CARRIER Package Units(both Units Combined) Manual L0522671

User Manual: CARRIER CARRIER Package Units(both units combined) Manual CARRIER Package Units(both units combined) Owner's Manual, CARRIER Package Units(both units combined) installation guides

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Hermetic

Start-Up, Operation,

and Maintenance

SAFETY

DO NOT VENT refrigerant relief valves within a buikting. Outlet
from rupture disc or relief valve must be vented outdoors in accordance with the latest edition of ANSI/ASHRAE
15 (American
National Standards Institute/American
Society of Heating, Refrigeration, and Air Conditioning
Engineers). The accumulation
of refrigerant in an enclosed space can displace oxygen and cause asphyxiation.
PROVIDE adequate ventilation in accordance with ANSI/ASHRAE
15, especially for enclosed and low overhead spaces. Inhalation of
high concentrations
of vapor is hamlfill and may cause heart irregularities, nnconsciousness,
or death. Misuse can be fatal. Vapor is heavier
than air and rednces the amonnt of oxygen available for breathing.
Product causes eye and skin irritation. Decomposition
products are
hazardous.
DO NOT USE OXYGEN to purge lines or to pressurize a chiller for
any purpose. Oxygen gas reacts violently with oil, grease, and other
COlnlllOn
substances.
NEVER EXCEED specified test pressures, VERIFY the allowable
test pressure by checking the instruction literature and the design pressures on the equipment nameplate.
USE

air for leak testing.

Use

only

refrigerant

Instructions

CONSIDERATIONS

Centrifugal liquid chillers are designed to provide safe
and reliable service when operated within design specifications.
When operating this equipment, use good
judgment and safety precautions to avoid damage to
equipment and property or injury to personnel.
Be sure you understand and follow the procedures
and safety precautions contained in the chiller instructions as well as those listed in this guide.

DO NOT
nitrogen.

19X RV
Centrifugal Liquid Chillers
with PIC III Controls
50/60 Hz
HFC-134a

or dry

soap and water. If liqnid refrigerant enters the eyes, IMMEDIATELY
FLUSH EYES with water and consult a physician.
NEVER APPLY an open flame or live steam to a refrigerant cylinder.
Dangerous over pressure can result. When it is necessary to heat
refrigerant, use only warm (110 F D3 C]) water.
DO NOT REUSE disposable (nonreturnable) cylinders or attempt to
refill them. It is DANGEROUS AND ILLEGAL. When cylinder is
emptied, evacuate remaining gas pressure, loosen the collar and
unscrew and discard the valve stem. DO NOT INCINERATE.
CHECK THE REFRIGERANT TYPE before adding refrigerant to
the chiller. The introdnction of the wrong refrigerant can cause
damage or malfunction to this chiller.
Operation of this equipment with refrigerants other than those
cited herein should comply with ANSI/ASHRAE 15 (latest edition).
Contact Carrier for timber information on use of this chiller with other
refrigerants.
DO NOT ATTEMPT TO REMOVE fittings, covers, etc., while
chiller is under pressure or while chiller is running. Be sum pressure is
at 0 psig C0kPa) before breaking any refrigerant connection.
CAREFULLY INSPECT all relief devices, rupture discs, and other
relief devices AT LEAST ONCE A YEAR. If chiller operates in a
corrosive atmosphere, inspect the devices at morn frequent intervals.
DO NOT ATTEMPT TO REPAIR OR RECONDITION any relief
device when corrosion or build-up of foreign material (rust, dirt, scale,
etc.) is found within the valve body or mechanism. Replace the
device.
DO NOT install relief devices in series or backwards.
USE CARE when working near or in line with a compressed spring.
Sudden release of the spring can cause it and objects in its path to act
as projectiles.

DO NOT VALVE OFF any safety device.
BE SURE that all pressure
fimctioning before operating

relief devices
any chiller.

are properly

installed

and

THERE IS A RISK OF INJURY OR DEATH by electrocution.
High
voltage may be present on the motor leads even though the motor is
not running. Open the power supply disconnect
before touching
motor leads or terminals.

DO NOT WELD OR FLAMECUT
any refrigerant line or vessel until
all refrigerant (liquM atM V'al)or) has been removed
from chiller.
Traces of vapor should be displaced with dry air or nitrogen and the
work area should be well ventilated. R@'ixemm
in contact _Hth an
o!)et_flame prodHc_,s toxic gaxes.
DO NOT USE eyebolts
entire assembly.

or eyebolt

DO NOT work on high-voltage
electrician.

holes to rig chiller sections

equipment

or the

unless yon are a qualified

DO NOT WORK
ON electrical components,
including
control
panels, switches, starters, or oil heater until you are sure ALL
POWER IS OFF and no residual voltage can leak from capacitors or
solid-state components.
LOCK OPEN AND TAG
WORK IS INTERRUPTED,
before resuming work.
AVOID SPILLING
eyes. USE SAFETY

Manufacturer

electrical circuits during servicing.
IF
confirm that all circuits are deenergized

DO NOT STEP on refrigerant lines. Broken lines can whip about and
release refrigerant, causing personal injury.
DO NOT climb over a chiller. Use platform, catwalk, or staging.
Follow safe practices when using ladders.
USE MECHANICAL EQUIPMENT (crone, hoist, etc.) to lilt
or move inspection covers or other heax.y components. Even if
components are light, use mechanical equipment when there is a risk
of slipping or losing your balance.
BE AWARE that certain automatic start arrangements CAN
ENGAGE THE STARTER, TOWER FAN, OR PUMPS. Open the
disconnect ahead of the starter, tower fans, or pumps.
USE only repair or replacement parts that meet the code requirements
of the original equipment.
DO NOT VENT OR DRAIN waterboxes containing industrial brines,
liquid, gases, or semisolids withont the permission of your process
control group.
DO NOT LOOSEN waterbox cover bolts until the waterbox has been
completely drained.
DO NOT LOOSEN a packing gland nut before checking that the nut
has a positive thread engagement.
PERIODICALLY INSPECT all valves, fittings, and piping for
corrosion, rest, leaks, or damage.
PROVIDE A DRAIN connection in the vent line near each pressure
relief device to prevent a build-up of condensate or rain watec

liquid refrigerant on skin or getting it into the
GOGGLES.
Wash any spills from the skin with

reserves the right to discontinue, or change at any time, specifications

PC 211

Catalog No. 531-986

Printed in U.S.A.

or designs without notice and without incurring obligations.

Form 19XRV-1SS

Pg 1

4-05

Replaces:

New

CONTENTS
Page
SAFETY CONSIDERATIONS ......................
1
INTRODUCTION ..................................
4
ABBREVIATIONS AND EXPLANATIONS ........
4,5
CHILLER FAMILIARIZATION ....................
5,6
Chiller Information Nameplate ....................
5
System Components .............................
5
Cooler ............................................
5
Condenser .......................................
5
Motor-Compressor ...............................
5
Control Panel .....................................
5
Variable Frequency Drive .........................
5
Storage Vessel (Optional) ........................
5
REFRIGERATION CYCLE .........................
7
MOTOR AND LUBRICATING OIL
COOLING CYCLE ..............................
7
VFD COOLING CYCLE ............................
8
LUBRICATION CYCLE ..........................
8,9
Summary .........................................
8
Details ............................................
8
Oil Reclaim System ...............................
8
• PRIMARY OIL RECOVERY MODE
• SECONDARY OIL RECOVERY METHOD
Bearings .........................................
8
STARTING EQUIPMENT .......................
9-ll
Unit-Mounted VFD ................................
9
CONTROLS ...................................
l 1-49
Definitions ......................................
ll
• ANALOG SIGNAL
• DISCRETE SIGNAL
General ..........................................
11
PIC III System Components
.....................
]]
• INTERNATIONAL (;;HILLER VISUAL
CONTROLLER (ICVC)
• CHILLER CONTROL MODULE (CCM)
• OIL HEATER CONTACTOR (lC)
• OIL PUMP CONTACTOR (2C)
• HOT GAS BYPASS CONTACTOR RELAY (3C)
(Optional)
• CONTROL TRANSFORMERS (TI, T2)
• OPTIONAL TRANSFORMER (T3)
• SENSORS
• FLOW DETECTION
ICVC Operation and Menus ......................
16
• GENERAL
• ALARMS AND ALERTS
• ICVC MENU ITEMS
• BASIC [CVC OPERATIONS (Using the Softkeys)
• TO VIEW STATUS
• FORCING OPERATIONS
• TIME SCHEDULE OPERATION
• TO VIEW AND CHANGE SET POINTS
• SERVICE OPERATION
PIC III System Functions ........................
34
• CAPACITY CONTROL
• ECW CONTROL OPTION
• CONTROL POINT DEADBAND
• DIFFUSER CONTROL
• PROPORTIONAL BANDS AND GAIN
• DEMAND LIMITING
• CHILLER TIMERS AND STARTS COUNTER
• OCCUPANCY SCHEDULE
Safety Controls ..................................
36
Shunt Trip (Option) ..............................
36
Default Screen Freeze ...........................
36
Ramp Loading ...................................
39
Capacity Override ...............................
39

Page
High Discharge Temperature Control ............
39
Oil Sump Temperature and Pump Control ....... 39
Oil Cooler .......................................
39
Remote Start/Stop Controls .....................
40
Spare Safety and Spare Temperature Inputs ..... 40
Alarm (Trip) Output Contacts ....................
40
Kilowatt Output ..................................
41
Remote Reset of Alarms .........................
41
Condenser Pump Control .......................
41
Condenser Freeze Prevention ...................
41
Evaporator Freeze Protection ...................
41
Tower Fan Relay Low and High ..................
41
Auto. Restart After Power Failure ................
42
WaterlBrine Reset ...............................
42
• RESET TYPE 1: 4 TO 20 mA TEMPERATURE RESET
• RESET TYPE 2: REMOTE TEMPERATURE RESET
• RESET TYPE 3
Surge Prevention
Algorithm .....................
42
Surge Protection
................................
43
Head Pressure
Reference
Output ................
44
Lead/Lag Control ................................
44
• COMMON POINT SENSOR USAGE AND
INSTALLATION
• CHILLER COMMUNICATION WIRING
• LEAD/LAG OPERATION
• FAULTED CHILLER OPERATION
• LOAD BALANCING
• AUTO. RESTART AFTER POWER FAILURE
Ice Build Control ................................
46
• 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 ...............
47
• ATTACHING TO OTHER CCN MODULES
Service Operation ...............................
48
• TO ACCESS THE SERVICE SCREENS
• TO LOG OUT OF NETWORK DEVICE
• TIME BROADCAST ENABLE
• HOLIDAY SCHEDULING
• DAYLIGHT SAVING TIME CONFIGURATION
START-U P/SH UTDOWN/R ECYCLE
SEQUENCE ................................
50-52
Local Start-Up ...................................
50
Shutdown Sequence ............................
51
Automatic Soft Stop Amps Threshold ...........
51
Chilled Water Recycle Mode .....................
51
Safety Shutdown ................................
52
BEFORE INITIAL START-UP ..................
52-67
Job Data Required ..............................
52
Equipment Required ............................
52
Using the Optional Storage Tank
and Pumpout System .........................
52
Remove Shipping Packaging ....................
52
Open Oil Circuit Valves ..........................
52
Oil Charge .......................................
52
Tighten All Gasketed Joints and
Guide Vane Shaft Packing .....................
52
Check Chiller Tightness .........................
53
Refrigerant Tracer ...............................
53
Leak Test Chiller ................................
55
Standing Vacuum Test ...........................
55
Chiller Dehydration ..............................
58
Inspect Water Piping ............................
58
Check Optional Pumpout Compressor
Water Piping ..................................
58

CONTENTS(cont)
Page
Check Relief Valves .............................
58
Identify the VFD .................................
58
Input Power Wiring ..............................
59
Checking the Installation ........................
59
Inspect Wiring ...................................
60
Ground Fault Troubleshooting
..................
60
Carrier Comfort Network Interface ...............
60
Power Up the Controls and
Check the Oil Heater ..........................
61
• SOFTWARE VERSION
Software Configuration
.........................
61
Input the Design Set Points .....................
61
Input the Local Occupied Schedule
(OCCPC01S) ..................................
61
Input Service Configurations
....................
61
• PASSWORD
• INPUT TIME AND DATE
• CHANGE ICVC CONFIGURATION
IF NECESSARY
• TO CHANGE THE PASSWORD
• TO CHANGE THE ICVC DISPLAY FROM
ENGLISH TO METRIC UNITS
• CHANGE LANGUAGE
• MODIFY CONTROLLER IDENTIFICATION
IF NECESSARY
• INPUT EQUIPMENT SERVICE PARAMETERS
IF NECESSARY
• VERIFY VFD CONFIGURATION AND CHANGE
PARAMETERS IF NECESSARY
• VFD CHILLER FIELD SET UP AND VERIFICATION
• CONFIGURE DIFFUSER CONTROL IF
NECESSARY
• MODIFY EQUIPMENT CONFIGURATION
IF NECESSARY
Perform a Control Test ..........................
64
• PRESSURE TRANSDUCER CALIBRATION
Check Optional Pumpout System
Controls and Compressor .....................
65
High Altitude Locations .........................
65
Charge Refrigerant Into Chiller ..................
65
• CHILLER EQUALIZATION WITHOUT A
PUMPOUT UNIT
• CHILLER EQUALIZATION WITH
PUMPOUT UNIT
• TRIMMING REFRIGERANT CHARGE
INITIAL START-UP .............................
67,68
Preparation
.....................................
67
Check Motor Rotation ...........................
67
Check Oil Pressure and Compressor Stop ...... 67
To Prevent Accidental Start-Up ..................
67
Check Chiller Operating Condition ..............
68
Instruct the Customer Operator .................
68
• COOLER-CONDENSER
• OPTIONAL PUMPOUT STORAGE TANK AND
PUMPOUT SYSTEM
• MOTOR COMPRESSOR ASSEMBLY
• MOTOR COMPRESSOR LUBRICATION SYSTEM
• CONTROL SYSTEM
• AUXILIARY EQUIPMENT
• DESCRIBE CHILLER CYCLES
• REVIEW MAINTENANCE
• SAFETY DEVICES AND PROCEDURES
• CHECK OPERATOR KNOWLEDGE
• REVIEW THE START-UR OPERATION, AND
MAINTENANCE MANUAL

Page
OPERATING INSTRUCTIONS .................
68-70
Operator Duties .................................
68
Prepare the Chiller for Start-Up .................
68
To Start the Chiller ..............................
68
Check the Running System .....................
68
To Stop the Chiller ..............................
69
After Limited Shutdown
.........................
69
Preparation
for Extended
Shutdown
............
69
After Extended
Shutdown .......................
69
Cold Weather Operation .........................
69
Manual Guide Vane Operation ...................
69
Refrigeration
Log ...............................
69
PUMPOUT AND REFRIGERANT TRANSFER
PROCEDURES .............................
71-74
Preparation .....................................
71
Operating the Optional Pumpout Unit ...........
71
• TO READ REFRIGERANT PRESSURES
• POSITIVE PRESSURE CHILLERS WITH
STORAGE TANKS
• CHILLERS WITH ISOLATION VALVES
• DISTILLING THE REFRIGERANT
GENERAL MAINTENANCE ....................
74,75
Refrigerant
Properties
..........................
74
Adding Refrigerant
..............................
74
Removing Refrigerant ...........................
74
Adjusting the Refrigerant
Charge ...............
74
Refrigerant
Leak Testing ........................
74
Leak Rate .......................................
74
Test After Service, Repair, or Major Leak ........
74
• TESTING WITH REFRIGERANT TRACER
• TESTING WITHOUT REFRIGERANT TRACER
• TO PRESSURIZE WITH DRY NITROGEN
Repair the Leak, Retest, and Apply
Standing Vacuum Test ........................
75
Checking Guide Vane Linkage ..................
75
Trim Refrigerant Charge .........................
75
WEEKLY MAINTENANCE ........................
75
Check the Lubrication System ..................
75
SCHEDULED MAINTENANCE ................
75-78
Service Ontime ..................................
75
Inspect the Control Panel .......................
76
Check Safety and Operating Controls
Monthly .......................................
76
Changing Oil Filter ..............................
76
Oil Specification
................................
76
Oil Changes .....................................
76
• TO CHANGE THE OIL
Refrigerant
Filter ................................
76
Oil Reclaim Filter ................................
76
VFD Refrigerant
Strainer ........................
77
Inspect Refrigerant
Float System
...............
77
Inspect Relief Valves and Piping ................
77
Compressor Bearing and Gear
Maintenance ..................................
77
Inspect the Heat Exchanger Tubes
and Flow Devices .............................
77
• COOLER AND OPTIONAL FLOW DEVICES
• CONDENSER AND OPTIONAL FLOW DEVICES
Water Leaks .....................................
77
Water Treatment .................................
78
Inspect the VFD .................................
78
Recalibrate Pressure Transducers ..............
78

CONTENTS

(cont)

Optional Pumpout System Maintenance
.........
• OPTIONAL
PUMPOUT COMPRESSOR
OIL
CHARGE
• OPTIONAL
PUMPOUT SAFETY CONTROL
SETTINGS

Ordering Replacement Chiller Parts .............
TROUBLESHOOTING
GUIDE
Overview ........................................

Checking
Checking
•
•
•
•

................

Page
78

78
79-I 26
79

Display Messages .....................
Temperature Sensors .................

79
79

RESISTANCE
CHECK
VOLTAGE DROP
CHECK SENSOR ACCURACY
DUAL TEMPERATURE
SENSORS

Checking Pressure Transducers .................

•

COOLER CONDENSER
PRESSURE
TRANSDUCER
AND OPTIONAL
WATERSIDE FLOW DEVICE
CALIBRATION
• TRANSDUCER
REPLACEMENT
Control Algorithms
Checkout Procedure
........
80

Control Test .....................................
Control Modules .................................
•
•

81
97

RED LED (Labeled as STAT)
GREEN LED (Labeled as COM)

Notes

on Module Operation

.....................

Chiller Control Module (CCM) ...................
97
• INPUTS
• OUTPUTS
Replacing
Defective Processor Modules
........
98
• INSTALLATION
Gateway Status LEDs ...........................
99
• DRIVE STATUS INDICATOR
• MS STATUS INDICATOR
• NET A STATUS INDICATOR
• NET B STATUS INDICATOR
Physical
Data ...................................
100
APPENDIX
-- 19XRV LIQUlFLO TM 2 ICVC
PARAMETER
INDEX ......................
127-135
INDEX ..........................................
136
INITIAL START-UP CHECKLIST
FOR
19XRV HERMETIC
CENTRIFUGAL
LIQUID CHILLER
....................

CL-I to CL-12

INTRODUCTION
Prior to initial start-up of the 19XRV unit, those involved in
the stall-up, operation, and maintenance should be thoroughly
familiar with these instructions and other necessary job data.
This book is outlined to fmnili;uize those involved in the
stmt-up, operation and maintenance of the unit with the control
system before performing stmt-up procedures. Procedures in
this manual ;ue arranged in the sequence required for proper
chiller start-up and operation.

This unit uses a microprocessor
control system. Do not
shol_t or jumper between terminations on circuit bo;uds or
modules; control or board failure may result.
Be aware of electrostatic discharge (static electricity) when
handling or making contact with circuit boards or module
connections. Always touch a chassis (grounded) part to
dissipate body electrostatic charge before working inside
control centel:
Use extreme c;ue when handling tools near bo;uds and
when connecting or disconnecting
terminal plugs. Circuit
boards can easily be &_maged. Always hold boards by the
edges and avoid touching components and connections.
This equipment
uses, and can radiate, radio frequency
energy. If not installed and used in accor&mce with the
instruction manu;fl, it may cause interference
to radio
communications.
It has been tested and found to comply
with the limits for a Class A computing device pursuant to
Subpart J of Pall 15 of FCC Rules, which are designed to
provide reasonable
protection against such interference
when operated in a commercial environment. Operation of
this equipment
in a residential area is likely to cause
interference, in which case the usel: at his own expense,
will be required to take whatever
measures
may be
required to correct the interference.
Always store and transport replacement
in anti-static shipping bag.

ABBREVIATIONS

or defective boards

AND EXPLANATIONS

Frequently used abbreviations in this manual include:
CCM
-- Chiller Control Module
CCN
CCW
CW
ECDW
ECW
EMS
HGBP
I/O
ICVC
LCD
LCDW
LCW
LED
OLTA
PIC III
RLA
SCR
Sl
TXV
VFD

---------------------

Carrier Comfort Network
Counterclockwise
Clockwise
Entering Condenser Water
Entering Chilled Water
Energy Management System
Het Gas Bypass
Input/Output
International Chiller Visual Controller
Liquid Crystal Display
Leaving Condenser Water
Leaving Chilled Water
Light-Emitting Diode
Overload Trip Amps
Product Integrated Controls III
Rated Load Amps
Silicon Controlled Rectifier
International System of Units
Thermostatic Expansion Valve
Variable Frequency Drive

Words printed in all capital lettel_ or in italics may be
viewed on the International Chiller Visual Controller (ICVC)
(e.g., LOCAL, CCN, ALARM, etc.).
W_rds printed in both all capital letters and italics can also
be viewed on the ICVC and are parmneters (e.g., CONTROL
MODE, COMPRESSOR
START RELAY, ICE BUILD
OPTION, etc.) with associated values (e.g., modes, temperatures, percentages, pressures, on, off. etc.).
W_rds printed in all capital lettel_ and in a box represent
softkeys on the ICVC control panel (e.g., _,
_,
[INCREASE[, _,
etc.).

Control

Panel -- The control panel is the user interface
for controlling the chiller It regulates the chiller's capacity as
lequiled to maintain proper leaving chilled water temperature.
The control panel:

FactolT-installed
additional components tue refen_ed to as
options in this manual; factou-supplied
but field-installed
additional components are referred to as accessories.
The chiller software pall number
located on the back of the ICVC.

CHILLER

unit is

•

FAMILIARIZATION
(Fig. 1 and 2)

Chiller Information
nameplate
panel.

of the 19XRV

is located

Nameplate

•
•
•

-- The information

on the right side of the chiller control
•
•

System Components

-- The components
include the
cooler and condenser heat exchangers
in separate vessels,
compressor-motor,
lubrication
package, control panel, and
motor sttutel: All connections fiom pressure vessels have external threads to enable each component to be plessure tested with
a thleaded pipe cap during factory assembly.

•
•

Variable Frequency Drive (VFD) -- The VFD allows for the proper st_ut and disconnect of electrical energy for

Cooler-

This vessel (also known as the evaporator)
is
located underneath the compressol: The cooler is maintained at
lower temperature/pressme
so evaporating
refrigerant
can
remove heat fiom water flowing through its internal tubes.
Condenser--The
temperature/pressure
through its internal
refrigerant.

the compressor-motor,

Vessel (Optional)--There
are 2 sizes of
storage vessels available. The vessels have double relief valves,
a magnetically-coupled
dial-type refrigerant
level gage, a
one-inch FPT drain valve, and a l/2-in, male flare vapor connection for the pumpout unit.
NOTE: If a storage vessel is not used at the jobsite, factoryinstalled isolation valves on the chiller may be used to isolate
the chiller charge in either the cooler or condenser. An optional
pumpout system is used to transfer refrigerant from vessel to
vessel.

Motor-Compressor-

This component mainttfins system temperature
and pressure differences
and moves the
heat-carrying refrigerant from the cooler to the condenser

19XRV

Cooler

Size

10-12 (Frame
15-17 (Frame
20-22 (Frame
30-32 (Frame
35-37 (Frame
40-42 (Frame
45-47 (Frame
50-52 (Frame
5A (Frame
5
5B (Frame
5
50 (Frame
5

Condenser
10-12
15-17
20-22
30-32
35-37
40-42
45-47
50-52
55-57
60-62
65-67
70-72

1 XR)
1 XR)
2 XR)
3 XR)
3 XR)
4 XR)
4 XR)
5 XR)
XR)
XR)
XR)

473

Special Order Indicator
- -- Standard
S -- Special Order

Motor
Code
62
63
64
52

55-57 (Frame
5 XR)
5F (Frame
5 XR)
5G (Frame
5 XR)
5H (Frame
5 XR)
60-62 (Frame
6 XR)
65-67 (Frame
6 XR)
70-72 (Frame
7 XR)

1
1
2
3
3
4
4
5
5
6
6
7

Voltage
Code
Volts-Phase-Hertz
380-3-60
416-3-60
460-3-60
400-3-50

Motor
BD
BE
BF
BG
BH
BJ

XR /
XR)
XR)
XR)
XR)
XR)
XR)
XR)
XR)
XR)
XR)

Code
Indicates

-----

Motor Efficiency Code
H -- High Efficiency
S -- Standard Efficiency

Size

(F ....
(Frame
(Frame
(Frame
(Frame
(Frame
(Frame
(Frame
(Frame
(Frame
(Frame
(Frame

Compressor
(First Digit

High Efficiency
Hermetic
Centrifugal
Liquid Chiller with
Variable
Frequency
Drive
Unit-Mounted

oil pump, oil heater, and control panel.

Storage

condenser
operates
at a higher
than the cooler and has water flowing
tubes in order to remove heat fi_)m the

19XRV

registers
cooler,
condenser,
and lubricating
system
pressures
shows chiller operating condition and alarm shutdown
conditions
records the total chiller operating hours
sequences chiller start, stop, and recycle under microprocessor control
displays status of motor starter
provides
access
to other
CCN
(Carrier
Comfort
Network) devices and energy management
systems
Languages
pre-installed
at factory
include:
English,
Chinese, Japanese, and Korean.
International
language translator
(ILT) is available
for
conversion of extended ASCII characters.

Compressor

Frame

Size) _

*Second
digit will be a letter (example
4G3)
on units equipped
with split ring diffuser.

MODELNUMBERNOMENCLATURE

59843

Year of Manufacture

SERIAL

Place of Manufacture

NUMBER

Fig. 1 -- 19XRV

BREAKDOWN

Identification

Code
CD
CE
CL
CM
ON
CP
CQ
OR

DB
DC
DD
DE
DF
DG
DH
DJ
DK

LB
LC
LD
LE
LF
LG
LH

FRONT VIEW

LEGEND

1
2
3
4
5
6
7
8

---------

10
11
12
13
14
15
16
17

---------

Guide Vane Actuator
Suction Elbow
International Chiller Visual Control (ICVC)
Chiller Identification Nameplate
Cooler, Auto Reset Relief Valve
Cooler Pressure Transducer
Condenser In/Out Temperature Thermistors
Condenser Waterflow Device (Optional
ICVC Inputs available)
Cooler Waterflow Device (Optional ICVC
Inputs available)
Cooler In/Out Temperature Thermistors
Liquid Line Service Valve
Typical Flange Connection
Oil Level Sight Glasses
Refrigerant Oil Cooler (Hidden)
Oil Drain Charging Valve (Hidden)
Power Panel
Compressor Motor Housing

18
19
20
21
22
23
24
25
26
27
28
29
3O

------------------

Condenser Auto. Reset Relief Valves
VFD Circuit Breaker
VFD Meter Package (Optional)
Unit-Mounted VFD
Motor Sight Glass
Cooler Waterbox Cover
ASME Nameplate (One Hidden)
Typical Waterbox Drain Port
Condenser Waterbox Cover
Refrigerant Moisture/Flow Indicator
Refrigerant Filter/Drier
Liquid Line Isolation Valve (Optional)
Linear Float Valve Chamber
Vessel Take-Apart Connector
Discharge Isolation Valve (Optional)
Refrigerant Charging Valve
Condenser Pressure Transducer (Hidden)

9 --

144
13

REAR VIEW
19

27
26
31

Fig. 2 --Typical

LEGEND

31
32
33
34

19XRV Components

REFRIGERATION

CYCLE

The compressor continuously draws refrigerant vapor from
the cooler at a rate set by the amount of guide vane opening or
compressor
speed. As the compressor
suction reduces the
pressure in the coolel: the remaining refrigerant boils at a fairly
low temperature (typically 38 to 42 F [3 to 6 C]). Tile energy
required for boiling is obtained from the water flowing through
the cooler tubes. With heat energy removed, the water becomes
cold enough to use in tin air conditioning circuit or for process
liquid cooling.
After taking heat from the water, the
compressed. Compression adds still more
refrigerant is quite wmm (typic_flly 98 to
when it is discharged t]om the compressor

refrigerant vapor is
heat energy, and the
102 F [37 to 40 C])
into the condensel:

Relatively cool (typically 65 to 90 F [18 to 32 C]) water
flowing into the condenser tubes removes heat from the refrigerant and the vapor condenses to liquid.
The liquid refi'igerant passes through orifices into the
FLASC (Flash Subcooler) chamber (Fig. 3). Since the FLASC
chamber is at a lower plessure, part of the liquid refrigerant
flashes to vapol: thereby cooling the lemaining liquid. The
FLASC vapor is recondensed on the tubes which are cooled by
entering condenser watel: The liquid drains into a float chamber between the FLASC chamber and cooler Here a float v_dve
forms a liquid seal to keep FLASC chamber vapor from entering the coolel: When liquid refrigerant passes through the
vMve, some of it flashes to vapor in the reduced pressure on the
cooler side. In flashing, it removes heat from the remaining liquid. The refrigerant is now at a temperature and plessure at
which the cycle began.

MOTOR

AND LUBRICATING
COOLING CYCLE

OIL

The motor and the lubricating oil are cooled by liquid refrigerant taken from the bottom of the condenser
vessel
(Fig. 3). Refrigerant flow is maintained by the pressure differential that exists due to compressor operation. After the refrigerant flows past an isolation valve, tin in-line filtel: and a sight
glass/moisture
indicatol: the flow is split between the motor
cooling and oil cooling systems.
Flow to the motor cooling system passes through an orifice
and into the motor. Once past the orifice, the refrigerant is
directed over the motor by a spray nozzle. The refrigerant
collects in the bottom of the motor casing and is then drained
back into the cooler through the motor refrigerant di'ain line.
An orifice (in the motor shell) maintains a higher pressure in
the motor shell than in the coolel: The motor is protected by a
temperature
sensor imbedded
in the stator windings.
An
increase in motor winding temperature past the motor override
set point overrides the temperatme capacity control to hold,
and if the motor temperature rises 10 ° F (5.5 ° C) above this set
point, closes the inlet guide vanes. If the temperature rises
above the safety limit, the compressor shuts down.
Refrigerant that flows to the oil cooling system is regulated
by thermostatic expansion valves (TXVs). The TXVs regulate
flow into the oil/lefrigerant plate and fralne-type heat exchanger (the oil cooler in Fig. 3). The expansion valve bulbs control
oil temperature to the bemings. The refrigerant leaving the oil
cooler heat exchanger returns to the chiller coolel:

FLASC CHAMBER

CONDENSER

WATER

FLOATVAWE.
CHAMBER

VALVE (OPTION)

DRIER
DIFFUSER
VANE

MOISTURE/
FLOW
INDICATOR

MOTOR

ORIFICEFITTING
REFRIGERANT
LIQUID
VFD'
COOLING
ISOLATION
VALVE

REFRIGERANT
VAPOR

THERMOSTATIC
EXPANSION
VALVE

EFRIGERANT
LIQUID/VAPOR

OIL

(TXV)
UNIT
MOUNTED
VFD
(VARIABLE
FREQUENCY
DRIVE)
HEAT
EXCHANGER

CHILLED
WATER

COOLER ISOLATION
VALVE (OPTION)
SOLENOID

Fig. 3 -- Refrigerant Motor Cooling and Oil Cooling

Cycles

VFD COOLING

CYCLE

The unit-mounted variable frequency drive (VFD) is cooled
in a manner similar to the motor and lubricating oil cooling
cycle (Fig. 3).
If equipped with a unit-mounted VFD, the refrigerant line
that feeds the motor cooling and oil cooler also feeds the heat
exchanger on the unit-mounted VFD. Refrigerant is metered
through a thermostatic expansion valve (TXV). To maintain
proper operating temperature in the VFD, the TXV bulb is
mounted to the heat exchanger to regulate the flow of refdgerant. The refdgerant leaving the heat exchanger returns to the
coolel:

LUBRICATION

CYCLE

Summary

-- The oil pump, oil filtel; and oil cooler make
up a package located p_utially in the transmission casing of the
compressor-motor
assembly. The oil is pumped into a filter
assembly to remove foreign particles and is then forced into an
oil cooler heat exchanger where the oil is cooled to proper
operational temperatures. After the oil cooler, part of the flow
is directed to the gems and the high speed shaft bearings; the
remaining flow is directed to the motor shaft bearings. Oil
drains into the transmission oil sump to complete the cycle
(Fig. 4).

