential of tubing damage due to corrosion, scaling, orerosion. Carrier assumes no responsibility for chiller dam-age resulting from untreated or improperly treatedwater.

Ordering Replacement Chiller Parts — When or-dering Carrier-specified parts, the following information mustaccompany an order.• chiller model and serial numbers• name, quantity, and part number of part required• delivery address and method of shipment.

TROUBLESHOOTING GUIDE

Overview — The PIC has many features to help the op-erator and technician troubleshoot a 16JB chiller.• The LID display shows the chiller’s actual operating con-

ditions and can be viewed while the chiller is running.• The default LID screen freezes when an alarm occurs. The

freeze enables the operator to view the chiller conditionsat the time of the alarm. The STATUS screens show cur-rent information. Once all alarms have been cleared (bycorrecting the problems and pressing the RESET soft-key), the default LID screen returns to normal operation.

• The CONTROLALGORITHM STATUS screens (COOL-ING, APPROCH, OVERRIDE, and CONCENTR) dis-play information that helps to diagnose problems with chilledwater control, chilled water temperature control overrides,and component performance.

• The control test feature facilitates the proper operation andtest of temperature sensors, pressure transducers, the ca-pacity valve, water pumps, tower control, and other on/offoutputs.

• Other SERVICE screens can access configured items suchas chilled water resets, override set points, approaches, ab-sorber loss, cycle concentrations, etc. If an operating faultis detected, an alarm message is generated and displayedon the LID default screen. A more detailed message, alongwith a diagnostic message, is stored in the ALARM HIS-TORY table.

Checking the LID Display Messages — The firstarea to check if a problem occurs with the 16JB chiller is theLID display screen. If the alarm light is flashing, check theprimary and secondary message line on the LID default screen(Fig. 13). These messages indicate where the fault is occur-ring. The ALARM HISTORY table, accessible from the LIDSERVICE menu, also carries an alarm message to furtherexpand on the alarm. For a complete list of possible alarmmessages, see Table 12. For a list of additional problems andsymptoms and their probable causes and remedies, seeTable 13.

If the alarm light starts to flash while accessing a menuscreen, press the EXIT softkey to return to the default LIDscreen to read the alarm message. The chiller will not runwhile an alarm condition exists unless the alarm is causedby an unauthorized start or a failure to shut down.

Checking Temperature Sensors — All tempera-ture sensors are thermistor-type sensors; that is, the resis-tance of the sensor varies with its temperature. All sensorshave the same resistance characteristics. Determine sensortemperature by measuring voltage drop if the controls arepowered on. There are 2 ranges of thermistors, 5K ohm and100K ohm. They are distinguished from each other by partnumber and a color band on the 100K ohm thermistor. Com-pare the readings to the values listed in Tables 14A-15B.

RESISTANCE CHECK — Turn off the control power anddisconnect the terminal plug of the sensor in question fromthe module. Measure the sensor resistance between recep-tacles designated by the wiring diagram with a digital ohm-meter. The resistance and corresponding temperature are listedin Tables 14A-15B. Check the resistance of both wires toground. This resistance should be infinite.

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Table 12 — LID Primary and Secondary Messages and Custom Alarm/Alert Messageswith Troubleshooting Guides

A. SHUTDOWN WITH ON/OFF/RESET-OFF

PRIMARY MESSAGE SECONDARY MESSAGE PROBABLE CAUSE/REMEDY

MANUALLY STOPPED PRESS CCN OR LOCAL TO START PIC in OFF mode; press the CCN or LOCAL softkey tostart unit.

SHUTDOWN IN PROGRESS COMPLETE IN XX.X MIN. This is a 15-minute cycle run to dilute the solution to pre-vent crystallization after shutdown.

DILUTION CYCLE SHUTDOWN COMPLETE IN XX.X MIN.Possible power outage. Chiller solution is too strongat last shutdown. If this is a safety shutdown, a dilutioncycle will be initiated.

B. TIMING OUT OR TIMED OUT


READY TO START UNOCCUPIED MODE Time schedule for PIC is unoccupied. Chillers will start onlywhen occupied.

READY TO START REMOTE CONTACTS OPEN Remote contacts have stopped the chiller. Close contacts tostart.

READY TO START STOP COMMAND IN EFFECT CHILLER START/STOP on MAINSTAT screen manuallyforced to stop. Release value to start.

C. IN RECYCLE SHUTDOWN


RECYCLE RESTART PENDING OCCUPIED MODE Unit in RECYCLE mode, chilled water temperature is nothigh enough to start.

RECYCLE RESTART PENDING REMOTE CONTACTS CLOSED Unit in RECYCLE mode, chilled water temperature is nothigh enough to start.

RECYCLE RESTART PENDING START COMMAND IN EFFECT

CHILLER START/STOP on MAINSTAT screen manuallyforced to start: chilled water temperature is not high enoughto start.

LEGEND FOR TABLE 12 (A-N)

ABSORB — AbsorberCCN — Carrier Comfort NetworkCHW — Chilled WaterCOND — CondenserECW — Entering Chilled WaterENT — EnteringGEN — GeneratorHITEMP — High TemperatureHX — High-Temperature Heat ExchangerLCD — Level Control Device

LIBR — Lithium BromideLID — Local Interface DeviceLVG — LeavingOVERLD — OverloadPIC — Product Integrated ControlPRESS — PressureRECIRC — RecirculatedREF — RefrigerantSOL — Solution

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Table 12 — LID Primary and Secondary Messages and Custom Alarm/Alert Messageswith Troubleshooting Guides (cont)

D. PRESTART FAILURES

PRIMARY MESSAGE SECONDARY MESSAGE ALARM MESSAGE/PRIMARY CAUSE ADDITIONAL CAUSE/REMEDYPRESTART ALERT LEAVING SOL HIGH TEMP Strong LiBr Leaving exceeded the

value of (LIMIT)* HITEMP (VALUE)*.Check capacity valve and linkage.Fill out chiller log and look for abnormaltemperatures; check absorber loss.

PRESTART ALERT LOW REFRIGERANT TEMP Refrigerant Temp. exceeded the value of(LIMIT)* EVAP_REF (VALUE)*.

Check chilled water pump. Checksolution concentrations and weaksolution saturation temperature.Log current chiller readings and investi-gate abnormal readings. Check absorberloss.

*(LIMIT) is shown on the LID as the temperature, pressure, voltage, etc., set point predefined or selected by the operator as an override, alert, oralarm condition. (VALUE) is the actual temperature, pressure, voltage, etc., at which the control is tripped.

E. NORMAL OR AUTO. RESTART

PRIMARY MESSAGE SECONDARY MESSAGE PROBABLE CAUSE / REMEDYSTARTUP IN PROGRESS OCCUPIED MODE Chiller starting. Time schedule for PIC is occupied.STARTUP IN PROGRESS REMOTE CONTACTS CLOSED Chiller starting. Remote contacts are closed.

STARTUP IN PROGRESS START COMMAND IN EFFECT Chiller starting. CHILLER START/STOP on MAINSTATmanually forced to start. Release value to stop.

STARTUP IN PROGRESS SOLUTION WARM-UP Chiller starting. Chiller is warming up.

F. START-UP FAILURES

PRIMARY MESSAGE SECONDARY MESSAGE ALARM HISTORY MESSAGE/PRIMARY CAUSE

ADDITIONAL CAUSE/REMEDY

FAILURE TO START LOW CHILLEDWATER FLOW

Startup: CHWFLOW Water Flow Fault:Check Chilled Water Flow

Verify chilled water flow. Make sure cool-ing water pump is operating properly. Checkwiring to the flow switch. Use control testto check for proper switch operation. Setup WATER FLOW VERIFY TIME.

FAILURE TO START LOW COOLINGWATER FLOW

Startup: COOLFLOW Water Flow Fault:Check Cooling Water Flow

Same as above except for the cooling wa-ter pump.

PROTECTIVE LIMIT SOLUTION PUMPPRESSURE

SOLPRS (VALUE)* exceeded limitof (LIMIT)*.Solution Pressure.

The solution pump pressure is greater than8.5 psia (58.7 kPa) with the pumps deen-ergized. The chiller may have a leak or iswarm from a previous run period.


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G. WARM-UP FAILURES


ADDITIONAL CAUSE / REMEDY

PROTECTIVE LIMIT SLOW PULLDOWN:CHW_OUT

Slow Pulldown At Startup:Check for Absorber Lossor for Non-Condensables

15 minutes has elapsed since the refrig-erant pump has been energized, and thechilled water pulldown is less than or equalto 0. The STARTUP PULLDOWN FAIL-URE has to be enabled. Check absorberloss and purge chiller.


H. EMERGENCY/LOSS OF COMMUNICATIONS



MACHINECRYSTALLIZATION

RUN DESOLIDIFICATION Low Solution Temp After Power Loss;Run Desolidification

Stored values for points 6 and 8 com-pared to current values indicate that thesolution in the chiller is very near or to theright of the crystallization line.

I. NORMAL RUN

PRIMARY MESSAGE SECONDARY MESSAGE PROBABLE CAUSE / REMEDYRUNNING - RESET ACTIVE 4-20 mA SIGNAL Reset program active based upon CONFIG table set-up.RUNNING - RESET ACTIVE REMOTE SENSOR CONTROL Reset program active based upon CONFIG table set-up.RUNNING - RESET ACTIVE CHW TEMP DIFFERENCE Reset program active based upon CONFIG table set-up.RUNNING - TEMP CONTROL LEAVING CHILLED WATER Default method of temperature control.RUNNING - TEMP CONTROL ENTERING CHILLED WATER ECW control activated on CONFIG table.RUNNING - TEMP CONTROL TEMPERATURE RAMP LOADING Ramp loading is in effect. Use SERVICE1 screen to modify.

DESOLIDIFICATION MODE XX MIN. TIL COMPLETIONDESOLID Mode is in effect. Use PUMPSTAT screen tomodify.

J. NORMAL RUN WITH OVERRIDES


LIMIT

RUN CAPACITY LIMITED GEN HIGH SATURATIONTEMP

GEN_SAT (VALUE)* exceeded limit of(LIMIT*). G1 High Saturation TempOverride.

See Capacity Overrides, Table 3for correct operating condition.

RUN CAPACITY LIMITED GEN HIGH SOLUTIONTEMP

GEN_SOL (VALUE)*, exceeded limit of(LIMIT)*. G1 High Solution TempOverride.


RUN CAPACITY LIMITED LOW REFRIGERANTTEMP

EVAP_REF (VALUE)*, exceeded limit of(LIMIT)*. Refrigerant Temp Override.


RUN CAPACITY LIMITED MANUAL CAPACITYVALVE

CV_TRG Run Capacity limited: ManualCapacity Valve Target.


RUN CAPACITY LIMITED HIGH CONCENTRATION CV_ACT Run Capacity Limited: HighLiBr Concentration.


(LIMIT) is shown on the LID as the temperature, pressure, voltage, etc., set point predefined or selected by the operator as an override, alert, oralarm condition. (VALUE) is the actual temperature, pressure, voltage, etc., at which the control is tripped.

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K. OUT OF RANGE SENSORS

PRIMARYMESSAGE

SECONDARY MESSAGE ALARM HISTORY MESSAGE/PRIMARY CAUSE


SENSOR FAULT REFRIGERANT LEVEL SENSOR Sensor Fault:Check Refrigerant Level Sensor

See sensor test procedure and checksensors for proper operation and wiring.

