REPLACEMENT COMPONENTS DIVISION
SERVICE BULLETIN
SUBJECT: Thermal Dispersion Flow Switch NUMBER: C0302C
DATE: 3-17-15
SUPERSEDES: C0302B
DATE: 11-11-11
MODELS AFFECTED: 19XR & 23XL Chillers with PIC-II PAGE: 1 OF: 4
CVC Controller
Installation, repair and service and equipment referenced in this Service Bulletin should be undertaken only by qualified persons. Carrier
Corporation: (1) makes no representations or warranties, expressed or implied, concerning the accuracy, completeness or right to use the
information contained herein. (2) Disclaims all liability for injuries, damages, infringements and other losses which may arise on account of,
or which may result from, the use or application of any information, method or apparatus disclosed herein.
SITUATION:
The subject chillers equipped with CVC controllers were provided with water side differential
pressure transducer pairs for flow detection (freeze protection) as standard equipment. The
need exists for a field retrofit substitute which is reliable and not significantly affected by
sediment, scaling, or deposits which are common in water side plumbing. This bulletin
describes a thermal dispersion flow switch which can meet this need.
If a chronic water side transducer problem exists at a jobsite, it is likely that it will be more cost
effective to replace the four transducers with two flow switches as described in this bulletin
than to replace or recalibrate the existing transducers on a periodic basis.
19XR chillers equipped with ICVC controllers do not rely upon these water side transducers,
however their systems may be optionally equipped with the same switch for flow detection.
SOLUTION:
Material Needed (for each water system)
• Switch: RCD part number HR81LG020 (w/o LED flow indication).See Figure 1
below.
• Cables: RCD part number EVC009 (32.8 ft length). The cable assembly (4 wire)
includes a connector with 3 LED’s, one green indicating power, one yellow indicating
switch input status, and the second yellow indicating flow.
• Resistors: RCD part number HT21AZ111. If replacing water pressure transducers,
2 required. If no flow sensing exists, 1 required.
Note: In a typical installation there will be two sensor and sensor cable sets, one for the chilled
water system and one for the condenser water system.
Water System Interface (for each sensor):
Install in a ¼” NPT tapped hole such that the sensing tip of the switch extends into or is at the
edge of the flow stream (i.e., not recessed in a branch cavity). When used as a direct
replacement for a waterside pressure transducer, install in place of the ¼” NPT Schrader
adapter in the waterbox nozzle to which a waterside pressure transducer has been connected.
REPLACEMENT COMPONENTS DIVISION BULLETIN NUMBER: C0302C
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For installation in horizontal pipes, recommended mounting is in the side, not top or bottom.
For installation in vertical pipes, recommended mounting is where the medium flows upward.
To avoid malfunction (faults “no flow” indications), recommended straight pipe distance (no
elbows or valves) is 5 pipe diameters before and 3 pipe diameters after the switch.
If possible, install the switch with the LED’s visible from a convenient location.
For chillers which have additional couplings which would prevent adequate penetration of the
sensor, or which have thick or cast nozzles (e.g., 23XL waterboxes), install the flow dispersion
switch in a ¼” NPT tapped hole elsewhere in the system piping where the pipe wall is thin
enough to permit adequate penetration. It does not matter if the flow dispersion switch is on
the inlet or outlet side.
Electrical Interfaces (for each sensor):
• At the switch, connect one of the cables (part number specified above), which has a
sealing threaded M12 connector, to the corresponding sensor terminal. Refer to
Figure 1.
Terminate the other end of each cable in the chiller Control Panel as follows:
• 24vac Power Supply (in the control panel): For later production 19XR chillers with
CVC or ICVC controllers, the brown and blue wires from each cable may be readily
connected to terminals 1 and 2 of the 6-screw terminal block in the control panel
(connected to red and gray wires, respectively). For earlier production chillers with
control panels not so equipped, consult the schematic to determine a convenient
location to splice these wires into either of the standard 24vac supplies: (a) on the
load side of circuit breaker CB1, joining to the red and gray leads, or (b) on the load
side of circuit breaker CB2, joining to the yellow (or black) and brown leads.
• Switch Input Wiring (control panel): The black and white wires from each sensor
cable are to be wired as the appropriate switch shown in Figure 2. The switch in the
cooler loop connects to CCM J3 17-18, and the switch in the condenser loop
connects to CCM J3 23-24. Add resistors as shown (3.3k or 3.9k ohm resistors will
work just as well, as long as the values are equal for each pair). An open switch
should indicate no flow.
• Provide strain relief for the cable at the switch end and at the control panel end. The
wires within the cable are AWG 22, which is smaller than standard chiller control
wiring.
Note: In a typical installation there will be two sensor and sensor cable sets.
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Controller Configuration and Usage:
• For ICVC controllers with Version 03 or later software, in the Equipment Service /
Options screen set Flow Delta P Display (line 14) to Enable for the calibration
procedure described below. After calibration, change the selection back to Disable.
(With 4.3 k ohm resistors installed, a “phony” delta p value of approximately 20 psi
will appear when the display option is Enabled).
• With the switches open or disconnected, calibrate (set) the zero point values in the
Status, HEAT_EX screen for Chilled Water Delta P and Condenser Water Delta P by
selecting each of these lines then pressing Enter. This will assure that the no-flow
differential will be interpreted as zero, taking into account tolerance differences
between the resistors.
Cable Connector Display and Adjustment:
• The cable assembly includes three light emitting diodes (LED), one green indicating
power is present, one yellow indicating switch input status, and the second yellow
indicating flow.
• The switch is factory-set to close at a water velocity of 20 cm/s (0.66 ft/sec).
Adjustment of the sensitivity (setpoint) is not recommended nor required unless the
factory setpoint results in a specific problem for a particular application, i.e. low flow
glycol. The sensitivity may be programmed, if necessary, using a Teach Button
Programming Tool, which allows the setpoint to be adjusted from 10 cm/sec to 60
cm/sec. P/N is 30HX680003 (5 wire cable assembly required).
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Figure 1. Thermal Dispersion Flow Switch & Cable Assembly
Figure 2. Recommended CCM Connection Schematic