Details

-- Oil is charged into the lubrication system through
a hand valve. Two sight glasses in the oil reservoir permit oil
level observation. Normal oil level is between the middle of the
upper sight glass and the top of the lower sight glass when the
compressor is shut down. The oil level should be visible in at
least one of the 2 sight glasses during operation. Oil sump
temperature is displayed on the ICVC (International Chiller
Visual Controller) default screen. During compressor operation, the oil sump temperature ranges between 125 and 150 F
(52 and 66 C).
The oil pump suction is fed from the oil reservoil: An oil
pressure relief valve maintains 18 to 30 psid (124 to 207 kPad)
differential pressure in the system at the pump discharge. The
normal oil pressme on compressors
equipped with rolling
element bearings is between
18 and 40 psid (124 and
276 kPad). This diffelential pressure can be read directly from
the [CVC default scleen. The oil pump discharges oil to the oil
filter assembly. This filter can be closed to permit removal of
the filter without dnfining the entire oil system (see Maintenance sections, pages 75 to 78, for details). The oil is then
piped to the oil cooler heat exchangel: The oil cooler uses
refrigerant from the condenser as the coolant. The refrigerant
cools the oil to a temperature between 120 and 140 F (49 and
60 C).
As the oil leaves the oil cooler, it passes the oil pressure
transducer and the thermal bulb for the refrigerant expansion
vNve on the oil cooler The oil is then divided. Pro1 of the oil
flows to the thrust bearing, %rward pinion bearing, and gear
spray. The rest of the oil lubricates the motor shaft bearings and
the rear pinion beming. The oil temperature is measured in the
bearing housing as it leaves the thrust and forwaN journal
bearings. The outer bearing race temperature is measured on
compressors with rolling element bemings. The oil then drains
into the oil reservoir at the base of the compmssol: The PIC III
(Product Integrated Control III) measures the temperature of
the oil in the sump and maintNns the temperature during shutdown (see Oil Sump Temperature and Pump Control section,
page 39). This temperature is mad on the ICVC default screen.
Dudng chiller stmt-up, the PIC Ill energizes the oil pump
and provides 45 seconds of pro-lubrication to the be_uings after
pressure is verified before starting the compressor
During

shutdown, the oil pump will mn for 60 seconds to postlubricate after the compressor shuts down. The oil pump can
also be energized for testing purposes during a Control Test.
Ramp loading can slow the rate of guide vane opening to
minimize oil foaming at st_ut-up. If the guide vanes open
quickly, the sudden drop in suction pressure can cause any
refrigerant in the oil to flash. The resulting oil foaln cannot be
pumped efficiently; therefore, oil pressure falls off and lubrication is pool: If oil pressure falls below 15 psid (103 kPad)
differential, the PIC III will shut down the compressol:
If the controls me subject to a power failure that lasts more
than 3 hours, the oil pump will be energized periodically when
the power is restored. This helps to eliminate lefrigerant that
has migrated to the oil sump during the power failure. The
controls energize the pump for 30 seconds every 30 minutes
until the chiller is started.

Oil Reclaim System

-- The oil reclaim system returns
oil lost from the compressor housing back to the oil reservoir
by recovering the oil from 2 meas on the chillel: The guide
vane housing is the primary area of recovery. Oil is also recovered by skimming it from the operating refrigerant level in the
cooler vessel.
PRIMARY OIL RECOVERY
MODE -- Oil is normally recovered through the guide vane housing on the chillel: This is
possible because oil is normally entrained with refrigerant in
the chillel: As the compressor pulls the refrigerant up from the
cooler into the guide vane housing to be compressed, the oil
norm_dly drops out at this point and falls to the bottom of the
guide vane housing where it accumulates. Using discharge gas
pressure to power an eductol: the oil is diawn from the housing
and is dischmged into the oil reservoil:
SECONDARY
OIL RECOVERY
METHOD
-- The secon&try method of oil recovery is significant under light load
conditions, when the refrigerant going up to the compressor
suction does not have enough velocity to bring oil along. Under
these conditions, oil collects in a greater concentration
at the
top level of the refrigerant in the coolel: This oil and refrigerant
mixture is skimmed from the side of the cooler and is then
drawn up to the guide vane housing. There is a filter in this line.
Because the guide vane housing pressure is much lower than
the cooler pressure, the refrigerant boils off. leaving the oil
behind to be collected by the primary oil recovery method.
Bearings
-- The 19XRV compressor
assemblies include
four radi_d bemings and four thrust bearings. The low speed
shaft assembly is suppolled by two journal bemings located
between the motor rotor and the bull gem: The bearing closer to
the rotor includes a babbitted thrust face which opposes the
normal axial forces which tend to pull the assembly towmds
the transmission. The beming closer to the bull gear includes a
smaller babbitted thrust face, designed to handle counterthmst
forces.
For most 19XRV compressors the high speed shaft assembly is supported by two journal bearings located at the
transmission end and mid-span, behind the labyrinth seal. The
transmission side of the midspan bearing _dso contains a tilting
shoe type thrust beming which opposes the main axkd forces
tending to pull the impeller towards the suction end. The
impeller side face of the midspan bearing includes a babbitted
thrust face, designed to handle counterthrust forces.
For 19XRV Frmne 3 compressors built since mid-2001, the
high speed shaft assembly has been redesigned to utilize rolling
element bearings (radial and thrust). Machines employing the
rolling element bearings can be expected to have higher oil
pressure and thrust beming temperatures than those compressors using the alternate bearing design.

REAR

MOTOR

FWD MOTOR

OIL SUPPLY TO
FORWARD
HIGH
SPEED

LABYRINTH
GAS LINE

BEARING

(

MOTOR
COOLING

LINE

ISOLATION
VALVE
PRESSURE
TRANSDUCER

OIL
PUMP

ISOLATION
VALVES
OIL
COOLER

OIL
HEATER

GLASS

OILPUMP
MOTOR

FILTER
ISOLATION
VALVE

SIGHT
GLASS

Fig. 4-

STARTING

LINE

Lubrication System

EQUIPMENT

All 19XRV units am equipped with a VFD to operate the
centrifugal hermetic compressor motoc A power panel controls
the oil pump, and various auxiliary equipment. The VFD and
power panel m'e the main field wiring interfaces for the
contractol: The VFDs are mounted directly on the chillel:
Three separate circuit breakers ale inside the st_utel: Circuit
breaker CBI is the VFD circuit breaker The disconnect switch
on the stmler fiont cover is connected to fills breakel: Circuit
breaker CBI supplies power to the VH).

The main circuit breaker (CBI) on the front of the starter
disconnects the main VFD current only. Power is still energized for the other circuits. Two more circuit breakers
inside the VH) must be turned off to disconnect power to
the oil pump, PIC III controls, and oil heatel:
Circuit breaker CB2 supplies l15-v power to the control
panel, oil heater, and portions of the starter controls.
Circuit breaker CB3 supplies power at line voltage to the oil
pump. Both CB2 and CB3 are wired in pm'allel with CBI so
that power is supplied to them if the CBI disconnect is open.

Do not touch the power wiring or motor terminals while
voltage is present, or serious injury will result.
Unit-Mounted

VFD -- The 19XRV chiller is equipped
with a variable frequency drive motor controller mounted on
file condensel: See Fig. 5-7. This VFD is used wifll low voltage
motors between 380 and 480 wtc. It reduces the starting current
inrush by controlling the voltage and fiequency to the compressor motol: Once the motor has accelerated to minimum speed
the PIC IIl modulates the compressor speed and guide vane
position to control chilled water temperature.
The VFD is
further explained in the Controls section and Troubleshooting
Guide section, pages 11 and 79.
Operational p_uameters and fault codes are displayed relative to the drive. Refer to specific (hive literatme along with
troubleshooting
sections. The display is _dso the interface for
entering specific chiller operational p_u'ametel_. These ptuameters have been preprogrammed
at the factory. An adhesive
backed label on the inside of the drive has been provided for
verification of the specific job paralneters. See Initial St_ut-Up
Checklist section for details.

[]
I

OPTIONAL
METER
PACKAGE

o./o

I .

OPTIONAL
METER
PACKAGE

/0o0

STANDARD 65 - KILO AMPS INTERRUPT
CAPACITY CIRCUIT BREAKER

OPTIONAL 100 - KILO AMPS INTERRUPT
CAPACITY CIRCUIT BREAKER

Fig. 5 -- Variable Frequency Drive (VFD)

LEGEND

14,15

10,11

Fig. 6 -- Variable Frequency Drive Internal

2
3
4
5

-----

6
7
8
9
10
11
12
13
14
15
16
17
18
19

---------------

Input Inductor Assembly
Capacitor Bank Assembly
Pre-Charge Resistor Assembly
AC Contactor
Fuse Block, 30A, 600 v,
Class CC, 3-Line
Ground Cable
Power Module Assembly
Power Module Nameplate
Terminal Block, 10-Position
Line Synch PC Board Assembly
Line Synch Board Cover
Fuse, Class CC, 600 v, 1 A
Fan, 115 v
Fuse, Class CC, 600 v, 15 A
Fuse, Class CC, 600 v, 4 A
Transformer, 3 kVA
Control Power Circuit Breaker
Circuit Breaker, 600 v
Lug, Ground, 2-600 MCM

COOLER CHARGING

CONTROL

PANEL

GUIDE VANE
ACTUATOR CABLE

POWER PANEL

CABLE

VALVE (HIDDEN)

WATER
CABLES

WATER SEN_

CABLES

j
COOLER PRESSURE
TRANSDUCER
CONNECTION

cO2?s s'S 2
CABLE

SCHRADER
FITTING(HIDDEN)
CONDENSER
PRESSURE
TRANSDUCER
CONNECTION

CONDENSER
3-WAY SHUTOFF
VALVE

CONDENSER
CHARGING
VALVE (HIDDEN)

COMPRESSOR
DISCHARGE
ELBOW JOINTS

Fig. 7 -- Chiller Controls and Sensor Locations

CONTROLS

with auxiliary equipment such as pumps and cooling tower
fans to turn them on when required. It continually checks all
safeties to prevent any unsafe operating condition. It also regulates the oil heater while the compressor is off and regulates the
hot gas bypass valve, if installed. The PIC III controls provide
critical protection for the compressor motor and controls the
motor stmlel: The PIC III can interface with the Carrier
Comfort Network (CCN) if desired. It can communicate with
other PIC I, PIC II or PIC III equipped chillers and other CCN
devices.

Definitions
ANALOG SIGNAL -- An analog signal varies in proportion
to the monitored source. It quantifies values between operating
limits. (Example: A temperature sensor is an analog device because its resistance changes in proportion to the temperature,
generating many values.)
DISCRETE SIGNAL --A discreW signal is a 2-position representation of the value of a monitored source. (Example: A
switch produces a discrete signal indicating whether a value is
above or below a set point or boun&uy by generating an on/off.
high/low, or open/closed signed.)

The PIC [II consists of 3 modules housed inside 3 major
components. The component names and corresponding control
voltages are listed below (also see Table 1):
•

General

-- The 19XRV herlnetic centrifuged liquid chiller
contains a microprocessor-based
control panel that monitors
and controls all operations of the chiller (see Fig. 7). The
microprocessor control system matches the cooling capacity of
the chiller to the cooling load while providing state-of-the-art
chiller protection. The system controls cooling load within the
set point plus the deadband by sensing the leaving chilled water
or brine temperature and regulating the inlet guide vane via a
mechanically
linked actuator motol: The guide vane is a
variable flow pre-whifl assembly that controls the refrigeration
effect in the cooler by regulating the amount of refrigerant
vapor flow into the compressor. An increase in guide vane
opening increases capacity. A decrease in guide vane opening
decreases capacity. The microprocessor-based
control center
protects the chiller by monitoring the digital and analog inputs
and executing capacity overrides or safety shutdowns,
if
required.

PIC III System

Components

•

control panel
-- all extra low-voltage
wiring (24 v or less)
power panel
-- 115 vac control voltage (per job requirement)
-- 115 vac power for oil heater and actuators
-- up to 480 vac for oil pump power
starter cabinet
-- chiller power wiring (per job requirement)

Table 1 -- Major PIC III Components
Panel Locations*
PIC III COMPONENT

The chiller

control
system is called the PIC 1II (Product Integrated Control [II).
See Table 1. The PIC III controls the operation of the chiller by
monitoring all operating conditions. The PIC III can diagnose a
problem and let the operator know what the problem is and
what to check. It promptly positions the guide vanes to
m_fint_fin leaving chilled water temperature.
It can interface

PANEL LOCATION

International Chiller Visual Controller
(ICVC) and Display

Control Panel

Chiller Control Module (CCM)

Control Panel

Oil Heater Contactor

Power Panel

(1C)

Oil Pump Contactor (2C)

Power Panel

Hot Gas Bypass Relay (3C) (Optional)

Power Panel
Power Panel

Control Transformers
Temperature Sensors
Pressure Transducers
*See Fig, 5-10.

and

(T1, T2, T3)

See Fig, 7.
See Fig, 7.

INTERNATIONAL
CHILLER
VISUAL
CONTROLLER
(ICVC) -- The ICVC is the "brain" of the PIC HI. This module contains all the operating software needed to control the
chillel: The ICVC is mounted to the control panel (Fig. 9) and
is the input center for all local chiller set points, schedules,
configurable
functions, and options. The [CVC has a stop
button, an alarm light, four bnttons for logic inputs, and a
backlight display. The backlight will automatically
turn off
after 15 minutes of non-use. The lhnctions of the four buttons
or "softkeys" me menu driven and are shown on the display
directly above the softkeys.

NOTE:

Plessing

vate the
function.

backlight

any one of the four
display

without

softkey

buttons

will

implementing

The [CVC may be identified
by viewing the back of the plate
on which the display is mounted.
(Open the control panel door
to view.) Note any of the following
distinguishing
features
in
Table 2.

Table 2 -- Identification

CONTROLLER

The viewing angle of the ICVC can be adjusted for optimum viewing. Remove the 2 bolts connecting the control panel
to the brackets attached to the coolec Place them in one of the
holes to pivot the control panel forw_ud to backward to change
the viewing angle. See Fig. 9. To change the contrast of the
display, access the adjustment on the back of the ICVC. See
Fig. 9.
The ICVC features 4 factory progrmnmed languages:

ICVC

COLOR
OF
PLATE

Metallic

Features of the ICVC

CEPL No.
(hardware)

CEPL
130445-02

SOFTWARE

OTHER
MARKINGS

CESR
131350-0X

"PIC IIr'
Marking
on back
of green
circuit
board

English (default)
Chinese

Japanese
Kolean

MOTOR TEMPERATURE

COMPRESSOR OIL DISCHARGE
PRESSURE CABLE

OIL RECLAIM
SIGHT GLASS_

BEARING TEMPERATURE
CABLE

COMPRESSOR
AND DIFFUSER

OIL SUMP

ACTUATOR

CABLE (FRAME 4 & 5
COMPRESSOR
ONLY)

GUIDE
ACTUATOR

acti-

a softkey

COMPRESSOR

OIL SUMP

CABLE FROM
CONTROL PANEL

CABLE

COMPRESSOR
DISCHARGE
TEMPERATURE
SENSOR
CABLE
OIL COOLER

HIGH PRESSURE
SWITCH LOCATION

EXPANSION

THERMOSTATIC
VALVE (TXV)

OIL COOLER THERMOSTATIC
EXPANSION VALVE (TXV) BULB
OIL HEATER TERMINAL
BOX

Fig. 8 -- 19XRV Compressor Controls and Sensor Locations

CHILLER CONTROL MODULE (CCM) -- This module is
located in file control panel. Tile CCM provides the input and
outputs necessa U to control the chillel: This module monitors
refiigerant pressure, entering and leaving water temperatures,
and outputs control for the guide vane actuator, oil heaters, and
oil pump. The CCM is the connection point for optional
demand limit, chilled water reset, remote temperature reset,
refi'igerant leak sensor and motor kilowatt output.
OIL HEATER CONTACTOR (IC) -- This contactor is located in the power panel (Fig. 10) and operates the heater tit
115 v. It is controlled by the PIC III to maintain oil temperature
during chiller shutdown. Refer to the control panel wiring
schematic.

For this type the sensor cable can be easily disconnected fiom
the sensok which is in direct contact with the fluid.
Figure 12 shows a typictd temperature sensor for which
sensor wells am used, in systems having an ICVC controllel:
For this type the sensor cable cannot be separated from the
sensor itself, but the sensor can be readily removed from the
well without breaking into the fluid boun&u-y.
The third type of temperature sensor is a thermistok which
is installed either in the motor windings or tit the thrust bearing
within the compressol: Both of these have redun&mt sensors
such flint if one fails, the other can be connected external to the
machine. See NiNe 3 for a list of stan&trd instrumentation
sensors.

OIL PUMP CONTACTOR (2C) -- This contactor is located
in the power panel. It operates all 380 to 480-v oil pumps.
The PIC HI energizes the contactor to turn on the oil pump as
necessm-y.
HOT GAS BYPASS CONTACTOR
RELAY (3C)
(Optional) -- This relay, located in the power panel, controls
the opening of the hot gas bypass valve. The PIC III energizes
the relay during low load, high lill conditions.
CONTROL TRANSFORMERS (TI, T2)- These transformers convert incoming control voltage to 24 vac power for the
3 power panel contactor relays, CCM, and ICVC.

The PIC [II control determines refrigerant temperature in
the condenser and evaporator fi_m pressure in those vessels,
mad fi_m the conesponding pressure transducers. See Fig. 13.
The pressure values are converted to the equivtdent saturation
temperatures for R-134a refrigerant. When the chiller is running, if the computed value for EVAPORATOR REFRIG
TEMP is greater than, or within 0.6° F (0.33 ° C) of the LEAVING CHILLED WATER temperature, its value is displayed as
0.6° F (0.33° C) below LEAVING CHILLED WATER tempe>
atum. When the chiller is running, if the computed value for
CONDENSER REFRIG TEMP is less than, or within 1.2° F
(0.67 ° C) of the LEAVING COND WATER temperature, its
value is displayed as 1.2° F (0.67 ° C) above LEAVING COND
WATER temperature.

OPTIONAL TRANSFORMER (T3)--This
transformer provides control power to DataPort'rWDataLINK TM modules.
SENSORS -- Throe types of temperature sensors am used:
Figure 11 shows a typictd temperature sensor with which
sensor wells am not used, in systems having a ICVC controllel:

Table 3 -- Standard Instrumentation
TYPE

LOCATION

Temperature

Pressure

Angular

Position

Pressure
Temperature

Switch
Switch

Sensors

MONITORED

REMARKS

Entering chilled water

Cooler inlet nozzle

Leaving chilled water

Cooler outlet nozzle

Entering condenser water

Condenser inlet nozzle

Leaving condenser water
Evaporator saturation

Condenser outlet nozzle
Sensor well on bottom of evaporator

Compressor discharge

Compressor

volute

Oil sump

Compressor

oil sump

Compressor thrust bearing

Redundant sensor provided

Motor winding

Redundant sensor provided

Evaporator
Condenser

Relief valve tee
Relief valve tee

Oil sump

Compressor

Oil sump discharge

Oil pump discharge line

Diffuser (Compressor

internal)

oil sump

Only in machines

equipped with split ring diffusers

Entering chilled water (Optional)

Cooler inlet nozzle

Leaving chilled water (Optional)

Cooler outlet nozzle

Entering condenser water (Optional)

Condenser inlet nozzle

Leaving condenser water (Optional)

Condenser outlet nozzle

Guide vane actuator

Potentiometer

High condenser

Compressor

(discharge) pressure

Oil pump motor winding temperature

inside of actuator
volute, wired into the starter control circuit

Wired into the oil pump control circuit

CARRIER
CONTROL

COMFORT
CONTROL

NETWORK
(CCN)
INTERFACE

PANEL

CIRCUIT

POWER
BREAKERS

DISPLAY
(FRONT VIEW)

fo_m_,
INTERNATIONAL
CHILLER
VISUAL
CONTROLLER
(ICVC)
FRONT VIEW

0000

OPTIONAL
DATAPORT/DATAU
>CIRCUIT

BREAKERS

HUMIDITY
SENSOR

@GG

( (
.............
SURGE/HGBP

_÷

CHILLER
MODULE

PARAMETER
LABEL

CONTROL
(CCM)
CONTROL

PANEL

INTERNAL

VIEW

CONTROL
PANEL
SIDE VIEW
CONTROl.
REMOVABLE
BOLT
DIFFUSER
SCHEDULE
SETTINGS

HINGE

(FRAME
5
COMPRESSOR
ONLY)
INTERNATIONAL
VISUAL
OONTRO_ER
REAR VIEW

CONTRAST
CHILLER

Fig. 9-

T1-24
FOR

VAC POWER
HOT

GAS

OIL PUMP
OIL HEATER

IDENTIFICATION

NAMEPLATE

Control Panel

TRANSFORMER

BYPASS

CONTACTOR,

RELAY,
AND

T2-24 VAC POWER TRANSFORMER
FOR ICVC AND CCM

CONTACTOR

T3-20 VAC POWER TRANSFORMER
FOR DATAPORT/DATALINK (OPTIONAL)

3C HOT GAS

OIL HEATER

CONDUIT

CONTROL
PANEL
POWER
CONDUIT

Fig. 10 -- Power Panel
14

OPTIONAL
BYPASS

HOT
CONDUIT

GAS

BYPASS

L,_

3 00in

_-_-_ _i6,35" mm)(762 mm)

............

_-J

_---- , .-

RECEPTACLE

NPT

Fig. 11 -- Control

than the EVAP REFRIG TRIPPOINT. (If the unit is in Pumpdown or Lockout mode, conditions (1) and (2) ;ue not required
to establish flow.) On the condenser side, positive detemrination of flow is made if the following conditions are tree: (1) the
CONDENSER
PRESSURE is less than 165 psig (1139 kPa),
and (2) CONDENSER
PRESSURE is less than the configured
COND PRESS OVERRIDE
threshold by more than 5 psi
(34.5 kPa). In addition, if the waterside differentkd pressure
measurement option is enabled, the watel_ide pressure differentials (cooler and condenser) must exceed their respective
configured cutout thresholds.

CONNECTOR

WATERPROOF

SEAL

Sensors (Temperature)

A No Flow determination is made on the evaporator side if
(1) the EVAP SATURATION
TEMP reads lower than 1° F
(0.6 ° C) below the EVAP REFRIG TRIPPOINT. or (2) EVAP
REFRIG TEMP (determined
from the Evaporator
Pressure
sensor) is less than the EVAP REFRIG TRIPPOINT
and the
EVAPORATOR
APPROACH
exceeds the configured EVAP
APPROACH
ALERT threshold. On the condenser side, a
No Flow determination
is also made if the CONDENSER
APPROACH
exceeds the configured COND APPROACH
ALERT threshold and either (1) CONDENSER
PRESSURE
exceeds 165 psig (1139 kPa) or (2) CONDENSER
PRESSURE exceeds the configured COND PRESS OVERRIDE
threshold by more than 5 psi (34.5 kPa). In addition, if the water side differential pressure measurement option is enabled, a
differential below the configured EVAP or COND FLOW
DELTA P CUTOUT v_due is sufficient to establish No Flow in
either heat exchangel:

(90MM)
3.6" TUBE
LENGTH

\EATSHR,NK\
2-CONDUCTOR

CABLE

Fig. 12 -- Temperature Sensor Used
With Thermal Well

1/4" SAE FEMALE
INTEGRAL

FLARE

SCHRADER

WITH

DEFLATOR

If No Flow (for either cooler or condenser) has been determined, and subsequently conditions change such that neither
conditions for Flow nor No Flow are _dl satisfied, the determination will remain No Flow.
In the standard [CVC setup, waterside differential pressure
indication is disabled by default. The displays for CHILLED
WATER DELTA P and CONDENSER
WATER DELTA P in
the HEAT_EX screen will show "*****". In order to enable
the option and display a value, change FLOW DELTA P
DISPLAY to ENABLE in the SETUPI scleen. Pairs of pressure transducers may be connected to the CCM at temrinals
J3 13-24 in place of the standard resistors and jumpers to determine water-side pressme differentials as in the standard ICVC
configuration. (NOTE: If the FLOW DELTA P DISPLAY is
enabled but the standard CCM connection is retained, a differential value of approximately 28.5 psi (197 kPa) will _flways be
displayed.)

Fig. 13 -- Control Sensors
(Pressure Transducers, Typical)
A Refrigerant Saturation Temperature sensor (thermistor) is
located in the base of the evaporator,
sensing refrigerant
temperature
directly. Evaporator and condenser water side
differential pressure transducers _u'e not stan&trd and are not
required. The [CVC software uses the evaporator saturation
refrigerant temperature in place of diffferential pressure flow
detection to provide evaporator fieeze protection.

If watel_ide diffelential plessure transducel_ me used, flow
is detected fi_m differential pressure between sensors (pressure
transducers) located in water inlet and outlet nozzles, for earl1
heat exchangeE The thresholds for flow determination (EVAP
FLOW DELTA P CUTOUT. COND FLOW DELTA P CUTOUT) are configured in the SETUPI screen. If the measured
differential is less than the corresponding
cutout value for 5
seconds, the determination is that flow is absent. If no flow is
detected after W_TER FLOW VERIFY TIME (configured in
the SETUPI screen) after the pump is commanded to start by
the PIC, a shutdown will result, and the corresponding loss-offlow _dmm (alarm state 229 or 230) will be declared. If the
measured differenti_d exceeds the Flow Delta P cutout value,
flow is considered to be present.

Approach temperatures are shown in the HEAT_EX scleen.
EVAPORATOR
APPROACH
is defined
as LEAVING
CHILLED WATER temperature minus EVAP SATURATION
TEMP (from the temperature
sensor). CONDENSER
APPROACH
is defined
as CONDENSER
REFRIG
TEMP
(derived from condenser pressure) minus LEAVING CONDENSER WATER temperature. When the chiller is running,
the displayed v_due for either approach will not be less than
0.2 ° F (0.1 o C). If either approach value exceeds the value configured in the SETUPI screen, the corresponding
Approach
Alert message will be entered into the Alert Histo U table.
FLOW DETECTIONFlow detection for the evaporator
and condenser is a required condition for stm-t-up and used in
the freeze protection safety. Flow and no flow conditions are
detected from a combination
of several measurements.
The
usage of waterside diffelential pressme measmements
is not
standard or required.

Alternatively. norm_dly open flow switches may be used for
flow indication. In this case, inst_dl an evaporator side flow
switch in parallel with a 4.3k ohm resistor between CCM
terminals J3 17-18, replacing the jumpel: See page 114. For a
condenser side flow switch do the same between CCM terminals J3 23-24. If this type of flow switch circuit is used, it is
important to perform a zero point calibration (with the flow
switch open).

Positive detemrination
of flow on the evaporator side is
made if the following conditions ale true: (1) the EVAP SATURATION TEMP reads higher than 1° F (0.6 ° C) above the
EVAP REFRIG TRIPPOINT. and (2) EVAP REFRIG TEMP
(determined from the Evaporator Pressure sensor) is greater

ICVC Operation

and Menus

(Fig. 14-20)

PRIMARY STATUS

COMPRESSOR
ON TIME

GENERAL
STATUS
MESSAGE

•

The [CVC display automatically
reverts to the default
screen after 15 minutes if no softkey activity takes place
and if the chiller is not in the pump down mode (Fig. 14).
• If a screen other than the default screen is displayed on
the ICVC, the name of that screen is in the top line
(Fig. 15).
• The ICVC may be set to display either English or SI
units. Use the ICVC configuration
screen (accessed from
the Service menu) to change the units. See the Service
Operation section, page 48.
NOTE: The date format on the default screen is MM-DD-YY
for English units and DD-MM-YY

(ILLUMINATED
WHEN POWER ON)
• BLINKS CONTINUOUSLY
ON FOR AN ALARM
• BLINKS ONCE TO
CONFIRM
A STOP

mmmm
/

• HOLD FOR ONE
SECOND TO STOP

SOFT KEYS

for SI metric units.

EACH KEY'S FUNCTION IS
DEFINED BY THE MENU DESCRIPTION

•

Local Operation -- In LOCAL mode the PIC III accepts
commands
fiom the ICVC only and uses the local time
occupancy
schedule to determine
chiller start and stop
times. The PIC III can be placed in the local operating
mode by pressing
the LOCAL
softkey. When RUN
STATUS is READY. the chiller will attempt to start up.
• CCN Opelation
--In
CCN mode the PIC III accepts
input from any CCN interface or module (with the proper
authority) as well as from the local ICVC. The PIC III
uses the CCN time occupancy
schedule to determine
start and stop times. The PIC III can be placed in the
local operating
mode by pressing
the CCN softkey.
When RUN STATUS is READY. the chiller will attempt
to start up.
• OFF -- The control is in OFF mode when neither the
LOCAL nor CCN softkey cue is highlighted.
Pressing
the STOP key or an alarm will place the control in this
mode. The PIC III control must be in this mode for
certain operations,
such as performing a Control Test or
accessing VFD Configuration
parameters.
ALARMS AND ALERTS -- An altu'm shuts down the compressor An alert does not shut down the compressol: but it
notifies the operator that an unusual condition has occurred. An
alarm (*) or alert (!) is indicated on the STATUS screens on the
far right field of the ICVC display screen.

ON MENU

Fig. 14--

•

the operator to view the chiller conditions at the time of alarm.
The STATUS tables will show the updated information. Once
soft-

key), the default ICVC screen will return to normal operation.

ICVC MENU ITEMS -- To perform any of the operations
described below, the PIC III must be powered up and have
successfully completed its self test. The self test takes place
automatically, after power-up.
tures:

LSETPOINT],

[SERVICE].

ISCHEDULEI,[SE OINTI, or

To view or change parmneters
use the _

within any of these

and [PREVIOUS[

softkeys

to scroll down to the desired item or table. Use the
softkey to select that item. The softkey choices that appear next
depend on the selected table or menu. The softkey choices and
their functions are described below.

and

[SERVICEI.
•

viewed:

menu structures,

softkey to view the list of menu struc[SCHEDULE],

The SCHEDULE
menu allows viewing and modification
of the local and CCN time schedules and Ice Build time
schedules.
The SETPOINT menu allows set point adjustments,
such
as the entering chilled water and leaving chilled water set
points.
The SERVICE
menu can be used to view or modify
information
on the Alarm History, Control Test, Control
Algorithm Status, Equipment Configuration,
VFD Configuration
data, Equipment
Service,
Time and Date,
Attach to Network Device, Log Out of Network Device,
and ICVC Configuration
screens.

For more information
on the menu structures, refer to
Fig. 17.
Press the softkey that corresponds to the menu structure to

An alarm condition must be rectified before a RESET will
be processed. However. an _dert will clear automatically
as
soon as the associated condition is rectified.

Press the _

SCREEN NAME

Fig. 15 -- ICVC Service Screen

When an alarm is detected, the ICVC default screen will
fieeze (stop up&_ting) at the time of alarm. The freeze enables

the _

Screen

mmm
•

(by pressing

MENU
LINE

LINE ABOVE

ICVC Default

DEVICE NAME

Alarms are indicated when the control center _darm light (!)
flashes. The primtuy alarm message is displayed on the default
screen. An additional, secondary message and troubleshooting
information are sent to the ALARM HISTORY table.

all aimms have been cleared

DATE

BASIC ICVC OPERATIONS
(Using the Softkeys) -- To perform any of the operations described below, the PIC III must be
powered up and have successfully completed its self test.

The STATUS menu allows viewing and limited calibration or modification
of control points and sensors, relays
and contacts, and the options board.

Press _
to leave tile selected decision or field without saving any changes.
_,

INCREASE

DECREASE

QUIT

ENTER

Press _
or IPREVIOUSI to highlight
status table. The list of tables is:
•
•

D
Press _
save changes.

to leave tile selected

INCREASE

DECREASE

decision

QUIT

MAINSTAT-Overall chiller status
STARTUP-Status required to perform start-up of
chiller
COMPRESS
-- Status of sensors related to the
compressor
HEAT_EX -- Status of sensors related to the heat
exchangers
POWER -- Status of motor input power
VFD_STAT-Status of motor starter
ICVC PSWD -- Service menu password fDrcing
access screen

•

or field and

ENTER

•
•
•
•

71QD

the desired

SELECT

ENTER

Press _
to scroll tile cursor bar down in order to
highlight a point or to view more points below the current screen.
Press _
_,

to view the desired point status table.

SELECT
t

SELECT

ENTER

D
Press [PREVIOUS[ to scroll tile cursor bar up in order to
highlight
a point or to view points above tile current
screen.
NEXT

On the point status table, press _

or [PREVIOUS]

until tile desired point is displayed
L

SELECT

on tile screen.

SELECT

ENTER

Q7!

Q
Press _
to view tile next screen level (highlighted with the cursor bar), or to override (if allowable)
the highlighted
point value.
_,

SELECT

7] Q
Press _

)

EXIT

to return to tile previous

screen level.

mmmm

NEXT PREV,OUS
SELECT EX,T )

Press ]INCREASE] or IDECREASEI
lighted point value.
INCREASE

DECREASE

QUIT

to change

tile high-

Fig. 16 -- Example of Status Screen
FORCING

ENTER

N] 7!

OPERATIONS

TD Force (manually
I. From

any

[PREVIOUS]
l

ovelTide) a Value or Status
point

status

TO VIEW STATUS (Fig. 16) -- The status table shows the
actual v_flue of overall chiller status such as CONTROL
MODE, RUN STATUS, AUTO CHILLED WATER RESET.
and REMOTE RESET SENSOR.
I.

On tile menu screen, press _
point status tables.
STATUS

SCHEDULE

to view tile list of

SETPOINT

SERVICE

press

SELECT

EXIT

QD
Press _

to select tile highlighted
NEXT

screen,

SELECT

v_due.
EXIT

to highlight the desired value.
)

DEFAULT SCREEN

I CCN][

LOCAL

__IStart Chiller

In CCN Control

Start Chiller

in Local Control

] [

RESET

]

(SOFTKEYS)

Clear

Alarms

_
T

[

STATUS

][SCHEDULE]

Access

Main Menu

Es l

I SERVICE

List the
Status Tables
•
•
•
•
•
•
•

]

-'_
......