SENSOR FAULT ENTERING CHILLED WATER Sensor Fault:Check Entering Chilled Water


SENSOR FAULT LEAVING CHILLED WATER Sensor Fault:Check Leaving Chilled Water


SENSOR FAULT COOLING WATER ENT ABSORB Sensor Fault:Check Cooling Water Ent Absorb


SENSOR FAULT COOLING WATER LVG ABSORB Sensor Fault:Check Cooling Water Lvg Absorb


SENSOR FAULT COOLING WATER LVG COND Sensor Fault:Check Cooling Water Lvg Cond


SENSOR FAULT WEAK LIBR LEAVING ABSORB Sensor Fault:Check Weak Libr Leaving Absorb


SENSOR FAULT RECIRC LIBR ENT SPRAYS Sensor Fault:Check Recirc LiBr Ent Sprays


SENSOR FAULT REFRIGERANT TEMP Sensor Fault:Check Refrigerant Temp


SENSOR FAULT VAPOR CONDENSATE TEMP Sensor Fault:Check Vapor Condensate Temp


SENSOR FAULT GEN LIBR OVERFLOW PIPE Sensor Fault:Check GEN Libr Overflow Pipe


SENSOR FAULT WEAK LIBR LVG HIGH HX Sensor Fault:Check Weak Libr Lvg High HX


SENSOR FAULT STRONG LIBR LEAVING GEN Sensor Fault:Check Strong Libr Leaving GEN


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L. PROTECTIVE LIMIT FAULTS

PRIMARYMESSAGE

SECONDARY MESSAGE ALARM HISTORY MESSAGE/PRIMARY CAUSE


PROTECTIVE LIMIT STRONG LIBR LEAVING GEN GEN_SOL (VALUE)* exceeds limit of(LIMIT)*, Strong LiBr Leaving GEN.

See sensor test procedure andcheck sensors for properoperation and wiring.

PROTECTIVE LIMIT GENERATOR HITEMP GENHITP Generator Hi Temp. See sensor test procedure andcheck sensors for properoperation and wiring.

PROTECTIVE LIMIT LOW CHILLED WATER TEMP LOWCHWT Low Chilled Water Temp. See sensor test procedure andcheck sensors for properoperation and wiring.

PROTECTIVE LIMIT LOW CHILLED WATER FLOW CHWFLOW Flow Fault:Check Water Pump/Flow switch.


PROTECTIVE LIMIT LOW COOLING WATER FLOW COOLFLOW Flow Fault:Check Water Pump/Flow switch.


PROTECTIVE LIMIT REF PUMP OVERLD/HITEMP RFPMPFLT Ref Pump Overld/Hi Temp. Internal wait until pump cools off.PROTECTIVE LIMIT SOL PUMP OVERLD/HITEMP SPMPFLT1 Sol Pump Overld/Hi Temp. Internal wait until pump cools off.PROTECTIVE LIMIT SPARE SAFETY DEVICE SPR_PL Spare Prot Limit Input. Check local wiring.PROTECTIVE LIMIT LOW REFRIGERANT TEMP Protective Limit: EVAP_REF (VALUE)*

exceeds limit of (LIMIT)*. Low Refriger-ant Temp.


PROTECTIVE LIMIT LOW CHILLED WATER TEMP Protective Limit: CWH_OUT (VALUE)* ex-ceeds limit of (LIMIT)*. Leaving ChilledWater.


PROTECTIVE LIMIT WEAK LIBR LEAVING ABSORB Protective Limit: ABS_SOL (VALUE)* ex-ceeds limit of (LIMIT)*. Weak LiBr Leav-ing Absorb


PROTECTIVE LIMIT GEN LIBR OVERFLOW PIPE Protective Limit: GENFLOW (VALUE)*exceeds limit of (LIMIT)*. GEN OverflowPipe.


PROTECTIVE LIMIT TRANSDUCER VOLTAGE FAULT Protective Limit: V_REF (VALUE)* ex-ceeds limit of (LIMIT)*. Transducer Volt-age Ref.


PROTECTIVE LIMIT TRANSDUCER VOLTAGE FAULT Protective Limit: V_REF (VALUE)* ex-ceeds limit of (LIMIT)*. Transducer Volt-age Ref.


PROTECTIVE LIMIT CCN OVERRIDE STOP CHIL_S_S CCN Override Stop While inLOCAL Run Mode.

Check BS (Building Supervisor)software.

PROTECTIVE LIMIT SLOW PULLDOWN: CHW_OUT Slow Pulldown At Startup: Check Ab-sorber Loss/Non-Condensables.

Check log.

PROTECTIVE LIMIT STRONG LIBR LEAVING GEN Protective Limit: _SOL (VALUE)* exceedslimit of (LIMIT)*. Strong LiBr Leaving GEN.


PROTECTIVE LIMIT HIGH CONCENTRATION FAULT High LiBr Concentration Shutdown: CheckCapacity Valve Linkage/Closure.

Check log.

PROTECTIVE LIMIT HIGH CONCENTRATION FAULT High LiBr Concentration Shutdown: CheckCapacity Valve Linkage/Closure.

Check log.

PROTECTIVE LIMIT SOLUTION PUMP PRESSURE SOLPRS (VALUE)* exceeds limit of(LIMIT)*. Solution Pump Pressure.



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M. MACHINE ALERTS



LOW TEMPERATURE ALERT COOLING WATER ENT ABSORB ABS_IN (VALUE)* exceeded limit of (LIMIT)*.Cooling Water Ent Absorb.

Check LID plugs.

HIGH TEMPERATURE ALERT COOLING WATER LVG ABSORB ABS_OUT (VALUE)* exceeded limit of(LIMIT)*.Cooling Water Lvg Absorb.

Check LID plugs.

HIGH TEMPERATURE ALERT COOLING WATER LVG COND COND_OUT exceeded limit of (LIMIT)*.Cooling Water Lvg Cond.

Check LID plugs.

MACHINE ALERT PURGE TANK FULL Build up on non-condensables or air in stor-age tank.

Exhaust pure tank.

NO MESSAGE NO MESSAGE Chiller Power Loss During Run Mode:Check Voltage Supply.

Check LID plugs.


N. SPARE SENSOR ALERTS


ADDITIONAL CAUSE / REM-EDY

SENSOR ALERTS COMMON SUPPLY SENSOR CHWS (VALUE)* exceeded limit of (LIMIT)*.Common Supply Sensor

Check alert temperature setpoints on Equipment ServiceSERVICE2 LID screen. Checksensor for accuracy if readingis not accurate.

SENSOR ALERTS COMMON RETURN SENSOR CHWR (VALUE)* exceeded limit of (LIMIT)*.Common Return Sensor

Same as above.

SENSOR ALERTS REMOTE RESET SENSOR R_RESET (VALUE)* exceeded limit of(LIMIT)*.Remote Reset Sensor

Same as above.

SENSOR ALERTS COMMON SUPPLY SENSOR CHWS (VALUE) exceeded limit of (LIMIT)*.Common Supply Sensor

Same as above.

SENSOR ALERTS COMMON RETURN SENSOR CHWR (VALUE)* exceeded limit of (LIMIT)*.Common Return Sensor

Same as above.

SENSOR ALERTS REMOTE RESET SENSOR R_RESET (VALUE)* exceeded limit of(LIMIT)*.Remote Reset Sensor

Same as above.


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Table 13 — Additional Problems/Symptoms and Their Probable Causes and Remedies

PROBLEM/SYMPTOM PROBABLE CAUSE REMEDYChiller Will Not Start orShuts Down(Panel RUN light out,pumps off.) LID not lit.

No power to control panel Check for building power failure. Check main circuit breaker.

Control panel fuse blown Examine circuits for ground or short.Replace fuse.

Control panel main circuit breaker open Close main circuit breaker.

Chilled water or condensing water pumpoverloads or flow switches open

Check chilled water and condensing water pumps, starters,and valves.

Solution pump overloads open Push overload reset button.Measure pump discharge pressure to check for solutioncrystallization. See Solution Decrystallization section onpage 82.

Refrigerant pump overloads open Push overload reset button.

Low temperature cutout Depress Reset button after chilled water has warmedat least 7° F (4° C).Measure chilled water temperature.Recalibrate or replace switch if temperature is above setpoint. Check set point setting and operation of capacityvalve if temperature is below switch setting. See PICControl Tests section on page 30 to test.

Generator solution temperature,high absorber pressure

Check cooling water temperature and flow.Check absorber pressure.Check for solution crystallization.

Leaving Chilled WaterTemperature Too High(Chiller running, chilled watertemperature above design.)

Capacity valve not open Verify that the capacity valve is operational. Check capacityvalve operation per Control Test.

Set point too high Reset set point temperature on LID SETPOINT screen.

Excessive cooling load (chillerat capacity)

Check for cause of excessive load.

Excessive chilled water flow(above design)

Check pressure drop per selection data and reset flow.

Low condensing water flow (below design) Check pressure drop per selection data and reset flow.

High supply cooling watertemperature (above design)

Check cooling tower operation and temperature controls.

Low steam pressure (below design) Raise to design per selection data.

Inadequate steam condensate drainage(condensate backs up into tube bundle)

Check operation of steam traps, strainers, valves, andcondensate receivers.

Fouled tubes (poor heat transfer) Clean tubes. Determine if water treatment is necessary.

Chiller needs octyl alcohol Check solution sample and add octyl alcohol if necessary.See Adding Octyl Alcohol section on page 78.

Noncondensables in chiller Check absorber loss. See Absorber Loss Determinationsection on page 76. If above 12° F (8° C), see causes andremedies under Inadequate Purging (high absorber loss)in this table.

Capacity valve malfunction Check calibration and operation of capacity valve.See PIC Control Tests section, page 30.

Solution crystallization(solution flow blockage)

See causes and remedies under Solution Crystallization inthis table.

Low refrigerant level Check the low-level switch operation valve operation, LLC valveoperation, and check for low cooling water temperature.

Cycle-GuardTM control malfunction(low solution concentration)

Check refrigerant charge and CYCLE GUARD LEVEL AD-JUST. See sections on Final Refrigerant Charge Adjustment(page 58), Cycle-Guard System Operation (page 79), Capac-ity Overrides (page 33), and Manual Capacity Valve Control(page 34). Verify that Cycle-Guard switch is set to AUTO.

Leaving Chilled WaterTemperature Too Low(Chiller running, chilled watertemperature below design.)

Set point too low Reset temperature control on SETPOINT screen.

Capacity control malfunction Check calibration and operation of capacity valve. SeeCapacity Control section on page 22.

LEGEND

GEN — GeneratorLID — Local Interface DeviceLLC — Low Level ControlPIC — Process Integrated Controls

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Table 13 — Additional Problems/Symptoms and Their Probable Causes and Remedies (cont)

PROBLEM/SYMPTOM PROBABLE CAUSE REMEDYLeaving Chilled Water TemperatureFluctuates(Chiller running, capacitycontrol hunting.)

Chilled water flow or load cycling Check chilled water system, controls, and load.

Condensing water flow or temperaturecycling

Check condensing water temperature control andcooling tower operation.

Steam pressure cycling Check steam pressure control.

Inadequate steam condensate drainage(condensate backs up into tube bundle)

Check operation of steam traps, strainer, valves,and condensate receivers.

Capacity control malfunctions Check calibration and operation of capacity valve. SeeCapacity Control section, page 22.Check configuration of CONTROL POINT DEADBAND, PRO-PORTIONAL INCR BAND, PROPORTIONAL DECR BAND,PROPORTIONAL CHW_IN GAIN, and GEN solution tempera-ture bias.

