Page
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . 1
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
ABBREVIATIONS AND EXPLANATIONS . . . . . . . 4
CHILLER FAMILIARIZATION . . . . . . . . . . . . . . . . . . 5
Chiller Information Plate . . . . . . . . . . . . . . . . . . . . . . 5
System Components . . . . . . . . . . . . . . . . . . . . . . . . . 5
Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Motor-Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Control Center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Factory-Mounted Starter (Optional) . . . . . . . . . . . . 5
Storage Vessel (Optional) . . . . . . . . . . . . . . . . . . . . . 5
REFRIGERATION CYCLE . . . . . . . . . . . . . . . . . . . . . 5
MOTOR/OIL REFRIGERATION
COOLING CYCLE . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
LUBRICATION CYCLE . . . . . . . . . . . . . . . . . . . . . . . 8,9
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Oil Reclaim System . . . . . . . . . . . . . . . . . . . . . . . . . . 9
·DURING NORMAL CHILLER OPERATION
·DURING LIGHT LOAD CONDITIONS
STARTING EQUIPMENT . . . . . . . . . . . . . . . . . . . . 10,11
Unit Mounted Solid-State Starter
(Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Unit Mounted Wye-Delta Starter
(Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-39 De®nitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
·ANALOG SIGNAL
·DIGITAL SIGNAL
·VOLATILE MEMORY
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 PIC System Components . . . . . . . . . . . . . . . . . . . . 11
·PROCESSOR MODULE (PSIO)
·STARTER MANAGEMENT MODULE (SMM)
·LOCAL INTERFACE DEVICE (LID)
·6-PACK RELAY BOARD
·8-INPUT MODULES
·OIL HEATER CONTACTOR (1C)
·OIL PUMP CONTACTOR (2C)
·HOT GAS BYPASS CONTACTOR RELAY (3C) (Optional)
·CONTROL TRANSFORMERS (T1-T4)
·CONTROL AND OIL HEATER VOLTAGE SELECTOR (S1)
LID Operation and Menus . . . . . . . . . . . . . . . . . . . 14
·GENERAL
·ALARMS AND ALERTS
·MENU STRUCTURE
·TO VIEW POINT STATUS
·OVERRIDE OPERATIONS
·TIME SCHEDULE OPERATION
·TO VIEW AND CHANGE SET POINTS
·SERVICE OPERATION
PIC System Functions . . . . . . . . . . . . . . . . . . . . . . . 28
·CAPACITY CONTROL
·ENTERING CHILLED WATER CONTROL
·DEADBAND
·PROPORTIONAL BANDS AND GAIN
·DEMAND LIMITING
·CHILLER TIMERS
·OCCUPANCY SCHEDULE
Safety Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
· SHUNT TRIP
Default Screen Freeze . . . . . . . . . . . . . . . . . . . . . . . 29
Page
Motor Cooling Control . . . . . . . . . . . . . . . . . . . . . . . 29
Ramp Loading Control . . . . . . . . . . . . . . . . . . . . . . 31
Capacity Override . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
High Discharge Temperature Control . . . . . . . . . 32
Oil Sump Temperature Control . . . . . . . . . . . . . . . 32
·PSIO SOFTWARE VERSIONS 08 AND LOWER
·PSIO SOFTWARE VERSIONS 09 AND HIGHER
Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Remote Start/Stop Controls . . . . . . . . . . . . . . . . . . 32
Spare Safety Inputs . . . . . . . . . . . . . . . . . . . . . . . . . 32
· SPARE ALARM CONTACTS
Condenser Pump Control . . . . . . . . . . . . . . . . . . . . 32
Condenser Freeze Protection . . . . . . . . . . . . . . . . 32
Tower Fan Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Auto. Restart After Power Failure . . . . . . . . . . . . 33
Water/Brine Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
·RESET TYPE 1
·RESET TYPE 2
·RESET TYPE 3
Demand Limit Control, Option
(Requires Optional 8-Input Module) . . . . . . . . . . 33
Surge Prevention Algorithm . . . . . . . . . . . . . . . . . 33
Surge Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Lead/Lag Control . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
·COMMON POINT SENSOR INSTALLATION
·CHILLER COMMUNICATION WIRING
·LEAD/LAG OPERATION
·FAULTED CHILLER OPERATION
·LOAD BALANCING
·AUTO. RESTART AFTER POWER FAILURE
Ice Build Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
·ICE BUILD INITIATION
·START-UP/RECYCLE OPERATION
·TEMPERATURE CONTROL DURING ICE BUILD
·TERMINATION OF ICE BUILD
·RETURN TO NON-ICE BUILD OPERATIONS
Attach to Network Device Control . . . . . . . . . . . . 37
·CHANGING REFRIGERANT TYPES
·ATTACHING TO OTHER CCN MODULES
Service Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
·TO LOG ON
·TO LOG OFF
·HOLIDAY SCHEDULING
START-UP/SHUTDOWN/RECYCLE
SEQUENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39-41
Local Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Shutdown Sequence . . . . . . . . . . . . . . . . . . . . . . . . 40
Automatic Soft-Stop Amps Threshold
(PSIO Software Version 09 and Higher) . . . . . . 40
Chilled Water Recycle Mode . . . . . . . . . . . . . . . . . 40
Safety Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
BEFORE INITIAL START-UP . . . . . . . . . . . . . . . . 41-54
Job Data Required . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Equipment Required . . . . . . . . . . . . . . . . . . . . . . . . 41
Using the Optional Storage Tank
and Pumpout System . . . . . . . . . . . . . . . . . . . . . . . 41
Remove Shipping Packaging . . . . . . . . . . . . . . . . 41
Open Oil Circuit Valves . . . . . . . . . . . . . . . . . . . . . . 41
Tighten All Gasketed Joints and
Guide Vane Shaft Packing . . . . . . . . . . . . . . . . . . 41
Check Chiller Tightness . . . . . . . . . . . . . . . . . . . . . 41
Refrigerant Tracer . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Leak Test Chiller . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Standing Vacuum Test . . . . . . . . . . . . . . . . . . . . . . 43
Chiller Dehydration . . . . . . . . . . . . . . . . . . . . . . . . . 47
Inspect Water Piping . . . . . . . . . . . . . . . . . . . . . . . . 47