(ENTER A 4-DIGIT PASSWORD)

Display The Setpoint

MAINSTAT
STARTUP
COMPRESS
HEAT EX
POWER
VFD STAT
ICV(_PSWD

•
•
•
•
•

]1 PREVIOUS]

Select a Modification
NEXT

][

Base Demand Limit
LCW Setpoint
ECW Setpoint
Ice Build Setpoint
Tower Fan High Setpcint

[

SELECT

] [

EXIT

Select the Setpoint
[ N_
][_-EVIOUS]

[

SELECT

] E

EXIT

[INCREASE
I[DECREASEII

] [

ENTER

Point

PREVIOUS]

Table

List the Schedules

Select a Statue Table
NEXT

(VALUES SHOWN AT FACTORY DEFAULT)
List the Service Tables

[

SELECT

[

EXIT

]

ENTER

]

Modify the Setpoint
QUIT

] [

Modify a Discrete Point
_,_

START
ON

]

STOP
OFF

] [ RELEASE

Modify an Analog Point
INCREASE]

IDECREASE]

Modify Control
ENABLE

[ RELEASE

] E ENTER

Options
DISABLE

] [

QUIT

I [

ENTER

• OCCPC01S - LOCAL TIME SCHEDULE
• OCCPC02S - ICE BUILD TIME SCHEDULE
• OCCPC03S - CCN TIME SCHEDULE
Select a Schedule
1[
NEXT
][ PREVIOUS]
I SELECT ] [
EXIT
1
2
3
4
5
6
7
8
Override
Select a Time Period/Override

NEX
T

SELECT

][

I ENTER
][

EXIT

]

EXIT

] (ANALOG VALUES)

EXIT

] (DISCRETE VALUES)

aDay
[ DISABLE

ENTER

ALARM HISTORY
ALERT HISTORY
CONTROL TEST
CONTROL ALGORITHM STATUS
EQUIPMENT CONFIGURATION
VFD CONFIG DATA
EQUIPMENT SERVICE
TIME AND DATE
ATTACH TO NETWORK DEVICE
LOG OUT OF DEVICE
ICVC CONFIGURATION
[

]I PREVIOUS][

SELECT I _

SEE FIGURE 18

Fig. 17 -- 19XRV Chiller Display Menu Structure

(ICVC)

SERVICE TABLE
[

][ PREVIOUS]
ALARM

[ SELECT

]

[

EXIT

ALERT

HISTORY

Alert History
(The table holds up to 25 alarms and
alerts with the most recent alarm
at the top of the screen,)

Display Alarm History
(The table holds up to 25 alarms and
alerts with the most recent alarm
at the top of the screen.)
CONTROL

TEST

CONTROL

ALGORITHM

List the Control Tests
STATUS

List the Control Algorithm Status Tables
• CAPACITY (Capacity Control)
• OVERRIDE (Override Status)
• LL MAINT (Lead Lag Status)
• VFD HIST (VFD Alarm History)
• LOADSHED
• CURALARM
(Current Alarm State)
• WSMDEFME (Water System Manager Control Status)
• OCCDEFCM (Time Schedule Status)
Select a Table

[NEXT

]EPREVIOUS]I

][

EXIT

][PREVIOus]E SELECT

OCCPC01S
OCCPC02S
OCCPC03S

EQUIPMENT

SELECT][

EXIT

(Time Schedule Status)
•
•
•
•

Data Select Table
NEXT

I[PREVIOus]E

]

a Test

CCM Thermistors
CCM Pressure Transducers
Pumps
Discrete Outputs
IGV and SRD Actuator
Head Pressure Output
Diffuser Actuator
Pumpdown/Lockout
Terminate Lockout
Guide Vane Calibration

I
OCCDEFM

SELECT

Select
]

•
•
•
•
•
•
•
•
•
•

CONFIGURATION

] [

EXIT

]

(Local Status)
(CCN, ICE BUILD Status)
(CCN Status)

List the Equipment

CAPACITY (Capacity Control Algorithm)
OVERRIDE (Override Status)
LLMAINT
(LEADLAG Status)
WSMDEFM2 (Water System Manager Control Status)

Maintenance

Configuration

Table Data

Tables

•
•
•
•
•
•

NET OPT
BRODEF
OCCDEFCS
HOLIDAYS
CONSUME
RUNTIME

Select a Table
E

][

PREVIOUS][

SELECT

] [

EXIT

]

Select a Parameter
[

][PREVIOUS]

Modify a Parameter
[INCREASE]
[DECREASE]
[ ENABLE
CONTINUED
ON NEXT PAGE

][

DISABLE

]

EXIT

[

QUIT

]

ENTER

](ANALOG

[

QUIT

]

ENTER

I (DISCRETE

SELECT (USE ENTER) TO SCROLL DOWN

Fig. 18 -- 19XRV Service Menu Structure

[ SELECT

VALUES)
VALUES)

]

SERVICE MENU CONTINUED
FROM PREVIOUS PAGE
EQUIPMENT

VFD CONFIG DATA

SERVICE

--_

(ENTER A 4-DIGIT PASSWORD)
(VALUES SHOWN AT FACTORY DEFAULT)

Service Tables:
• OPTIONS
• SETUPt
• SETUP2
• LEADLAG
• RAMP DEM
• TEMP CTL

Service Tables:
• VFD (STARTER)
• VFD CONF

CONFIG

PASSWORD

Select a Service Table

[NEXT

] I PREVIouslI SELECTI E

Select

a Service Table Parameter

[NEXT

] I PREVIOUS]

SELECT

I E

vice Table Parameter
I_AS_]
I
QUIT
[ ENABLE

] E DISABLE

]

] [

QUIT

EXIT

EXit

]

ENTER

] E ENTER

] (ANALOG VALUES)
](DISCRETE

VALUES)

TIME AND DATE

A'I-rACH TO NETWORK

DEVICE

List NetJrk
•
•
•
•
•
•

Display Time and Date Table:
• To Modify -- Current Time
-- Current Date

Local
Device
Device
Device
Device
Device

[INCREASE
I [DECREASE]
I ENTER
[
YES
I [ NO ] I ENTER

Devices
•
•
•
•

1
2
3
4
5

Device
Device
Device
Attach

6
7
8
to any Device

---

Day of Week
Holiday Today

] I

EXIT

I(ANALOG

] I

EXIT

I(DISCRETE

VALUE)
VALUE)

Select a Device
[

]1 PREVIOUS
I[

Modify Device Address

SELECT
_

ATTACH

]

[

[INCREASE]IDECREASE]I
ENTER
I E
EXIT
• Use to attach ICVC to another CCN network or device/
• Attach to "LOCAL" to enter this machine
• To upload new tables

]
/

LOG OUT OF DEVICE

Default Screen
[

CON

LOCAL

ICVC Configuration

Table I

RESET

ICVC CONFIGURATION

[

LEGEND
CCN
ICVC
PIC III
VFD

-----

• To Modify ------

ENTER

] [

EXIT

ICVC CCN Address
• To View -Baud Rate (Do not change this)
English (U.S. IMP.) or S.I. Metric Units
Password
LID Language

Carrier Comfort Network
International Chiller Visual Controller
Product Integrated Control III
Variable Frequency Drive

Fig. 18 -- 19XR Service Menu Structure (cont)

]
ICVC Software Version
(last 2 digits of part number
indicate software version)

For Discrete Poin_ -- Press _
lect the desired state.

or _

OCCPC03S

to se-

-- CCN Time Schedule

NEXT
START

STOP

RELEASE

ENTER

Poin_
-Press
IINCREASEI
to select tile desiled value.

INCREASE

DECREASE

RELEASE

ENTER

SELECT

EXIT

)

Press _
For
Analog
[DECREASE]

to view the desired time schedule.
NEXT

SELECT

EXIT

)

Press _
or IPREVIOUSI to highlight
period or oveMde to change.
3.

Press _

to legister the new value.

INCREASE

DECREASE

RELEASE

On tile point status table press _
to highlight the desired value.

NE_

Press _
OVERRIDE.
_,

PREVIOUS
SELECT EX.

to access tile highlighted
NEXT

SELECT

INCREASE

DECREASE

RELEASE

SELECT

PERIOD

EXIT

ENTER

DECREASE

ENTER

EXIT

IDISABLEI to eliminate

ENABLED,SA_LEENTER EXIT )

On tile Menu screen, press ]SCHEDULE].
SETPOINT

SERVICE

D
2. Pless _
schedule.

days from the

D
(Fig. 19)

SCHEDULE

to select days in the day-of-week

TIME SCHEDULE

STATUS

up to 4 hours.

[ENABLE]

fields. Press
period.

value is indicated
by
fla. hmg next to the point

INCREASE

b. Press

Force Indication
-A forced
"SUPVSR," "SERVC," or BEST
value on the STATUS table.
OPERATION

to access tile highlighted

EXIT

Pless [RELEASE]
to remove tile force and return tile
point to the PIC III's automatic control.
t

value.

D
3.

EXIT

Press IINCREASE I or [DECREASE] to change tile
time values. OVERRIDE
values are in one-hour

)
_

Pless _

SELECT

or IPREVIOUS]

increments,

the desired

ENTER

NOTE: When forcing or changing metric values, it is necessalT to hold down the sollkey for a few seconds in order to see
a value change, especially on kilopascal values.
To Remove a Force
I.

or [PREVIOUS] to highlight tile desired
Fig. 19 -- Example of Time Schedule
Operation Screen

OCCPC01S -- LOCAL Time Schedule
OCCPC02S -- ICE BUILD Time Schedule

Press _

to register

tile values and to move holi-

There are 5 set points on this screen: BASE DEMAND
LIMIT. LCW SETPOINT
(leaving chilled water set
point), ECW SETPOINT
(entering chilled water set
point), ICE BUILD SETPOINT,
and TOWER FAN
HIGH SETPOINT.
Only one of the chilled water set
points can be active at one time. The set point that is
active is determined from the SERVICE menu. See the
Service Operation section, page 48. The ice build (ICE
BUILD) function is _flso activated and configured from
the SERVICE menu.

Press _
or [PREVIOUS]
set point entry.

zontally (left to right) within a pedod.
ENABLE

DISABLE

ENTER

EXIT

7]
Press _

to leave the PERIOD
NEXT

or OVERRIDE.

SELECT

EXIT

DQQ

to highlight

SELECT

the desired

EXIT

)

Either return to Step 4 to select another PERIOD or
OVERRIDE,
or press _
again to leave the current
time schedule screen and save the changes.
4.
t

SELECT

EXIT

Press _

to modify the highlighted

set point.

PREV,OUS
SELECT EX,T )

D
10.

The Holiday Designation
(HOLIDEF
table) may be
found in the Service Operation
section, page 48. The
month, day, and duration
for the holiday must be
assigned.
The Broadcast
function
in the BRODEF
table also must be enabled
for holiday
periods to
function.

TO VIEW AND CHANGE SET POINTS (Fig. 20)
I. To view the SETPOINT table, fiom the MENU
pless ISETPOINT 1.
STATUS

SCHEDULE

SETPOINT

SERVICE

Press IINCREASEI
ed set point value.
_,

INCREASE

or IDECREASEI

DECREASE

QUIT

to change the select-

)

ENTER

screen

6. Press _
vious screen.

)

INCREASE

to save the changes and return to the pre-

DECREASE

QUIT

ENTER

)

SERVICE OPERATIONTo view the menu-&iven programs available for Service Operation, see Service Operation
section, page 48. For examples of ICVC display screens, see
Table 4.

mmmm
Fig. 20 -- Example of Set Point Screen

Table 4 -- ICVC Display Data

examples.
IMPORTANT:

The

following

1. Only 12 lines of information

notes

apply

to all

6. Reference Point Names shown in these tables in all capital letters can be read by CCN and BS software. Of these capitalized
names, those preceded by a dagger can also be changed (that
is, written to) by the CCN, BS, and the ICVC. Capitalized Reference Point Names preceded by two asterisks can be changed
only from the ICVC. Reference Point Names in lower case type
can be viewed by CCN or BS only by viewing the whole table.

Table 4

appear on the chiller display screen

at any one time. Press the _

or I PREVlOUS I softkey to

highlight a point or to view items below or above the current
screen. Double click the _
the IPREVIOUS]

7. Alarms and Alerts: An asterisk in the far right field of a ICVC status screen indicates that the chiller is in an alarm state; an exclamation point in the far right field of the ICVC screen indicates an
alert state. The asterisk (or exclamation point) indicates that the
value on that line has exceeded (or is approaching) a limit. For
more information on alarms and alerts, see the Alarms and
Alerts section, page 16.
LEGEND

softkey to page forward; press

softkey twice to page back.

2. To access the information

shown in Examples

10 through

enter a 4-digit password after pressing the _

22,

softkey. If

no softkeys are pressed for 15 minutes, the ICVC automatically
logs off (to prevent unrestricted

access to PIC III controls)

and

reverts to the default screen. If this happens,

re-enter the pass-

word to access the tables shown in Examples

10 through 22.

CCN
CHW
CHWR
CHWS
CT
ECW
HGBP
ICVC
LOW
LRA
mA
P
PIC III
SS
T
VFD
WSM

3. Terms in the Description column of these tables are listed as
they appear on the chiller display screen.
4. The ICVC may be configured in English or Metric (Sl) units using
the ICVC CONFIGURATION screen. See the Service Operation
section, page 48, for instructions on making this change.
5. The items in the Reference Point Name column do not appear on
the chiller display screen. They are data or variable names used
in CCN or Building Supervisor (BS) software. They are listed in
these tables as a convenience to the operator if it is necessary to
cross reference CCN/BS documentation or use CCN/BS programs. For more information, see the 19XRV CCN literature.

EXAMPLE

------------------

Carrier Comfort Network
Chilled Water
Chilled Water Return
Chilled Water Supply
Current Transformer
Entering Chilled Water
Hot Gas Bypass
International Chiller Visual Controller
Leaving Chilled Water
Locked Rotor Amps
Milliamps
Pressure
Product Integrated Controls III
Solid State
Temperature
Variable Frequency Drive
Water System Manager

1 -- CHILLER DISPLAY DEFAULT SCREEN

The following data is displayed in the Default screen.
DESCRIPTION
(PRIMARY MESSAGE)
(SECONDARY MESSAGE)
(DATE AND TIME)
Compressor Ontime
Entering Chilled Water
Leaving Chilled Water
Evaporator Temperature
Entering Condenser Water
Leaving Condenser Water
Condenser Temperature
Oil Pressure
Oil Sump Temp
Average Line Current

STATUS

UNITS

0-500000.0
-40-245
-40-245
-40-245
-40-245
-40-245
-40-245
0-420
40-245
0-999
0-1
0-1
0-1

HOURS
DEG F
DEG F
DEG F
DEG F
DEG F
DEG F
PSI
DEG F
%

REFERENCE POINT NAME
(ALARM HISTORY)

C HRS
ECW
LCW
ERT
ECDW
LCDW
CRT
OILPD
OILT
AMPS_%
CCN
LOCAL
RESET

NOTE: The last three entries are used to indicate operating mode to the PIC Ill. These values may be forced by the ICVC only.

DISPLAY

CHW IN
CHW OUT
EVAP REF
CDW IN
CDW OUT
COND REF
OILPRESS
OIL TEMP
AMPS%

Table 4 -- ICVC Display Data (cont)
EXAMPLE 2 -- MAINTSTAT DISPLAY SCREEN
To access this display from the ICVC default screen:
1. Press [MEffO_.
2. Press _

(IMAINSTAT]

will be highlighted).

3. Press _.
DESCRIPTION

STATUS

Control Mode
Run Status
Start Inhibit Timer
Occupied'?.
System Alert/Alarm
*Chiller Start/Stop
*Remote Start Contact
Temperature Reset
*Control Point
Chilled Water Temp
*Active Demand Limit
Percent Line Current
Percent Line Kilowatts
Auto Demand Limit Input
Auto Chilled Water Reset
Remote Reset Sensor
Total Compressor Starts
Starts in 12 Hours
Compressor Ontime
*Service Ontime
Ice Build Contact
Emergency Stop

NOTE 2
NOTE 3
0-15
0/1
0-2
0/1
0/1
-30-30
10-120
-40-245
40-100
0-999
0-999
4-20
4-20
-40-245
0-99999
0-8
0-500000.0
0-32767

UNITS

POINT

NOTE 2
NOTE 3
rain
NO/YES
NOTE 4
STOP/START
OPEN/CLOSE
DEG F
DEG F
DEG F
%
%
%
mA
mA
DEG F

MODE
STATUS
T START
O-CO
SYS_ALM
CHIL_S_S
REMCON
T RESET
LCW STPT
CHW_TMP
DEM LIM
LNAMPS P
LINEKW P
AUTODEM
AUTORES
R RESET
c starts
S-TARTS
c hrs
S-HRS
lEE CON
EMSTOP

HOURS
HOURS
OPEN/CLOSE
ENABLE/EMSTOP

0-1
0/1

NOTES:
1. Numbers in parenthesis indicate the equivalent CCN index for BEST programming or BACnet TM Translator use.
2. Off (0), Local (1), CCN (2), Reset (3)
3. Timeout (0), Ready (1), Recycle (2), Startup (3), Running (4), Demand (5), Ramping (6), Tripout (7), Override (6), Tripout (9), Ctl Test (10),
Lockout (11), Pumpdown (12), Prestart (13)
4. Normal, Alert, Alarm
5. All variables with capital letter point names are available for CCN read operation. Those shown with (*) support write operations for all CCN
devices.

EXAMPLE 3 -- STARTUP DISPLAY SCREEN
To access this display from the IOVC default screen:
1. Press _MENO].
2. Press ISTATOS].
3. Scroll down to highlight [STARTUP].
4. Press _SEEECT].
DESCRIPTION
Actual Guide Vane Pos
**Chilled Water Pump
Chilled Water Flow
**Condenser Water Pump
Condenser Water Flow
Oil Pump Relay
**Oil Pump Delta P
Oil Sump Temp
VFD Start
Start Complete
Stop Complete
Target VFD Speed
**Tower Fan Relay Low
**Tower Fan Relay High
Spare Safety Input
Shunt Trip Relay

STATUS

UNITS

0-100
0-1
0-1
0-1
0-1
0-1
-6.7-200
-6,7-200
0-1
0-1
0-1
0,0-100.0
0-1
0-1
0-1
0-1

%
OFF/ON
NO/YES
OFF/ON
NO/YES
OFF/ON
^PSI
DEG F
NO/YES
FALSE/TRUE
FALSE/TRUE
%
OFF/ON
OFF/ON
ALARM/NORMAL
OFF/ON

POINT
GV POS
CH_/P
CHW FLOW
CDP
CDW_FLOW
OILR
OILPD
OILT
VFDSTART
START OK
STOP ()K
VFD_OUT
TFR_LOW
TFR HIGH
SAFETY
TRIPR

NOTE: All variables with CAPITAL LETTER point names are available for CCN read operation. Those shown with (**) shall support write
operations for the ICVC only.

Table 4 -- ICVC Display Data (cont)
EXAMPLE 4 -- COMPRESS

DISPLAY SCREEN

To access this display from the ICVC default screen:
1. Press _MEN0].
2. Press [S_TOS].
3. Scroll down to highlight ICOMPRESS I .
4. Press [SELECt.
DESCRIPTION

STATUS
0.0-100.0
0.0-100.0
0-100
0-100
0-100
-40-245
-6.7-200
-40-245
-40-245
-40-245
-40-245
-40-245
0/1
0-100
0-5

Actual VFD Speed
**Target VFD Speed
Actual Guide Vane Pos
Guide Vane Delta
**Target Guide Vane Pos
Oil Sump Temp
**Oil Pump Delta P
Comp Discharge Temp
Comp Thrust Brg Temp
Comp Motor Winding Temp
Spare Temperature 1
Spare Temperature 2
Oil Heater Relay
Diffuser Actuator
Surge Protection Counts
NOTE: All variables with CAPITAL LETTER
for the ICVC only.

UNITS

POINT

%
%
%
%
%
DEG F
^PSI
DEG F
DEG F
DEG F
DEG F
DEG F
OFF/ON
%

VFD_ACT
VFD OUT
GV POS
GV DELTA
GV TRG
OIL_OILPD
CMPD
MTRB
MTRW
SPARE_T1
SPARE T2
OILHE/_T
DIFF ACT
SPC

)oint names are available for CCN read operation. Those shown with (**) shall support write operations

EXAMPLE

5 -- HEAT_EX DISPLAY SCREEN

To access this display from the ICVC default screen:
1. Press _MEN0].
2. Press [STATOS].
3. Scroll down to highlight _.
4. Press [SEL_T].
DESCRIPTION
**Chilled Water Delta P
Entering Chilled Water
Leaving Chilled Water
Chilled Water Delta T
Chill Water Pulldown/Min
Evaporator Refrig Temp
**Evaporator Pressure
Evaporator Approach
**Condenser Water Delta P
Entering Condenser Water
Leaving Condenser Water
Condenser Refrig Temp
**Condenser Pressure
Condenser Approach
VFD Coolant Flow
Hot Gas Bypass Relay
Surge / HGBP Active?
Active Delta P
Active Delta T
Surge / HGBP Delta T
Head Pressure Reference
Evaporator Saturation Temp

STATUS

UNITS
PSI
DEG F
DEG F
^F
^F
DEG F
PSI
^F
PSI
DEG F
DEG F
DEG F
PSI
^F
%
OFF/ON
NO/YES
PSI
^F
^F
%
DEG F

-6.7-420
-40-245
-40-245
-40-245
-20-20
-40-245
-6.7-420
0-99
-6.7-420
-40-245
-40-245
-40-245
-6.7-420
0-99
0.0-I00.0
0/I
0/I
0-200
0-200
0-200
0-100
-40-245

POINT
CHWPD
ECW
LCW
CHW_DT
CHW_PULL
ERT
ERP
EVAP APP
CDWPD
ECDW
LCDW
CRT
CRP
COND APP
VFD F-OUT
HGB-YPASS
SHG ACT
dp a
dt a
dt c
hpr
EST

NOTE: All variables with CAPITAL LETTER point names are available for CCN read operation. Those shown with (**) shall support write operations
for the ICVC only.

2.5

Table 4 -- ICVC Display Data (cont)
EXAMPLE 6 -- POWER DISPLAY SCREEN
To access this display from the ICVC default

screen:

1. Press [MEN0].
2. Press ISTATOS].
3. Scroll down to highlight _P6WER].
4. Press _SE_CT].
DESCRIPTION
Percent Line Current
Average Line Current
Percent Line Voltage
Average Line Voltage
Line Power Factor
Line Kilowatts
Percent Line Kilowatts
Percent Load Current
Average Load Current
Motor Power Factor
Motor Kilowatts
Percent Motor Kilowatts
Motor Kilowatt Hours
Demand Kilowatts
Line Current Phf(R)
Line Current Ph2 (S)
Line Current Ph3 (T)
Load Current Phl (U)
Load Current Ph2 (V)
Load Current Ph3 (W)
Line Voltage Phl (RS)
Line Voltage Ph2 (ST)
Line Voltage Ph3 (TR)
Ground Fault Current
Line Frequency
Rectifier Overload
Inverter Overload
Motor Overload
Line Current Imbalance
Motor Current Imbalance
Line Voltage Imbalance
Line Active Current
Line Reactive Current
Line Active Voltage
Line Reactive Voltage
DC Bus Voltage Reference
DC Bus Voltage
Flux Current
Torque Current
Inverter Temperature
Rectifier Temperature
VFD Enclosure Temp
VFD Cold Plate Temp
Humidity Sensor Input
Relative Humidity
VFD Coolant Flow
Actual VFD Speed

STATUS

UNITS
%
AMPS
%
VOLTS

0.0-999.0
0.0-99999.0
0.0-999.0
0.0-99999.0
0.00-2.00
0.0-99999.0
0.0-99999.0
0.0-99999.0
0.0-99999.0
0.00-2.00
0-99999
0-99999
0-99999
0-99999
0-99999
0-99999
0-99999
0-99999
0-99999
0-99999
0-99999
0-99999
0-99999
0.0-999.0
0.0-99.0
0.0-100.0
0.0-100.0
0.0-100.0
0.0-100.0
0.0-100.0
0.0-100.0
0-99999
0-99999
0-99999
0-99999
0-99999
0-99999
0-99999
0-99999
0.0-300.0
0.0-300.0
0.0-300.0
0.0-300.0
0.0-5.0
0.0-100.0
0.0-100.0
0.0-100.0

kW
%
%
AMPS
kW
%
kWH
kW
AMPS
AMPS
AMPS
AMPS
AMPS
AMPS
VOLTS
VOLTS
VOLTS
AMPS
HZ
%
%
%
%
%
%
AMPS
AMPS
VOLTS
VOLTS
VOLTS
VOLTS
AMPS
AMPS
DEG F
DEG F
DEG F
DEG F
VOLTS
%
%
%

NOTES:
1. All variables with CAPITAL LETTER point names are available for CCN read operation.
2. Those shown with (**) shall support write operations for ICVC only.

POINT
LNAMPS P
LNAMPS A
LNVOLT -P
LNVOLT A
LINE_PFLINE KW
LIN EK,W P
LDAMPS_P
LDAMPS A
MOTOR PF
MOTOR KW
MOTORKWP
MOTORKWH
DEM KW
LN A-MPSl
LN_AMPS2
LN AMPS3
LD AMPSl
LD AMPS2
LD_AMPS3
LN_VOLT1
LN_VOLT2
LN VOLT3
GF-AMPS
LINEFREQ
RECT OV
INV O-V
MOTOR OV
LN IMB I
MT- IMB- I
LN IMB V
AM-PS_,g,CT
AMPS RE
VOLT ACT
VOLT RE
BUS -REF
BUS VOLT
FLUXAMPS
TORQAMPS
INV TEMP
REC TEMP
VFD ENCL
CP TEMP
H U_]ID SR
HUMIDITY
VFD FOUT
VFD ACT

Table 4 -- ICVC Display Data (cont)
EXAMPLE 7 -- VFD STAT DISPLAY SCREEN
To access this display from the ICVC default screen:
1. Press [MEN0].
2. Press [S_T0S].
3. Scroll down to highlight ]VFD STAT].
4. Press [S_EC_.
DESCRIPTION
VFD Fault Code
Single Cycle Dropout
Line Current Imbalance
Line Voltage Imbalance
Line Phase Reversal
High Line Voltage
Low Line Voltage
High DC Bus Voltage
Low DC Bus Voltage
Motor Current Imbalance
Motor Overload
Rectifier Overcurrent
Rectifier Overtemp
Rectifier Power Fault
Inverter Overcurrent
Inverter Overtemp
Inverter Power Fault
Ground Fault
Frequency Fault
VFD Power On Reset
Start Complete
Stop Complete
Condenser High Pressure
Motor Amps Not Sensed
Start Acceleration Fault
Stop Fault
VFD Start Inhibit
VFD Checksum Error
VFD Comm Fault
VFD Fault
VFD Gateway Version #
VFD Inverter Version #
VFD Rectifier Version #

STATUS
0-223
0/1
0/1
0/1
0/1
0/1
0/1
0/1
0/1
0/1
0/1
0/1
0/1
0/1
0/1
0/1
0/1
0/1
0/1
0/1
0/1
0/1
0/1
0/1
0/1
0/1
0/1
0/1
0/1
0/1
0-255
0-1000
0-1000

UNITS
NORMAL/ALARM
NORMAL!ALARM
NORMAL!ALARM
NORMAL!ALARM
NORMAL!ALARM
NORMAL!ALARM
NORMAL!ALARM
NORMAL!ALARM
NORMAL!ALARM
NORMAL!ALARM
NORMAL!ALARM
NORMAL!ALARM
NORMAL/ALARM
NORMAL!ALARM
NORMAL!ALARM
NORMAL!ALARM
NORMAL!ALARM
NORMAL!ALARM
NORMAL!ALARM
FALSE/TRUE
FALSE/TRUE
NORMAL!ALARM
NORMAL!ALARM
NORMAL!ALARM
NORMAL!ALARM
NORMAL!ALARM
NORMAL!ALARM
NORMAL!ALARM
NORMAL!ALARM

POINT
VFD FLT
CYCLE_I
LINEIM I
LINEIM V
PH REV

HI _VOLT
LdW VOLT
HI DCBUS
L(9 DCBUS
MO-TIM I
MOTOR- OV
RECT_C_
RECT OT
RECT PU
INV O]
INV OT
INV PU
GRIND FLT
FREQ#LT
VFD POR
STAtgT OK
STOP OK
PRS TRIP
NO _,MPS
ACCELFLT
AMPSTOP
STRT INH
CHECKSUM
VFD COMM
VFDFAULT
VFG VER
INV _/ER
RECVER

NOTES:
1. All variables with point names written in capital letters are available for CCN Read operation only.
(*) Variables support write operations for all CCN Devices.
(**) Variables shall support write operations for the ICVC only.
2. This table supports the service tool password disable access. It will only allow forcing with the service tool for a one-time bypass of both the
Service menu and the VFD config data table. Exit from the Service menu reverts to normal password operation.
EXAMPLE 8 -- ICVC PWD DISPLAY SCREEN
To access this display from the IOVC default screen:
1. Press [MEN0].
2. Press [_AT0S].
3. Scroll down to highlight [ ICVC
4. Press [_T_T].

PWD].

DESCRIPTION
Disable Service Password
**Remote Reset Option
Reset Alarm?
CCN Mode?

STATUS

UNITS
DSABLE/ENABLE
DSABLE/ENABLE
NO/YES
NO/YES

0-1
0-1
0-1
0-1

POINT
PSWD DiS
RESE]_OPT
REMRESET
REM CCN

NOTE: All variables with CAPITAL LETTER point names are available for CCN read operation. Those shown with (**) shall support write operations
for the ICVC only.
To Disable Service Password, force that item to a value of "1" using Service Tool. Once this has been done, the Service menu and the VFD Config
Data screens can be accessed without a password. This access is cancelled the time the user exits the Service menu/screen.
**If the Remote Reset Option is set to a value of "1" at the ICVC, alarms may be reset and CCN mode may be reinstated remotely using Service
Tool, Building Supervisor, or ComfortWORKS®
controls.
EXAMPLE g -- SETPOINT

DISPLAY SCREEN

To access this display from the ICVC default screen:
1. Press [MEN0].
2. Press [SETPOINT].
3. Press [S_E_].
DESCRIPTION
Base Demand Limit
Control Point
LCW Setpoint
ECW Setpoint
Ice Build Setpoint
Tower Fan High Setpoint

STATUS
40-100

UNITS
%

POINT
DLM

10-120
15-120
15-60
55-105

DEG
DEG
DEG
DEG

Icwsp
ecwsp
ice sp
TFH SP

F
F
F
F

NOTE: All variables are available for CCN read operation; forcing shall not be supported on setpoint screens.

DEFAULT
100
50.0
60.0
40.0
75

Table 4 -- ICVC Display Data (cont)
EXAMPLE

10-

CAPACITY

DISPLAY SCREEN

To access this display from the ICVC default screen:
1. Press [MENO].
2. Press _.
3. Scroll down to highlight

[CONTROL ALGORITHM

STATUS[.

4. Press _SELECf].
5. Scroll down to highlight [CAPACITY].
6. Press _SELECT].
DESCRIPTION

STATUS

Entering Chilled Water
Leaving Chilled Water
Capacity Control
Control Point
Control Point Error
ECW Delta T
ECW Reset
LCW Reset
Total Error + Resets
Guide Vane Delta
Target Guide Vane Pos
Actual Guide Vane Poe
Target VFD Speed
Actual VFD Speed
Demand Limit Inhibit
Amps/kW Ramp

-40-245
-40-245

UNITS
DEC F
DEC F

POINT
ECW
LCW

10-120
-99-99
-99-99
-99-99
-99-99
-99-99
-2-2
0-100
0-100
0-100
0-110
0-100
40-100

DEC F
^F
^F
^F
^F
^F
%
%
%
%
%
%
%

ctrlpt
cperr
ecwdt
ecwres
Icwres
error
gvd
GV TRG
GV POS
VF[3_OUT
VFD_ACT
DEM INH
DMDLIM

NOTE: All variables with CAPITAL LETTER point names are available for CCN read operation;
screen.
EXAMPLE 11 -- OVERRIDE

forcing shall not be supported

on maintenance

DISPLAY SCREEN

To access this display from the IOVC default screen:
1. Press [MENU].
2. Press _.
3. Scroll down to highlight

ICONTROL ALGORITHM

STATUS I.

4. Press ISELECT].
5. Scroll down to highlight [OVERRIDE[.
6. Press _SELECT].
DESCRIPTION
Comp Motor Winding Temp
Comp Motor Temp Override
Condenser Pressure
Cond Press Override
Evaporator Refrig Temp
Evap Ref Override Temp
Comp Discharge Temp
Comp Discharge Alert
Comp Thrust Brg Temp
Comp Thrust Brg Alert
Rectifier Temperature
Rectifier Temp Override
Inverter Temperature
Inverter Temp Override
Actual Superheat
Superheat Required
Condenser Refrig Temp

STATUS

UNITS
DEC F
DEC F
PSI
PSI
DEC F
DEC F
DEC F
DEC F
DEC F
DEC F
DEC F
DEC F
DEC F
DEC F
^F
^F
DEC F

-40-245
150-200
0-420
90-180
-40-245
2-45
-40-245
125-200
-40-245
185-185
0-300
125.0-200.0
0-300
125-200
-20-99
6-99
-40-245

NOTE: All variables with CAPITAL LETTER point names are available for CCN read operation;
screens.

POINT
MTRW
mt over
CR-P
cp_over
ERT
ert over
CMPD
cd alert
MTRB
tb alert
RECT TEMP
REC OVER
INV TEMP
INV OVER
SUFTRHEAT
SUPR_REQ
CRT
forcing shall not be supported

on maintenance

Table 4 -- ICVC Display Data (cont)
EXAMPLE 12To access this display from the ICVC default screen:
1. Press _MENO].
2. Press _.
3. Scroll down to highlight [CONTROL ALGORITHM
4. Press [SELECT].
5. Scroll down to highlight ILL_MAINT.I
6. Press [S_EC_.
DESCRIPTION

LL_MAINT

DISPLAY SCREEN

STATUS].