Inadequate Purging(Low chiller capacity andhigh absorber loss. SeeAbsorber Loss Determination,page 76, and APPROACHscreen [from CONTROLALGORITHM STATUS tables]on the LID.)

Air leakage in vacuum side of chiller(high noncondensable accumulation rate)

Have solution analyzed for indication of air leaks. Leak testand repair if necessary. See Noncondensable Accumu-lation Rate, Solution Analysis, and Chiller Leak Testsections on pages 76, 78, and 76, respectively.

Inhibitor depleted (high noncondensableaccumulation rate)

Have solution analyzed. Add inhibitor and adjust solutionalkalinity if necessary. See Noncondensable AccumulationRate, Solution Analysis, and Inhibitor sections on pages 76,78, and 78, respectively.

Purge valves not positioned correctly Check valve positions. See Purge Manual Exhaust Proceduresection on page 75.

Purge solution supply lines crystallized(not able to exhaust purge)

Heat solution supply lines, See Purge Manual Exhaust pro-cedure and Solution Decrystallization sections on pages 75and 82.

Solution Crystallization DuringOperation(Strong solution overflowpipe hot.)G2 Overflow Alarm

Cycle-Guard™ control malfunction(solution overconcentration)

Check refrigerant charge, Cycle-Guard system, and valve op-eration. See Final Refrigerant Charge Adjustment and Cycle-Guard System Operation sections on pages 58 and 79,respectively.

Noncondensables in chiller(high absorber loss)

Check absorber loss. See APPROACH screen on the CON-TROL ALGORITHM STATUS menu or Absorber Loss Deter-mination section on page 76. If above 12° F (8° C), see Causesand Remedies under Inadequate Purging above.

High steam pressure temperature(above design)

See Chiller Selection Data provided with the chiller.Set at design.

Absorber tubes fouled(poor heat transfer)

Clean tubes. Determine if water treatment is necessary.

Octyl alcohol depletion Check solution sample and add octyl alcohol if necessary.See Adding Octyl Alcohol section on page 78.

Solution Crystallization atShutdown(Crystallization symptoms whenchiller is started.)

Insufficient solution dilution at shutdown After shutdown, restart chiller and measure concentrationof weak solution. See Solution or Refrigerant Sampling sec-tion on page 77. If above 56%, check dilution level switch andCycle-Guard transfer valve.

Abnormal Noise fromSolution Pump

Cavitation of solution pump(low solution level in absorber)

Open the Cycle-Guard valve manually for about 3 minutes whilechiller is running. Adjust the charge.

Abnormal Noise fromRefrigerant Pump

Temperature of cooling watersupply below 59 F (15 C)

Raise cooling water temperature above 59 F (15 C). Stopthe chiller and then restart it about 20 minutes later. CheckFinal Refrigerant Charge Adjustment section (see page 58).

Frequent Cycle-Guard SystemOperation

Fouled absorber or evaporator tubes Clean tubes.

Excessive noncondensable gas(high absorber loss)

See Inadequate Purging, above.

Refrigerant overcharge or tube leak Remove refrigerant to trim charge, per start-up instructions.Repair tube leak.

See Legend on page 92.

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VOLTAGE DROP — Using a digital voltmeter, the voltagedrop across any energized sensor can be measured while thecontrol is energized. Tables 14A-15B list the relationship be-tween temperature and sensor voltage drop (volts dc mea-sured across the energized sensor). Exercise care when mea-suring voltage to prevent damage to the sensor leads, connectorplugs, and modules. Voltage should also be checked at thesensor plugs. Check the sensor wire at the sensor for 5 vdcif the control is powered.

Relieve all water pressure or drain the water before re-placing the temperature sensors.

CHECK TEMPERATURE SENSOR ACCURACY — Placethe sensor in a medium of a known temperature and com-pare that temperature to the measured reading. The ther-mometer used to determine the temperature of the mediumshould be of laboratory quality with 0.5 F (0.25 C) gradu-ations. The sensor in question should be accurate to within2 F (1.2 C) for both the 5K and 100K ohm sensors.

See Fig. 47 for the sensor locations. The sensors are im-mersed in wells on the chiller or directly in water circuits.The wiring at each sensor is easily disconnected by unlatch-ing the connector. These connectors allow only a one-wayconnection to the sensor. When installing a new sensor, ap-ply a pipe sealant or thread sealant to the sensor threads.

Pressure Transducers — If the PIC pressure read-ings for the solution pump is within acceptable ranges butthose readings do not agree with manually obtained read-ings, the pressure transducer(s) should be replaced.

CHECK PRESSURE TRANSDUCERS —To take a manualreading of discharge solution pump attach a pressure gage tothe service valve on the pump(s). See Fig. 5, for the servicevalve location(s). When the pump(s) is off, the correct pres-sure should be <20 psia (138 kPa). When the pump(s) is on,the correct pressure should be >25 psia (172 kPa). See Pre-Start section, page 66.

REPLACING TRANSDUCERS — Since the PIC does notallow transducers to be calibrated, they must be replaced ifthey are malfunctioning. Because the transducers are mountedon Schrader fittings, there is no need to break the chiller vacuumto change the transducers. Disconnect the transducer wiringby pulling up on the locking tab while pulling up on the weather-tight connecting plug from the end of the transducer. Do notpull on the transducer wires. Unscrew the transducer fromthe Schrader fitting. When installing a new transducer, donot use pipe sealer, which can plug the sensor. Put the plugconnector back on the sensor and snap it into place. Checkfor chiller leaks.

Control Algorithm Checkout Procedure — Oneof the tables in the LID SERVICE menu is CONTROLALGORITHM STATUS. This table contains 4 maintenancescreens which may be viewed on the LID to see how a par-ticular control algorithm is operating; that is, to see whatparameters and values the PIC is using to control the chiller.The 4 screens are:

COOLING Capacity ControlShows all values used to calcu-late chilled water/brine controlpoint.

APPROACH PerformanceProvides details on all DeltaTs, approaches, and absorberloss.

OVERRIDE Override AlertDisplays the strong LiBrleaving GEN and condensatetemperatures.

CONCENTR ConcentrationStatus

Displays the conditions atconcentration Points 6, 8, 6X,and 8X.

These maintenance tables are very useful in determininghow the control temperature is calculated, how the heat ex-changer is performing, and the status of absorber loss, cycletemperatures, and concentrations.

Control Test — The control test feature can check thethermistor temperature sensors, pressure transducers, pumpsand their associated flow switches, control assembly, and othercontrol outputs. For example, the test can help to determinewhether a switch is defective or a pump relay is not oper-ating. For more details on control tests, see the sections, PICControl Tests, page 30, and Perform an Automated ControlTest, page 56.

Control Modules

Turn controller power off before servicing controls. Thisensures safety and prevents damage to the controller.

The processor module (PC6400), slave PSIO modules, andthe local interface device (LID) module perform continuousdiagnostic evaluations of the hardware to determine its con-dition. Proper operation of all modules is indicated by LEDs(light-emitting diodes) located on the side of the LID and onthe front surfaces of the PC6400, and slave PSIO module.

RED LED — If the LED blinks continuously at a 2-secondrate, it indicates proper operation. If it is lit continuously, itindicates a problem requiring replacement of the module. Offcontinuously indicates that the power should be checked. Ifthe red LED blinks 3 times per second, a software error hasbeen discovered and the module must be replaced. If thereis no input power, check fuses and the circuit breaker. If thefuses are good, check for a shorted secondary of the trans-former or, if power is present to the module, replace themodule.

94

GREEN LEDS — There are one or 2 green LEDs on eachtype of module. These LEDs indicate the communication sta-tus between different parts of the controller and the networkmodules as follows:LID ModuleUpper LED — Communication with CCN network if present;blinks when communication occurs.Lower LED — Communication with PC6400 module; it mustblink every 5 to 8 seconds when the LID default screen isdisplayed.PC6400 Module

Green LID — Communication with the slave PSIO; it mustblink continuously.

Yellow LID — Communication with the LID and other CCNdevices; it must blink every 3 to 5 seconds.Slave PSIO ModuleGreen LED Closest to Communications Connection —Communication with PC6400 module; it must blinkcontinuously.

Notes on Module Operation1. The chiller operator monitors and modifies configura-

tions in the microprocessor through the 4 softkeys andthe LID. Communication with the LID and the PC6400module is accomplished through the CCN bus. The com-munication between the PC6400, slave PSIO is accom-plished through the sensor bus, which is a 3-wire cable.On the sensor bus terminal strips (COMM3), Terminal 1of the PC6400 module is connected to Terminal 1 of eachof the other modules. Terminals 2 and 3 are connected inthe same manner. If a Terminal 2 wire is connected toTerminal 1, the system does not work.

2. If a green LED is on continuously, check the communi-cation wiring. If a green LED is off, check the red LEDoperation. If the red LED is normal, check the moduleaddress switches. Proper addresses are:

MODULE ADDRESSING (COMM3)ADDRESS

S1 S2Slave PSIO-1 (Processor/Sensor

Input/Output Module) 1 7

Slave PSIO-2 3 5CCN MODULE ADDRESSING (COMM1) BUS ADDRESSPC6400 Comfort Controller 0 1LID (Local Interface Device) 0 230

If all modules indicate a communications failure, checkthe communications plug on the PC6400 module for properseating. Also check the wiring terminations (Level II —1:red, 2:wht, 3:blk; Sensor bus — 1:red, 2:wht, 3:blk). Ifthe connections are good and the condition persists, per-form an ATTACH TO NETWORK DEVICE upload ofthe PC6400 module. Enter the correct PC6400 moduleaddress (the factory-set address is Bus 0 Address1). If theATTACH TO NETWORK DEVICE upload does not elimi-nate the failure, replace the module.All system operating intelligence resides in the PC6400module. The PC6400 module monitors conditions usinginput ports on the PC6400, slave PSIO modules. Outputsare controlled by the PC6400 module and the slave PSIOmodule via the PC6400 module as well.

3. Power is supplied to modules within the control panel via21-vac power sources.The transformers are located within the power panel, withthe exception of the PC6400 module, which operates froma 24-vac power source and has its own 24-vac trans-former located within the control box.Within the power panel, TR1 supplies power to the LID,the slave PSIO module, and the 5-vac power supply forthe transducers. Another 21-vac transformer, TR2, sup-plies power to the second slave PSIO. If additional mod-ules are added, another power supply will be required.TR5 is a 24 vac power supply that powers the PC6400module.Power is connected to Terminals 1 and 2 of the powerinput connection on each module.

PC6400 Module (Fig. 52)INPUTS — Each input channel has 3 terminals; only 2 ter-minals are used. Always refer to the job-specific certified wir-ing diagrams for the correct terminal numbers.

OUTPUTS — Output is 20 vdc or 4 to 20 mA. There are 2terminals per output. Refer to the job-specific wiring dia-grams for the correct terminal numbers.

The PC6400 hardware address and I/O selectors for theDIP switches are shown in Fig. 49.

Processor Module (Slave PSIO) (Fig. 50)INPUTS — Each input channel has 3 terminals; only 2 ofthe terminals are used. The chiller application determines whichterminals are normally used. Always refer to the job-specificwiring diagrams for the correct terminal numbers.

