CONTENTS
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
Definitions ..................................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
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