STATUS

UNITS

POINT

LeadLag Control
LEADLAG: Configuration
NOTE 1
leadlag
Current Mode
NOTE 2
Ilmode
DSABLE/ENABLE
Ioadbal
Load Balance Option
0/1
LAG START Time
2-60
MIN
lagstart
LAG STOP Time
2-60
MIN
lagstop
Prestart Fault Time
2-30
MIN
preflt
Pulldown:
Delta T/Min
x.xx
^F
pull dt
Satisfied?
0/1
NO/YES
pull_sat
LEAD CHILLER in Control
0/1
NO/YES
leadctrl
LAG CHILLER: Mode
NOTE 3
lagmode
Run Status
NOTE 4
lagstat
Start/Stop
NOTE 5
lag_s_s
NO/YES
Recovery Start Request
0/1
lag_rec
STANDBY CHILLER: Mode
NOTE 3
stdmode
Run Status
NOTE 4
stdstat
Std s_s
Start/Stop
NOTE 5
NO/YES
std rec
Recovery Start Request
0/1
DEG
F
SP,_RE_T1
Spare Temperature
1
-40-245
DEG
F
SPARE_T2
Spare Temperature
2
-40-245
NOTES:
1. DISABLE, LEAD, LAG, STANDBY, INVALID
2. DISABLE, LEAD, LAG, STANDBY, RECOVERY, CONFIG
3. Reset, Off, Local, CCN
4. Timeout, Ready, Recycle, Prestart, Startup, Ramping, Running, Demand, Override, Shutdown, Trippout, Pumpdown, Lockout, Ctl Test
5. Stop, Start, Retain
6. All variables with CAPITAL LETTER point names are available for CCN read operation; forcing shall not be supported on maintenance screens.
EXAMPLE
To access this display from the ICVC default screen:
1. Press [MEN0].
2. Press _.
3. Scroll down to highlight [CONTROL ALGORITHM
4. Press [SELECT].
5. Scroll down to highlight _VFD HIST].
6. Press [_TEC_.
DESCRIPTION
VFD FAULT HISTORY
Values at Last Fault:
Line Current Phl(R)
Line Current Ph2(S)
Line Current Ph3(T)
Load Current Phl(U)
Load Current Ph2(V)
Load Current Ph3(W)
Line Voltage Phl(RS)
Line Voltage Ph2(ST)
Line Voltage Ph3(TR)
Ground Fault Current
Line Frequency
Line Power Factor
Line Current Imbalance
Line Voltage Imbalance
Motor Power Factor
Motor Current Imbalance
Motor Overload
Line Active Current
Line Reactive Current
Line Active Voltage
Line Reactive Voltage
DC Bus Voltage
DC Bus Voltage Reference
Flux Current
Torque Current
Inverter Temperature
Rectifier Temperature
VFD Enclosure Temp
VFD Cold Plate Temp
Actual VFD Speed
Chiller Fault State
VFD Fault Code

13 -- VFD_HIST

DISPLAY SCREEN

STATUS].

STATUS

0.0-99999.0
0.0-99999.0
0.0-99999.0
0.0-99999.0
0.0-99999.0
0.0-99999.0
0.0-99999.0
0.0-99999.0
0.0-99999.0
0.0-999.0
0.0-99.0
0.00-2.00
0.0-100.0
0.0-100.0
0.00-2.00
0.0-100.0
0.0-100.0
0.0-99999.0
0.0-99999.0
0.0-99999.0
0.0-99999.0
0.0-99999.0
0.0-99999.0
0.0-99999.0
0.0-99999.0
0.0-300.0
0.0-300.0
0.0-300.0
0.0-300.0
0.0-100.0
200-225
200-225

UNITS

POINT

AMPS
AMPS
AMPS
AMPS
AMPS
AMPS
VOLTS
VOLTS
VOLTS
AMPS
Hz

LNAMPS1H
LNAMPS2H
LNAMPS3H
LDAMPS1H
LDAMPS2H
LDAMPS3H
LNVOLT1H
LNVOLT2H
LNVOLT3H
GF AMPSH
LIN-EFRQH
LINE PFH
LN_IIV1BIH
LN IMBVH
MO-TORPFH
MT IMBIH
MOTOROVH
AMPSACTH
AMPS REH
VOLTA-CTH
VOLT REH
BUSV-OLTH
BUS REFH
FLU)(AMPH
TORQAMPH
INVTEMPH
RECTEMPH
VFDENCLH
CP TEMPH
VFD ACTH
VFDSTATH
VFD_FLTH

%
%
%
%
AMPS
AMPS
VOLTS
VOLTS
VOLTS
VOLTS
AMPS
AMPS
DEG F
DEG F
DEG F
DEG F
%

NOTE: All variables with point names written in capital letters are available for CCN read operation. Forcing shall not be supported on maintenance
screens.

Table 4 -- ICVC Display Data (cont)
EXAMPLE 14 --WSMDEFME

DISPLAY SCREEN

To access this display from the ICVC default screen:
1. Press [MENU].
2. Press _.
3. Scroll down to highlight

ICONTROL ALGORITHM

STATUS I.

4. Press [SELECT].
5. Scroll down to highlight [WSMDEFME].
6. Press [SELECT].
DESCRIPTION
WSM Active'?.

STATUS
0/1

UNITS
NO/YES

POINT
WSMSTAT

Chilled Water Temp
Equipment Status
Commanded State
CHW setpt Reset Value
Current CHW Set Point

0.0-99.9
0/1
XXXXXXXX
0.0-25.0
0.0-99.9

DEG F
OFF/ON
TEXT
^F
DEG F

CHWTEMP
CHWRST
CHWRENA
CHWRVAL
CHWSTPT

NOTE: All variables with CAPITAL LETTER point names are available for CCN read operation;
screens.
EXAMPLE

15--

forcing shall not be supported

on maintenance

NET OPT DISPLAY SCREEN

To access this display from the ICVC default screen:
1. Press [MENU].
2. Press _.
3. Scroll down to highlight [EQUIPMENT

CONFIGURATION

4. Press [_T].
5. Scroll down to highlight [NET OPT].
6. Press [SE_CT].
DESCRIPTION
Loadshed Function
Group Number
Demand Limit Decrease
Maximum Loadshed Time
CCN Occupancy Config:
Schedule Number
Broadcast Option
Alarm Configuration
Re-Alarm Time
Alarm Routing

STATUS

UNITS

POINT

DEFAULT

0-16
0-60
0-480

%
MIN

Idsgrp
Idsdlta
maxshed

o
2o
6o

3-99
0-1

DSABLE/ENABLE

occ num
occbrcst

3
DSABLE

retime
routing

30
10000000

0-1440
xxxxxxxx

MIN

NOTE: No variables are available for CCN read or write operation.

Table 4 -- ICVC Display Data (cont)
EXAMPLE 16-

VFD CONF DISPLAY SCREEN

To access this display from the ICVC default screen:
1. Press rMEN0].
2. Press _.
3. Scroll down to highlight [VFD CONFIG DATA[.
4. Press FSELECT1.
5. Enter password (4444 Factory Default).
6. Scroll down to highlight [VFD CONF[.
7. Press [SELECT1.
DESCRIPTION

STATUS

UNITS
VOLTS
Hz
NO/YES
VOLTS
AMPS
kW
kW
AMPS
AMPS

346-480
45.0-62.0
0/1
346-480
10-1500
0-7200
0-7200
10-1500
10-1500
1500-3600
0-5600
O/1
0.0-102.0
0.0-102.0
0.0-102.0
0.0-102.0
1-10
1-10
5-40
1-10
5-40
1-10
5-60
5-60
0/1

Motor Nameplate Voltage
Compressor
100% Speed
Line Freq=60 Hz? (No=50)
* Rated Line Voltage
* Rated Line Amps
* Rated Line Kilowatts
* Motor Rated Load KW
* Motor Rated Load Amps
Motor Nameplate Amps
Motor Nameplate RPM
Motor Nameplate KW
Inverter PWM Frequency (0=4 k Hz, 1=2 k Hz)
Skip Frequency 1
Skip Frequency 2
Skip Frequency 3
Skip Frequency Band
Line Voltage % Imbalance
Line Volt Imbalance Time
Line Current % Imbalance
Line Current Imbal Time
Motor Current % Imbalance
Motor Current Imbal Time
Increase Ramp Time
Decrease Ramp Time
Single Cycle Dropout

NOTE: Those parameters marked with a * shall not be downloaded
EXAMPLE

kW
Nz

Hz
Hz
Hz
%
SEC
%
SEC
%
SEC
SEC
SEC
DSABLE/ENABLE

POINT

460
60.0
YES
46O
2OO
100
100
2OO
100
3456
100
0
102.0
102.0
102.0
0.0
10
10
4O
10
4O
10
3O
3O
DSABLE

comp 100
line frq
vfd volt
vfd amps
vfd rlkw
mot rlkw
mot rla
motorni
motorpm
motorkw
pwm freq
skipfrql
skipfrq2
skipfrq3
skipband
v unbal
v time
lineim i
lineim t
motim i
motim t
ramp Tnc
rampdec
cycdrop

to the VFD, but shall be used in other calculations

17 -- OPTIONS

DEFAULT

motornv

and algorithms in the ICVC.

DISPLAY SCREEN

To access this display from the ICVC default screen:
1. Press [M_U].
2. Press _.
3. Scroll down to highlight IEQUIPMENT

SERVICE I.

4. Press [SEL_T].
5. Scroll down to highlight _.
6. Press [_LECT].
DESCRIPTION
Auto Restart Option
Remote Contacts Option
Soft Stop Amps Threshold
Surge/Hot
Gas Bypass
Surge Limit/HGBP Option
Select: Surge=0, HGBP=I
Min. Load Point (T1,P1)
Surge/HGBP Delta T1
Surge/HGBP Delta P1
Full Load Point (T2,P2)
Surge/HGBP Delta T2
Surge/HGBP Delta P2
Surge/HGBP Deadband
Surge Protection
Surge Delta% Amps
Surge Time Period
Ice Build Control
Ice Build Option
Ice Build Termination
0=Temp, 1=Contacts, 2=Both
Ice Build Recycle
Head Pressure Reference
Delta P at 0% (4mA)
Delta P at 100% (20mA)
Minimum Output

STATUS
0/1
0/1
40-100

UNITS
DSABLE/ENABLE
DSABLE/ENABLE
%

0/1

POINT
astart
modes
strtstop

DEFAULT
DSABLE
DSABLE
100

srg hgbp

0.5-20
30-170

^F
PSI

hgbdtl
hgbdpl

1.5
5O

0.5-20
50-170
0.5-3

^F
PSI
^F

hgbdt2
hgb dp2
hgb db

lO
85
1

5-20
7-10

%
MIN

surge_a
surge t

lO
8

0/1
0-2

DSABLE/ENABLE

ibopt
ibterm

DSABLE
0

0/1

DSABLE/ENABLE

ibrecyc

DSABLE

20-85
20-85
0-100

PSI
PSI
%

HPDPO
HPDP100
HPDPMIN%

25
5O
0

NOTE: No variables are available for CCN read or write operation.

Table 4 -- ICVC Display Data (cont)
EXAMPLE 18 -- SETUP1 DISPLAY SCREEN
To access this display from the ICVC default screen:
1. Press _MENU_.
2. Press _.
3. Scroll down to highlight [EQUIPMENT

SERVICE I .

4. Press _SELECTI.
5. Scroll down to highlight ISEf0P1].
6. Press [SE_].
DESCRIPTION

STATUS

UNITS

Comp Motor Temp Override
Cond Press Override
Rectifier Temp Override
Inverter Temp Override
Comp Discharge Alert
Comp Thrust Brg Alert

150-200
90-165
155-170
155-170
125-200
165-185

DEG
PSI
DEG
DEG
DEG
DEG

Chilled Medium
Chilled Water Deadband
Evap Refrig Trippoint
Refrig Override Delta T
Evap Approach Alert
Cond Approach Alert
Condenser Freeze Point

0/1
0.5-2.0
0.0-40.0
2.0-5.0
0.5-15
0.5-15
-20 - 35

Flow Delta P Display
Evap Flow Delta P Cutout
Cond Flow Delta P Cutout
Water Flow Verify Time
Oil Press Verify Time
Recycle Control
Restart Delta T
Shutdown Delta T

POINT

DEFAULT

MT_OVER
CP OVER
REC OVER
INV -OVER
CD _,LERT
TB ALERT

20O
125
160
160
200
175

WATER/BRINE
^F
DEG F
^F
^F
^F
DEG F

MEDIUM
CWDB
ERT TRIP
REF OVER
EVAP AL
CONE) AL
CDFRt_EZE

WATER
1.0
33
3
5
6
34

0-1
0.5 - 50.0
0.5 - 50.0
0.5-5
15-300

DSABLE/ENABLE
PSI
PSI
MIN
SEC

FLOWDISP
EVAP CUT
CONE) CUT
WFLO_/ T
OILPR T

DSABLE
5.0
5.0
5
4O

2.0-10.0
0.5-4.0

DEG F
DEG F

rcycr dt
rcycs dt

F
F
F
F

Spare Alert/Alarm Enable
Disable=0, Lo=1/3,Hi=2/4
Spare
Spare
Spare
Spare

Temp
Temp
Temp
Temp

#1
#1
#2
#2

0-4
-40-245
0-4
-40-245

Enable
Limit
Enable
Limit

DEG F
DEG F

splen
spllim
sp2_en
sp21im

0
245
0
245

NOTE: No variables are available for CCN read operation. Forcing shall not be supported on service screens.
EXAMPLE 19 -- SETUP2 DISPLAY SCREEN
To access this display from the ICVC default screen:
1. Press [MENU].
2. Press _.
3. Scroll down to highlight [EQUIPMENT

SERVICE].

4. Press _SE[EC_.
5. Scroll down to highlight ISETUP2].
6. Press FSELEC_.
DESCRIPTION

STATUS

POINT

DEFAULT

gv_inc
gv_dec
gw_ecw

6.5
6.0
2

gv_ctrl

0/1
0-78
0-100
0-78
0-10o
0-78
0-10o
15-22

DSABLE/ENABLE
%
%
%
%
%
%
mA

diff_opt
gv25
df 25
gv 50
df 50
gv_75
df 75
diff ma

DSABLE
25
0
5O
0
75
0
18

0.1-1.5
1-5
65-100
90-100

%
%
%

vfd gain
vfd step
vfd min
vfd_max

0.75
2
7O
100

Capacity Control
Proportional
Inc Band
Proportional
DEC Band
Proportional
ECW Band

2-I0
2-I0
I-3

Guide Vane Travel Limit

30- I O0

Diffuser Control
Diffuser Option
Guide Vane 25% Load Pt
Diffuser 25% Load Point
Guide Vane 50% Load Pt
Diffuser 50% Load Point
Guide Vane 75% Load Pt
Diffuser 75% Load Point
Diffuser Full Span mA
VFD Speed Control
VFD Gain
VFD Increase Step
VFD Minimum Speed
VFD Maximum Speed

UNITS

NOTE: No variables are available for CCN read or write operation; forcing shall not be supported on service screens.

Table 4 -- ICVC Display Data (cont)
EXAMPLE

20 -- LEADLAG

DISPLAY SCREEN

To access this display from the ICVC default screen:
1. Press [MENU].
2. Press _.
3. Scroll down to highlight IEQUIPMENT

SERVICE I .

4. Press [SELECT].
5. Scroll down to highlight ILEADLAG

6. Press [SEL_T].
DESCRIPTION

STATUS

Lead Lag Control
LEAD/LAG: Configuration
DSABLE=0, Lead=l
LAG=2, STANDBY=3
Load Balance Option
Common Sensor Option
LAG % Capacity
LAG Address
LAG START Timer
LAG STOP Timer
PRESTART FAULT Timer
STANDBY Chiller Option
STANDBY % Capacity
STANDBY Address

UNITS

0-3
DSABLE/ENABLE
DSABLE/ENABLE
%

0/1
0/1
25-75
1-236
2-60
2-60
2-30
0/1
25-75
1-236

MIN
MIN
MIN
DSABLE/ENABLE
%

POINT

DEFAULT

leadlag

Ioadbal
commsens
lag_per
lagadd
lagstart
lagstop
preflt
stndopt
stnd_per
stnd_add

DSABLE
DSABLE
5O
92
10
10
5
DSABLE
5O
93

POINT

DEFAULT
1

NOTE: No variables are available for CCN read or write operation.
EXAMPLE

21 -- RAMP

DEM DISPLAY SCREEN

To access this display from the IOVC default screen:
1. Press [MENO].
2. Press _.
3. Scroll down to highlight IEQUIPMENT

SERVICE I .

4. Press [SELECT].
5. Scroll down to highlight IRAMP

DEM I .

6. Press [S_E_].
DESCRIPTION

STATUS
0/1

Pulldown Ramp Type:
Select: Temp=0, Load=l
Demand Limit and kW Ramp
Demand Limit Source
Select: Amps=0, kW=l
Amps or Kw Ramp%/Min
Demand Limit Prop Band
Demand Limit At 20 mA
20 mA Demand Limit Opt
Demand Watts Interval

UNITS

rampslct

0/1
5-20
3-15
40-100
0/1
5-60

dem_src
kw ramp
dem_app
dem_20ma
dem sel
dw_i_t

lO
lO
4o
DSABLE
15

UNITS

POINT

DEFAULT

0/1
2-10

DSABLE/ENABLE
^F

ecw_opt
trap ramp

DSABLE
3

-30- 30

deg_20ma

-40-245
-40-245
-30-30

DEG F
DEG F
^F

res_rtl
res rt2
deg- rt

85
65
10

0-15
0-15
-30-30

restd_l
restd 2
deg_chw

10
0
5

res_sel

%
%
DSABLE/ENABLE
MIN

NOTE: No variables are available for CCN read or write operation.
EXAMPLE 221TEMP_CTL

DISPLAY SCREEN

To access this display from the ICVC default screen:
1. Press[MEN

0].

2. Press_.
3. Scroll down to highlightlEQUIPMENT

SERVICE I .

4. Press[SELECT].
5. Scroll down to highlightlTEMP

CTq.

6. Press[SEL_T].
DESCRIPTION
Control Point
ECW Control Option
Temp Pulldown Deg/Min
Temperature Reset
RESET TYPE f
Degrees Reset At 20 mA
RESET TYPE 2
Remote Temp 1> No Reset
Remote Temp 1> Full Reset
Degrees Reset
RESET TYPE 3
CHW Delta T 1> No Reset
CHW Delta T 1> Full Reset
Degrees Reset
Enable Reset Type

STATUS

AF
AF

0-3

PIC III System

Table 5 --

Functions

IMPORTANT: Words not Du't of ptu'agraph headings and
printed in all capit_d letters can be viewed on the [CVC
(e.g., LOCAL, CCN, RUNNING ALARM, etc.). Words
printed both in _dl capit_d letters and it_dics can also be
viewed on the ICVC and tu'e parameters (CONTROL
MODE, TARGET GUIDE VANE POS, etc.) with associated
v_dues (e.g., modes, temperatures, pressures, percentages,
on, off. enable, disable, etc.). Words printed in _dlcapital letters and in a box represent sollkeys on the ICVC (e.g.,
and _
). See Table 4 for exmnples of the type
of information that can appegu on the ICVC screens. Figures
14-20 give an overview of ICVC operations and menus.

Guide Vane

Delta Modes

NORMAL
CONTROL
MODE

GUIDE VANE
DELTA
IGV

VFD

From +0,2 to
+2.0

Increase
1st

Increase
when IGV
= max

From -0.2 to
-2.0

Decrease
when VFD
speed =
rnin

Decrease
1st

Normal Control mode occurs
SURGE/HGBP
DELTA T_

SURGE
PREVENTION
MODE
IGV
VFD
Increase
only if VFD
speed =
max and if
Increase
hot gas
1st
bypass is
present
and open
Decrease

when ACTIVE

DELTA

T >

CAPACITY
CONTROL
-- Generally the chiller adjusts capacity in response to deviation of leaving or entering chilled water temperature from control point. CONTROL POINT is based
on the configured SETPOINT (in the SETPOINT screen: LCW
SET POINT or ECW SET POINT or ICE BUILD SET
POINT), and CONTROL POINT is equal to this SETPOINT
plus any active chilled water reset value. A reset v_due may
originate from any of the three chilled water/brine reset options
configured
in the
ICVC
Service/Equipment
Service/
TEMP CTL screen (see page 42) or from a CCN device. The
default reset v_due is 0 ° E CONTROL POINT may be viewed
or manually overridden from the MAINSTAT screen.

Surge Prevention Mode occurs
< SURGE/HGBP
DELTA T_

Minor adjustments to the rate of capacity adjustment can be
made by changing PROPORTIONAL
INC (Increase) BAND,
PROPORTIONAL
DEC (Decrease) BAND, and PROPORTIONAL ECW (Entering Chilled Water) GAIN in the Service/
Equipment Service/SETUP2
screen. Increasing the PROPORTIONAL [NC BAND or PROPORTIONAL
DEC BAND, or
decreasing PROPORTIONAL
ECW GAIN will reduce the
amplitude of the capacity control response (within limits). See
also Proportional Bands and Gain on page 35.

The TARGET VFD SPEED, ACTUAL VFD SPEED and the
VFD GAIN can be viewed and modified in the CAPACITY
display screen. The TARGET VFD SPEED can be manually
overridden by the operator fi'om the COMPRESS
screen. The
VFD MINIMUM
SPEED, VFD MAXIMUM
SPEED, VFD
GAIN and VFD INCREASE STEP can be selected and modified in the SETUP2 display screen. TARGET and ACTUAL
VFD SPEED can be viewed in the COMPRESS screen.

when ACTIVE

DELTA

The VFD GAIN ptuameter allows for additional adjustment
of the VFD response. Increasing VFD GAIN will increase the
rate of speed change.
Generally for the case of line voltage equaling motor voltage (460 volts), VFD output 0notor) current is a few percent
higher than line current at full speed (60 Hz). As drive speeds
decrease fiom maximum,
drive output voltage decreases
linedy with output frequency, and motor current continues to
increase relative to line current.

ECW CONTROL
OPTION -- If this option is enabled, the
PIC III uses the ENTERING CHILLED WATER temperature to
modulate
the vanes instead of the LEAVING
CHILLED
WATER temperature. The ECW CONTROL OPTION may be
viewed on the TEMP_CTL screen, which is accessed fiom the
EQUIPMENT SERVICE screen.
CONTROL
POINT DEAD)BAND-This is the tolerance
range on the chilled water/brine temperature control point. If the
water temperature goes outside the CHILLED WATER DEADBAND, the PIC III opens or closes the guide vanes until the temperature is within tolerance. The PIC III may be configured with
a 0.5 to 2 F (0.3 to 1.1 C) deadband. CHILLED WATER DEADBAND may be viewed or modified on the SETUPI screen,
which is accessed from the EQUIPMENT SERVICE table.

Factors and variables used in the capacity control determination are displayed in the Service/Control
Algorithln Status/
Capacity screen and in the Status/COMPR
screen. Viewing this
data will aid in troubleshooting
and understanding
current
operation.
Variable Speed (VFD) Application
-- The PIC III controls
the machine capacity by modulating both motor speed and
inlet guide vanes in response to chilled water temperature deviation from the CONTROL POINT (see above). During operation
when the CONTROL POINT is not met within 1/3 the width of
the CHILLED WATER DEAD)BAND, the controller will calculate a GUIDE VANE DELTA which will effect a percentage
change to either the guide vane position or TARGET VFD
SPEED. Factol.s considered in the capacity control algorithln include: (1) the sign and magnitude of GUIDE VANE DELTA
(based on deviation from CONTROL POINT adjusted for the
error trends and CHILLED WATER DEAl)BAND),
(2) ACTUAL GUIDE
VANE POSITION,
(3) ACTUAL
VFD
SPEED, and (4) surge prevention mode. Generally the controller will maintain the highest inlet guide vane setting at the lowest speed to maximize efficiency while avoiding surge.

For example, a 1° F (0.6 ° C) deadband setting controls the
water temperature within _+0.5° F (0.3 ° C) of the control point.
This may cause fiequent guide vane movement if the chilled
water load fluctuates frequently. A value of 1° F (0.6 ° C) is the
default setting.
DIFFUSER
CONTROL--On
all units with Frmne 5 compmssol.s and those Frmne 4 compressors with the variable (split
ring) dilluser option, the PIC III adjusts the difluser actuator
position (DIFFUSER ACTUATOR on the COMPRESS screen)
based on the ACTUAL GUIDE VANE POSITION. This is
done in accordance with a compressor build-specific "schedule"
entered in the SETUP2 screen. The schedule consists of guide
wme and diffuser positions for three points (designated as the
25%, 50%, and 75% Load Points). In order for the schedule to
be valid, the guide vane values must be ascending and the diffuser values must be descending for the three points. Diflhser
actuator output is controlled by a 4 to 20 mA output from CCM
terminals J8-3(+) and J8-4(-). Figure shows the relationship
between diffuser-related
pguameters for a typic_d build. See
Fig. 21.

First the c',_culation of GUIDE VANE DELTA is performed.
If GUIDE VANE DELTA is positive, the response will be an
IGV or VFD position increase (within limits). If GUIDE VANE
DELTA is negative, the response will be gm IGV or VFD position decrease (within limits). Next, the surge prevention mode is
detemfined based on location of the present operating point on
the CHILLED WATER DELTA T/ACTIVE DELTA P map relative the configured stage prevention line. This mode will either
be Norm_d or Surge Prevention. The table below indicates which
output is modulated that. When the Ih.st output roaches its limit
(ACTUAL GUIDE VANE position roaches maximum), the second output is modulated. See Table 5.
34

Full
Open

2 mA
(O%)
4 mA
(0.2%

KILOWATTS (demand) by limiting capacity via guide vane
control. The limit applied is called ACTIVE
DEMAND
LIMIT. which is equ_d to a BASE DEMAND LIMIT value
(set in the SETPOINTS Screen, page 22, default value 100%),
or that determined by AUTO DEMAND LIMIT INPUT (tin
optional 4 to 20 mA input, described
below). ACTIVE
DEMAND LIMIT may _flso be forced to be different from
BASE DEMAND LIMIT by manually overriding the value
(forcing) from the MAINSTAT screen or writing a value via a
CCN network device, or controlled by another chiller in Lead
Lag operation (see page 44).

surge more likely

*6
c£

75 % Load Point
o

surge
50 % Load

less

likely

Point

rotating stall
less likely

rJ.

The demand limit may be based on either line cunent or
kW. as indicated by DEMAND
LIMIT SOURCE
in the
EQUIPMENT SERVICE/RAMP_DEM
table. The default is 0,
for demand limiting based on AVERAGE LINE CURRENT
(percent of RATED LINE AMPS, as displayed on the default
screen). Setting DEMAND
LIMIT SOURCE
to 1 makes
demand limiting based on PERCENT
LINE KILOWATTS
(displayed in the MAINSTAT scleen). LINE KILOWATTS is
measured by the VFD, and the MOTOR RATED LOAD kW
value (100% rated kW) is set in the VFD_CONF table.

Full -Closed
25 % Load

approx,
4 rnA*

Point

(_00%) 0 %
* Diffuser full Span mA.

Fig. 21 --

50 %

78 %

GUIDE VANE OPENING (%)

Diffuser

Control

If the DEMAND LIMIT SOURCE (percent line current)
exceeds the ACTIVE DEMAND LIMIT by 5% or less, increases in guide vane opening will be prevented. If the DEMAND LIMIT SOURCE (percent line current) exceeds the
ACTIVE DEMAND LIMIT by more than 5%, the guide vanes
will be forced to close. Also, as the DEMAND
LIMIT
SOURCE approaches the ACTIVE DEMAND LIMIT from a
lower value, allowable capacity increases become increasingly
more limited,
beginning
when
the DEMAND
LIMIT
SOURCE is within the DEMAND LIMIT PROP BAND (configumble in the RAMP_DEM table).

Diffuser control output is enabled whenever the DIFFUSER
OPTION is enabled, whether the machine is rtmning or not. As
shown in Fig. 21,0% output corresponds to a full open diffusel:
The minimum closed position (25% Load Point value) will be
at less than 100% for most diffusers (depending upon the
model). This coordinated guide vane-diffiJser operation may be
tested in the Control Test selection "IGV & SRD Actuator".
Note that the diffuser actuator should NOT be forced to a greater percent than the configured 25% Load Point (maximum)
value. The diffuser opening can be incremented from fully open
to completely closed. A 0% setting is tully open; a 100% setting
is completely closed. To obtain file proper settings for Diffuser
Control, contact a Carrier Engineering representative.

Demand Limit Control Option -- The demand limit control
option (20 mA DEMAND
LIMIT OPT) is extern_flly
controlled by a 4 to 20 mA signal from an energy management
system (EMS). The option is set up on the RAMP_DEM
screen. When enabled, 4 mA will set ACTIVE DEMAND
LIMIT to 100% of the DEMAND LIMIT SOURCE Qegardless of the value of BASE DEMAND LIMIT), and 20 mA will
set ACTIVE DEMAND LIMIT to the value configured as
"20MA DEMAND LIMIT OPT" in the RAMP_DEM
table.

PROPORTIONAL
BANDS AND GAIN -- Proportiomfl band
is the rote at which capacity control (including guide vane
position and, if applicable, VFD speed) is adjusted in proportion to how far the chilled water/brine temperature is from the
CONTROL POINT. Proportional gain determines how quickly
capacity control reacts to how quickly the temperature
is
moving from the CONTROL POINT. The proportional bands
and gain may be viewed or modified from the SETUP2 scleen,
which is accessed from the EQUIPMENT SERVICE table.

Wire the auto demand limit input to terminals J5-1 (-) and
J5-2 (+) on the CCM. In order to use a 1 to 5 vdc input instead
of 4 to 20 mA, install a 25 ohm resistor in series with the + lead
at terminal J5-2.

The Proportional Band -- Thele gu'e two response modes, one
for temperature response above the control point, the other for
the response below the control point.

A DEMAND
KILOWATI'S
monitoring
feature is also
available. This feature provides a display of average demand
(power) in kilowatts (in the POWER screen). This v_due is
continuously updated and averaged over the preceding time
interval specified as DEMAND WATFS INTERVAL in the SERVICE / EQUIPMENT
SERVICE/RAMP
DEM screen.
CHILLER TIMERS AND STARTS COUNTER
-- The PIC
III m_dntains two run time clocks: COMPRESSOR
ONTIME
and SERVICE ONTIME. COMPRESSOR
ONTIME indicates
file total lifetime compressor run hours. SERVICE ONTIME is
a _esettable timer that can be used to indicate the hours since
file last service visit or any other event. A separate counter
tallies compressor stmls as TOTAL COMPRESSOR
STARTS.
All of these can be viewed on the MA[NSTAT screen on the
ICVC. Both ontime counters roll over to 0 at 500,000 hom.s.
Manual changes to SERVICE ONTIME from the ICVC me
permitted at any time. If the controller is replaced, one opportunity, before the first st_utup with the new controllel; is
provided
to set COMPRESSOR
ONTIME
and TOTAL
COMPRESSOR
STARTS to the last readings retained with the
prior controllel: The SERVICE ONTIME timer can register up
to 32,767 hours before it rolls over to zero.

The temperature response above the control point is called
the PROPORTIONAL
INC BAND, and it can slow or quicken
capacity control response to chilled water/brine temperatures
above the CHILLED WATER DEADBAND.
The PROPORTIONAL INCBAND can be adjusted from a setting of 2 to 10;
the default setting is 6.5.
The response below the control point is called the PROPORTIONAL DEC BAND, and it can slow or quicken the capacity control response to chilled water temperature below the
deadband plus file control point. The PROPORTIONAL
DEC
BAND can be adjusted on the ICVC from a setting of 2 to 10.
The default setting is 6.0.
NOTE: Increasing either of these settings causes the capacity
control to respond more slowly than at a lower setting.
The PROPORTIONAL
ECW GAIN can be adjusted on the
ICVC display for v_dues of 1, 2, or 3; the default setting is 2.
Increase this setting to increase guide vane response to a
change in entering chilled water temperatme.
DEMAND LIMITING--The
PIC III controls provide a
feature for limiting AVERAGE LINE CURRENT
or LINE

Thechilleralsomaintains
a start-to-stmt
timer and a
stop-to-start time_: These timers limit how soon the chiller
can be started. START INHIBIT TIMER is displayed on
the MAINSTAT screen. See the Start-Up/Shutdown/Recycle
Sequence section, page 50, for more information on this topic.

• VFD power faults
• VFD over temperature
• dew formation on the VFD cold plate
*Superlleat is the difference between saturation temperature
and sensible temperature. The high discharge temperature
safety measures only sensible temperature.
VFD faults or optional protective devices within the VFD
can shut down the chillel:

OCCUPANCY
SCHEDULE--The
chiller schedule,
described in the Time Schedule Operation section (page 21 ), determines when the chiller can ran. Each schedule consists of from
1 to 8 occupied or unoccupied time periods, set by the operatol:
The chiller can be stm-ted and run during an occupied time
period (when OCCUPIED?
is set to YES on the MAINSTAT
display screen). It cannot be started or run during an unoccupied
time period (when OCCUPIED?
is set to NO on file MAINSTAT display screen). These time periods can be set for each
&ty of file week and for holi&tys. The day begins wifll 0000
hours and ends with 2400 hours. The default setting for OCCUPIED? is YES, unless an unoccupied time period is in effect.