OUTPUTS — Output is 20 vdc. There are 3 terminals peroutput, only 2 of which are used, depending on the appli-cation. Refer to the job-specific wiring diagrams for the cor-rect terminal numbers.

95

Replacing Defective Processor Modules — Thereplacement part number is printed in a small label on thefront of the PC6400 module. The chiller model and serialnumbers are printed on the unit nameplate located on an ex-terior corner post. The proper software is factory installedby Carrier in the replacement module. When ordering a re-placement processor module (PC6400), specify complete re-placement part number, full chiller model number, and serialnumber. This new unit requires reconfiguration to the origi-nal chiller data by the installer. Follow the procedures de-scribed in the Set Up Chiller Control Configuration sectionon page 54.

Electrical shock can cause personal injury. Disconnectall electrical power before servicing.

INSTALLATION

1. Verify if the existing PC6400 module is defective by us-ing the procedure described in the Notes on Module Op-eration section, page 95, and Control Modules section,page 94. Do not select the ATTACH TO NETWORKDEVICE table if the LID displays communicationfailure.

2. Data regarding the PC6400 configuration should havebeen recorded and saved. This data will have to be re-configured into the LID. If this data is not available, fol-low the procedures described in the Set Up Chiller Con-trol Configuration section.

(–)G

(+)

CCNCOMMUNICATIONS

(COMM1)

RED

WHT, CLEAROR GRN

SHIELD

BLKCOMM3SENSOR

BUS

32

1

32

1

(–)(+)

CHASSISGND

POWERCONNECTOR

(PLUG-IN TYPEON 6400

MODULE)

NOTE: DO NOT BUNDLE POWER ANDCOMMUNICATION WIRING WITHSENSOR AND DEVICE WIRING.

OUTPUTS

INPUTS

PLUG-INTYPE

CONNECTORON 6400MODULE

24VACOR

33VDC

Carrier

LEGEND

CCN — Carrier Comfort NetworkCOMM — CommunicationsGND — GroundSW — Module Address Switches

Fig. 49 — PC6400 Module

1 2 3 4 5 6 7 8

1 2 3 4 5 6 7 8

1 2 3 4 5 6 7 8

1 2 3 4 5 6 7 8

1 2 3 4

1 2 3 4

PC6400 HARDWARE ADDRESS

SW1

SW2

SW3

SW4

SW5

SW6

LEGEND

J — Module ConnectorPSIO — Processor Sensor Input/OutputPWR — PowerS1 — Switch Setting 1S2 — Switch Setting 2

Fig. 50 — Processor Module (Slave PSIO)

96

If a CCN Building Supervisor or Service Tool is present,the module configuration should have already been up-loaded into memory; then, when the new module is in-stalled, the configuration can be downloaded from thecomputer.Any communication wires from other chillers or CCNmodules should be disconnected to prevent the new PC6400module from uploading incorrect run hours into memory.

3. To install this module, first record the SOLUTIONPUMP STARTS and the SOLUTION PUMP ONTIMEfrom the PUMPSTAT screen on the LID.

4. Turn off the power to the controls.5. Remove the old PC6400. DO NOT install the new PC6400

at this time.6. Turn on the power to the controls. When the LID screen

reappears, press the MENU softkey, then press theSERVICE softkey. Enter the password, if applicable.

Move the highlight bar down to the ATTACH TONETWORK DEVICE line. Press the SELECT soft-key. Press the ATTACH softkey. The LID will thendisplay UPLOADING TABLES, PLEASE WAIT and thendisplay, COMMUNICATIONS FAILURE. Press theEXIT softkey.

7. Turn off the power to the controls.8. Install the new PC6400 module. Turn on the power to

the controls.9. The LID will now automatically upload the new

PC6400 module.10. Access the SERVICE3 table and move the highlight

bar down to the SOLUTION PUMP STARTS line. Pressthe SELECT softkey. Increase the value to indicate thecorrect starts value as recorded in Step 3. PressENTER when you reach the correct value. Move the

highlight bar to the SOLUTION PUMP ONTIME line.Press SELECT . Increase the run hours value to indi-cate the value recorded in Step 3. Press ENTER whenyou reach the correct value.

11. Complete the PC6400 installation. Following instruc-tions in this manual, input all the proper configurations,time, date, etc.

Physical Data — For operator convenience during trouble-shooting , additional details regarding physical data may befound in Tables 16A-17B. For information on wiring, referto the wiring schematics provided for your specific jobsite.

97

Table 14A — 5K Ohm Thermistor Temperature (C) vs Resistance/Voltage Drop

TEMPERATURE VOLTAGE RESISTANCE(F) DROP (V) (OHMS)

−25.0 4.821 98010−24.0 4.818 94707−23.0 4.814 91522−22.0 4.806 88449−21.0 4.800 85486−20.0 4.793 82627−19.0 4.786 79871−18.0 4.779 77212−17.0 4.772 74648−16.0 4.764 72175−15.0 4.757 69790−14.0 4.749 67490−13.0 4.740 65272−12.0 4.734 63133−11.0 4.724 61070−10.0 4.715 59081−9.0 4.705 57162−8.0 4.696 55311−7.0 4.688 53526−6.0 4.676 51804−5.0 4.666 50143−4.0 4.657 48541−3.0 4.648 46996−2.0 4.636 45505−1.0 4.624 44066

0.0 4.613 426791.0 4.602 413392.0 4.592 400473.0 4.579 388004.0 4.567 375965.0 4.554 364356.0 4.540 353137.0 4.527 342318.0 4.514 331859.0 4.501 32176

10.0 4.487 3120211.0 4.472 3026012.0 4.457 2935113.0 4.442 2847314.0 4.427 2762415.0 4.413 2680416.0 4.397 2601117.0 4.381 2524518.0 4.366 2450519.0 4.348 2378920.0 4.330 2309621.0 4.313 2242722.0 4.295 2177923.0 4.278 2115324.0 4.258 2054725.0 4.241 1996026.0 4.223 1939327.0 4.202 1884328.0 4.184 1831129.0 4.165 1779630.0 4.145 1729731.0 4.125 1681432.0 4.103 1634633.0 4.082 1589234.0 4.059 1545335.0 4.037 1502736.0 4.017 1461437.0 3.994 1421438.0 3.968 1382639.0 3.948 1344940.0 3.927 1308441.0 3.902 1273042.0 3.878 1238743.0 3.854 1205344.0 3.828 1173045.0 3.805 1141646.0 3.781 1111247.0 3.757 1081648.0 3.729 1052949.0 3.705 1025050.0 3.679 997951.0 3.653 971752.0 3.627 946153.0 3.600 921354.0 3.575 897355.0 3.547 873956.0 3.520 851157.0 3.493 829158.0 3.464 807659.0 3.437 786860.0 3.409 766561.0 3.382 746862.0 3.353 727763.0 3.323 709164.0 3.295 691165.0 3.267 673566.0 3.238 656467.0 3.210 639968.0 3.181 623869.0 3.152 608170.0 3.123 5929

TEMPERATURE VOLTAGE RESISTANCE(F) DROP (V) (OHMS)71 3.093 578172 3.064 563773 3.034 549774 3.005 536175 2.977 522976 2.947 510177 2.917 497678 2.884 485579 2.857 473780 2.827 462281 2.797 451182 2.766 440383 2.738 429884 2.708 419685 2.679 409686 2.650 400087 2.622 390688 2.593 381489 2.563 372690 2.533 364091 2.505 355692 2.476 347493 2.447 339594 2.417 331895 2.388 324396 2.360 317097 2.332 309998 2.305 303199 2.277 2964

100 2.251 2898101 2.217 2835102 2.189 2773103 2.162 2713104 2.136 2655105 2.107 2597106 2.080 2542107 2.053 2488108 2.028 2436109 2.001 2385110 1.973 2335111 1.946 2286112 1.919 2239113 1.897 2192114 1.870 2147115 1.846 2103116 1.822 2060117 1.792 2018118 1.771 1977119 1.748 1937120 1.724 1898121 1.702 1860122 1.676 1822123 1.653 1786124 1.630 1750125 1.607 1715126 1.585 1680127 1.562 1647128 1.538 1614129 1.517 1582130 1.496 1550131 1.474 1519132 1.453 1489133 1.431 1459134 1.408 1430135 1.389 1401136 1.369 1373137 1.348 1345138 1.327 1318139 1.308 1291140 1.291 1265141 1.289 1240142 1.269 1214143 1.250 1190144 1.230 1165145 1.211 1141146 1.192 1118147 1.173 1095148 1.155 1072149 1.136 1050150 1.118 1029151 1.100 1007152 1.082 986153 1.064 965154 1.047 945155 1.029 925156 1.012 906157 0.995 887158 0.978 868159 0.962 850160 0.945 832161 0.929 815162 0.914 798163 0.898 782164 0.883 765165 0.868 750166 0.853 734

TEMPERATURE VOLTAGE RESISTANCE(F) DROP (V) (OHMS)167 0.838 719168 0.824 705169 0.810 690170 0.797 677171 0.783 663172 0.770 650173 0.758 638174 0.745 626175 0.734 614176 0.722 602177 0.710 591178 0.700 581179 0.689 570180 0.678 561181 0.668 551182 0.659 542183 0.649 533184 0.640 524185 0.632 516186 0.623 508187 0.615 501188 0.607 494189 0.600 487190 0.592 480191 0.585 473192 0.579 467193 0.572 461194 0.566 456195 0.560 450196 0.554 445197 0.548 439198 0.542 434199 0.537 429200 0.531 424201 0.526 419202 0.520 415203 0.515 410204 0.510 405205 0.505 401206 0.499 396207 0.494 391208 0.488 386209 0.483 382210 0.477 377211 0.471 372212 0.465 367213 0.459 361214 0.453 356215 0.446 350216 0.439 344217 0.432 338218 0.425 332219 0.417 325220 0.409 318221 0.401 311222 0.393 304223 0.384 297224 0.375 289225 0.366 282

98

Table 14B — 5K Ohm Thermistor Temperature (C) vs Resistance/Voltage Drop

TEMPERATURE VOLTAGE RESISTANCE(C) DROP (V) (Ohms)−40 4.896 168 230−39 4.889 157 440−38 4.882 147 410−37 4.874 138 090−36 4.866 129 410−35 4.857 121 330−34 4.848 113 810−33 4.838 106 880−32 4.828 100 260−31 4.817 94 165−30 4.806 88 480−29 4.794 83 170−28 4.782 78 125−27 4.769 73 580−26 4.755 69 250−25 4.740 65 205−24 4.725 61 420−23 4.710 57 875−22 4.693 54 555−21 4.676 51 450−20 4.657 48 536−19 4.639 45 807−18 4.619 43 247−17 4.598 40 845−16 4.577 38 592−15 4.554 38 476−14 4.531 34 489−13 4.507 32 621−12 4.482 30 866−11 4.456 29 216−10 4.428 27 633−9 4.400 26 202−8 4.371 24 827−7 4.341 23 532−6 4.310 22 313−5 4.278 21 163−4 4.245 20 079−3 4.211 19 058−2 4.176 18 094−1 4.140 17 184

0 4.103 16 3251 4.065 15 5152 4.026 14 7493 3.986 14 0264 3.945 13 3425 3.903 12 6966 3.860 12 0857 3.816 11 5068 3.771 10 9599 3.726 10 441