If compressor motor overload occurs, check the motor for
grounded or open phases before attempting a restart.
If the PIC [IXcontrol initiates a safety shutdown, it displays
the reason for the shutdown (the fault) on the ICVC display
screen along with a primmy and seconda q message, and blinks
the alarm light on the control panel. The ahum is stored in
memory and can be viewed on the ALARM HISTORY and
VFD_HIST screens on the ICVC, along with a message for
troubleshooting. If the safety shutdown was also initiated by a
fault detected in the motor stm-tek the conditions at the time of
the fault will be stored in VFD_HIST.

These schedules can be set up to follow a building's
occupancy schedule, or the chiller can be set so to run 100% of
the time, if the operator wishes. The schedules also can be
bypassed by forcing the CHILLER START/STOP parameter on
the MAINSTAT screen to START. For more information on
forced starts, see Loc_fl Start-Up, page 50.
The schedules also can be overridden to keep file chiller in
an occupied state for up to 4 hours, on a one time basis. See the
Time Schedule Operation section, page 21.

To give morn precise information
or warnings on the
chiller's operating condition, the operator can define alert
limits on various monitored inputs in the SETUPI screen.
A partkd list of protective safety and alert limits is provided
in Table 6. A complete list of alarm and alert messages is provided in the Troubleshooting
Guide section, page 79.

Figure 19 shows a schedule for a typical office building
with a 3-horn: off-peak, cool-down period from midnight to
3 a.m., following a weekend shutdown. Holickly periods are in
an unoccupied
state 24 hours per day. The building operates
Monday through Friday. 7:00 a.m. to 6:00 p.m., and Saturdays
from 6:00 a.m. to 1:00 p.m. This schedule also includes the
Monday midnight to 3:00 a.m. weekend cool-down schedule.

Shunt

Trip (Option) -- The function of the shunt trip
option on the PIC Ill is to act as a safety trip. The shunt trip is
wired from the stan&trd I/O board to a shunt trip equipped
VFD circuit breakel: If the HC IIl tries to shut down the compressor using a normal shutdown procedure but is unsuccessful
for 20 seconds, the shunt trip output is energized and causes the
circuit breaker to trip off. If ground fault protection has been
applied to the startel; file ground fault trip also energizes the
shunt trip to trip the circuit breakel: Protective devices in the
starter can also energize the shunt trip. The shunt trip feature
can be tested using the Control Test feature in the DISCRETE
OUTPUTS CONTROL TEST screen.

NOTE: This schedule
is for illustration
only and is not
intended to be a recommended
schedule for chiller operation.
Whenever
the chiller is in the LOCAL mode, it uses
Occupancy Schedule 01 (OCCPC01S). When the chiller is in
the ICE BUILD mode, it uses Occupancy
Schedule 02
(OCCPC02S).
When the chiller is in CCN mode, it uses
Occupancy Schedule 03 (OCCPC03S).
The CCN SCHEDULE
NUMBER is configured on the
NET OPT display scleen, accessed from the EQUIPMENT
CONFIGURATION
table. See NiNe 4, Exalnple 15. SCHEDULE NUMBER can be changed to tiny v_flue from 03 to 99. If
this number is changed on the NET OPT screen, the operator
must go to the ATTACH TO NETWORK DEVICE screen to upload the new number into the SCHEDULE screen. See Fig. 17.

Default Screen Freeze -- When the chiller is in an al;um
state, the default ICVC display "freezes," that is, it stops updating.
The til_t line of the ICVC default screen displays a primary akum
message; the second line displays a secon&lry ;darm message.
The ICVC default screen freezes to enable the operator to
see the conditions of the chiller at the time of the alarm. If the
value in almm is one nommlly displayed on the default screen,
it flashes between normal and reverse contrast. The ICVC
default screen remains frozen until the condition that caused
the akum is remedied by the operator Use [CVC display and
alarm shutdown record sheet (CL-12) to record all v;dues from
default screen freeze.

Safety

Controls -- _n_e PIC III monitors all safety control inputs and, if required, shuts down the chiller or limits the
guide wines to protect the chiller from possible damage from
any of the following conditions:
• high bearing temperature
• high motor winding temperature
• high discharge temperature
• low discharge superlleat*
• low oil pressure
• low cooler refrigerant temperature/pressure
• condenser high pressure or low pressure
• inadequate water/brine
cooler and condenser flow
• high, low, or loss of voltage
• ground fault
• voltage imbalance
• current imbalance
• excessive motor acceleration
time
• excessive starter transition time
• lack of motor current signal
• excessive motor amps
• excessive compressor
surge
• temperature and transducer faults

Knowledge of the operating state of the chiller at file time an
alarm occurs is useful when troubleshooting. Additional chiller
information
can be viewed on the status screens and the
VFD_HIST screen. Troubleshooting
information is recorded in
the ALARM HISTORY table, which can be accessed from the
SERVICE menu.
To determine what caused the _flmm, the operator should mad
both file primary and secondm-y default screen messages, as well
as the aimin history. The primmy message indicates file most
recent almm condition. The secon&lry message gives more
derail on the algum condition. Since there may be more than one
alarm condition, another _darm message may appetu after the
fil.st condition is clemed. Check the ALARM HISTORY screen
for additional help in determining the reasons for file _flarms.
Once _dl existing _dmms me clemed (by pressing the
softkey), the default ICVC display returns to norm_fl operation.
36

Table 6 -- Protective Safety Limits and Control Settings
MONITORED
Temperature
Pressure

PARAMETER

Sensors Out of Range

Transducers

High Compressor

Out of Range

Discharge

Temperature

ALARM/
ALERT

.O6>Voltage Ratio>.98 or - 40 F>
Temperature>245
F for 3 seconds

Preset Alarm, Voltage Ratio=Input
Voltage Reference(5 Volts)

Voltage/

260-271

.06>Voltage

Preset Alarm, Voltage Ratio=Input
Voltage Reference(5 Volts)

Voltage/

231

103
233
102
Compressor

Thrust

Bearing Temperature

101
234
243

Low Evaporator Temperature
Freeze Protection)

232

1 o4

Transducer

239

Voltage Fault

High Condenser

Pressure

--Control

235

Ratio>.98

COMP DISCHARGE
(104.4 C)
COMP DISCHARGE
ALERT

for 3 seconds
TEMP > 220 F

Preset Alarm, Configure COMP
ALERT in SETUP1 screen

TEMP > COMP DISCHARGE

Configure COMP DISCHARGE
screen

COMP DISCHARGE TEMP > COMP DISCHARGE
ALERT - 10 F (5.6 C)
COMP MOTOR WINDING TEMP > 220 F
(104 C)
COMP MOTOR WINDING TEMP > COMP MOTOR
TEMP OVERRIDE - 10 F (5.6 C)
COMP THRUST BRG TEMP > COMP THRUST
BRG ALERT - 10 F (5.6 C)
COMP THRUST BRG TEMP > 185 F
(85 C)
Chiller in RECYCLE SHUTDOWN and EVAP
TEMP EVAP APPROACH ALERT

Preset Alarm, Configure EVAP APPROACH
ALERT in SETUP1 screen

0 ° F (-17.8 C) EVAP APPROACH ALERT

Configure EVAP REFRIG TRIP POINT and
CHILLED MEDIUM in SETUP1 screen

EVAPORATOR REFRIG TEMP < 33 F
+ REFRIG OVERRIDE DELTA T (water)
EVAPORATOR REFRIG TEMP < EVAP REFRIG
TRIPPOINT (brine)

Prestart Alert, Configure REFRIG OVERRIDE
DELTA T in SETUP1 screen

5.5 VDC< Voltage Reference<4.5 VDC
CONDENSER PRESSURE > 165 PSI

Preset Alarm

Preset Alarm, Switch closes at 110 _+- PSIG

Preset Alarm, Configure COMP MOTOR TEMP
OVERRIDE in SETUP1 screen
Prestart Alert, Configure COMP MOTOR TEMP
OVERRIDE in SETUP1 screen
Preset Alert, Configure COMP THRUST
ALERT in SETUP1 screen

Preset Alarm, configure EVAP REFRIG
TRIPPOINT in SETUP1 screen

Prestart Alert, Configure EVAP REFRIG TRIPPOINT and CHILLED MEDIUM in SETUP1 screen

Preset Alarm, Configure COND PRESS
OVERRIDE in SETUP1 screen

Prestart

106

CONDENSER PRESSURE
OVERRIDE - 20 PSI

> COND PRESS

Prestart Alert, Configure COND PRESS
OVERRIDE in SETUP1 screen

CONDENSER

> 145 PSI

Prestart Alert

PRESSURE

_+5 PSIG) &

244

Chiller in PUMPDOWN mode and CONDENSER
REFRIG TEMP < CONDENSER FREEZE POINT

Preset Alarm, Configure CONDENSER
POINT in SETUP1 screen.

154

Energizes condenser pump relay if CONDENSER
REFRIGTEMP CONDENSER
FREEZE POINT + 5 ° F (2.8 ° C) and ENTERING
COND LIQUID > CONDENSER FREEZE POINT

Configure CONDENSER
SETUP1 screen

228

OIL PRESSURE DELTA P < 13 PSlD and
VFD START = TRUE

Preset Alarm

OIL PRESSURE DELTA P < 18 PSlD and startup
complete after OIL PRESS VERIFY TIME elapsed

Preset Alarm, Configure OIL PRESS VERIFY
TIME in SETUP1 screen
Preset Alert

Low Pressure

142

OIL PRESSURE
complete

Pressure

227

OIL PRESSURE DELTA P > 4 PSI immediately
before oil pump turned on
OILSUMPTEMP
< 150 Fand OILSUMPTEMP
EVAP REFRIG TEMP + 50 F (27.8 C)

Sensor Fault

Low Temperature
Line Voltage--High

105
211/145

DELTA P < 18 PSlD and startup

Line voltage > approximately
calculated by VFD

High

108

Low

212/146

Low

107

PERCENT
threshold

Imbalance

216

LINE VOLTAGE IMBALANCE
% IMBALANCE

Single Cycle Dropout
Imbalance

Line Frequency Out of Range
ICVC Power on Reset

BRG

Preset Alarm

High Pressure Switch Open(165
VFD START = YES

Low Pressure

Power --

ALERT in SETUP1

207

Low Pressure

Line Current --

DISCHARGE

Switch

Low Condenser Pressure
Freeze Protection)

Oil--

COMMENTS

260-271,
140,141

167

High Motor Temperature

LIMIT

210/144
209/143

222
214/148

PERCENT
threshold

528 V, limits are

LINE VOLTAGE > Overveltage

DC BUS VOLTAGE < approximately
limits are calculated by a VFD

408 V,

LINE VOLTAGE < Undervoltage
> LINE VOLTAGE

Prestart Alert
Preset Alarm/Alert
Preset Prestart Alert
Preset Alarm/Alert
Preset Prestart Alert
Configure LINE VOLTAGE % IMBALANCE and
LINE VOLT IMBALANCE TIME in VFD CONF
screen
Preset Alarm

47 Hz < LINE FREQUENCY

Preset Alarm

< 63 Hz

POINT in

Preset Alarm

Line Voltage on 2 Phases < 50% for 1 Cycle
LINE CURRENT IMBALANCE>LINE
CURRENT
% IMBALANCE

Loss of control power to ICVC for excessive time
_eriod

FREEZE

Configure LINE CURRENT % IMBALANCE
LINE CURRENT IMBALANCE TIME in
VFD CONF screen
Preset Alarm

and

Table 6 -- Protective Limits and Control Settings
MONITORED
Motor-

PARAMETER

ALARM/ALERT

(cont)

LIMIT

COMMENTS

Surge

236

> 5 surge events within SURGE TIME PERIOD
and VFD SPEED > 90%

Preset Alarm, Configure SURGE DELTA% AMPS
and SURGE TIME PERIOD in OPTIONS screen

Surge

236

> 5 surge events within SURGE TIME PERIOD
and VFD SPEED < 90%

Preset Alarm, Configure SURGE DELTA% AMPS
and SURGE TIME PERIOD in OPTIONS screen

Current Imbalance

225

MOTOR CURRENT IMBALANCE>MOTOR
CURRENT % IMBALANCE

Configure MOTOR CURRENT % IMBALANCE and
MOTOR CURRENT IMBAL TIME in VFD CONF
screen

Overload

217

Any LOAD CURRENT PHASE > 108% for
Excessive Time Period

Preset Alarm, Configure MOTOR LOAD ACTIVE
DEMAND LIMIT in MAINSTAT screen

Excessive Amps
Acceleration Fault

206

PERCENT

Preset Alarm

2O3

PERCENT LOAD CURRENT > 95% and
VFDSTART = TRUE for 5 to 40 sec

Preset Alarm, PERCENT LOAD CURRENT =
AVERAGE LOAD CURRENT/MOTOR
RATED
LOAD AMPS

Amps Not Sensed

202

PERCENT LOAD CURRENT < 5% for 3 seconds
and VFD START=TRUE for 20 sec

Preset Alarm, PERCENT LOAD CURRENT =
AVERAGE LOAD CURRENT/MOTOR
RATED
LOAD AMPS

Starts Limit Exceeded

Trip

LOAD CURRENT

> 110% for 30 sec.

100

More than 8 starts in 12 hours

Preset Prestart Alert

Low Chilled Water Flow

229

Optional Alarm, Configure WATER FLOW VERIFY
TIME in SETUP1 screen

Low Cond Water Flow

230

High Approach--Evaporator

162

CHILLED LIQUID FLOW = FALSE after CHILLED
WATER PUMP = ON & WATER FLOW VERIFY
TIME elapsed
COND WATER FLOW = FALSE after COND
WATER PUMP = ON & WATER FLOW VERIFY
TIME elapsed
EVAPORATOR APPROACH > EVAP APPROACH
ALERT and startup complete
CONDENSER APPROACH > COND APPROACH
ALERT and startup complete
ACTUAL VFD SPEED > VFD SPEED OUTPUT
+ 10%

204

PERCENT LOAD CURRENT
VFDSTART = NO for 20 sec

>15% and

Preset Alarm, PERCENT LOAD CURRENT =
AVERAGE LOAD CURRENT/MOTOR
RATED
LOAD AMPS

218

RECTIFIER

limit exceeded

Preset Alarm, Configure RECTIFIER
OVERRIDE in SETUP1 screen

TEMP

110

RECTIFIER TEMPERATURE > RECTIFIER
OVERRIDE -20 F (11.1 C)
Rectifier current limit exceeded

Prestart Alert, Configure RECTIFIER
OVERRIDE in SETUP1 screen

TEMP

Condenser
VFD--High

Inverter--

245

VFD Speed

Failureto

Rectifier--

163

Stop

High Temperature

TEMP

Configure EVAP APPROACH
screen
Configure COND APPROACH
screen

ALERT in SETUP1
ALERT in SETUP1

Preset Alarm, Must be outside +10% threshold
75 sec.

Overcurrent

241

Power Fault

2OO

IGBT current limit exceeded or a fault was detected
in the rectifier

Preset Alarm

High Temperature

219

INVERTER

Preset Alarm, Configure INVERTER TEMP
OVERRIDE in SETUP1 screen

111
286

INVERTER TEMPERATURE > INVERTER
OVERRIDE-20
F (11.1 C)
Inverter current limit exceeded

201

IGBT current limit exceeded

Preset Alarm

256

Inductor temperature

Preset Alarm, Temperature
opened
Preset Alarm/Alert

Power Fault
Inductor

TEMPERATURE

Optional Alarm, Configure WATER FLOW VERIFY
TIME in SETUP1 screen

-- Overtemperature

DC Bus Voltage --

Switch

High
Low

Ground Fault
Optional Limits --

205/166
215
22O

Spare Temperature

Guide Vane Position

Low Discharge Superheat

158,159,
248,249
253

240

TEMPERATURE

Preset Alarm

limit exceeded
TEMP

limit exceeded

DC BUS VOLTAGE Limit Exceeded

Prestart Alert, Configure INVERTER
OVERRIDE in SETUP1 screen

TEMP

Preset Alarm

DC BUS VOLTAGE <407VDC at 400/480 V Line
Side Voltage
GROUND FAULT CURRENT > 7% of Drive Rated
Amps Sensed
SPARE TEMPERATURE
> SPARE TEMP LIMIT

Preset Alarm

ACTUAL GUIDE VANE POS > 4% after 4 minutes
of closing
ACTUAL GUIDE VANE POSITION < .045 volts
after startup complete
ACTUAL GUIDE VANE POSITION > 3.15 volts
after startup complete
ACTUAL GUIDE VANE POSITION < -1% after
startup complete
ACTUAL GUIDE VANE POSITION > 103% after
startup complete
DISCHARGE SUPERHEAT < SUPERHEAT
REQUIRED -3 ° F (1.7 ° C) for 60 seconds

Preset Alarm

for

switch in reactor has

Preset Alarm
Optional Alarm/Alert, Configure SPARE TEMP
ENABLE and SPARE TEMP LIMIT in SETUP1
screen

Preset Alarm
Preset Alarm
Preset Alarm
Preset Alarm
Preset Alarm, DISCHARGE SUPERHEAT = COMP
DISCHARGE TEMP - CONDENSER REFRIG
TEMP

Ramp Loading

-- Tile rmnp loading control slows down
tile rate at which the compressor loads up. This control can prevent the compressor fiom loading up during the short period of
time when tile chiller is started and tile chilled water loop has to
be brought down to CONTROL POINT. This helps reduce
electlical demand charges by slowly bringing the chilled water
to CONTROL POINT. The total power draw during this period
remains ahnost unchanged.

Whenever
the motor current
demand limit set point
(ACTIVE DEMAND LIMIT) is reached, it activates a capacity
ovenide, again, with a 2-step process. Exceeding 110% of the
rated load amps for more than 30 seconds will initiate a safety
shutdown.
The high compressor lift (surge prevention) set point will
cause a capacity ovenide as well. When the surge prevention
set point is reached, the controller normally will only prevent
the guide vanes from opening. If so equipped, the hot gas
bypass valve will open instead of holding the vanes. The hot
gas bypass will only open if the compressor is at 100% speed.
See the Surge Prevention Algorithm section, page 42.

There are several methods of romp loading with the PIC III.
Ramp loading can be based on LEAVING CHILLED WATER,
ENTERING CHILLED WATER, PERCENT LINE CURENT or
PERCENT
MOTOR
KILOWATFS.
PULLDOWN
RAMP
TYPE is selected fiom tile RAMP
DEM screen.

High Discharge Temperature

1. Temperature ramp loading (TEMP PULLDOWN
DE(;/
MIN) limits the degrees per minute rote at which either
LEA VING CHILLED WATER or ENTERING CHILLED
WATER temperature decreases. This rate is configured by
the operator on the TEMP_CTL screen.
NOTE: If chiller control power has been off for 3 hours or
more, file next startup (only) will follow temperature ramp
loading using the minimum rate regardless of the rmnp loading
method and rate which m:e configured in the screens. This is
used to maximize oil reclaim during stmtup.
2.

Oil Sump
Temperature
and
Pump
Control -- The oil sump telnperature is regulated by the PIC III,
with the oil heater relay when the chiller is shut down.
As part of the pre-start checks executed by the controls, the
oil sump temperature
(OIL SUMP TEMP) is compared to
the cooler refrigerant temperature (EVAPORATOR REFRIG
TEMP) if the OIL SUMP TEMP is less than 150 F (65.6). If
the diffelence between these 2 temperatures is 50 F (27.8 C) or
less, the start-up will be delayed until either of these conditions
is no longer true. Once this temperature criteria is satisfied, the
start-up continues.
The oil heater relay is energized whenever the chiller compressor is off and the oil sump temperature is less than 140 F
(60.0 C) or the OIL SUMP TEMP is less than the EVAP
REFRIG TEMP plus 53 ° F (29.4 ° C). The oil heater is turned
off when the OIL SUMP TEMP is either:
• morethan
152 F (66.7 C), or
• more than 142 F (61.1 C) and more than the EVAP
REFRIG TEMP plus 55 ° F (30.6 ° C).
The oil heater is always off during start-up or when the
compressor is running.
The oil pump is also energized dnring the time the oil is being heated (for 30 seconds at the end of every 30 minutes).
The oil pump will not operate if the EVAPORATOR PRESSURE is less than -5 psig (-34.5 kPa).

Motor load ramp loading (AMPS OR KW RAMP %/
MINI limits the rate at which tile compressor motor current or complessor motor load increases. The AMPS OR
KW RAMP %/MIN rate is configured by the operator
on the RAMP_DEM
screen in line current or motor
kilowatts.

If kilowatts is selected for the DEMAND LIMIT SOURCE,
the MOTOR RATED LOAD KILOWATTS must be entered in
the VFD_CONF screen.
The TEMP PULLDOWN
DEG/MIN may be viewed or
modified on the TEMP_CTL
screen which is accessed from
the EQUIPMENT
SERVICE screen. PULLDOWN
RAMP
TYPE, DEMAND LIMIT SO URCE, and AMPS OR KW RAMP
_/MIN may be viewed or modified on the RAMP_DEM
screen.

Capacity

Override

Control -- If the

COMP DISCltARGE
TEMP increases above 160 F (71.1 C),
the guide vanes _ue proportionally opened to increase gas flow
through the compressol: If the LEAVING CHILLED WATER
temperature decreases 5 ° F (2.8 ° C) below the control set point
temperature, as a result of opening the guide vanes, the PIC III
will bring the chiller into the recycle mode.

(Table 7) -- Capacity overrides can

prevent some safety shutdowns caused by exceeding the motor
amperage limit, low evaporator temperature safety limit, high
motor temperature safety limit, and high condenser pressure
limit. In all cases there are two stages of compressor capacity
control applied by guide vane operation.
1. When the value of interest crosses the First Stage Set
point into the Override Region, the guide vanes are
prevented from opening furthel: and the status line on the
ICVC indicates the reason for the override. Normal
capacity control operation is restoled when the value
crosses back over the First Stage Set point, leaving the
Override Region. (Refer to Table 7.)

Oil Cooler

-- The oil must be cooled when the compressor is running. This is accomplished through a small, plate-type
heat exchanger (also called the oil cooler) located behind the
oil pump. The heat exchanger uses liquid condenser refrigerant
as the cooling liquid. Refrigerant
thermostatic
expansion
valves (TXVs) regulate refrigerant flow to control the oil temperature entering the bearings. The bulbs for the expansion
valves are strapped to the oil supply line leaving the heat
exchangel: and the valves are set to maintain 110 F (43 C).

2. When the value of interest is in the Override Region and
further crosses the Second Stage Set point, the guide
vanes me closed until the value meets the Ovenide
Termination
Condition. The PIC III controls resume
norm_d capacity control operation after the override
termination condition has been satisfied. (In the case of
high dischmge supeflleat, there is an intermediate stage).

NOTE: The TXVs me not adjustable. The oil sump tempemtme
may be at a lower temperature during compressor operation.

Table

7 -- Capacity

Overrides

FIRST STAGE SET POINT

OVERRIDE
CONDITION

View/Modify on
ICVC Screen

High Condenser Pressure
(COND PRESS OVERRIDE)

SETUP1

High Motor Temperature
(COMP MOTOR TEMP
OVERRIDE)

Override Default
Value
CONDENSER
PRESSURE
>125 psig (862 kPa)

SECOND
Configurable
Range

90 to 165 psig
(621 to 1138 kPa)

COMP MOTOR
WINDING TEMP
> 2OO F (93 C)

SETUP1

150 to 200 F
(66 to 93 C)

REFRIG TEMP
< EVAP REFRIG
TRIPPOINT + 3 F
(1.7 C)

SETUP1

Min TI: 1.5 F (0.8 C)

High Compressor
Lift
(SURGE/HGBP DELTA T,P)

OVERRIDE TERMINATION

Value

CONDENSER PRESSURE
> COND PRESS OVERRIDE
+ 2.4 psig (16.5 kPA)

CONDENSER PRESSURE
< CONDENSER PRESS
OVERRIDE - 1 PSI (6.9 kPa)

COMP MOTOR WINDING TEMP
> COMP MOTOR TEMP OVERRIDE + 10 F (5.6 C)

COMPR MOTOR WINDING
TEMP < COMP MOTOR TEMP
OVERRIDE2 F (1.1 C)

2 to 5 F
(1.1 to 2.8 C)

- 1 F (.6 C)
NOTE: EVAP REF OVERRIDE
TEMP = EVAP REFRIG TRIPPOINT + REFRIG OVERRIDE
DELTA T

EVAP REFRIG TEMP
> EVAP REF OVERRIDE TEMP
+2F(1.1C)

0.5 - 2.0 F
(0.3- 1.1 C)
30 - 170 psid
(207 - 1172 kPad)
0.5 - 20 F
(0.3- 11,1 C)
50 - 170 psid
(345 - 1172 kPad)

None

ACTIVE DELTA T > SURGE/
HGBP DELTA T + SURGE/HGBP
DEADBAND

Automatic

0 to 100%

None

Press RELEASE softkey after
selecting
TARGET GUIDE VANE
POS

COMPRESS

Automatic

VFD MINIMUM
SPEED to 100%

MAINSTAT

Automatic

40 to 100%

OPTIONS

Min PI: 50 psid
(345 kPa)
Max T2:10 F (5.6 C)
Max P2:85 psid
(586 kPad)

Manual Guide Vane Target
(TARGET GUIDE VANE POS)

STAGE SET POINT

EVAPORATOR REFRIG TEMP
< EVAP REF OVERRIDE TEMP

EVAPORATOR
Low Evaporator Temperature
(REFRIG OVERRIDE
DELTA T)

Table

COMPRESS

Forced TARGET VFD SPEED
Manual Speed Control
(TARGET VFD SPEED)

Motor Load
(ACTIVE DEMAND

LIMIT)

ACTUAL SUPERLow Discharge

Superheat

OVERRIDE

HEAT<
SUPERHEAT
REQUIRED
for
conditions

High Rectifier Temperature
(RECTIFIER TEMP
OVERRIDE)

SETUP1

RECTIFIER
TEMPERATURE>
160 F (71 C)

High Inverter Temperature
(INVERTER TEMP
OVERRIDE)

SETUP1

INVERTER
TEMPERATURE
160 F(71 C)

Remote Start/Stop

Controls

None

ACTIVE DEMAND
< Set Point - 2%

LIMIT

ACTUAL SUPERHEAT
< SUPERHEAT REQUIRED

ACTUAL SUPERHEAT
> SUPERHEAT REQUIRED
+ 1 F (0.56 C)

RECTIFIER TEMP
> RECTIFIER TEMP OVERRIDE
+ 10 F (5,6 C)

RECTIFIER TEMP
< RECTIFIER TEMP OVERRIDE
- 5 F (2.8 C)

155 to 170 F

INVERTER TEMP
> INVERTER TEMP OVERRIDE
+ 10 F(5,6C)

INVERTER TEMP
< INVERTER TEMP OVERRIDE
-5 F(2.8C)

(66 to 77 C)

the certified drawings for further details on contact ratings. The
contacts must have 24 vac dry contact rating.

may be used to stmt

Spare

Safety

and Spare Temperature

Inputs

Norln_dly closed (NC) discrete inputs for addition_d fieldsupplied safeties may be wired to the spare protective limits
input channel in place of the factory-installed
jumper on
terminals 19 and 20 of the low voltage terminal strip. The
opening of tiny contact will result in a safety shutdown and a
display on the ICVC. Refer to the certified drawings for safety
contact ratings.

IN 12 HOURS parmneter on the MAINSTAT screen) occur.
(not counting either lecycle restmts or auto restarts after power
failure) an excessive starts alarm displays, preventing the
from starting. Tile operator

ACTIVE DEMAND
> Set Point + 5%

- 1.25 F (0,7 C)

and stop the chillel: Howevel; the device should not be progmmmed to st_ut and stop file chiller in excess of 2 or 3 times
every 12 hours. If more than 8 st_uts in 12 hom_ (the STARTS

chiller

Press RELEASE softkey after
selecting TARGET VFD SPEED

155 to 170 F
(66 to 77 C)

-- A remote device, such

as a timeclock that uses a set of contacts,

cannot override either a
capacity inhibit
or a capacity
decrease
command
generated by
the PIC III

must press the

softkey on the ICVC to override the starts counter and start the
chillel: If the chiller records 12 starts (excluding recycle starts)
in a sliding 12-hour period, it can be lestarted only by pressing

Extra amdog telnperature sensors may also be added to the
CCM module (SPARE TEMPERATURE
#l and SPARE
TEMPERATURE
#2) at terminals J4 25-26 and J4 27-28,
respectively. The analog temperature sensors may be configured in the EQUIPMENT
SERVICE/SETUPI
table to cause
an alert (Enable value l or 2) or almm (Enable value 3 or 4),
or neither (Enable value 0). An alarm will shut down a running
chiller, but an alert will not. The fault condition will be
triggered when crossing a high limit (Enable value 2 or 4) or
low limit (Enable value l or 3), configurable between -40 F to
245 F (-40 C to 118 C). The spare temperature sensors are
readable on the CCN netwoN. They also have specific uses
as common temperature sensors in a Lead/Lag system (see
page 44).

the _
softkey followed by the _
or _
softkey. This ensures that, if the automatic system is m_dfunctioning, the chiller will not repeatedly cycle on and off. If the
AUTORESTART
OPTION in the OPTIONS scieen and the
REMOTE CONTACTS
OPTION are enabled, the REMOTE
CONTRACTS
must be closed in order for the chiller to lest_ut
following a power failure. If the automatic restmt after a power
failure option (AUTO RESTART OPTION on file OPTIONS
screen) is not activated when a power failure occurs, and if the
remote contact is closed, the chiller will indicate an _darm

Alarm (Trip) Output

Contacts

-- One set of alarm

contacts is provided in file stmlel: The contact ratings are
provided in the certified drawings. The contacts are located on
terminals 9 and l0 of the TB2 field wiring terminal strip in the
VFD enclosure.

because of the loss of voltage.
The contacts for remote start are wired into terminals 23 trod
24 of the low voltage terminal strip in the VFD enclosure. See

When the chiller is off and CONDENSER
REFRIG TEMP
is less than the CONDENSER
FREEZE
POINT,
the
CONDENSER
WATER PUMP will be energized (Alert State
154) Howevel, if the chiller is in pump down, and when it
entered pump down mode the CONDENSING REFRIG TEMP
was more than 5 ° F (2.7 ° C) above the CONDENSER
FREEZE POINT. the same low temperature condition will
generate Alarm State 244 trod the CONDENSER
WATER
PUMP will be energized. In either case, the fault state will clem
and the pump will turn off when the CONDENSER
REFRIG
TEMP is more than 5 ° F (2.7 ° C) above the CONDENSER
FREEZE POINT and the entering condenser water temperature
is greater than the CONDENSER FREEZE POINT. If the chiller is in Recycle Shutdown Mode when the condition occurs,
the controls will transition to a non-recycle shutdown.

Kilowatt

Output -- An output is available on tile CCM
module [Terminal J8-1 (+) and J8-2 (-)1 to represent the power
consumption of the chiller Tile 4 to 20 mA signal generated by
the CCM module can be wired to the building automation or
energy management
system to monitor the chiller's energy
consumption.
Output is 2 mA with the chiller off. and it
varies linedy
from 4 mA (representing 0% rated kilowatt
consumption)
to 20 mA (representing
100% RATED LINE
KILOWATFS).
The rated peak kilowatt
consumption
is
configured by the user in the VFD_CONF display screen by
the setting the RATED LINE KILOWATFS fiom the machine
electrical &tta nameplate.
Remote

Reset of Alarms

A stan&u'd feature of the

PIC |II controls is the ability to reset a chiller in a shutdown
alarm state from a remote location. [f the condition which
caused the alarm has cleared the chiller can be placed back into
a normal CCN operating mode when the REMOTE RESET
OPTION (ICVC_PSWD
menu) is set to ENABLE. A variety
of Career
Comfort Network
software systems including
ComfortVIEW TM or Network Sel-v'ice Tool TM can access the
PIC III controls and reset the displayed alarm. Third party
software from building automation systems (BAS) or energy
management
systems (EMS) can also access the PIC III
controls through a Carrier DataLINK rM module and reset the
fault displayed. Both methods would access the ICVC_PSWD
screen and fome the RESETALARM?
point to YES to reset the
fault condition. [f the P[C III controls have determined that is
safe to start the chiller the CCN MODE? point (ICVC_PSWD
screen) can be forced to YES to place the chiller back into
norln;fl CCN operating mode. The only exceptions am the
following ahums that cannot be reset from a remote location:
Aimm/Alert
STATE
100, 200, 201, 204, 206, 217-220,
233, 234, 247, and 259. To view alarm codes, refer to Troubleshooting Guide, Checking Display Messages, page 79. After
the alarm has been reset the PIC HI control will increment the
STARTS IN 12 HOURS counter by one upon restart. If the limit
of 8 starts in a 12-hour period is reached (Pmstart/Alert
state
100), this must be reset at the local chiller control panel

Evaporator

Freeze Protection -- When the EVAPORATOR REFRIG
TEMP is less than the EVAP REFRIG
TRIPPOINT plus the REFRIG OVERRIDE DELTA T (configurable fi_m 2 ° to 5 ° F or 1.1 ° to 2.8 ° C), Alert State 122 will be
displayed, and a capacity override will occm: (See Table 7.)
When the unit is running or in recycle, if the EVAPORATOR
REFRIG TEMP is equal to or less than the EVAP REFRIG
TRIPPOINT (33 ° F or 0.6 ° C for watek configurable for brine),
Protective Limit Alarm State 232 will be displayed, the unit
will shut down, and the CHILLED WATER PUMP will remgfin
on. The alarm will be clem'able when the leaving chilled water
temperature rises 5°F (2.8°C) above the CONTROL POINT.
When the unit is off, if the EVAPORATOR REFRIG TEMP
is less than the EVAP REFRIG TRIPPOINTplus
1° F (0.6 ° C),
Alarm State 243 will be generated and the CHILLED WATER
PUMP will be turned on. The _flmm can be reset when the
EVAPORATOR REFRIG TEMP rises 5 ° F (2.8 ° C) above the
EVAP REFRIG TRIPPOINT`

Tower Fan Relay Low and High -- Low

condenser water temperature can cause the chiller to shut down when
refrigerant temperature is low. The tower fan relays, located in
the stmter, am controlled by the PIC III to energize and deenergize as the pressure differential between cooler and condenser
vessels changes. This prevents low condenser water temperaturn and maximizes chiller efficiency. The tower fan relay can
only accomplish flris if the relay has been added to the cooling
tower temperature controllel:
TOWER FAN RELAY LOW is turned on whenever the
condenser water pump is running, flow is verified, ;rod the
difference between cooler and condenser pressure is more than
30 psid (207 kPad) for entering condenser water temperature
greater than 65 F (18.3 C).
TOWER FAN RELAY LOW is turned off when the condenser pump is off. flow is stopped, or the EVAP REFRIGERANT
TEMP is less than the EVAP REF OVERRIDE
TEMP for
ENTERING
CONDENSER
WATER temperature
less than
62 F (16.7 C), or the difference between the CONDENSER
PRESSURE
and EVAPORATOR
PRESSURE
is less than
25 psi d (172.4 kPad) for ENTERING CONDENSER water less
than 80 F (27 C).
TOWER
FAN RELAY HIGH
is turned on whenever
the condenser water pump is running, flow is verified and
the difference
between
EVAPORATOR
PRESSURE
and
CONDENSER
PRESSURE is more than 35 psid (241.3 kPa)
for ENTERING
COND WATER temperature greater than the
TOWER FAN HIGH SETPOINT (SETPOINT
menu, default
75 F [23.9 C]).

(IeVC).
Condenser

Pump Control -- The chiller will monitor the CONDENSER
PRESSURE and may turn on the condenser pump if the condenser pressure becomes too high while
the compressor is shut down. The COND PRESS OVERRIDE
paralneter is used to determine this pressure point. COND
PRESS OVERRIDE is found in the SETUPI display screen,
which is accessed from the EQUIPMENT
SERVICE table.
The default value is 125 psig (862 kPa).
If the CONDENSER PRESSURE is greater than or equal to
the COND PRESS OVERRIDE,
and the ENTERING
CONDENSER WATER temperature is less than 115 F (46 C), the
condenser pump will energize to try to decrease the pressure
and Alert 151 will be generated. The pump will turn off when
the condenser pressure is 3.5 psi (24.1 kPa) less than the
pressure override and the CONDENSER
REFRIG TEMP is
within 3 ° F (1.7 ° C)of the ENTERING CONDENSER WATER
temperature.

Condenser

Freeze Prevention -- This control _dgorithm helps prevent condenser tube freeze-up by energizing the
condenser pump relay. The PIC III controls the pump and, by
starting it, helps to prevent the water in the condenser fiom
freezing. The PIC III can perform this lhnction whenever the
chiller is not running excq)t when it is either actively in pumpdown or in pumpdown/lockout
with the fieeze prevention
disabled.

TileTOWER FAN RELAY HIGH is turned off when the
condenser pump is off, flow is stopped, or the EVAPORATOR
REFRIG TEMP is less than the EVAP REF OVERRIDE TEMP
and ENTERING
CONDENSER
WATER is less than 70 F
(21.1 C), or the difference between EVAPORATOR
PRESSURE and CONDENSER
PRESSURE
is less than 28 Psid
(193 kPa), and ENTERING CONDENSER
WATER temperature is less than TOWER FAN HIGH SETPOINT minus 3 F
(-16.1 C).
Tile TOWER FAN RELAY LOW and TOWER FAN RELAY
HIGH parameters are accessed fiom the STARTUP screen.

input the reset type number (1, 2, or 3) in the SELECT/
ENABLE RESET TYPE input line.
RESET TYPE 1:4 to 20 mA (1 to 5 vdc) TEMPERATURE
RESET - Reset Type 1 is "automatic" reset utilizing a 4 to
20 mA or 1 to 5 vdc analog input signal provided from any
external sensol; controllel: or other device which is appropriately configured. Reset Type 1 permits up to _+30° F (_+16.7 ° C)
of reset to the chilled water set point. Inputs are wired to terlninals J5-3 (-) and J5-4 (+) on the CCM (for 4-20 mA input). In
order to utilize a 1 to 5 vdc input, a 250 ohln resistor must be
wired in series with the + input lead (J5-4). For either input
type, SW2 DIP switches should be set in the ON (up) position.
Inputs equivalent to less than 4 mA result in no reset, and
inputs exceeding 20 mA are treated as 20 mA.
RESET TYPE 2: REMOTE
TEMPERATURE
RESET -Reset Type 2 is an automatic chilled water temperature reset
based on a remote temperature sensor input signal. Reset type
2 permits _+30 ° F (_+ 16 ° C) of automatic reset to the set point
based on a temperature sensor wired to the CCM module (see
wiring diagrams or certified diawings). The temperature sensor
must be wired to terminal J4-13 and J4-14. To configure Reset
Type 2, enter the temperature of the remote sensor at the point
where no temperature reset will occur (REMOTE TEMP ->
NO RESET). Next, enter the temperatme
at which the full
amount of reset will occur (REMOTE TEMP -> FULL
RESET). Then, enter the maximum mnount of reset requiled to
operate the chiller (DEGREES RESET). Reset Type 2 can now
be activated.

IMPORTANT: A field-supplied water temperature control
system for condenser water should be installed. Tile system
should maintain the leaving condenser water temperature
at a temperatme
that is at least 20 ° F (11 ° C) above file
leaving chilled water temperature.

The tower fan relay control is not a substitute for a condenser water temperature control. When used with a water
temperature control system, the tower fan relay control can
be used to help prevent low condenser water temperatures.

Auto.

Restart

After

Power Failure

Tiais option

may be enabled or disabled and may be viewed or modified
on the OPTIONS
screen, which is accessed
from the
EQUIPMENT
CONFIGURATION
table. If the AUTO
RESTART OPTION is enabled, the chiller will st:ut up automatically after a power failure has occurred, generating one of the
following faults: single cycle dropout (if enabled), line cunent
imbalance, high line voltage, low line voltage, low DC bus
voltage, high DC bus voltage, VFD power on reset, and ICVC
power on reset (alerts 143-148, 165 and 166). With this feature
enabled, these faults _u'e treated as alerts instead of alarms, so
st_utup proceeds as soon as the condition is rectified. The 15 and
1-minute start inhibit timers are ignoled during this type of startup, and the STARTS IN 12 HOURS counter is not incremented.

RESET TYPE 3 -- Reset Type 3 is an automatic chilled water
temperature
reset based on cooler temperature
difference.
Reset Type 3 adds _+30 ° F (_+ 16° C) based on the temperature
diffelence between the ENTERING
CHILLED WATER and
LEA VIAl(; CHILLED WATER temperature.
To configure Reset Type 3, enter the chilled water temperature difference (the difference between entering and leaving
chilled water) at which no temperature reset occurs (CHW
DELTA T-> NO RESET). Tills chilled water temperature difference is usually the full design load temperature difference.
Next, enter the difference in chilled water temperature at which
the full amount of reset occurs (CttWDELTA
T-> FULL RESET). Finally. enter the amount of reset (DEGREES RESET).
Reset Type 3 can now be activated.

When power is restored after file power failure and if the
compressor
had been running, the oil pump will energize
for one minute before energizing the cooler pump. AUTO
RESTART will then continue like a normal start-up.

Surge Prevention Algorithm

-- This is an operator
configumble feature that can determine if lift conditions are too
high for the compressor and then take corrective action. Lift is
defined as the difference between the plessure at the impeller
eye and at the impeller discharge. Tile maximum lift a particular impeller wheel can perform varies with the gas flow
through the impeller and the dialneter of the impellec

If power to the ICVC module has been off for mole than
3 hours or the timeclock has been set for the fi_t time, start the
compressor with the slowest TEMP PULLDOWN
DEG/MIN
rate possible in order to minimize oil foaming.
Tile oil pump is energized occasionally during the time the
oil is being brought up to proper tempemtme in order to eliminate refiigemnt that has migrated to the oil sump during the
power failure. The pump turns on for 30 seconds at the end of
every 30-minute period until the chiller is started.

Tile lift capability (surge line) of a v_uiable speed compressor shifts upward as speed increases. Consequently. the line
which serves as the surge prevention threshold is made to shift
upward in a similar fashion as speed is increased. If the operating point goes above the surge prevention line as adjusted for
the current operating speed, then surge prevention actions are
taken. Note that the line constructed
fiom SURGE/HGBP
DELTA TI, SURGE/HBBP
DELTA PI, SURGE/HBBP
DELTA T2, and SURGE/HBBP
DELTA P2 values is applied to the
full speed condition only. These surge characteristics are factory set based on the original selection, with the values printed on
a label affixed to the bottom interior face of the control panel.
Since operating conditions may affect the surge plevention algorithm, some field adjustments may be necessary.

Water/Brine Reset

-- Chilled water capacity control is
based on achieving and maintaining
a CONTROL
POINT
temperatme, which is the sum of the LCWSETPOINTorECW
SETPOINT (from the SETPOINT screen) and a Water/Brine
Reset value, if any. CONTROL POINTis limited to a minimum
of 35 F (+1.7 C) for water, or 10 F (-12.2 C) for brine. Tilree
types of chilled water or brine reset are available and can be
viewed or modified on the TEMP_CTL
screen, which is
accessed from the EQUIPMENT
SERVICE table.
Tile ICVC default screen indicates when the chilled water
reset is active. TEMPERATURE
RESET on the MAINSTAT
screen indicates the amount of reset. Tile CONTROL POINT
will be determined by adding the TEMPERATURE
RESET to
the SETPOINT.

A chiller equipped with a VFD can adjust inlet guide position or compressor
speed to avoid surge (if not already at
COMPRESSOR
100% SPEED). Thus, the primary response
to entering the surge prevention region or incurring an actual
surge event (see file Surge Protection section) is to increase
complessor speed. This moves the compressor's surge line and

To activate a reset type, access the TEMP_CTL scleen and
input all configuration
information for that reset type. Tilen,
42

thecontrol's
modelof thesurgeprevention
lineup.Guide
vanes
arenotpermitted
toopenfurther
whensurge
prevention
ison.Oncespeed
hasbeenincreased
tomaximum,
if stilloperatinginthesurge
prevention
region
andif theHotGasBypass
optionisinstalled,
thehotgasbypass
valve
will open.
When
in
Surge
Prevention
mode,
withacommand
todecrease
capacity
theguide
vanes
willclose
butspeed
willnotdecrease.
NOTE:If uponromp-up
a chillerwithVFDtends
togotofull
speed
before
guidevanes
openfully,that is an indication that
the lift at low load is excessive, and the operating point moved
directly into the surge prevention region. In this case, investigate the ability of the condenser cooling means (e.g., cooling
tower) to provide cooling water in accor&mce with the design
load/entering condenser water temperature schedule.

The portion of the surge count threshold attributable

to cur-

rent can be adjusted from the OPTIONS screen (see Table 4).
Scroll down to the SURGE DELTA % AMPS parameter, and
use the [INCREASE] or [DECREASE]
softkey to adjust the
percent current fluctuation. The default setting is 10% amps.
The SURGE TIME PERIOD can also be adjusted from the
OPTIONS
soeen. Scroll to the SURGE
TIME PERIOD
parameter, and use the [INCREASE] or [DECREASE]softkey
to adjust the amount of time. The default setting is 8 minutes.
Access the display soeen (COMPRESS)
to monitor
surge count (SURGE PROTECTION
COUNTS).

A surge condition occm:s when the lift becomes so high the
gas flow across the impeller reverses. This condition can
eventu_dly cause chiller damage. When enabled, the Surge
Prevention Algorithm will adjust either the ACTUAL GUIDE
VANE POSITION or ACTUAL VFD SPEED to maintain the
complessor at a safe distance from surge while maintaining
machine efficiency. If the surge condition degrades then the
algorithm will move aggressively
away from surge. This
condition can be identified when the SURGE/H(;BP
ACTIVE?
on the HEAT EX display screen displays a YES.

the

19XRV DEFAULTS:ATt
= 1.5= F
AP1 = 50 psid
AT2 = llY" F
AP2 = 85 psid

HGBP/SURGE

PREVENTION
ON

85-

_p
(psi)

The surge prevention algorithm first determines if corrective action is necessary. The algorithm checks two sets of
operator-configured
data points, the lower stage point (MIN.
LOAD POINT [T1,P1]) and the upper surge point (FULL
LOAD
POINT [T2,P2]).
The surge characteristics
vary
between
different
chiller
configurations
and operating
conditions.

DEADBAND

REGION

(lo, 85)

50-

The surge prevention algorithm function and settings are
graphically displayed on Fig. 22 and 23. The two sets of load
points on the graph (default settings m'e shown) describe a
line the algorithm uses to determine the maximum lift of
the compressor
for the design maximum operating speed.
When the actual differential pressme between the cooler and
condenser (delta P) and the temperature difference between the
entering and leaving chilled water (delta T) are above the line
on the graph (as defined by the MIN LOAD POINTS and FULL
LOAD POINTS), the algorithm operates in Surge Prevention
mode. This is determined when the ACTIVE DELTA T is less
than SURGE/HGBP
DELTA T minus the SURGE/HGBP
DEADBAND.

AT (F)
LEGEND

ECW
HGBP
LOW

----

Entering Chilled Water
Hot Gas Bypass
Leaving Chilled Water

AP = (Condenser Psi) -(Cooler
AT = (ECW) - (LCW)

Psi)

Fig. 22-19XRV Not Gas Bypass/Surge
Prevention with Default English Settings
zxp
(kPa)
19XRV DEFAULTS:

When in Surge Prevention
mode, with a command to
increase capacity, the VFD speed will increase until VFD
MAXIMUM SPEED is reached. At VFD MAXIMUM SPEED,
when Capacity still needs to increase, the IGV's open. When in
Surge Plevention mode, with a command to decrease capacity,
the IGVs will close. The optional hot gas bypass will open in
surge prevention mode only if the TARGET VFD SPEED is at
the VFD MAXIMUM SPEED.

AT1 =.8° C
APt = 345 kPad
AT2 = 5.6° C
AP2 = 586 kPad

HGBP/SURGE

PREVENTION
ON

DEADBAND

(&6, 586)

REGION

500-

Surge Protection

-- The PIC III monitors surge, which
is detected as a fluctuation in compressor motor amperage.
Each time the fluctuation exceeds an operator-specified
limit,
the PIC III registers a stage protection count. The current
fluctuation threshold that triggers a surge protection count is
equal to the sum of SURGE DELTA % AMPS plus the
CHILLED WATER DELTA T. If more than 5 surges occur
within an operator-specified
time (SURGE TIME PERIOD),
the PIC III initiates a surge protection shutdown of the chillec
The SURGE PROTECTION
COUNTS remain displayed in the
COMPRESS screen until the almm is reset, at which time they
are re-zeroed.

400-

300-

.2 A

.6 .81,0

2.0

3.0

4.0

5.0

&T (C)
LEGEND
ECW
RGBP
LOW

If a surge count is registered and if ACTUAL VFD SPEED
is less than VFD MAXIMUM SPEED then motor speed will be
increased by the configured VFD INCREASE
STER While
the SURGE PROTECTION
COUNTS are >0, a speed decrease
will not be honored.

----

Entering Chilled Water
Hot Gas Bypass
Leaving Chilled Water

AP = (Condenser kPa) - (Cooler kPa)
AT = (ECW) - (LCW)

Fig. 23 i 19XRV Hot Gas Bypass/Surge
Prevention
with Default Metric Settings

6.0

Head Pressure Reference

Output (See Fig. 24) --

•
•
•
•
•

The PIC [II control outputs a 4 to 20 mA signal for the
configurable
Delta P (CONDENSER
PRESSURE
minus
EVAPORATOR PRESSURE) leference cmwe shown in Fig. 24.
The DELTA P AT 100% (chiller at maximum load condition
default at 50 psi), DELTA P AT 0% (chiller at minimum load
condition default at 25 psi) trod MINIMUM
OUTPUT points
are configurable in the EQUIPMENT SERVICE-OPTIONS
table. When configuring this output ensure that minimum requirements for oil pressure and proper condenser FLASC onlice performance are mtdntained. The 4 to 20 mA output from
VFD TBI terminals 17 and 18 may be useful as a reference
signal to control a towel bypass valve, tower speed control,
condenser pump speed control, etc. Note that it is up to the site
design engineering agent to integrate this analog output with
any external system device(s) to produce the desired effect.
Carrier does not make any claim that this output is directly usable to control any specific piece of equipment (that is, without
further control elements or signal conditioning),
although it
may be.

COMMON
POINT
TIONLead/lag
chilled water point
(Spare Temp #1 and
desired.

SENSOR
USAGE AND INSTALLAoperation does not require a common
sensor However. common point sensors
#2) may be added to the CCM module, if

NOTE: If the common point sensor option is chosen on a
chilled water system, each chiller should have its own common
point sensor installed. Each chiller uses its own common point
sensor for control when that chiller is designated as the lead
chillel: The PIC III cannot read the value of common point
sensors installed on the other chillers in the chilled water
system.
If leaving chilled water control (ECW CONTROL OPTION
is set to 0 [DSABLEI TEMP CTL screen) and a common
point sensor is desired (COMMON SENSOR
OPTION
in
LEADLAG
screen selected as 1) then the sensor is wired in
Spare Temp #1 position on the CCM (terminals J4-25 and
J4-J26).

The head pressure reference output will be on whenever the
condenser pump is operating. It may also be manually operated
in CONTROLS TEST. When the head pressure differential is
less than the value entered forDELTA PATO%, the output will
be maintained at 4 mA.

If the entering chilled water control option (ECW CONTROL OPTION)
is enabled
(configured
in TEMP_CTL
screen) and a common point sensor is desired (COMMON
SENSOR OPTION in LEADLAG
screen selected as 1) then
the sensor is wired in Spare Temp #2 position on the CCM
(terminals J4-27 and J4-28).

Lead/Lag Control

-- The lead/lag control system automatically starts and stops a lag or second chiller in a 2-chiller
water system. A third chiller can be added to the lead/lag
system as a standby chiller to start up in case the lead or lag
chiller in the system has shut down during an ahum condition
and additional cooling is required. Refer to Fig. 17 and 18 for
menu, table, and screen selection information.

When installing chillers in series, either a common point
sensor should be used (preferred), or the LEAVING CHILLED
WATER sensor of the upstremn chiller must be moved into the
leaving chilled water pipe of the downstream chillel: In this
application the COMMON SENSOR OPTION should only be
enabled for the upstremn chiller if that chiller is configured as
the Lead.

NOTE: The lead/lag function can be configured on the LEADLAG screen, which is accessed from the SERVICE menu and
EQUIPMENT
SERVICE table. See Table 4, Example 20.
Lead/lag status during chiller operation can be viewed on the
LL_MAINT
display screen, which is accessed
from the
SERVICE menu and CONTROL
ALGORITHM
STATUS
table. See Table 4, Example 12.

If ENTERING
CHILLED
WATER control is required on
chillers piped in series, either the common point return chilled
water sensor should be used (preferred), or the LEAVING
CHILLED WATER sensor of the downstream chiller must be
relocated to the LEAVING CHILLED
WATER pipe of the
upstream chiller. In this application the COMMON SENSOR
OPTION should only be enabled for the downstream chiller if
that chiller is configured as the Lead. Note that ENTERING
CHILLED WATER control is not recommended
for chillers
installed in series due to potential control stability problems.
To properly control the LEAVING
CHILLED
WATER
TEMPERATURE
when chillers me piped in parallel, the water
flow through the shutdown chiller(s) should be isolated so that
no water bypass around the operating chiller occurs. However.
if water bypass around the operating chiller is unavoi&_ble, a
common point sensor in the mixed LEAVING
CHILLED
WATER piping should be provided and enabled for the Lead
chillel:

Lead/Lag System Requirements:
• all chillers in the system must have software capable of
performing the lead/lag function
• water pumps MUST be energized
from the PIC III
controls
• water flows should be constant
• the CCN time schedules for all chillers must be identical

Operation Features:
• 2chiller lead/lag
DELTAP
AT100% "3

l NON-ZERO
',EXAMPLE OF
' M N MUM
',REFERENCE
',OUTPUT

DE LTA P

addition of a third chiller for backup
manual rotation of lead chiller
load balancing if configured
staggered restart of the chillers after a power failure
chillers may be piped in parallel or in series chilled water
flow

CHILLER COMMUNICATION
chiller's Installation
Instructions,
Interface section for infommtion
wiring.
s" a"
i

DELTA P__
AT0%

===7

LEAD/LAG
OPERATIONThe PIC III not only has the
ability to operate 2 chillers in lead/lag, but it can also start a
designated standby chiller when either the lead or lag chiller is
faulted and capacity requirements
are not met. The lead/lag
option only operates when the chillel_ are in CCN mode. If any
other chiller configured for lead/lag is set to the LOCAL or
OFF modes, it will be unavailable for lead/lag operation.

= ..........
]11

0mA 2 mA4mA
(O%)

20 mA
(100%)

4T0 20 mA OUTPUT

Fig. 24-

Head

Pressure

Reference

WIRING -- Refer to the
Cmrier Comfort Network
on chiller communication

Output
44

Lead/Lag Chiller Configuration and Operation
• A chiller
is designated
the lead chiller
when its
LEADLAG:
CONFIGURATION
value on the LEADLAG screen is set to "1 ."
• A chiller
is designated
the lag chiller
when
its
LEADLAG:
CONFIGURATION
value is set to "2."
• A chiller is designated
as a standby chiller when its
LEADLAG:
CONFIGURATION
value is set to "3."
• A value of "0" disables the lead/lag designation
of a
chiller. This setting should also be used when "normal"
operation without regard to lead/lag rules is desired (in
LOCAL or CCN mode).

only if one of the other two chillel_ is in an alarm (*) condition
(as shown on file ICVC panel). If both lead and lag chillers
me in an alarm (*) condition, the standby chiller defaults to
operate in CCN mode, will operate based on its configured
CCN occupancy schedule and remote contacts input.
Lag Chiller Start-Up Requirements
-- Before the lag chiller
can be started, the following conditions must be met:
1. Lead chiller ramp loading must be complete.
2.

When configuring
the LAG ADDRESS
value on the
LEADLAG
screen of chiller "A" enter the address of the
chiller on the system which will serve as lag when/if chiller
"A" is configured as lead. For example, if you ale configuring
chiller A, enter the address for chiller B as file lag address. [f
you ale configuring chiller B, enter the addiess for chiller A as
the lag address. This makes it easier to rotate the lead and lag
chillers. Note that only the lag and standby chiller addresses
specified in the configmed lead chiller's table me relevant at a
given time.

Lead chilled water temperature must be greater than the
CONTROL
POINT temperature
(see the MAINSTAT
screen) plus 1/2 the CHILLED WATER DEADBAND
temperature (see the SETUPI screen).
NOTE: The chilled water telnperature sensor may be the
leaving chilled water sensor, the return water sensol: the
common supply water sensor, or the common return
water sensor, depending on which options are configured
and enabled.

file address
assignlnents
in the LAG ADDRESS
and STANDBY ADDRESS
parameters conflict, the lead/lag
function is disabled and an alert (!) message displays. For
example, if the LAG ADDRESS
matches the lead chiller's
addiess, the lead/lag will be disabled and an alert (!) message
displayed. The lead/lag maintenance screen (LL_MAINT) displays the message 'INVALID
CONFIG' in the LEADLAG:
CONFIGURATION
and CURRENT MODE fields.
The lead chiller responds to normal start/stop controls such
as the occupancy schedule, a forced start or stop, and lemote
start contact inputs. After completing
stmt-up and ramp
loading, the PIC III evaluates the need for additional capacity.
If additional capacity is needed, the PIC III initiates the stmt-up
of the chiller configured at the LAG ADDRESS.
If the lag
chiller is faulted (in _darm) or is in the OFF or LOCAL modes,
the chiller at file STANDBY
ADDRESS
(if configured)
is
requested to start. After the second chiller is stmted and is
running, the lead chiller monitors conditions and evaluates
whether the capacity has been reduced enough for the lead
chiller to sustain the system alone. If the capacity is reduced
enough for file lead chiller to sustain the CONTROL POINT
temperatures alone, then the operating lag chiller is stopped.

Lead chiller ACTIVE DEMAND LIMIT (see the MAINSTAT screen) value must be greater than 95% of lhll load
mnps.
Lead chiller telnperature pulldown rate (TEMP PULLDOWN DEG_IN
on the TEMP_CTL
screen) of the
chilled water temperature is less than 0.5 ° F (0.27 ° C) per
minute for a susttdned period of 100 seconds.

The lag chiller status indicates it is in CCN mode and is
not in an alarm condition. If the current lag chiller is in tin
alarm condition, the standby chiller becomes the active
lag chiller, if it is configured and available.

The configured LAG START TIMER entry has elapsed.
The LAG START TIMER stmts when the lead chiller rmnp
loading is completed. The LAG START TIMER entry is
on the LEADLAG
screen, which is accessed from the
EQUIPMENT SERVICE table of the SERVICE menu.

When all the above requirements
have been met, file lag
chiller is commanded
to a STARTUP mode (indicated by
"CONTRL"
flashing next to the CHILLER
START/STOP
parameter in the MAINSTAT screen). The PIC III control then
monitors the lag chiller for a successful stark If the lag chiller
fails to start, the standby chiller, if configured, is started.
Lag Chiller Shutdown Requirements -- The following conditions must be met in order for the lag chiller to be stopped.
1. Lead chiller AVERAGE LINE CURRENT or MOTOR
PERCENT KILOWATTS (on the MAINSTAT screen) is
less than the lead chiller percent capacity.
NOTE: Lead Chiller Pement Capacity = 115 - LAG %
CAPACITY The LAG % CAPACITY parameter is on the
LEADLAG screen, which is accessed from the EQUIPMENT SERVICE table on the SERVICE menu.

If the lead chiller is stopped in CCN mode for tiny reason
other than an almm (*) condition, the lag and standby chillers
are also stopped. If the configured lead chiller stops for an
alarln condition, the configured
lag chiller takes the lead
chiller's place as the lead chillel: and the standby chiller serves
as the lag chillel:
The PRESTART FAULT TIMER provides a timeout if
there is a prestart alert condition that prevents a chiller from
starting in a timely mannel: If the configured lead chiller does
not complete its start-up before the PRESTART
FAULT
TIMER (a user-configured
v_due) elapses, then the lag chiller
starts, and the lead chiller shuts down. The lead chiller then
monitors the lag, acting as the lead, for a stm't request. The
PRESTART FAULT TIMER parameter is on the LEADLAG
screen, which is accessed fi_m the EQUIPMENT
SERVICE
table of the SERVICE menu.
If the lag chiller does not achieve start-up before the
PRESTART FAULT TIMER elapses, the lag chiller stops, and
the standby chiller is requested to start, if configured and ready.

The lead chiller chilled water temperature is less than the
CONTROL
POINT temperature
(see the MAINSTAT
screen) plus I/2 the CHILLED WATER DEADBAND
temperature (see the SETUPI screen).

The configured LAG STOP TIMER entry has elapsed.
The LAG STOP TIMER starts when the lead chiller
chilled water temperature is less than file chilled water
CONTROL
POINT plus 1/2 of the CHILLED WATER
DEADBAND trod the lead chiller compressor motor load
(MOTOR PERCENT
KILOWATT or AVERAGE LINE
CURRENT on the MAINSTAT screen) is less than the
Lead Chiller Percent Capacity.

NOTE: Lead Chiller Percent Capacity = 115 - LAG %
CAPACITY The LAG % CAPACITY
parameter
is on the
LEADLAG screen, which is accessed fi_>mthe EQUIPMENT
SERVICE table on the SERVICE menu.

Standby Chiller Configuration
and Operation -- A chiller is
designated as a standby chiller when its LEADLAG: CONFIGURATION wdue on the LEADLAG
screen is set to "3." The
standby chiller can operate as a replacement for the lag chiller

FAULTED CHILLER OPERATION --If
file lead chiller
shuts down because of an alarm (*) condition, it stops communicating to the lag and standby chillers. After 30 seconds, the
lag chiller becomes the acting lead chiller and starts and stops
the standby chiller, if necessary.
If the lag chiller goes into alarm when file lead chiller is also
in aimm, the standby chiller reverts to a stand-alone CCN
mode of operation.
If the lead chiller is in an alarm (*) condition (as shown on
tile ICVC panel), press tile _
softkey to clear tile alarm.
The chiller is placed in CCN mode. The lead chiller communicates and monitors the RUN STATUS of the lag and standby
chillers. If both the lag and standby chillers are running, the
lead chiller does not attempt to start and does not assume the
role of lead chiller until either the lag or standby chiller shuts
down. If only one chiller is running, the lead chiller waits for a
stmt request from the operating chiller When the configured
lead chiller stm-ts,it assumes its role as lead chillel:

lee Btlih:l Control -- The selectable ice build mode permits use of the chiller to refmeze or control the temperature of
an ice mselwoir which may, for example, be used for thermtd
storage. This mode differs from water or brine chilling in flint
terlnination (indication that the need for cooling has been
satisfied) is based on input(s) other than the temperature which
is being controlled during operation.
NOTE: For ice build control to operate properly, the PIC HI
must be in CCN mode.
The PIC III can be configured for ice build operation.
• From the SERVICE menu, access the EQUIPMENT
SERVICE table. From there, select the OPT'IONS screen
to enable or disable the ICE BUILD OPTION. See
Table 4, Example 17.
• The ICE BUILD SETPOINT can be configured from the
SETPOINT display, which is accessed fiom the PIC III
main menu. See Table 4, Example 9.
• The ice build schedule can be viewed or modified from
the SCHEDULE table. From this table, select the ice
build schedule (OCCPC02S) screen. See Fig. 19 and the
section on Time Schedule Operation, page 21, for morn
information on modifying chiller schedules.
The ice build time schedule defines the period(s) during
which ice build is active if the ice build option is enabled. If the
ice build time schedule overlaps other schedules, the ice build
time schedule takes priority. During the ice build period, the
CONTROL POINT is set to the ICE BUILD SETPOINT for
temperature control. The ICE BUILD RECYCLE and ICE
BUILD TERMINATION parameters, accessed from the
OPTIONS screen, allow the chiller operator to recycle or
terminate the ice build cycle. The ice build cycle can be
configured to terminate when:
• the ENTERING CHILLED WATER temperature is less
than the ICE BUILD SETPOINZ In this case, the operator sets the ICE BUILD TERMINATION parameter to 0
(the default setting) on the OPTIONS screen.
• the ICE BUILD CONTACTS input from an ice level
indicator are opened. In this case, the operator sets the
ICE BUILD TERMINATION parameter to 1 on the
OPTIONS screen.
• the chilled water temperature is less than the ICE BUILD
SETPOINT and the ICE BUILD CONTACTS input
from an ice level indicator are open. In this case, the
operator sets the ICE BUILD TERMINATION parameter
to 2 on the OPTIONS screen.
• the end of the ice build time schedule (OCCPC02S) has
been reached.
ICE BUILD INITIATION--The
ice build time schedule
(OCCPC02S) is the means for activating the ice build option.
Ice Build is enabled if:

If the lag chiller is the only chiller running when the lead
chiller assumes its role as a lead chiller then the lag chiller will
perfoml
a RECOVERY
START REQUEST
(LL_MAINT
screen). The lead chiller will stmt up when the following conditions am met.
1. Lag chiller romp loading must be complete.
2.

Lag CHILLED WATER TEMP (MAINSTAT
screen) is
greater than CONTROL POINT plus q2 the CHILLED
WATER DEADBAND temperature.

3.
4.

Lag chiller ACTI1/E DEMAND LIMIT value must be
gleater than 95% of full load amps.
Lag chiller temperature
pulldown rate (TEMP PULLDOWN DEG/MIN)
of the chilled water temperature is
less than 0.5 F (0.27 C) per minute.

The standby chiller is not running as a lag chiller.

The configured LAG START TIMER configured in the lag
(acting lead) chiller has elapsed. The LAG START TIMER
is sttu-ted when the lag (acting lead) chiller's romp loading
is completed.
LOAD BALANCING--When
the LOAD BALANCE
OPTION (see LEADLAG screen) is enabled, the lead chiller sets
the ACTI1/E DEMAND LIMIT in the lag chiller to the lead
chiller's compressor
motor load value MOTOR PERCENT
KILOWATTS
or AVERAGE
LINE
CURRENT
on the
MAINSTAT screen). This value has limits of 40% to 100%. In
addition, the CONTROL POINT for the lag chiller must be
modified to a value of 3 ° F (1.67 ° C) less than the lead chiller's
CONTROL POINT value. If the LOAD BALANCE OPTION is
disabled, the ACTIVE DEMAND LIMIT and the CONTROL
POINTme both forced to the sallle value as the lead chillel:

•

AUTO. RESTART AFTER POWER FAILURE -- When an
auto. restart condition occurs, each chiller may have a delay
added to the stm-t-up sequence, depending on its lead/lag
configuration.
The lead chiller does not have a delay. The
lag chiller has a 45-second delay. The standby chiller has a
90-second delay. The delay time is added after the chiller water
flow is verified. The PIC III ensures the guide vanes me closed.
After the guide vane position is confirmed, the delay for lag
and standby chillers occurs prior to energizing the oil pump.
The normtd start-up sequence then continues. The auto. rests.u1
delay sequence occurs whether the chiller is in CCN or
LOCAL mode and is intended to stagger the compressor motor
sttu-ts. Preventing
the motors from st_uling simultaneously
helps reduce the inrush demands on the building power system.