10 3.680 9 94911 3.633 9 48512 3.585 9 04413 3.537 8 62714 3.487 8 23115 3.438 7 85516 3.387 7 49917 3.337 7 16118 3.285 6 84019 3.234 6 53620 3.181 6 24621 3.129 5 97122 3.076 5 71023 3.023 5 46124 2.970 5 22525 2.917 5 00026 2.864 4 78627 2.810 4 58328 2.757 4 38929 2.704 4 20430 2.651 4 02831 2.598 3 86132 2.545 3 70133 2.493 3 54934 2.441 3 40435 2.389 3 26636 2.337 3 13437 2.286 3 00838 2.236 2 88839 2.186 2 77340 2.137 2 66341 2.087 2 55942 2.039 2 45943 1.991 2 36344 1.944 2 272

TEMPERATURE VOLTAGE RESISTANCE(C) DROP (V) (Ohms)45 1.898 2 18446 1.852 2 10147 1.807 2 02148 1.763 1 94449 1.719 1 87150 1.677 1 80151 1.635 1 73452 1.594 1 67053 1.553 1 60954 1.513 1 55055 1.474 1 49356 1.436 1 43957 1.399 1 38758 1.363 1 33759 1.327 1 29060 1.291 1 24461 1.258 1 20062 1.225 1 15863 1.192 1 11864 1.160 1 07965 1.129 1 04166 1.099 1 00667 1.069 97168 1.040 93869 1.012 90670 0.984 87671 0.949 83672 0.920 80573 0.892 77574 0.865 74775 0.838 71976 0.813 69377 0.789 66978 0.765 64579 0.743 62380 0.722 60281 0.702 58382 0.683 56483 0.665 54784 0.648 53185 0.632 51686 0.617 50287 0.603 48988 0.590 47789 0.577 46690 0.566 45691 0.555 44692 0.545 43693 0.535 42794 0.525 41995 0.515 41096 0.506 40297 0.496 39398 0.486 38599 0.476 376

100 0.466 367101 0.454 357102 0.442 346103 0.429 335104 0.416 324105 0.401 312106 0.386 299107 0.370 285

99

Table 15A — 100K Ohm Thermistor Temperature (F) vs Resistance/Voltage Drop

TEMPERATURE VOLTAGE RESISTANCE(F) DROP (V) (OHMS)442 0.300 395441 0.303 399440 0.305 403439 0.308 407438 0.311 410437 0.314 414436 0.317 418435 0.319 422434 0.322 426433 0.325 430432 0.328 435431 0.331 439429 0.337 447428 0.340 452426 0.346 460425 0.349 465424 0.352 469423 0.356 474422 0.359 479421 0.362 483420 0.366 488419 0.369 493418 0.372 498417 0.376 503416 0.379 508415 0.383 513414 0.386 518413 0.390 523412 0.393 528411 0.397 534410 0.401 539409 0.404 545408 0.408 550407 0.412 556406 0.416 561405 0.420 567404 0.424 573403 0.428 579402 0.432 585401 0.436 591400 0.440 597399 0.444 603398 0.448 609397 0.452 615396 0.456 622395 0.461 628394 0.465 635393 0.470 642392 0.474 648391 0.479 655390 0.483 662389 0.488 669388 0.492 676387 0.497 683386 0.502 691385 0.507 698384 0.511 705383 0.516 713382 0.521 721381 0.526 728380 0.531 736379 0.537 744378 0.542 752377 0.547 760376 0.552 769375 0.558 777374 0.563 785373 0.568 794372 0.574 803371 0.580 812370 0.585 821369 0.591 830368 0.597 839367 0.602 848366 0.608 858365 0.614 867364 0.620 877363 0.626 887362 0.633 897361 0.639 907360 0.645 917359 0.651 927358 0.658 938357 0.664 948356 0.671 959355 0.677 970354 0.684 981353 0.691 993352 0.698 1,004351 0.705 1,015350 0.712 1,027349 0.719 1,039348 0.726 1,051347 0.733 1,063346 0.740 1,076345 0.748 1,088344 0.755 1,101343 0.763 1,114

TEMPERATURE VOLTAGE RESISTANCE(F) DROP (V) (OHMS)342 0.770 1,127341 0.778 1,140340 0.786 1,154339 0.793 1,168338 0.801 1,181337 0.809 1,196336 0.817 1,210335 0.826 1,124334 0.834 1,239333 0.842 1,254332 0.851 1,269331 0.859 1,284330 0.868 1,300329 0.876 1,316328 0.885 1,332327 0.894 1,348326 0.903 1,364325 0.912 1,381324 0.921 1,398323 0.930 1,415322 0.940 1,433321 0.949 1,450320 0.959 1,468319 0.968 1,487318 0.978 1,505317 0.988 1,524316 0.998 1,543315 1.008 1,562314 1.018 1,582313 1.028 1,602312 1.038 1,622311 1.049 1,643310 1.059 1,664309 1.070 1,865308 1.081 1,706307 1.091 1,728306 1.102 1,751305 1.113 1,773304 1.124 1,796303 1.136 1,819302 1.147 1,843301 1.158 1,867300 1.170 1,891299 1.182 1,916298 1.193 1,941297 1.205 1,966296 1.217 1,992295 1.229 2,018294 1.242 2,045293 1.254 2,072292 1.266 2,100291 1.279 2,128290 1.292 2,156289 1.304 2,185288 1.317 2,214287 1.330 2,244286 1.343 2,274285 1.357 2,305284 1.370 2,336283 1.384 2,368282 1.397 2,400281 1.411 2,433280 1.425 2,466279 1.439 2,500278 1.453 2,535277 1.467 2,570276 1.481 2,605275 1.495 2,641274 1.510 2,678273 1.525 2,715272 1.539 2,753271 1.554 2,792270 1.569 2,831269 1.584 2,871268 1.600 2,912267 1.615 2,953266 1.630 2,995265 1.646 3,037264 1.662 3,081263 1.677 3,125262 1.693 3,170261 1.709 3,215260 1.725 3,262259 1.742 3,309258 1.758 3,357257 1.774 3,405256 1.791 3,455255 1.808 3,505254 1.825 3,557253 1.842 3,609252 1.859 3,662251 1.876 3,716250 1.893 3,771249 1.910 3,827248 1.928 3,884247 1.945 3,942246 1.963 4,001245 1.981 4,061

TEMPERATURE VOLTAGE RESISTANCE(F) DROP (V) (OHMS)244 1.999 4,122243 2.017 4,184242 2.035 4,247241 2.053 4,312240 2.071 4,377239 2.089 4,444238 2.108 4,512237 2.127 4,581236 2.145 4,651235 2.164 4,723234 2.183 4,796233 2.202 4,870232 2.221 4,946231 2.240 5,023230 2.259 5,101229 2.278 5,181228 2.297 5,262227 2.317 5,345226 2.336 5,429225 2.356 5,515224 2.375 5,602223 2.395 5,692222 2.415 5,782221 2.435 5,875220 2.455 5,969219 2.474 6,065218 2.494 6,163217 2.515 6,262216 2.535 6,364215 2.555 6,467214 2.575 6,573213 2.595 6,680212 2.615 6,790211 2.636 6,901210 2.656 7,015209 2.677 7,131208 2.697 7,249207 2.717 7,369206 2.738 7,492205 2.758 7,617204 2.779 7,745203 2.800 7,875202 2.820 8,008201 2.841 8,143200 2.861 8,281199 2.882 8,422198 2.902 8,565197 2.923 8,712196 2.944 8,861195 2.964 9,013194 2.985 9,169193 3.005 9,327192 3.026 9,489191 3.047 9,654190 3.067 9,822189 3.088 9,993188 3.108 10,169187 3.128 10,347186 3.149 10,530185 3.169 10,716184 3.190 10,906183 3.210 11,100182 3.230 11,297181 3.250 11,499180 3.271 11,706179 3.291 11,916178 3.311 12,131177 3.331 12,350176 3.351 12,574175 3.370 12,803174 3.390 13,037173 3.410 13,275172 3.430 13,519171 3.449 13,768170 3.469 14,022169 3.488 14,281168 3.507 14,546167 3.527 14,817166 3.546 15,094165 3.565 15,377164 3.584 15,665163 3.603 15,960162 3.621 16,262161 3.640 16,570160 3.659 16,885159 3.677 17,207158 3.696 17,536157 3.714 17,872156 3.732 18,215155 3.750 18,567154 3.768 18,926153 3.785 19,293152 3.803 19,669151 3.821 20,053150 3.838 20,445149 3.855 20,846148 3.872 21,257147 3.889 21,677

100

Table 15A — 100K Ohm Thermistor Temperature (F) vs Resistance/Voltage Drop (cont)

TEMPERATURE VOLTAGE RESISTANCE(F) DROP (V) (OHMS)146 3.906 22,106145 3.923 22,545144 3.940 22,995143 3.956 23,454142 3.972 23,925141 3.988 24,406140 4.004 24,898139 4.020 25,402138 4.036 25,917137 4.052 26,445136 4.067 26,985135 4.082 27,538134 4.097 28,103133 4.112 28,682132 4.127 29,275131 4.142 29,882130 4.157 30,504129 4.171 31,140128 4.185 31,791127 4.199 32,458126 4.213 33,142125 4.227 33,842124 4.240 34,558

TEMPERATURE VOLTAGE RESISTANCE(F) DROP (V) (OHMS)123 4.254 35,293122 4.267 36,045121 4.280 36,816120 4.293 37,606119 4.306 38,415118 4.319 39,243117 4.331 40,093116 4.344 40,964115 4.356 41,856114 4.368 42,771113 4.380 43,708112 4.391 44,669111 4.403 45,655110 4.414 46,665109 4.426 47,701108 4.437 48,763107 4.448 49,853106 4.459 50,970105 4.469 52,116104 4.480 53,291103 4.490 54,497102 4.500 55,734101 4.510 57,003

TEMPERATURE VOLTAGE RESISTANCE(F) DROP (V) (OHMS)100 4.520 58,30599 4.530 59,64198 4.539 61,01297 4.549 62,42096 4.558 63,86495 4.567 65,34694 4.576 66,86893 4.585 68,43092 4.594 70,03491 4.603 71,68190 4.611 73,37289 4.619 75,10888 4.627 76,89287 4.636 78,72486 4.643 80,60585 4.651 82,53884 4.659 84,52383 4.666 86,56382 4.674 88,65981 4.681 90,81380 4.688 93,02779 4.695 95,30278 4.702 97,64077 4.709 100,044

Table 15B — 100K Ohm Thermistor Temperature (C) vs Resistance/Voltage Drop

TEMPERATURE VOLTAGE RESISTANCE(C) DROP (V) (OHMS)228 0.299 394227 0.304 401226 0.309 407225 0.314 414224 0.319 422223 0.324 429222 0.329 436221 0.335 444220 0.340 452219 0.346 460218 0.351 468217 0.357 476216 0.363 484215 0.369 493214 0.375 502213 0.381 511212 0.388 520211 0.394 530210 0.401 539209 0.407 549208 0.414 559207 0.421 569206 0.428 580205 0.436 591204 0.443 602203 0.451 613202 0.458 624201 0.466 636200 0.474 648199 0.482 661198 0.490 673197 0.499 686196 0.508 699195 0.516 713194 0.525 727193 0.534 741192 0.544 755191 0.553 770190 0.563 785189 0.573 801188 0.583 817187 0.593 833186 0.604 850185 0.614 867184 0.625 885183 0.636 903182 0.648 921181 0.659 940180 0.671 959179 0.683 979178 0.695 999177 0.707 1020176 0.720 1041175 0.733 1063174 0.746 1086173 0.760 1109172 0.773 1132171 0.787 1157170 0.801 1181169 0.816 1207168 0.831 1233167 0.846 1260166 0.861 1287165 0.876 1316164 0.892 1345163 0.908 1374162 0.925 1405161 0.942 1436