•

a day of the week and a time period on the ice build time
schedule are enabled. The SCHEDULE
screen shows an
X in the day field and ON/OFF times are designated for
the day(s),
a,_d the ICE BUILD OPTION is enabled.

The following events take place (unless overridden by a
higher authority CCN device).
• CHILLER START/STOP is forced to START.
• The CONTROL POINT is forced to the ICE BUILD
SETPOINT.
• Any force (Auto) is removed from the ACTIVE
DEMAND LIMIT.
NOTE: A pmameter's value can be forced, that is, file vtdue
can be manually changed tit the ICVC by tin operatok changed
fiom another CCN device, or changed by other algorithms in
the PIC III control system.

NOTE:
TheIceBuildsteps
donotoccurif thechillerisconfiguredandoperating
asa lagor standby
chillerfor lead/lag
operation
andisactively
beingcontrolled
byaleadchillerThe
leadchillercommunicates
theICE BUILD SET POINZ the

CONTACTS me open and the ICE BUILD RECYCLE is
set to DSABLE
(0). In this case, the ICE BUILD
CONTACTS provide ice level termination control. The
contacts m'e used to stop the ice build function when a
time period on the ice build schedule (OCCPC02S) is set
for ice build operation. The remote contacts can still be
opened and closed to start and stop the chiller when a
specific time period on the ice build schedule is not set for
ice build.

desired CHILLER
START/STOP
state, and the ACTIVE
DEMAND LIMIT to the lag or standby chiller as required for
ice build, if configured to do so.
START-UP/RECYCLE
OPERATION
-- If the chiller is not
running when ice build activates, the HC III checks the following conditions, based on the ICE BUILD TERMINATION
value, to avoid starting the compressor unnecessarily:
• if ICE BUILD TERMINATION
is set to the TEMP option
and the ENTERING
CHILLED
WATER temperature
is
less than or equal to the ICE BUILD SETPOINT;
• if ICE BUILD TERMINATION
is set to the CONTACTS
option and the ICE BUILD CONTACT is open;
• if the ICE BUILD TERMINATION
is set to the BOTH
(temperature
and contacts)
option and the ENTERING
CHILLED
WATER temperature
is less than or equal
to the ICE BUILD SETPOINT
and the ICE BUILD
CONTACT
is open.
The ICE BUILD RECYCLE
on the OPTIONS
screen
determines whether or not the chiller will go into an ice build
RECYCLE mode.

NOTE: It is not possible to override file CHILLER START/
STOP, CONTROL
POINE and ACTIVE DEMAND
LIMIT
variables from CCN devices (with a priority 4 or greater)
during the ice build period. Howevel: a CCN device can
override these settings during 2-chiller lead/lag operation.
RETURN TO NON-ICE BUILD OPERATIONS
-- Tile ice
build lunction forces the chiller to start, even if _dl other schedules indicate that file chiller should stop. When file ice build
lunction terminates, the chiller returns to normal temperatme
control and st_u't!stop schedule operation. The CHILLER START/
STOP and CONTROL POINT return to normal operation. If the
CHILLER START/STOP or CONTROL POINT has been forced
(wifll a device of less than 4 priority) before file ice build function stmted, when the ice build lunction ends, the plevious forces
(of less than 4 priority) me not automatic_dly restored.

•

If the ICE BUILD RECYCLE is set to DSABLE (disable),
the HC III reverts to normal (non-ice build) temperature
control when the ice build function is terminated
by
satisfying one of the above conditions. Once ice build is
terminated in this manner, it will not be reinitiated until
the next ice build schedule period begins.
• If the ICE BUILD RECYCLE is set to ENABLE, the PIC
III goes into an ICE BUILD RECYCLE
mode, and the
chilled water pump relay remains energized to keep the
chilled water flowing when the compressor
shuts down.
If the temperature
of the LEA1/ING CHILLED
WATER
later increases above the ICE BUILD SETPOINT
plus
half the RECYCLE
RESTART
DELTA
T value, the
compressor
restarts, controlling
the chilled water/brine
temperature to the ICE BUILD SETPOINT.
TEMPERATURE
CONTROL
DURING
ICE BUILD -During ice build, the capacity control algorithm shall use the
CONTROL
POINT minus 5 F (-2.8 C) for control of
the LEAVING
CHILLED WATER temperature.
The ECW
CONTROL OPTION and any temperature reset option shall be
ignored, if enabled, during ice build. Also, the following
control options will be ignored during ice build operation:

Attach to Network

Device Control -- _qle Service
menu includes
the ATTACH TO NETWORK
DEVICE
screen. From this screen, the operator can:
• enter
the time schedule
number
(if changed)
for
OCCPC03S,
as defined in the NET_OPT screen
• attach the ICVC to any CCN device, if the chiller has
been connected
to a CCN network. This may include
other PIC-controlled
chillers.
• upgrade software
Figure 25 shows the ATTACH TO NETWORK DEVICE
screen. The LOCAL parameter is _dways the ICVC module
address of the chiller on which it is mounted. Whenever the
controller identification of the ICVC changes, the change is
reflected automatically
in the BUS and ADDRESS columns
for the local device. See Fig. 18. Default addiess for local
device is BUS 0 ADDRESS 1.

•

ECW CONTROL
OPTION
and any temperature
reset
options (confiigured on TEMP_CTL
screen).
• 20
mA
DEMAND
LIMIT
OPT
(configured
on
RAMP_DEM
screen).
TERMINATION
OF ICE BUILD -- The ice build lhnction
terminates under the following conditions:
1. Time Schedule --When
the current time on the ice build
time schedule (OCCPC02S) is i,ot set as an ice build time
period.
2.

Entering Chilled Water Temperature and ICE BUILD
Contacts --Ice Build operation terminates when the ICE
BUILD TERMINATION
parameter is set to 2 (BOTH)
and the conditions described above in items 2 and 3 for
ENTERING
CHILLED WATER temperature
and ICE
BUILD CONTACTS have occurred.

When the ATFACH TO NETWORK
DEVICE screen is
accessed, infomlation can not be lead from the ICVC on any
device until one of the devices listed on that screen is attached.
The ICVC erases information about the module to which it was
attached to make room for information
on another device.
Therefore, a CCN module must be attached when this screen is
entered.
To attach any CCN device, highlight
softkey and press the ]ATTACH]
"UPLOADING
TABLES, PLEASE
ICVC then uploads the highlighted

Entering Chilled Water Temperature -- Ice build operation terminates, based on temperature, if the ICE BUILD
TERMINATION
paralneter
is set to 0 (TEMP), the
ENTERING
CHILLED
WATER temperature
is less
than the ICE BUILD SETPOINT. and the ICE BUILD
RECYCLE
is set to DSABLE.
ff the ICE BUILD
RECYCLE
OPTION
is set to ENABLE,
a recycle
shutdown
occms and recycle
start-up depends
on
the LEA1/ING CHILLED
WATER temperature
being
greater than the water/brine CONTROL POINT plus the
RESTART DELTA Ttemperature.

it using the
sollkey.
WAIT'
device

The message
displays. The
or module. If

the module addi'ess cannot be found, the message "COMMUNICATION FAILURE" appems. The ICVC then reverts back
to the ATTACH TO DEVICE screen. Try another device or
check the addiess of the device that would not attach. The
upload process time for each CCN module is different. In
gener_d, the uploading process takes 1 to 2 minutes. Befole
leaving the ATTACH TO NETWORK DEVICE screen, select
the LOCAL device. Otherwise, the ICVC will be unable to

Remote Contacts/Ice Level Input -- Ice build operation
terminates when the ICE BUILD TERMINATION
parameter is set to 1 (CONTACTS)
and the ICE BUILD

display information

on the local chillel:

ATTACHING
TOOTHERCCNMODULES
-- If thechillerICVChasbeenconnected
toaCCNNetwork
orotherPIC
controlled
chillel.s
through
CCNwiring,theICVCcanbeused
tovieworchange
ptuameters
ontheothercontrollers.
Other
PICIII chillers
canbeviewed
andsetpointschanged
(if the
otherunitis in CCNcontrol),
if desired,
fromthisparticular
ICVCmodule.
If themodule
number
is notvalid,the"COMMUNICATIONFAILURE"message
will showanda newad&ess
number
mustbeentered
orthewiringchecked.
If filemodule
is
communicating
properly,
the"UPLOADIN PROGRESS"
message
will flashandfilenewmodule
cannowbeviewed.
Whenever
thereisa question
regarding
whichmodule
on
theICVCis cunently
beingshown,
checkthedevicename
descriptor
ontheupperlefthandcorner
of theICVCscreen.
SeeFig.25.
WhentheCCNdevice
hasbeenviewed,
theATI'ACH
TO
NETWORK
DEVICE
tableshould
beused
toattach
tothePIC
thatis onthechillel:MovetotheATFACH
TONETWORK
DEVICE
table(LOCALshould
behighlighted)
andpress
the
softkey
toupload
theLOCALdevice.
TheICVC
forthe19XRV
willbeuploaded
anddefault
screen
willdisplay.
NOTE:TheICVCwill notautomatically
reattach
tothelocal
module
onthechillel:Press
the_
soflkey
toattach
to
theLOCALdevice
andviewthechilleroperation.
NAME
ALWAYS
ICVC

THE

MODULE("

ON THE

DESCRIPTOR

TABLE

19XRV-_

OTH E R CCN _

MODULES
/
|

,vrrAc'H-_o_v_c_

NAME

r_l_cR1r,_ON

_US

A_r_R_SS

NVICE

I_VlCE _

k._
o_,_a
.......

_ _---.----,_

_
o

_,_H_mc-aJ

............

LOCATION

_/
OFCCN
_/MODULE

Fig. 25 -- Example of Attach to Network
Device Screen
Service

SELECT

EXIT

F--I
F--I
NOTE: The SERVICE screen password can be changed
by entering the ICVC CONFIGURATION
screen under
SERVICE menu. The password is located at the bottom
of the menu.
The [CVC screen displays the following
SERVICE screens:
•
•
•
•
•
•
•
•
•
•
•

list of available

Alarm History
Alert History
Control Test
Control Algorithm Status
Equipment Configuration
VFD Config Data
Equipment Service
Time and Date
Attach to Network Device
Log Out of Device
ICVC Configuration

See Fig. 18 for additional

screens and tables available

from

softkey to

screen and log out of a network device, from the default ICVC

Operation

-- An overview of the tables and
for the SERVICE
function is shown in

screen, press the _
and [SERVICE] softkeys. Enter the
password and, flom the SERVICE menu, highlight LOG OUT

screens available
Fig. 18.
TO ACCESS THE SERVICE SCREENS -- When the SERVICE screens are accessed, a password must be entered.

OF NETWORK
DEVICE and press the _
The ICVC default screen will now be displayed.

1. From the main MENU screen, press the [SERVICE]
soflkey. The soflkeys now correspond to the numerals 1,
2,3,4.
2.

NOTE: To prevent unauthorized pe_.sons D_m accessing the
ICVC service screens, the ICVC automatically
signs off and
password-protects
itself if a key has not been pressed for
15 minutes. The sequence is as follows. Filleen minutes after
the last key is pressed, the default screen displays, the ICVC
screen light goes out (analogous to a screen saver), and the
ICVC logs out of the password-protected
SERVICE menu.
Other screen and menus, such as the STATUS screen can be
accessed without the password by pressing the appropriate
softkey.
TO LOG OUT OF NETWORK
DEVICE -- To access this

"XI

DEvicesi

I _ tll_llllllllllll_

the SERVICE screens listed above. Use the _
return to the main MENU screen.

l_x_ j_

If fl_is occurs, return to Step 1 and try to access the
SERVICE screens again. If the password is correct, the
softkey labels change to:

TIME BROADCAST
ENABLE -- The first displayed line,
"Time Broadcast
Enable", in the SERVICE/EQUIPMENT
CONFIGURATION/BRODEF
screen, is used to designate the
loc_d chiller as the sole time broadcaster on a CCN network
(there may only be one). If there is no CCN network present
and/or there is no designated time broadcaster on the netwoN,
current time and date, Daylight Saving Time (DST), and holidays as configured in the local chiller's control will be applied.
If a network is present and one time broadcaster on the network
has been enabled, current time and date, DST. and holi&ty
schedules as configured in the controls of the designated time
broadcaster will be applied to all CCN devices (including chillers) on the network.

Press the four digits of the password, one at a time. An asterisk (*) appetus as each digit is entered
ENTER

A 4 DIGIT

PASSWORD:*

NOTE: The initial factory-set password is 1-1-1-1. If the
password is incorrect, an error message is displayed
INVALID

softkey.

PASSWORD

HOLIDAYSCHEDULING
(Fig.26)-- Up to 18different
holidays
canbedefined
for special
schedule
consideration.
Thereale two differentscreensto be configured.
Filet,in theSERVICE/EQUIPMENT
CONFIGURATION/
HOLIDAYS
screen,
selectthe fil_t unused
holidayently
(HOLDY01
S,forexmnple).
Asshown
inFig.26,enteranumberforSt_u-t
Month(1=January,
2=February
..... 12=December),anumber
forStartDay(1- 31),andDuration
indays(099).Bydefault
there
alenoholidays
setup.Second,
intheoccupancy
Schedule
tables,
specify
andenable
(bysetting
"X"under
the"H"column)
runtimeperiod(s)
whichwillapplytoallholidays.
(Refer
toFig.19onpage
21.)A runtimeperiod
whichis
enabled
forholidays
maybeapplied
tooneormorenon-holiday
daysoftheweekaswell.Thismaybedoneforthelocal(table
OCCPC01S),
Ice Build (OCCPC02S),
trod/orCCN
(OCCPC03S) schedule(s). If the chiller is on a CCN netwoN,
the active holiday definition will be that configured in the
device designated at the sole time broadcaster (if one is so
enabled). See the TIME BROADCAST
ENABLE section.

screen, see the SERVICE

Press IINCREASEI
selected value.

11. Press _
12.

screen,

press

[SERVICE]

Press _

to return to the previous menu.

To disable the Daylight Savings Time function
0 minutes for "Start Advance" and "Stop Back".

simply enter

ITEM

DEFINITION

Month

1 = January. 2 = February .....
12 = December.

Day of Week

1 = Monday...., 7 = Sunday
1 = first occurrence of selected
Day of Week in the selected
month, 2 = second occurrence
of the selected Day, etc. This is
not necessarily what one would
conclude from looking at a
standard calendar. For example,
April 14, 2003, is Day 1 Week 2,
but April 15, 2003, is Day 2
Week 3.

Week

the

2. If not logged on, follow the instructions for Attach to
Network Device or To Log Out. Once logged on, press
until Equipment Configuration is highlighted.
3. Once Equipment Configuration is highlighted,
_to
access.

Time

Time of day in 24-hour format
when the time advance or set
back will occur.

Advance/Back

"Advance" occurs first in the
year, setting the time ahead by
the specified number of minutes
on the selected date. "Back"
sets the time back by the specified amount (later in the year).

press

4. Press _
until HOLIDAYS is highlighted. This is
the Holiday Definition table.
5. Press _
to enter the Data Table Select screen.
This screen lists 18 holiday tables.
6. Press _
to highlight the holiday table that is to be
viewed or changed. Each table is one holiday period,
stm-tingon a specific date, and lasting up to 99 days.
7. Press _
to access the holiday table. The Configuration Select table now shows the holiday start month
and day. and how many days the holiday period will last.
Fig. 26 -- Example of Holiday Period Screen

8. Pless _
or [PREVIOUS] to highlight tfie month,
day, or duration.
9. Press _

the

DAYLIGHT
SAVING TIME CONFIGURATION
-- The
BRODEF table also defines Daylight Saving Time (DST)
changes. This feature is by default enabled, and the settings
should be reviewed and adjusted if desired. The following
line-item entries ;ue configurable
for both DST "Stall" and
"Stop", and they are defined in Table 8.

to access

to change

to save the changes.

To view or change the holiday periods for up to 18 different
holidays, perform the following operation:
1. At the Menu
Service menu.

or IDECREASEI

Table 8 -- Daylight Saving Time Values

The broadcast function must be activated for the holidays
configured
on the HOLIDEF
screen to work properly.
Access
the BRODEF
screen
fi_)m the EQUIPMENT
CONFIGURATION
table and select ENABLE
to activate
function. Note that when the chiller is connected to a CCN
Network, only one chiller or CCN device c_m be configured as
the broadcast device. The controller that is configured as the
broadcaster is the device responsible for transmitting holiday,
time, and daylight-savings
dates throughout the network.
To access the BRODEF
structure, Fig. 18.

10.

to modify the month, day, or duration.

START-UP/SHUTDOWN/
RECYCLE SEQUENCE (Fig. 27)
Local

Start-Up

screen, press the _

L_cal start-up (ora manual start-up) is

initiated by pressing the _

menu softkey on the default

CONTACT

ICVC scleen. Ix_c_d start-up can proceed when the chiller
schedule indicates that the CURRENT TIME and CURRENT
DATE have been established

CONTACTS

as a mn time and date, and after

screens. Both timel_ must expire before the chiller

will stall. If the timers have not expired, the RUN STATUS
pm'ameter on the MAINSTAT screen will read TIMEOUT.

If the OCCUPIED
? pm'ameter on the MAINSTAT screen
is set to NO, the chiller can be forced to stm't as follows. From

softkey to override the schedule

MAINSTAT screen and press the [RELEASE]
softkey. This
action returns the chiller to the stmt and stop times established
by the schedule.

default

screen,

press

the

and

[SCHEDULE]
softkeys. Scroll down and select the current
schedule. Select OVERRIDE, and set the desiled override time.

QUANTITY

REMOTE

] softkey.

9 -- Prestart

Checks

REQUIREMENT

ALERT STATE IF FALSE

STARTS IN 12 HOURS

< 8 (not counting recycle restarts or auto restarts after power failure)
ALERT is cleared once RESET is pressed.

100

COMP THRUST BRG TEMP

< [COMP THRUST BRG ALERT] -10 ° F (5.6 ° C)

101

COMP MOTOR WINDING TEMP

< [COMP MOTOR TEMP OVERRIDE] -10 ° F (5.6 ° C)
< [COMP DISCHARGE ALERT] -10 ° F (5.6 ° C)

102

COMP DISCHARGE

CHECKED

select

Ftfilure to verily any of the requirements up to this point will
result in the PIC III aborting the stall and displaying the applicable pre-start mode of failure on the ICVC default screen. A
pre-start failure does not advance the STARTS IN 12 HOURS
countel: Any failure after the VFD has energized results in a
safety shutdown, advances the starts in 12 hours counter by
one, and displays the applicable shutdown status on the [CVC
display. The minimum time to complete the entire prestart
sequence is approximately 185 seconds.

Another condition for st;ut-up must be met for chillers that
have the REMOTE
CONTACTS
OPTION on the EQUIPMENT SERVICE screen set to ENABLE. For these chillers,
the REMOTE START CONTACT parameter on the MAINSTAT screen must be CLOSED. From the ICVC default
Table

INPUT and press the [RELEASE

Compressor ontime and service ontime timers start, and the
complessor STARTS IN 12 HOURS counter and the number of
stalls over a 12-hour period counter advance by one.

The chiller may also be stmted by overriding the time schedthe

override,

If the water/brine temperature is high enough, the st;u't-up
sequence continues and checks the guide vane position. If the
guide vanes are more than 4% open, the stall-up is delayed
until the PIC IIl closes the vanes. If the vanes are closed and
the oil pump pressure is less than 4 psi (28 kPa), the oil pump
relay energizes. The PIC [II then waits until the oil pressure
(OIL PRESS VERIFY TIME, operator-configured,
default of
40 seconds) leaches a maximum of 18 psi (124 kPa). After oil
pressure is verified, the PIC III waits 40 seconds, and the VFD
energizes to start the compressol:

Press the

and start the chiflel:

released, regardless of the progrmnmed schedule. To release
the forced start, highlight CHILLER START/STOP fiom the

From

softkey. Then, press the
the

NOTE: 19XRV units are not available with factou-installed
chilled water or condenser water flow devices (available as an
accesso U for use with the CCM Control board).

and

NOTE: The chiller will continue to run until this forced start is

ule.

To end

Scroll to

softkey. Scroll
REMOTE START

Five seconds latel', the CONDENSER WATER PUMP relay
energizes. Thirty seconds later the PIC III monitors the chilled
water trod condenser water flow devices and waits until the
WATER FLOW VERIFY TIME (operator-configured,
default
5 minutes) expires to confirm flow. After flow is verified, the
chilled water temperature is compmed to CONTROL POINT
plus/_ CHILLED WATER DEADBAND. If the temperature is
less than or equal to this value, the PIC III turns off
the CONDENSER
WATER PUMP relay and goes into a
RECYCLE mode.

NOTE: The time schedule is said to be "occupied"
if the
OCCUPIED
? pmameter on the MAINSTAT scleen is set to
YES. For more information on occupancy schedules, see the
sections on Time Schedule Operation (page 21), Occupancy
Schedule (page 36), and To Prevent Accidental
Stall-Up
(page 67), and Fig. 19.

softkeys. Scroll to highlight MAINSTAT. Pless the
softkey. Scroll to highlight CHILLER START/STOP.

softkeys.

Once local start-up begins, the PIC III performs a series of
pre-start tests to verify that all pre-start alefls and safeties are
within the limits shown in Table 7. The RUN STATUS parameter on the MAINSTAT screen line now reads PRESTART. If a
test is not successful, the start-up is delayed or aborted. If the
tests are successful, the CHILLED WATER PUMP relay energizes, and the RUN STATUS line now reads STARTUR See
Table 9.

of the motol: The value of these timers is displayed as START
INHIBIT TIMER and can be viewed on the MAINSTAT and

the default [CVC screen, press the _

and press the _
softkey.

the internal timers have expired.
The timers include a
15-minute start-to-start timer and a l-minute stop-to-start timel. which together serve to prevent excessive cycling and abuse

DEFAULT

and _

highlight MAINSTAT and press the _
down the MAINSTAT screen to highlight

EVAPORATOR

TEMP

REFRIG TEMP

< [EVAP REFRIG TRIPPOINT]

+ [REFRIG OVERRIDE

103
DELTA T]

104

OIL SUMP TEMP

< 150 ° F (65.5 ° C) or <[EVAP REFRIG TEMP] + 50 ° F (10 ° C)

105

CONDENSER

< CONDENSER PRESSURE
< 145 psi (1000 kPa)

106

PRESSURE

OVERRIDE -20 PSI (138 kPa) and

PERCENT

LINE VOLTAGE

< [UNDERVOLTAGE

PERCENT

LINE VOLTAGE

> [OVERVOLTAGE THRESHOLD]
Must have been calibrated

ACTUAL GUIDE VANE POS

THRESHOLD]

107
108
109

•
MACHINE SAFETIES,
EVAPORATOR PUMP
CONDENSER
WATER PUMP
WATER FLOW, CHILLED
WATER TEMP, GUIDE VANES
OIL PUMP,TOWER FAN CONTROL

•

OIL PRESSURE
COMPRESSOR,
COMPRESSOR ONTIME,
SERVICE ONTIME

3OM_RESSC
tUNNIN

15-MINUTE
START*TO-START

Automatic
I

1-MINUTE
STOP-TO-START

ODE

Pre-start

checks

are

made;

evaporator

START INITIATED:
started,

Condenser

pump

Water flows verified (30 seconds to 5 minutes maximum after B).
Chilled water temperatures
checked against control point, Guide
vanes checked for closure, Oil pump started; tower fan control
enabled.

Oil pressure
after C).

Compressor
motor starts; compressor ontime and service ontime
start, 15-minute inhibit timer starts (10 seconds after D), total compressor starts advances by one, and the number of starts over a
12-hour period advances by one.

•

water pump started (5 seconds after A),

minimum,

•
•
•

300 seconds maximum

SHUTDOWN
INITIATED -- Compressor
motor stops; compressor
ontime and service ontime stop, and 1-minute inhibit timer starts.

Oil pump and evaporator pumps deenergized (60 seconds after F).
Condenser pump and tower fan control may continue to operate if
condenser pressure is high. Evaporator pump may continue if in
RECYCLE mode.

O/A--

To activate the soft stop amps threshold feature, scroll to the
bottom
of OPTIONS
screen
on the [CVC.
Use the
[INCREASE] or [DECREASE[ softkey to set the SOFT STOP
AMPS THRESHOLD
parmneter to the percent of amps at
which the motor will shut down. The default setting is 100%
alnps (no soft stop). The range is 40 to 100%.
When the soft stop amps threshold feature is being applied,
a status message, "SHUTDOWN
IN PROGRESS,
COMPRESSOR UNLOADING"
displays on the ICVC.

Sequence

The soft stop amps threshold function can be terminated and
the compressor motor deenergized immediately by depressing
the STOP button twice.

Shutdown

Sequence--Chiller
shutdown
begins if
any of the following occurs:
• the STOP button is pressed for at least one second (the
alarm light blinks once to confirm the stop command)
• a recycle condition is present (see Chilled W_tter Recycle
Mode section)
• the time schedule has gone into unoccupied
mode
• the chiller protective limit has been reached and chiller is
in alarm
• the start/stop status is overridden
to stop from the CCN
network or the [CVC

Chilled

•

that occur during shutdown

Water Recycle

Mode--

The

chiller

may

cycle off and wait until the load increases to restart when the
compressor
is running in a lightly loaded condition. This
cycling is norlnal and is known as "recycle." A recycle shutdown is initiated when any of the following conditions are true:
•

When a stop signfd occurs, the shutdown sequence first
stops the compressor by deactivating the VFD output to the
motor A status message of "SHUTDOWN
IN PROGRESS,
COMPRESSOR
DEENERGIZED"
is displayed,
and the
comptessor ontime and service ontime stop. The guide vanes
are then brought to the closed position. The oil pump relay and
the chilled water/brine pump telay shut down 60 seconds after
the compressor stops. The condenser water pump shuts down
at the same time if the ENTERING
CONDENSER
WATER
temperature is greater than or equal to 115 F (46.1 C) find
the CONDENSER
REFRIG
TEMP
is greater titan the
CONDENSER
FREEZE
POINT plus 5 F (-15.0 C). The
stop-to-statl
timer now begins to count
down. If the
statl-to-stmt timer value is still greater than the value of the
start-to-stop timet: then this time displays on the ICVC.
Certain conditions
this sequence.

AVERAGE
LINE CURRENT
(%) drops below the
SOFT STOP AMPS THRESHOLD
ACTUAL GUIDE VANE POSITION drops below 4%
4 minutes have elapsed
the STOP button is pressed twice

If file chiller enters an alarm state or if the compressor enters
a RECYCLE mode, the compressor deenergizes immediately.

Restart permitted (both inhibit timers expired: minimum of 15 minutes
after E; minimum of 1 minute after F).

Fig. 27 -- Control

-- The soft

Any time the compressor is directed to STOP (except in the
cases of a fault or recycle shutdown), the guide vanes ate
directed to close, and the compressor shuts off when any of the
following is true:

O/A

verified (15 seconds

Soft Stop Amps Threshold

stop fillips threshold feature closes the guide vanes of the
compressor
automaticfflly if a non-recycle,
non-alarm
stop
signal occurs before the compressor motor is deenergized.

*'TIME

The condenser
pump shuts down when the CONDENSER
PRESSURE
is less than the COND PRESS
OVERRIDE
threshold minus 3.5 psi (24.1 kPa) and the
CONDENSER
REFRIG TEMP is less than or equal to the
ENTERING
CONDENSER
WATER
temperature
plus
3° F (-1.6° C).
If the chiller shuts down due to low refl'igerant temperature, the chilled water pump continues to run until the
LEAVING (/HILLED
WATER temperature is greater than
the CONTROL POINTtemperature,
plus 5° F (2.8 ° C).

•

LEA1/ING CHILLED WATER temperature
(or ENTERING CHILLED
WATER
temperature,
if the ECW
CONTROL
OPTION
is enabled)
is more than 5 ° F
(2.8 ° C) below the CONTROL POINT.
LEAI/ING
CHILLED
WATER temperature (or ENTERING CHILLED
WATER
temperature,
if the ECW
CONTROL OPTION is enabled) is below the CONTROL
POINT. and the chilled water temperature
difference is
less than the (RECYCLE
CONTROL)
SHUTDOWN
DELTA T (configured
in the EQUIPMENT
SERVICE/
SETUPI table).
the LEA1/ING (/HILLED
WATER temperature
is within
3 ° F (1.7 ° C) of the EI/AP REFRIG TRIPPOINT.

NOTE: Recycle shutdown will not occur if the CONTROL
POINT has been modified (e.g., by a chilled water reset input)
within the previous 5 minutes of operation.
Also, chilled water recycle logic does not apply to Ice Build
operation (refer to page 46).
When the chiller is in RECYCLE mode, the chilled water
pump relay remains energized so the chilled water temperatute
can be monitored for increasing load. The recycle control uses
RESTART DELTA T to check when the compressor should be
restarted.
This is an opettltor-configured
function which
defaults to 5 ° F (2.8 ° C). This value can be viewed or modified

can change

[f the AVERAGE
LINE CURRENT
is greater than 5%
alter shutdown, the oil pump and chilled water pump
remain energized and the alarm is displayed.

ontheSETUPItable.Thecompressor
will restart
whenthe
chilleris:
• in LCW CONTROLandthe LEAVING (7HILLED

•

WATER temperature
is greater than the
POINT
plus the (RECYCLE
CONTROL)
DELTA T.
in ECW CONTROL
and the ENTERING
WATER temperature
is greater than the
POINT
plus the (RECYCLE
CONTROL)
DELTA T.

Once these conditions am met, the compressor
st_ut-up with a normal start-up sequence.

_'SAE PLUG_
_"SAE FLARENUT

CHILLED
CONTROL
RESTART

THERMC

8"
initiates

(203 mm)

An alert condition may be generated if 5 or more recycle
stmt-ups occur in less than 4 hom.s. Excessive recycling can
reduce chiller life; therefore, compressor
recycling due to
extremely low loads should be reduced.

SIGHT
DISTI
WATER OR
METHYL
ALCOHOL

To reduce compressor recycling, use the time schedule to
shut file chiller down dunng known low load operation period,
or incmase the chiller load by running the fan systems. If the
hot gas bypass is installed, adjust the values to ensum that hot
gas is energized during light load conditions. Increase the
(RECYCLE
CONTROL) RESTART DELTA T on the SETUPI
table to lengthen the time between restmts.

Fig. 28 -- Typical Wet-Bulb Type
Vacuum Indicator

The chiller should not be operated below design minimum
load without a hot gas bypass installed.

Open Oil Circuit Valves
-- Check to ensure the oil filter isolation valves (Fig. 4) am open by removing the valve cap
and checking the valve stem.

Safety Shutdown-

A safety shutdown is identic_d to
a manual shutdown with the exception that, during a safety
shutdown, the ICVC displays the mason for the shutdown, the
alarm light blinks continuously, and the spare alarm contacts
am energized.

Oil Charge

-- The oil chmge for the 19XRV compmssor
depends on the compressor Frame size:
•
•
•
•

After a safety shutdown, the _
soflkey must be pressed
to clem the ahum. If the ahum condition is still present, the _dmln
light continues to blink. Once file ;tlarm is clemed, file operator
must press the _
or_
softkeys to restart the chillel:

BEFORE

INITIAL

•

•
•
•
•

START-UP

list of applicable
design temperatums
and pressures
(product data submittal)
chiller certified prints
starting equipment details and wiring diagrams
diagrams and instructions for special controls or options
pumpout unit instructions

Equipment
•
•

•
•
•

Required

mechanic's tools (refrigeration)
including T30 torx
True RMS digital multimeter
with clamp-on
current
probe or True RMS digital clamp-on meter rated for at
least 480 vac or 650 vdc
electronic leak detector
absolute
pressure
manometer
or wet-bulb
vacuum
indicator (Fig. 28)
500-v insulation tester (megohmmeter)
for compressor
motors with nameplate
voltage of 600 v or less, or a
5000-v insulation
tester for compressor
motor rated
above 600 v

Using

the Optional

Storage

Frame
Frame
Frame
Frame
12 gal
Frame

2 compressor-3 compressor-4 compressor-4 compressor
(,45 L)
5 compressor--

8
8
10
with

gal (30 L)
gal (30 L)
gal (37.8 L)
split ring diffuser

option

18 gal (67.8 L)

The chiller is shipped with oil in the compressor When the
sump is full, the oil level should be no higher than the middle
of the upper sight glass, and minimum level is the bottom
of the lower sight glass (Fig. 2). [f oil is added, it must meet
C_urier's specification
for centrilhgal
compressor
use as
described in the Oil Specification
section. Charge the oil
through the oil charging valve located near the bottom of the
transmission housing (Fig. 2). The oil must be pumped from
the oil container through file charging valve due to higher
refrigerant pressure. The pumping device must be able to lift
from 0 to 200 psig (0 to 1380 kPa) or above unit pressure. Oil
should only be charged or removed when the chiller is shut
down.

Job Data Required
•

I_-

CONTROL
RESTART

Tighten All Gasketed Joints and Guide Vane
Shaft Packing -- Gaskets ;rod packing normally relax by
the time the chiller rerives at the jobsite. Tighten all gasketed
joints and the guide vane shaft packing to ensum a leak-tight
chillel: Gasketed joints (excluding O-rings) may include joints
at some or all of the following:
• Waterbox covers
• Compressor suction elbow flanges (at compressor
and at
the cooler)
• Compressor discharge flange
• Compressor discharge line spacer (both sides) if no isolation valve
• Cooler inlet line spacer (both sides) if no isolation valve
• Hot gas bypass valve (both sides of valve)
• Hot gas bypass flange at compressor

Tank and Pump-

out System

-- Refer to Chillers with Storage Tanks section, page 71 for pumpout system prepmation,
refngerant
transfeL and chiller evacuation.