TEMPERATURE VOLTAGE RESISTANCE(C) DROP (V) (OHMS)160 0.959 1468159 0.976 1501158 0.994 1535157 1.012 1570156 1.030 1606155 1.049 1643154 1.068 1681153 1.087 1720152 1.107 1759151 1.127 1801150 1.147 1843149 1.168 1886148 1.189 1931147 1.210 1977146 1.232 2024145 1.254 2072144 1.276 2122143 1.299 2173142 1.323 2226141 1.346 2280140 1.370 2336139 1.394 2394138 1.419 2453137 1.444 2514136 1.470 2577135 1.495 2641134 1.522 2708133 1.548 2776132 1.575 2847131 1.603 2920130 1.630 2995129 1.658 3072128 1.687 3152127 1.716 3234126 1.745 3318125 1.774 3405124 1.804 3495123 1.835 3588122 1.865 3684121 1.896 3782120 1.928 3884119 1.959 3989118 1.991 4097117 2.024 4209116 2.056 4325115 2.089 4444114 2.123 4567113 2.156 4694112 2.190 4825111 2.224 4961110 2.259 5101109 2.294 5246108 2.328 5395107 2.364 5550106 2.399 5710105 2.435 5875104 2.470 6046103 2.506 6222102 2.543 6405101 2.579 6594100 2.615 679099 2.652 699298 2.689 720197 2.726 741896 2.763 764395 2.800 787594 2.837 811693 2.874 8365

TEMPERATURE VOLTAGE RESISTANCE(C) DROP (V) (OHMS)92 2.911 8 62491 2.948 8 89190 2.985 9 16989 3.022 9 45688 3.059 9 75487 3.096 10 06386 3.133 10 38385 3.169 10 71684 3.206 11 06183 3.242 11 41882 3.279 11 78981 3.315 12 17580 3.351 12 57479 3.386 12 99078 3.422 13 42177 3.457 13 86976 3.492 14 33475 3.527 14 81774 3.561 15 32073 3.595 15 84272 3.629 16 38471 3.662 16 94970 3.696 17 53669 3.728 18 14668 3.761 18 78167 3.793 19 44266 3.824 20 13065 3.855 20 84664 3.886 21 59263 3.916 22 36962 3.946 23 17761 3.976 24 02060 4.004 24 89859 4.033 25 81358 4.061 26 76757 4.088 27 76256 4.115 28 80055 4.142 29 88254 4.168 31 01153 4.194 32 19052 4.219 33 42051 4.243 34 70450 4.267 36 04549 4.291 37 44648 4.314 38 90947 4.336 40 43946 4.358 42 03745 4.380 43 70844 4.401 45 45643 4.421 47 28442 4.441 49 19641 4.461 51 19740 4.480 53 29139 4.498 55 48438 4.516 57 78037 4.534 60 18636 4.551 62 70535 4.567 65 34634 4.583 68 11533 4.599 71 01732 4.614 74 06131 4.629 77 25430 4.643 80 60529 4.657 84 12228 4.671 87 81427 4.684 91 69126 4.696 95 76425 4.709 100 044

101

Table 16A — 16JB 150 LB Waterbox Cover Weights (English)

16JBUNIT SIZE

CONDENSER COVER ABSORBER COVER EVAPORATOR COVERWith Nozzle Without Nozzle With Nozzle Without Nozzle With Nozzle Without Nozzle

010 40 n/a 99 104 101 104012 40 n/a 99 104 101 104014 40 n/a 99 104 101 104018 44 n/a 181 190 187 187021 44 n/a 181 190 187 187024 73 n/a 253 286 280 287028 73 n/a 253 286 280 287032 73 n/a 309 342 335 342036 73 n/a 309 342 335 342041 79 n/a 403 476 467 476047 79 n/a 403 476 467 476054 150 n/a 339 421 476 500057 150 n/a 339 421 476 500061 150 n/a 432 514 624 655068 150 n/a 432 514 624 655

Table 16B — 16JB 150 LB Waterbox Cover Weights (SI)

16JBUNIT SIZE

CONDENSER COVER ABSORBER COVER EVAPORATOR COVERWith Nozzle Without Nozzle With Nozzle Without Nozzle With Nozzle Without Nozzle

010 18 n/a 45 47 46 47012 18 n/a 45 47 46 47014 18 n/a 45 47 46 47018 20 n/a 82 86 85 85021 20 n/a 82 86 85 85024 33 n/a 115 130 127 130028 33 n/a 115 103 127 130032 33 n/a 140 155 152 155036 33 n/a 140 155 152 155041 36 n/a 183 216 212 216047 36 n/a 183 216 212 216054 68 n/a 154 191 216 227057 68 n/a 154 191 216 227061 68 n/a 196 233 283 297068 68 n/a 196 233 283 297

102

Table 17A — 16JB Heat Exchanger Weights (English)

16JBUNIT SIZE

ABSORBER/EVAPORATOR

(lb)

GENERATOR/CONDENSER

(lb)

LiBr(gal)

REFRIGERANT(gal)

OPERATINGWEIGHT

(lb)

SHIPPINGWEIGHT

(lb)010 6600 2700 110 40 11840 9300012 6600 2730 110 40 12000 9330014 6670 2730 110 40 12080 9400018 8350 3450 160 50 15460 11800021 8910 3690 160 50 16350 12600024 10520 4380 200 65 19160 14900028 10670 4440 200 65 19710 15110032 13250 5550 240 70 24190 18800036 13530 5670 240 70 24730 19200041 18300 5550 300 90 30370 23850047 18800 5550 300 90 31150 24350054 21800 7000 300 175 37200 28800057 22300 7000 300 175 38040 29300061 26800 7000 360 265 43780 33800068 28300 7400 360 265 46190 35700

Table 17B — 16JB Heat Exchanger Weights (SI)

16JBUNIT SIZE

ABSORBER/EVAPORATOR

(kg)

GENERATOR/CONDENSER

(kg)

LiBr(L)

REFRIGERANT(L)

OPERATINGWEIGHT

(kg)

SHIPPINGWEIGHT

(kg)010 2994 1225 416.4 151.4 5371 4218012 2994 1238 416.4 151.4 5443 4232014 3026 1238 416.4 151.4 5479 4264018 3788 1565 605.6 189.3 7013 5352021 4042 1674 605.6 189.3 7416 5715024 4772 1987 757.0 246.0 8691 6759028 4840 2014 757.0 246.0 8940 6854032 6010 2517 908.4 264.9 10973 8528036 6137 2572 908.4 264.9 11218 8709041 8301 2517 1135.5 340.6 13776 10818047 8528 2517 1135.5 340.6 14130 11045054 9888 3175 1135.5 662.3 16874 13064057 10115 3175 1135.5 662.3 17255 13290061 12156 3175 1362.6 1003.0 19859 15332068 12837 3357 1362.6 1003.0 20952 16194

103

INDEXAbbreviations and Explanations, 4Abnormal Shutdown, Actions After, 73Absorber Loss Determination, 76Absorber/Condenser (Inspect the Heat ExchangerTubes), 75

Absorption Cycle, Basic, 4Accidental Start-Up, To Prevent, 56Accumulation Rate,Determine Noncondensable, 65Noncondensable, 76

Adding Octyl Alcohol, 78Alarm Contact, Spare, 47Alarms and Alerts, 16Alcohol, Adding Octyl, 78Alerts, Alarms and, 16Analog Signal, 12Analysis, Solution, 78Attach to Network Device Control, 51Attaching Other CCN Modules, 51Automated Control Test, Perform an, 56Automated Test, 30Auxiliary Equipment (Instruct the Operator), 65Below Freezing Conditions,Chiller Shutdown, 73Start-Up After, 73

Capacity Control, 22Capacity Controls, Final Adjustment of, 58Capacity Overrides, 33Capacity Valve Actuator Test, 32Capacity Valve Control, Manual, 34Carrier Comfort Network (CCN) Interface, 51Cavitation Protection, Refrigerant Pump,Low Concentration Limit, 70

CCN Modules, Attaching Other, 51Change the LID Configuration, If Necessary, 54Change the LID Display From English toMetric Units, To, 50

Change the Password, To, 50Charge Adjustment,Final Refrigerant, 58Refrigerant, 79

Charge Chiller With Solution and Refrigerant, 55Charging Solution, 55Charging Solution for Conditions Other Than Nominal, 55Charging, Initial Refrigerant, 56Check Method 1, Concentration Protection DuringStart-Up/Pulldown Failures, 68

Check Method 2, Control Override and FaultProtection, 70

Checklist, Start-Up, CL-1Chilled Water Control, Entering, 22Chilled Water Recycle Mode, 70Chiller Control Configuration, Set Up, 54Chiller Cycles (Instruct the Operator), 65Chiller Description, 4Chiller Evacuation, 54, 77Chiller Information and Nameplate, 4Chiller Leak Test, 76Chiller Operating Conditions, Check, 59Chiller Parts, Ordering Replacement, 85Chiller Shutdown — Below Freezing Conditions, 73Chiller Shutdown — Normal Conditions, 73Chiller Shutdown, Check, 59Chiller Solution Cycle, Equilibrium Diagram and, 5Chiller Timers, 30Completion (Hermetic Pump Inspection), 82Components, PIC System, 12Concentration Control, Cycle-Guard™, 70Concentration Control, PIC, Solution HighConcentration, 34

Concentration Protection During Start-Up/PulldownFailures, Check Method 1, 68

Condensing Water Tube Scale, 85Configuration,

Input the Service, 54Set Up Chiller Control, 54

Control Algorithm Checkout Procedure, 94Control Center, Inspect the, 74Control Checkout and Adjustments, Initial, 56Control Configuration, Set Up Chiller, 54Control Modules, 94Control Override and Fault Protection, Check

Method 2, 70Control Point Deadband, 22Control System (Instruct the Operator), 65Control Test, 94Control Test, Perform an Automated, 56Control Tests, PIC, 30Control Wiring, 34Control,

Capacity, 22Ramp Loading, 32Solution Concentration,33

Controller Identification, Modify, If Necessary, 54Controls, 12Controls,

Remote Start/Stop, 34Safety, 47

Crystallization, Severe, 84Cycle-Guard Concentration Control, 70Cycle-Guard System Operation, 79Data, Physical, 97Date, Input Time and, 54Deadband, Control Point, 22Decrystallization Using the PIC Controls, 84Decrystallization, Solution, 82Defective Processor Modules, Replacing, 96Definitions (Controls), 12Description, Chiller, 4Design Set Points, Input the, 54Desolidification Mode, DESOLID, 70Digital Signal, 12Dilution Cycle, Power Loss, 72Disassembly (Hermetic Pump), 82Display Screens, LID, 22Dry Nitrogen (Chiller Leak Test), 77Duties, Operator, 72English to Metric Units, To Change the

LID Display From, 50Entering Chilled Water Control, 22Equilibrium Diagram and Chiller Solution Cycle, 5Equipment Configuration, Modify, As Necessary, 54Equipment Service Parameters, Input, As Necessary, 54Evacuation, Chiller, 54, 77Evaporator (Inspect the Heat Exchanger Tubes), 75Explanations, Abbreviations and, 4Extended Shutdown, Start-Up After, 73Failure, Warm-Up, 68Fault Protection, Check Method 2, Control

Override and, 70Field Piping, Inspect, 52Field Wiring, Inspect, 52Final Adjustment of Capacity Controls, 58First Stage (Solution Concentration Control), 33Flow Circuits, 4Green LEDs, 95Heat Exchanger Tubes, Inspect the, 75Hermetic Pump Inspection, 82Holidays, To Schedule, 50

104

INDEX (cont)Information and Nameplate, Chiller, 4Inhibitor (Solution), 78Initial Control Checkout and Adjustment, 56Initial Refrigerant Charging, 56Initial Start-Up, 58Initial Start-Up, Before, 52Input Equipment Service Parameters, As Necessary, 54Input the Design Set Points, 54Input the Local Occupied Schedule (OCCPC01S), 54Input the Service Configuration, 54Input Time and Date, 54Inputs Test,PC6400, 30Slave PSIO-1, 31Slave PSIO-2, 32

Inputs, Spare Safety, 47Inspect Field Piping, 52Inspect Field Wiring, 52Inspect the Control Center, 74Inspect the Heat Exchanger Tubes, 75Inspection, Hermetic Pump, 82Inspection (Hermetic Pump), 82Instruct the Operator, 65Instructions, Operating, 72Internal Service, 79Introduction, 4Job Data and Tools Required, 52Leak Test, Chiller, 76Leaks, Water, 75LED, Red, 94LEDs, Green, 95LID Configuration, Change the, If Necessary, 54LID Display From English to Metric Units,To Change the, 50

LID Display Messages, Checking the, 85LID Display Screens, 22LID Menu Items, 16LID Operation and Menus, 15LID Operations Using the Softkeys, Basic, 20LID, Local Interface Device, 15Limited Shutdown, Start-Up After, 72Lithium Bromide (LiBr) Solution, Handling, 55Lithium Bromide from Refrigerant, Removing, 78Local Interface Device (LID), 15Local Occupied Schedule (OCCPC01S), Input the, 54Local Start-Up, 65Log Out of Network Device, 52Log Sheets, 74Long Interval Test (Standing Vacuum Test), 53Low Concentration Limit, Refrigeration PumpCavitation Protection, 70

Low Refrigerant Level Operation, Check, 65Low Temperature Cutout Adjustment, 79Machine Construction, 4Maintenance (Instruct the Operator), 65Maintenance Procedures, 74Maintenance,Every 2 Months, 74Every 3 Years, 74Every 5 Years or 50,000 Hours (Whichever

Comes First), 74Every 6 Months, 74Every Day, 74Every Month, 74Every Year, 74Periodic Scheduled, 74

Manual Capacity Valve Control, 34Manual Exhaust Procedure, Purge, 75Master Comfort Controller (PC6400) Module, 15Menu Items, LID, 16Menus, LID Operation and, 15

Messages, Checking the LID Display, 85Metric Units, To Change the LID Display From

English to, 50Mode,

Chilled Water Recycle, 70(DESOLID), Desolidification, 70Normal Run, 68Ramp Loading, 68

Modify Controller Identification, If Necessary, 54Modify Equipment Configuration, As Necessary, 54Module (Slave PSIO), Processor, 95Module Operation, Notes On, 95Module,

(Slave PSIO-1), Processor/Sensor Input/Output, 15Master Comfort Controller (PC6400), 15PC6400, 95Slave PSIO-2, 15

Modules,Control, 94Replacing Defective Processor, 96

Nameplate, Chiller Information and, 4Network Device Control, Attach to, 51Network Device, Log Out of, 52Nitrogen, Dry (Chiller Leak Test), 77Noncondensable Accumulation Rate, 76Noncondensable Accumulation Rate, Determine, 65Normal Conditions, Chiller Shutdown, 73Normal Run Mode, 68Occupancy Schedule, 30Occupied Schedule (OCCPC01S), Input the Local, 54Octyl Alcohol, Adding, 78Ontime, Service, 74Operating Conditions, Check Chiller, 59Operating Controls Monthly, Check Safety and, 74Operating Instructions, 72Operation and Menus, LID, 15Operation,

Cycle-Guard System, 79Service, 47Time Schedule, 21

Operations Knowledge (Instruct the Operator), 65Operations, Override, 20Operator Duties, 72Operator, Instruct the, 65Ordering Replacement Chiller Parts, 85Outputs Test,

PC6400, 31Slave PSIO-1, 31

Override Operations, 20Overrides, Capacity, 33Overview

Controls, 12LID Operation and Menus, 15Troubleshooting Guide, 85

Parts, Ordering Replacement Chiller, 85Password, 54Password, To Change the, 50PC6400 Inputs Test, 30PC6400 Module, 95PC6400 Module,

Inputs, 95Outputs, 95

PC6400 Module, Master Comfort Controller, 15PC6400 Outputs Test, 31Periodic Scheduled Maintenance, 74Physical Data, 97PIC Concentration Control, Solution High

Concentration, 34PIC Control Tests, 30PIC System Components, 12PIC System Functions, 22

105

INDEX (cont)Plotting the Solution Cycle, 11Point Status, To View, 20Power Interruption, Actions After, 74Power Loss Dilution Cycle, 72Power-Up, 52Pre-Start (Start-Up/Shutdown/Recycle Sequence), 66Preliminary Check (Initial Start-Up), 58Preparation (Preliminary Check, Initial Start-Up), 58Pressure Transducers, 15, 94Prevent Accidental Start-Up, To, 56Processor Module (Slave PSIO), 95Processor Module (Slave PSIO),Inputs, 95Outputs, 95

Processor Modules, Replacing Defective, 96Processor/Sensor Input/Output Module (Slave PSIO-1), 15Proportional Bands and Gain, 22PSIO-1 Inputs Test, Slave, 31PSIO-1 Outputs Test, Slave, 31PSIO-2 Inputs Teest, Slave, 32Pump Inspection, Hermetic, 82Purge Manual Exhaust Procedure, 75Purge Operation (Instruct the Operator), 65Purge System, 11Ramp Loading Control, 32Ramp Loading Mode, 68Reassembly (Hermetic Pump), 82Recycle Mode, Chilled Water, 70Red LED, 94Refrigerant Charge Adjustment, 79Refrigerant Charge Adjustment, Final, 58Refrigerant Charging, Initial, 56Refrigerant Level Operation, Check Low, 65Refrigerant Sampling, Solution or, 77Refrigerant Tracer (Chiller Leak Test), 77Refrigerant,Charge Chiller with Solution and, 55Removing Lithium Bromide from, 78

Refrigeration Pump Cavitation Protection, LowConcentration Limit, 70

Relay Boards, Six-Pack, 15Relay, Tower Fan, 34Remote Start/Stop Controls, 34Removing Lithium Bromide from Refrigerant, 78Repair the Chiller Leak, Retest, and Applya Standing Vacuum Test, 77

Replacement Chiller Parts, Ordering, 85Replacing Defective Processor Modules, 96Reset, Water/Brine, 47Resistance Check (Temperature Sensors), 85Run Mode, Normal, 68Rupture Disc and Piping, Inspect, 74Safety and Operating Controls Monthly, Check, 74Safety Considerations, 1Safety Controls, 47Safety Devices and Procedures (Instruct the Operator), 65Safety Inputs, Spare, 47Safety Shutdown, 72Sample, Solution, 78Sample Range, 30Sampling, Solution or Refrigerant, 77Scale, Condensing Water Tube, 85Schedule (OCCPC01S), Input the Local Occupied, 54Schedule, Holidays, to, 50Scheduled Maintenance, Periodic, 74Screens, LID Display, 22Second Stage (Solution Concentration Control), 33Sensor Input/Output Module (Slave PSIO-1), 15Sensors,Checking Temperature, 85Temperature, 15

Sequence, Start-Up/Shutdown/Recycle, 65Service Configuration, Input the, 54Service Menu Tables, To Access the, 22Service Ontime, 74Service Operation, 47Service Screens, To Access the,47Service Valve Diaphragm Replacement, 79Service, Internal, 79Set Points,

Input the Design, 54To View and Change, 22

Set Up Chiller Control Configuration, 54Severe Crystallization, 84Short Interval Test (Standing Vacuum), 53Shutdown — Below Freezing Conditions, Chiller, 73Shutdown — Normal Conditions, Chiller, 73Shutdown Sequence, 70Shutdown,

Actions After Abnormal, 73Check Chiller, 59Safety, 72

Signal,Analog, 12Digital, 12

Six-Pack Relay Boards, 15Slave PSIO-1 Inputs Test, 31Slave PSIO-1 Outputs Test, 31Slave PSIO-2 Inputs Test, 32Slave PSIO-2 Module, 15Slave PSIO, Processor Module, 95Softkeys, Basic LID Operations, Using the, 20Solution Analysis, 78Solution and Refrigerant, Charge Chiller With, 55Solution Concentration Control, 33Solution Concentration Control,

First Stage, 33Second Stage, 33Third Stage, 33

Solution Cycle,Equilibrium Diagram and Chiller, 5Plotting the, 11

Solution Decrystallization, 82Solution or Refrigerant Sampling, 77Solution Sample, 78Solution,

Charging, 55Handling Lithium Bromide (LiBr), 55Inhibitor, 78

Spare Alarm Contact, 47Spare Safety Inputs, 47Standing Vacuum Test, 53Start the Chiller, 72Start-Up After Below Freezing Conditions, 73Start-Up After Extended Shutdown, 73Start-Up After Limited Shutdown, 72Start-Up Checklist, CL-1Start-Up,

Before Initial, 52Initial, 58Local, 65

Start-Up, Operation, and Maintenance Manuals(Instruct the Operator), 65

Start-Up/Pulldown Failures, Check Method 1,Concentration Protection During, 68

Start-Up/Shutdown/Recycle Sequence, 65Start/Stop Controls Remote, 34Starting Chiller, Before, 72Status, To View Point, 20

106

INDEX (cont)Stop the Chiller, 72Switch,Generator Temperature Thermoswitch, 47High Stage Generator Pressure Switch, 47

Temperature Accuracy, Check (CheckingTemperature Sensors), 94

Temperature Sensors (PIC System Components), 15Temperature Sensors, Checking, 85Test,Automated, 30Capacity Valve Actuator, 32Chiller Leak, 76Control, 94Long Interval, 53PC6400 Inputs, 30PC6400 Outputs, 31Perform an Automated Control, 56Short Interval, 53Slave PSIO-1 Inputs, 31Slave PSIO-1 Outputs, 31Slave PSIO-2 Inputs, 32Standing Vacuum, 53

Tests, PIC Control, 30Third Stage (Solution Concentration Control), 33Time and Date, Input, 54Time Schedule Operation, 21Timers, Chiller, 30

Tools Required, Job Data and, 52Tower Fan Relay, 34Tracer, Refrigerant (Chiller Leak Test), 77Transducers,

Check Pressure, 94Pressure, 15, 94Replacing, 94

Treatment, Water, 75, 85Troubleshooting Guide, 85Tube Scale, Condensing Water, 85Tubes, Inspect the Heat Exchanger, 75Using the Softkeys, Basic LID Operations, 20Vacuum Test, Standing, 53View and Change Set Points, To, 22Voltage Drop (Temperature Sensors), 94Warm-Up (Start-Up/Shutdown/Recycle Sequence), 68Warm-Up Failures, 68Water Leaks, 75Water Treatment, 75, 85Water/Brine,

Reset Type 1, 47Reset Type 2, 47Reset Type 3, 47

Water/Brine Reset, 47Wiring,

Control, 34Inspect Field, 52

107

INITIAL START-UP CHECKLIST FOR16JB SINGLE-EFFECT HERMETIC ABSORPTION LIQUID CHILLER

(Remove and use for job file.)

MACHINE INFORMATION:

NAME JOB NO.

ADDRESS MODEL

CITY STATE ZIP

SUPPLY STEAM PRESSURE

STEAM PRESSURE AT GENERATOR

DESIGN DATA:

TONS FLOWRATE

TEMPERATUREIN

TEMPERATUREOUT

PRESSUREDROP PASS

EVAPORATOR

ABSORBER

COOLER

ELECTRICAL DATA: Volts

INHIBITOR:

CARRIER OBLIGATIONS: Assemble . . . . . . . . . . . . . . . Yes � No �

Leak Test . . . . . . . . . . . . . . . Yes � No �

Dehydrate . . . . . . . . . . . . . . . Yes � No �

Charging . . . . . . . . . . . . . . . . Yes � No �

Operating Instructions Hrs.

START-UP TO BE PERFORMED IN ACCORDANCE WITH APPROPRIATE MACHINE START-UPINSTRUCTIONS

JOB DATA REQUIRED:1. Machine Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . Yes � No �2. Machine Assembly, Wiring, and Piping Diagrams . . . . . . . . . . . . Yes � No �3. Starting Equipment Details and Wiring Diagrams . . . . . . . . . . . . Yes � No �4. Applicable Design Data (see above) . . . . . . . . . . . . . . . . . . . . . . Yes � No �5. Diagrams and Instructions for Special Controls . . . . . . . . . . . . . Yes � No �

INITIAL MACHINE PRESSURE:

YES NO

Was Machine Tight?

If Not, Were Leaks Corrected?

WHAT WAS FINAL VACUUM AFTER REPAIRS?

RECORD PRESSURE DROPS: Cooler Condenser Absorber

CHARGE LiBr: Initial Charge Final Charge After Trim

CHARGE REFRIGERANT: Initial Charge Final Charge After Trim

CU

TA

LON

GD

OT

TE

DLI

NE

CU

TA

LON

GD

OT

TE

DLI

NE

--

--

--

--

--

--

--

--

--

--

--

--

--

--

--

--

--

--

--

--

--

--

--

--

--

--

--

--

--

--

--

--

--

--

--

--

--

--

--

--

--

--

--

CL-1

INSPECT WIRING AND RECORD ELECTRICAL DATA:

RATINGS:

Line Voltages: Controls

CONTROLS: SAFETY, OPERATING, ETC.

Perform Control Test (Yes/No)

PIC CAUTIONPUMP MOTORSAND CONTROL CENTER MUST BE PROPERLYAND INDIVIDUALLY CONNECTED BACKTO THE EARTH GROUND IN CONTROL BOX (IN ACCORDANCE WITH CERTIFIED DRAWINGS).

Yes

RUN MACHINE: Do these safeties shut down machine?Chilled Water Flow Switch Yes � No �Cooling Water Flow Switch Yes � No �Pump Interlocks Yes � No �

GEN Temperature Yes � No �

GEN Pressure Yes � No �

LCWCO (Leaving Chilled Water Cutout) Yes � No �

INITIAL START:

Line Up All Valves in Accordance With Instruction Manual:

LiBr is Charged gal. Refrigerant is Charged gal.

Check Solution Pump Rotation and Record:Correct Incorrect

Check Refrigerant Pump Rotation and Record:Correct Incorrect

Start Water Pumps and Establish Water Flow

START MACHINE AND OPERATE. COMPLETE THE FOLLOWING:

1. Complete Any Remaining Control Calibration and Record Under Controls Section (pages 13-55).2. Take At Least 2 Sets of Operational Log Readings and Record.3. Trim Charge. Check Operation of Cycle-Guard™ Valve. Add Alcohol.4. Give Operating Instructions to Owner’s Operating Personnel. Hours Given: Hours5. Call your local Carrier factory representative to report start up (1-800-333-CHIL).

SIGNATURES:

CARRIER TECHNICIAN DATE

CUSTOMER REPRESENTATIVE DATE

CL-2

16JB SINGLE-EFFECT ABSORPTION LIQUID CHILLERCONFIGURATION SETTINGS LOG

(Remove and use for job file.)

16JB SET POINT TABLE CONFIGURATION SHEET

DESCRIPTION UNITS RANGE DEFAULT VALUE

Cooling Setpoint DEG F(DEG C)

41 to 65(5 to 18.3)

50.0(10)

PC6400 Software: VersionLID Software: Version

PC6400 Controller Identification: Bus Address

Default Bus: 0 Default Address: 1

LID Identification: Bus Address

Default Bus: 0 Default Address: 230

CU

TA

LON

GD

OT

TE

DLI

NE

CU

TA

LON

GD

OT

TE

DLI

NE

--

--

--

--

--

--

--

--

--

--

--

--

--

--

--

--

--

--

--

--

--

--

--

--

--

--

--

--

--

--

--

--

--

--

--

--

--

--

--

--

--

--

--

CL-3

LOCAL 16JB PIC TIME SCHEDULE CONFIGURATION SHEET OCCPC01S

Day Flag Occupied UnoccupiedM 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 each day.

CCN 16JB PIC TIME SCHEDULE CONFIGURATION SHEET OCCPC02S


Period 1:

Period 2:

Period 3:

Period 4:

Period 5:

Period 6:

Period 7:

Period 8:


16JB PIC TIME SCHEDULE CONFIGURATION SHEET OCCPC S


Period 1:

Period 2:

Period 3:

Period 4:

Period 5:

Period 6:

Period 7:

Period 8:


CL-4

16JB PIC CONFIG TABLE CONFIGURATION SHEET

DESCRIPTION RANGE UNITS DEFAULT VALUE

RESET TYPE 1

Degrees Reset at 20 mA −15 to 15(−8.3 to 8.3)

DEG F(DEG C)

10(5.6)

RESET TYPE 2

Remote Temp (No Reset) −40 to 245(−40 to 118)

DEG F(DEC C)

65(18.3)

Remote Temp (Full Reset) −40 to 245(−40 to 118)

DEG F(DEG C)

85(29.4)

Degrees Reset −15 to 15(−8.3 to 8.3)

DEG F(DEG C)

10(5.6)

RESET TYPE 3

CHW Temp (No Reset) 0 to 15(0 to 8)

DEG F(DEG C)

10(5.6)

CHW Temp (Full Reset) 0 to 15(0 to 8)

DEG F(DEG C)

0(0)

Degrees Reset −15 to 15(−8.3 to 8.3)

DEG F(DEG C)

5(2.8)

Select/Enable Reset Type 0 to 3 0

CHW_IN Control Option DSABLE/ENABLE DSABLE

Remote Contacts Option DSABLE/ENABLE DSABLE

Temp Pulldown Deg/Min 2 to 10 (1.1 to 5.6) DEG F/MIN.(DEG C/MIN.)

3(1.7)

CCN Occupancy Config:Schedule Number 2 to 99 2

CCN Occupancy Config:Broadcast Option DSABLE/ENABLE DSABLE

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CL-5

16JB PIC SERVICE1 TABLE CONFIGURATION SHEET


Refrigerant Trip Point 37 to 42(2.8 to 5.5)

DEG F(DEG C)

38(3.3)

Refrigerant Override Delta T 2 to 5(1.1 to 2.8)

DEG F(DEG C)

2(1.1)

Water Flow Verify Time 0.5 to 5 MIN 0.5

Recycle Restart Delta T 2 to 10(1.1 to 5.6)

DEG F(DEG C)

5(2.8)

Recycle Stop Delta T 0.0 to 5.0(0 to 2.8)

DEG F(DEG C) 2.5

Sample Range 1 to 25 N/A 2

Weak LiBr Lvg Abs Alert 100 to 150(37.8 to 65.6)

DEG F(DEG C)

110(43.3)

Vapor Condensate Override 100 to 150(37.8 to 65.6)

DEG F(DEG C)

125(51.6)

GEN Strong LiBr Override 200 to 250(93.3 to 121.1 )

DEG F(DEG C)

225(107.2)

GEN Overflow Alarm 150 to 240(65.5 to 15.5)

DEG F(DEG C)

175(79.4)

Desolidification Time 15 to 240 MIN 60

Concentration Sensor Cal:

Conc at Low Level 50 to 60 % 55

Volts at Low Level 0 to 5.0 VOLTS 4.5

Conc at High Level 50 to 60 % 60

Volts at High Level 0 to 5.0 VOLTS 3.0

Cycle-Guard™ Level Adjust 50 to 60 % 55

Line FrequencySelect: 0 = 60 Hz,

1 = 50 Hz

0/1 Hz 0

CL-6



CHWS Temp Enable

0 to 2(0 = DSABLE1 = LOW2 = HIGH)

0

CHWS Temp Alert −40 to 245(−40 to 118)

DEG F(DEG C)

245(118.3)

CHWR Temp Enable


0

CHWR Temp Alert −40 to 245(−40 to 118)

DEG F(DEG C)

245(118.3)

Reset Temp Enable


0

Reset Temp Alert −40 to 245(−40 to 118)

DEG F(DEG C)

245(118.3)

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CL-7



Control Point Deadband 0.5 to 2.0(0.3 to 1.1)

DEG F(DEG C)

1.0(0.56)

Proportional Inc Band 2 to 10 6.5

Proportional Dec Band 2 to 10 6.0

Proportional CHW_IN Gain 1 to 3 2.0

GEN Solution Temp Bias 1 to 10 5.0

Capacity Valve Setup:

Warmup Travel Limit 15 to 80 % 65

Running Travel Limit 15 to 100 % 100

Linear Valve Type 0/1 NO/YES NO

Pneumatic Valve Type 0/1 NO/YES NO

Solution Pump:

Ontime 0 to 500,000 Hours 0

Starts 0 to 65,534 0

CL-8

HOLIDAY CONFIGURATION SHEET (HOLDY S)

DESCRIPTION RANGE UNITS VALUE

Start Month 1 to 12

Start Day 1 to 31

Duration 0 to 99 DAYS



Start Month 1 to 12

Start Day 1 to 31




Start Month 1 to 12

Start Day 1 to 31


1NOTE: There are no holidays defined on the default menu. Holiday dates must be updated yearly if they are used.

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CL-9

Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.PC 211 Catalog No. 531-614 Printed in U.S.A. Form 16JB-6SS Pg CL-10 901 12-97 Replaces: NewBook 2

Tab 5b

Copyright 1997 Carrier Corporation

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BROADCAST (BRODEF) CONFIGURATION SHEET


Time Broadcast Enable ENABLE/DSABLE DSABLE

Daylight Savings Start

Start Month 1 to 12 4

Start Day of Week 1 to 31 15

Start Time 00:00 to 23:59 HH:MM 02:00

Start Advance 1 to 1440 MIN 60

Stop Month 1 to 12 10

Stop Day of Week 1 to 31 15

Stop Time 00:00 to 23:59 HH:MM 02:00

Stop Back 1 to 1440 MIN 60

Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.PC 211 Catalog No. 531-614 Printed in U.S.A. Form 16JB-6SS Pg 110 901 12-97 Replaces: NewBook 2

Tab 5b

Copyright 1997 Carrier Corporation

start-up, operation, and maintenance...

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