Remove

Shipping Packaging -- Remove any packaging material from the control centeL power panel, guide vane
actuatoL motor cooling and oil reclaim solenoids, motor and
bearing temperatum sensor covers, and the VFD.

Refer to Table 10 for bolt torque requimments.

Table 10SAE
BOLT SIZE
(in.)

LOW

Bolt Torque Requirements,

2, A307 GR A
HEX HEAD
NO MARKS
CARBON
STEEL

Foot Pounds

SAE 5, SA449
SOCKET
HEAD OR HEX
WITH 3 RADIAL
LINES
MEDIUM
CARBON
STEEL
Minimum

SAE

8, SAE354
GR BD
HEX HEAD
WITH 6 RADIAL
LINES
MEDIUM
CARBON
STEEL

Minimum

Maximum

Maximum
9

Minimum
9

Maximum
13

_16

28
46

318

_16

115

_16

110

115

168

5/8

105

150

160

225

314

105

150

175

250

260

370

718

140

200

265

380

415

590

210

300

410

580

625

893

1 l&

330

475

545

780

985

1,410

11/4

460

660

770

1,100

1,380

1,960

13/8

620

885

1,020

1,460

1,840

2,630

1 l&

740

1060

1,220

1,750

2,200

3,150

1 s/8

101 O

1450

1,670

2,390

3,020

4,31 O

1_4

1320

1890

2,180

3,110

3,930

5,610

17/8

1630

2340

2,930

4,190

5,280

7,550

1900

2720

3,150

4,500

5,670

8,100

2114

2180

3120

4,550

6,500

8,200

11,710

216

3070

4380

5,000

7,140

11,350

16,210

2_4

5120

7320

8,460

12,090

15,710

22,440

6620

9460

11,040

15,770

19,900

28,440

Check Chiller Tightness-proper sequence and procedures

Figure 29
for leak testing.

outlines

tile

transferred. Adjust the springs when the refrigerant
ing condition and the water circuits are full.

The 19XRV chillers me shipped with the refrigerant
contained in the condenser shell and the oil charge in the
compressor. The cooler is shipped with a 15 psig (103 kPa)
refrigerant charge. Units may be ordered with the refiigemnt
shipped separately, along with a 15 psig (103 kPa) nitrogenholding chmge in each vessel.

is in operat-

Refrigerant Tracer

-- C_urier recommends the use of an
environment_dly acceptable refrigerant tracer for leak testing
with an electronic detector or halide torch.
Ultrasonic leak detectors
under pressure.

To determine if there are any leaks, the chiller should be
chmged with refrigerant. Use an electronic leak detector to
check all flanges and solder joints after the chiller is pressurized. If any leaks me detected, follow the leak test procedure.

can also be used if the chiller is

Do not use air or oxygen as a means of pressurizing
the chillel: Mixtures of HFC-134a and air can undergo
combustion.

If the chiller is spring isolated, keep all springs blocked in
both directions to prevent possible piping stress and dmnage
during the transfer of refrigerant from vessel to vessel during
the leak test process,
or any time refrigerant
is being

LEAK TEST OF 19XRV
1, ATTACH COMPOUND

GAGE TO EACH VESSEL

2. NOTE AMBLENT TEN_IPERATURE GAGE READINGS

I
MACHINES

WITH REFRIGERANT

I MAGHNESW,THN,TROGEN
ROLD,NGDHARGE
I

CHARGE

4,
PRESSURE ON CONDENSER VESSEL IS LESS THAN
SA/URA_ED
REFRIGERAN F PRESSURE
(SEE REFRIGERANT PRESSURETEMPERATURE TABLES 11A AND 1113)

PRESSURE ON
CONDENSERVESBELtS
AT REFRIGERANT
SATURATED COND!TIONS
SEE REFRIGERANT
PRESSURE*TEMPERATURETABLES
1AAND
1E

_AK

COOLER PRESSURE READING
IS BELOW 15 PRIG (103 kP_,t)

COOLER PRESSURE READING
S 15 PSIG (103 kPej OR HIGHER

PRESSURE READING IS LESS THAN
15 PSIG (103 kPei BUr
GREATER THAN 0 PSIG (0 kPa)
SUSPEC

PRBSSURE IS AT 15 PRIG (103 kP_,)
(FACTORY CHARGE)

LEAK SUSPECTED

EVACUATE HOLDING CHARGE
RELEASE
FROMNITROGEN
VESSELS AND

REDORDRRESSURES
I

POWER UP CONTROLS TO ENSURE
OIL HEATER IS ON AND OIL IS HOT,
EQUAUZE PRESSURE BE,,_,:_4EEN
COOLER AND CONDENSER

(IF USING ELECTRONIC DETECTOR, L
ADD TRACER GAS NOW)
r'_

1
BERPORM_.EA_TEST
I

POWER UP CONTROLS TO ENSURE
OIL HEATER IS ON AND OIL I9 HOT,
EQUALIZE PRESSURE BETWEEN
COOLER AND CONDENSER

[

FIoAK[_

:;I-

USING SOAP BUBBLE SOLU]ION_
ULTRASONICS
ELECTRONIC
PERFORMORLEAK
TEST
DETECTOR

{

PBRFORMLEAK,SS,"
1
FOUND

EVACUATB
]

AND MARK
ALL LEAK
SOURCES

AND MARK

ilcco
,

STANDING

ALL LEAK
[ SOURCES
LODATEJ

,1i:

IN THE VESSEL
REPAIR ALL LEAKS
RETEST ONLY THO_E JOtNTS
RELEASE
THE REPAIRED
PRESSURE
THAT WERE

REPAIR

DEHYDRATE

VESSEL IF VESSEL WAS

I
CONTINUE

WITH MACHINE

STARTUP

/
.I

COMPLETE

CHARGING

Fig. 29 -- 19XRV Leak Test Procedures

MACHINE

IIC
I

BERFORMLEA_TEST
I

UNTIL PRESSURE iS ABOVE
ADD
REFRIGERANT
35 PSIG
(241kP_)

UNTIL PRESSURE S ABOVE
30 PSIG
(241kPa)
ADD
REFRIGERANT

_,>,,'ss

[

Leak Test

Chiller -- Due to regulations regarding refiigerant emissions and the difficulties associated with separating
contaminants
from the refrigerant,
Carrier recommends
the
following leak test procedure. See Fig. 29 for an outline of the
leak test procedure. Refer to Fig. 30 and 31 during pumpout
procedures and Tables 11A and 11B for refi'igerant pressure/
temperature values.
1. [f the pressure
condition:

readings

the holding

are

normal

charge

for

the

chiller

Evacuate
present.

fiom the vessels,

Raise the chiller pressure, if necessary, by adding
refrigerant until pressure is at the equivalent
saturated pressure
for the surrounding
temperature.
Follow the pumpout procedures
in the Transfer
Refrigerant from Pumpout Storage Tank to Chiller
section, Steps I a - e, page 72.

Prepare to leak test chillers
ant (Step 2h).

Check for large leaks by connecting a nitrogen bottle
and raising the pressure to 30 psig (207 kPa). Soap
test all joints. If the test pressure holds for 30 minutes,
prepare the test for small leaks (Steps 2g-h).
Plainly mark any leaks that are found.

Release

Repair all leaks.

Retest the joints

After successfully
completing
the test for large
leaks, remove as much nitrogen, air. and moisture
as possible, given the fact that small leaks may be
present in the system. This can be accomplished
by
following the dehydration
procedure,
outlined in
the Chiller Dehydration
section, page 58.

3.
4.

the pressure

Transfer the refrigerant
to the pumpout
tank and perform
a standing
vacuum
outlined
in the Standing
Vacuum Test
below.

If the chiller fails the standing
for large leaks (Step 2b).

If the chiller passes the standing vacuum test,
dehydrate
the chiller. Follow
the procedure
in
the Chiller Dehydration
section. Charge the chiller
with refrigerant
(see Transfer
Refrigerant
fiom
Pumpout
Storage
Tank
to Chiller
section,
page 72).

with refriger-

vacuum

storage
test as
section,

test, check

If a leak is found after a retest, pump the refrigerant back
into the pumpout storage tank or, if isolation valves are
present, pump the refrigerant
into the non-leaking
vessel (see Pumpout and Refrigerant Transfer procedures
section).

Transfer the refrigerant until the chiller pressure is at
18 in. Hg (40 kPa absolute).
Repair the leak and repeat the procedure, beginning from
Step 2h, to ensure a leak-tight repail: (If the chiller is
opened to the atmosphere for an extended period, evacuate it before repeating the leak test.)

c. Leak test chiller as outlined in Steps 3-9.
If the pressure readings are abnormal for the chiller
condition:
shipped

If no leak is found after a retest:

Never charge liquid refrigerant into the chiller if the pressure in the chiller is less than 35 psig (241 kPa) for
HFC-134a.
Charge as a gas only, with the cooler and
condenser pumps running, until this pressure is reached,
using PUMPDOWN
LOCKOUT
and TERMINATE
LOCKOUT
mode on the PIC III. Flashing of liquid
lefrigerant at low pressures can cause tube freeze-up and
considerable damage.

be repaired. Note the toted chiller leak rate on the start-up
_eport.
If no leak is found during the initi_d start-up procedures,
complete the transfer of refrigerant gas from the pumpout
storage tank to the chiller (see Transfer Refiigerant from
Pumpout Storage Tank to Chiller section, page 72).
Retest for leaks.

Standing Vacuum Test

-- When perforlning the standing vacuum test or chiller dehydi'ation, use a manometer or a
wet bulb indicatol: Dial gages cannot indicate the small amount
of acceptable leakage during a short period of time.
1. Attach an absolute pressure
indicator to the chillel:

Valve off the pump to hold the vacuum
manometer or indicator reading.

a. If the leakage rate is less than 0.05 in. Hg (0.17 kPa) in
24 hours, the chiller is sufficiently tight.
b.

bulb

Evacuate
the vessel (see Pumpout
and Refrigerant
Transfer Procedures section, page 71 ) to at least 18 in. Hg
vac, ref 30-in. bar (41 kPa), using a vacuum pump or the
pump out unit.

that were repaired.

Check the chiller carefully with an electronic leak detectol: halide torch, or soap bubble solution.
Leak Determination
--If
an electronic leak detector
indicates a leak, use a soap bubble solution, if possible, to
confirm. Total all leak rates for the entire chillel: Leakage
at rates greater than 0.1% of the total charge per year must

or wet

in the system.

Slowly raise the system pressure to a maximum of
160 psig (1103 kPa) but no less than 35 psig
(241 kPa) for HFC-134a
by adding refrigerant.
Proceed with the test for small leaks (Steps 3-9).

manometer

and record the

ffthe leakage rate exceeds 0.05 in. Hg (0.17 kPa) in
24 hours, repressurize the vessel and test for leaks.
If refrigerant is available in the other vessel, pressurize by following Steps 2-10 of Return Chiller To
Normal Operating Conditions section, page 73. If
not, use nitrogen and a refi'igerant tracer Raise the
vessel plessure
in increments
until the leak is
detected. If refrigerant is used, the maximum gas
pressure is approximately
70 psig (483 kPa) for
HFC-134a at normal ambient temperature. If nitrogen is used, limit the leak test pressure to 160 psig
(1103 kPa) maximum.

Fig. 30 -- Typical Optional

Pumpout System Piping Schematic

STORAGE TANK
VAPOR VALVE

with Storage Tank

REFRIGERANT
CHARGING
VALVE

REFRIGERANT
ISOLATION
VALVE

REFRIGERANT
CHARGING

PRESSURE
RELIEF SAFETY

LIQUID LIVE
SERVICE
VALVE

........ ::

VALVE

VALVE_

OIL

....._
PUMPOUT

= SERVICE
PUMPOUTVALVE
UNIT ON

1_=

SERVICE VALVE ON
CHILLER

_SEPARATOR

_.//**./_*f

COMPRESSOR

___ i

.......

CONDENSER

"....
-_
q

PUMPOUT

PUMPOUT
WATER SUPPLY
CONDENSER
AND
RETURN

Fig. 31 -- Typical Optional Pumpout System Piping Schematic without Storage Tank

Table 11AHFC-134a PressureTemperature (F)
TEMPERATURE,
F
0
2
4
6
8

Table 11B -- HFC-134a PressureTemperature (C)

PRESSURE
(psig)
6.60
7.52
8.60
9.66
10.79

TEMPERATURE,
C
-18.0
-16.7
-15.6
-14.4
-13.3

PRESSURE
(kPa)
44.8
51.9
59.3
66.6
74.4

10
12
14
16
18

11.96
13.17
14.42
15.72
17.06

-12.2
-11.1
-10.0
-8.9
-7.8

82.5
90.8
99.4
106.0
118.0

20
22
24
26
28

18.45
19.88
21.37
22.90
24.46

-6.7
-5.6
-4.4
-3.3
-2.2

127.0
137.0
147.0
158.0
169.0

30
32
34
36
38

26.11
27.80
29.53
31.32
33.17

-1.1
0.0
1.1
2.2
3.3

180.0
192.0
204.0
216.0
229.0

40
42
44
46
48
50
52
54
56
58

35.08
37.04
39.06
41.14
43.26
45.46
47.74
50.07
52.47
54.93

4.4
5.0
5.6
6.1
6.7
7.2
7.8
8.3
8.9
9.4

242.0
248.0
255.0
261.0
269.0
276.0
284.0
290.0
298.0
305.0

60
62
64
66
68

57.46
60.06
62.73
65.47
68.29

10.0
11.1
12.2
13.3
14.4

314.0
329.0
345.0
362.0
379.0

70
72
74
76
78
80
82
84
86
88

71.18
74.14
77.18
80.30
83.49
66.17
90.13
93.57
97.09
100.70

15.6
16.7
17.8
18.9
20.0
21.1
22.2
23.3
24.4
25.6

396.0
414.0
433.0
451.0
471.0
491.0
511.0
532.0
554.0
576.0

90
92
94
96
98

104.40
108.18
112.06
116.02
120.08

26.7
27.8
28.9
30.0
31.1

598.0
621.0
645.0
669.0
694.0

100
102
104
106
108

124.23
128.47
132.81
137.25
141.79

32.2
33.3
34.4
35.6
36.7

720.0
746.0
773.0
800.0
826.0

110
112
114
116
118

146.43
151.17
156.01
160.96
166.01

37.8
38.9
40.0
41.1
42.2

657.0
886.0
916.0
946.0
978.0

120
122
124
126
128

171.17
176.45
181.83
187.32
192.93

43.3
44.4
45.6
46.7
47.8

1010.0
1042.0
1076.0
1110.0
1145.0

130
132
134
136
138
140

198.66
204.50
210.47
216.55
222.76
229.09

48.9
50.0
51.1
52.2
53.3

1180.0
1217.0
1254.0
1292.0
1330.0

54.4
55.6
56.7
57.8
58.9
60.0

1370.0
1410.0
1451.0
1493.0
1536.0
1580.0

Chiller

Dehydration

the chiller
the chiller
complete

has been
is known

Dehy&'ation

is recommended

open for a considerable
period
to contain moisture,
or if there

loss of chiller

holding

chmge

of time, if
has been a

or refrigerant

pressure.

_...,.

FROM

TO VACUUM

IIL:--;:L4

PUMP

S¥STEM-' I

_A_l_'n Im_
_I_I_E_ENS_ES_
ON COLD
SURFACES

Do not start o1 megohm-test the compressor motor or oil
pump motor, even for a rotation check, if tile chiller is
under dehydration
vacuum. Insulation
breakdown
and
severe &tmage may result.

-.4IP- _]1
_

MIXTURE OF
DRYICEAND
METHYL ALCOHOL

Fig. 32 -- Dehydration Cold Trap
Dehydiation

can

done

at room

temperatures.

Using

cold trap (Fig. 32) may substanti_dly
reduce the time required
to complete
the dehydration.
The higher the room temperature,
the faster dehydration
takes place. At low room temperatures,
a
very deep vacuum
is required
to boil off any moisture.
If low
ambient temperatures
am involved,
contact
representative
for the dehydration
techniques
Perform
1.

dehydiation

a qualified
required.

vacuum

as possible

pressure
manometer
or a wet bulb
to measure
the vacuum.
Open
the
vacuum
indicator only when taking a
valve open for 3 minutes
to allow the

to equalize

witi1 the chiller

With the chiller ambient
temperature
at 60 F (15.6 C) or
highel:
operate
tile vacuum
pump until the manometer
roads
29.8
in. Hg vac,
mf 30 in. bin: (0.1
psia)
(-100.61
kPa) or a vacuum
indicator
roads 35 F (1.7 C).
the pump

is to be dehydiated,

an additional

open

condenser
water has been piped in. Check
for field-supplied
shutoff valves and controls
as specified
in the job data. Check
for refrigerant
leaks on field-inst_dled
piping.
See Fig. 30
and 31.

all isolation

Check Relief Valves --

Be sure the relief valves have
been piped to the outdoors in compliance with tile latest edition
of ANSI/ASHRAE
Standard 15 and applicable local safety
codes. Piping connections must allow for access to the v_tive
mechanism for periodic inspection and leak testing.

2 hours.

Do not apply a greater
vacuum
than 29.82 in. Hg vac
(757.4 mm Hg) or go below 33 F (.56 C) on the wet bulb
vacuum
indicatol:
At this temperature
and pressure,

The 19XRV relief valves are set to relieve at the 185 psig
(1275 kPa) chiller design pressure.

isolated
pockets
of moisture
can turn into ice. The slow
rate of evaporation
(sublimation)
of ice at these low
temperatures
and plessums
greatly
increases
dehydi'ation
time.
off tile vacuum

the instrument
6.

After

pump,

stop

the pump,

and record

instrument

reading.

wait,

take

another

has not changed,
indicates
vacuum

dehydi'ation
loss, repeat

Inspect

the VFD -- Tile LiquiFlo TM 2.0 AC di'ive is a
PWM (Pulse Width Modulated),
liquid-cooled
drive that
provides vector and general purpose regulation for a wide
range of applications. Identify the drive from the Drive Pall
Number on the drive's nameplate (Fig. 33) and the model
number matrix in (Fig. 34).

The control center is designed
environmental conditions:

is complete.
If
Steps 4 and 5.

If tile reading
continues
to change after several
perform
a leak test up to the maximum
(1103
kPa) pressure.
Ix)cate
and lepair
the
repeat

Identify

reading.

a 2-hour

the reading
the reading

CONDITION

attempts,
160 psig
leak, and

dehydration.

Water Piping

specifications

have been

to operate

in the following

SPECIFICATION

Ambient Temperature
(outside NEMA 1 enclosure)

32 to 122 F (0 ° to 50 C)

Storage Temperature
(ambient)

-40 to 149 F (-40 to 65 C)

Refer to piping diagrams
provided in the certified
di'awings.
[nspect the piping to the cooler
and condense1:
Be sum that the flow directions
am conect
and
that all piping

the

Check Optional Pumpout Compressor
Water
PipingIf the optkmal
pumpout
storage
tank and/or
pmnpout system _u'e installed, check to ensure the pmnpout

vacuum.

Valve

Measure

Water must be within design limits, clean, and treated to
ensure proper chiller perfommnce and to reduce the potential of tube &tmage due to corrosion, scaling, or erosion.
Carrier assumes no responsibility for chiller damage resulting from unUeated or improperly treated watel:

If the entire chiller
v_tives (if present).

vented with no stress on
flows through
the cooler

service

Operate

must be properly
and covel.s. Water

as follows:

Use an absolute
vacuum
indicator
shutoff valve to the
reading. Leave the
indicator

systems
nozzles

and condenser
must
meet job requirements.
pressure
drop across tile cooler and the condenser

Connect
a high capacity
vacuum
pump (5 cfin [.002 m:Vsl
or Ireget is lecommended)
to the refiigemnt
chmging
v_dve (Fig. 2). Tubing from the pump to the chiller should
be as short in length and as large in diameter
provide least resistance
to gas flow.

Piping
waterbox

Humidity

5% to 95%
(non-condensing)

This section describes how to identify tile drive using the
model number matrix and shows the major drive components.

met.

Input Power Wiring

-- All wiring should be installed in
conformance with applicable local, national, and international
codes. Use grommets, when hubs are not provided, to guard
against wire chafing.
Use the following steps to connect
main input circuit breaker:

12=ncm@[j n_
ID NO.:

AC input power to the

18O7(X)-X)(X-XXX

1. Turn off. lockout, and tag the input power to the diive.

Input Rating: XXXVAC X)O(A 50/60Hz 3PH
Oulput Rating: 0-48OVAC X)O(A 0-400Hz 3PH
Short Circuit Rating: XXXXXX

Remove the input wiring panel and drill the required
number of openings in the top of the drive enclosure.
Take care that metal chips do not enter the enclosure.

Wire the AC input power leads by routing them through
the openings to the main input circuit breakel:

Interrupt Capacity Ragng: )OOOO¢,X
Max. Ambient Temperature: 50°C

Enclosure Type: TYPE 1
Coolant Type: _
Design Pressure: X)O( X)O(X
Carder Part Number: 19XRA2X)O(XX
VFD Sedal Number. XXXXXX_OO(
Carrier Dwg. Number: 19XV04004501
Mfd. In XX)O(on XJoc)O(

Do not route control wiring carrying 30 v or less within a
conduit carrying 50 v or highel: Failure to observe this
precaution could result in electromagnetic
interference in
the control wiring.

Made In USA for Carder Colporagon,
Syracuse. NY 13221-4808.

Fig. 33 -- VFD Nameplate

LF20

0608CC

Connect the three-phase AC input power leads (per job
specification)
to the appropriate
input terminals of the
circuit breaker

Tighten the AC input power terminals to the proper
torque as specified on the input circuit breakel:

LF20 = LiquiFIo 2.0

Checking the Installation -- Use

Continuous Ampere Rating
and Frame Size

structions to verify the condition

in-

1. Turn off. lockout, and tag the input power to the diive.

Coolant Method
R = refrigerant

the following
of the instalhttion:

R134a

Wait a minimum of 5 minutes for the DC bus to dischtuge.

Fig. 34 -- Identifying the Drive Model Number

All wiring should be installed in conformance
with the
applicable local, national, and international codes (e.g.,
NEC/CEC).

IDENTIFYING
THE DRIVE BY PART NUMBER -- Each
AC drive can be identified by its assembly number. See
Fig. 33. This number appears on the shipping label and on the
drive's nameplate. LiquiFlo TM 2.0 AC power module can be
identified by its model number See Fig. 34. This number
appears on the shipping htbel and on the power module's
nameplate. Power ratings are provided in Table 12.

Remove any debris,
enclosure.

Check that
machine.

Verify that the wiring to the terminal strip and the power
terminals is coned.

Verify that all of the VFD power module circuit bo_ud
connectors are fully engaged and taped in phtce.

Check that the wire size is within terminal
and that the wiles me tightened properly.

Check that specified
and conectly rated.

BE AWARE that certtfin automatic start arrangements can
engage the startel: Open the disconnect ahead of the starter
in addition to shutting off the chiller or pump. Failure to do
so could result in serious personal inju U or death from
electric shock.

10.

PARTNUMBER

12 -- Drive Assembly

FRAME
SIZE

19XVA2AA

2AA

19XVA2CC

2CC

*110% outputcurrentcapabilityforl

is adequate

cle_u'ance

around

the

specifications

branch circuit protection

Check that the incoming
nameplate voltage.

from the

is installed

power is within _+10% of chiller

11. Verify that a properly sized ground wile is installed and a
suitable emlh ground is used. Check for and eliminate any
grounds between the power leads. Verify that all ground
leads are unbroken.

The mtfin disconnect on the starter fiont panel may not deenergize all internal circuits. Open all internal and lemote
disconnects before servicing the st_uter Failure to do so could
lesult in serious peLson_d injmy or death from electric shock.

Table

there

such as metal shavings,

and Power Module

ENCLOSURE
RATING

NEMA1

minute. 150% outputcurrentcapability

_r5sec.

Ratings

NOMINAL
INPUT
VOLTAGE
(V)
380 TO
460

INPUT
CURRENT
(AMPS)
440
608

OUTPUT
CURRENT
AT 4 kHz*
(AMPS)
460
608

Inspect

Wiring

Ground

Fault Troubleshooting
-- Follow this procedure only if ground faults are declared by tile chiller controls.
Test the chiller compressor
motor and its power lead
insulation resistance with a 500-v insukition tester such as a
megohlnmetec

Do not check the voltage supply without proper equipment
and precautions. Sedous personal injury may result. Follow
power company recommen&ttions.

1. Examine the wiring for conformance
to the job wiring
diagrmns and all applicable electrical codes.

Compare the ampere rating on the VFD enclosure
nmneplate to the rating on the compressor nameplate.
OVERLOAD
TRIP AMPS must be 108% of the
MOTOR RATED LOAD AMPS.

The control center must be wired to components
and
terminals required for PIC III refrigeration control. Check
line side power and for control components shown on the
Cellified Prints. The control center must share control of
cooler and condenser liquid pumps and cooling tower
fans.

Connect a voltmeter across the power wires to the VFD
and measure the phase to phase and phase to ground
voltage. Compare this reading to the voltage rating on the
compressor and st_uter nameplates.

Ensure all electrical equipment and controls are properly
grounded in accordance with the job di'awings, certified
drawings, and all applicable electrical codes.

Ensure the customer's contractor has
ation of the pumps, cooling tower
auxiliary equipment. This includes
properly lubricated and have proper
proper rotation.

Tighten _dl wiring connections
on the high and low
voltage termimd blocks in the control center enclosure
below the control panel.

10.

Inspect the control panel in file control center enclosure to
ensure that the contractor has used the knockouts to feed
the wires into the back of the control panel. Wiring into
the top of the panel can cause debris to fall into the
control centel: Clean and inspect the interior of the
control center if this has occurred.

With the tester connected to the motor leads, take
10-second
and 60-second
megohm
readings
as
follows:
Tie terminals 1, 2, and 3 together
the group and ground.

and test between

Divide the 60-second
resistance
reading
by the
10-second
reading.
The ratio,
or polarization
index, must be one or higher. Both the 10 and
60-second readings must be at least 50 megohms.
If the readings are unsatisfactory,
repeat the test at
the motor with the power
leads disconnected.
Satisfactory
readings in this second test indicate
the fault is in the power leads.

Carrier

Comfort

Network

Interface

Tile C_urier

Colnfol-t Network
(CCN) connnunication
bus wiring
is
supplied and inst_dled by the electrical contractol: It consists of
shielded, 3-conductor cable with di'ain wire.

Check the phase to phase and phase to ground line
voltage to the control center and the optional pumpout
compressoc Compare voltages against nameplate values.
Ensure that fused disconnects or circuit breakers have
been supplied to the control center and optional pumpout
unit.

switch and follow

The motor leads must be disconnected from the VFD
before an insulation test is performed. The voltage
generated from the tester can damage the starter solid-state
components in the VFD.

Do not apply any kind of test voltage, even for a rotation
check, if the chiller is under a dehydration vacuum. Insulation breakdown and serious &image may result.

Open the starter main disconnect
lockout/tagout rules.

The system elements are connected to the communication
bus in a daisy chgdn m'rangement. The positive pin of each
system element communication
connector must be wired to the
positive pins of the system element on either side of it. Tile
negative pins must be wired to the negative pins. The signal
ground pins must be wired to file signal ground pins. See
installation manual.
NOTE: Conductors
and drain wire must be 20 AWG
(American Wire Gage) minimum stranded, tinned coppel:
Individual 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,
chrome vinyl, or Teflon with a minimum operating temperature range of -4 F to 140 F (-9-0 C to 60 C) is required. See
table below for cables flint meet the requirements.

verified proper operfans, and associated
ensuring motors are
electric_d supply and

MANUFACTURER

CABLE NO.

Alpha
American
Belden
Columbia

2413 or 5463
A22503
8772
02525

When connecting tile CCN communication
bus to a system
element, a color code system for the entire network is recommended to simplify installation and checkout. The following
color code is recommended:

Do not apply power unless a qualified Carrier technician is
present. Serious personal injuU may result.
11. Apply power to the control center. Go to the ICVC and
access
the
MENU>SERVICE>VFD
CONFIG
DATA>VFD_CONF
screen. Confirm that the parameters entered in VFD_CONF
match the information
on
the Machine Nameplate
and Sales Requisition.
Confirm that the serial numbers on the chiller, Machine
Nameplate, and Sales Requisition are consistent.

SIGNAL
TYPE
+
Ground

CCN BUS
CONDUCTOR
INSULATION
COLOR

CCN
TERMINAL
CONNECTION

ICVC PLUG J1
PIN NO.

Red
White
Black

RED (+)
WHITE (G)
BLACK (-)

1
2
3

Power Up the Controls
and Check the Oil
Heater -- Ensure that an oil level is visible in the compres-

date, and day of the week. The HOLIDAY parameter should
only be configured to YES if the present &ty is a holiday.
NOTE: Because a schedule is integral to the chiller control
sequence, the chiller will not start until the time and &tte have
been set.

sor before energizing the controls. A circuit bleaker in the
starter energizes the oil heater and the control circuit. When
first powered, the ICVC should display the default screen
within a short period of time.

NOTE: The date format is MM-DD-YY
DD-MM-YY format for SI metric units.

Tile oil heater is energized by powering the control circuit.
This should be done several hours before sta-t-up to minimize
oil-refiigerant
migration. The oil heater is controlled by the
PIC Ill and is poweled through a contactor in the power panel.
A separate circuit breaker powers the heater and the control
circuit. This ammgement
allows the heater to energize when
the main motor circuit breaker is off for service work or
extended shutdowns. Tile oil heater relax/status (OIL HEATER
RELAY) can be viewed on the COMPRI_SS table on the ICVC.
Oil sump temperature can be viewed on the ICVC default
screen.

CHANGE ICVC CONFIGURATION
IF NECESSARY
-From the SERVICE
table, access the ICVC CONFIGURATION screen. From there, view or modify the ICVC CCN
address, change to English or SI units, and change the
password. If fllere is more than one chiller at the jobsite,
change the ICVC addiess on each chiller so that each chiller
has its own address. Note and record the new addiess. Change
the screen to SI units as required, and change the password if
desiled.
TO CHANGE
THE PASSWORD
-- The password
changed from the ICVC CONFIGURATION
screen.

SOFTWARE VERSIONThe software part number
is
labeled on the backside of the [CVC module, The software
velMon also appears on the ICVC configuration screen as the
last two digits of the software part numbel:

Software

1. Press the _
current password

Do not operate the chiller befole the control configuraions
have been checked
and a Control
Test has been
satisfactorily
completed.
Protection
by safety controls
cannot be assumed until all control configurations
have
been confirmed.

and [SERVICE] softkeys. Enter the
and highlight ICVC CONFIGURA-

Use file _
softkey to scroll to PASSWORD. The
first digit of file password is highlighted on the screen.

change

[DECREASE]
As the 19XRV unit is configured, all configuration settings
should be written down. A log, such as the one shown on pages
CL-I to CL-I 2, provides a list for configuration values.

press the _

Input the Design Set Points -- Access the ICVC set
point screen and view/modify the BASE DEMAND LIMIT set
point, and either the LCW SETPOINT
or the ECW SETPOINT. The PIC III can control a set point to either the leaving
or entering chilled water This control method is set in the
EQUIPMENT SERVICE (TEMP_CTL) table.

For more information about how to set up a time schedule,
see the Controls section, page 11.

the

IINCREASE]

softkey.

The next digit is highlighted. Change it, and the third and
fourth digits in the same way the lil.st was changed.

After the last digit is changed, the ICVC goes to file BUS
to leave

1. Press the _
and [SERVICE] softkeys. Enter the
password and highlight ICVC CONFIGURATION.
Press

Input Service Configurations -- Ti_e following configurations require the ICVC scleen to be in the SERVICE
tion of the menu.

press

When the desired digit is seen,

TO CHANGE THE ICVC DISPLAY FROM ENGLISH TO
METRIC UNITS --By
default, the ICVC displays information in English units. To change to metric units, access the
ICVC CONFIGURATION
scleen:

The CCN Occupied Schedule (OCCPC03S) should be configured if a CCN system is being installed or if a secon&try
time schedule is needed.
OCCPC03S

digit,

soflkey.

Be sure to remember
the password.
Retain a copy
for future reference. Without the password, access to the
SERVICE
menu
will not be possible
unless
the
ICVC PSWD menu on the STATUS screen is accessed by
a Carrier representative.

Access the schedule OCCPC01S screen on the ICVC and set
up the occupied time schedule according to the customer's
requirements. If no schedule is available, the default is factory
set for 24 hours occupied, 7 days per week including holi&tys.

Schedule

the

NUMBER pmametel: Press the _
softkey
that screen and leturn to the SERVICE menu.

Input the Local Occupied Schedule (OCCPC01S) --

•
•
•
•
•
•

may be

TION. Press the _
softkey. Only the last
5 entries on the ICVC CONFIG screen c_m be changed:
BUS NUMBER,
ADDRESS,
BAUD RATE, US IMP/
METRIC, and PASSWORD.

Configuration

NOTE: The default CCN Occupied
configmed to be unoccupied.

for English units and

the _

por-

password
input time and date
ICVC configuration
service parameters
equipment configuration
automated control test

softkey.

Use file _

softkey to scroll to US IMP/METRIC.

Press the softkey flint conesponds to file units desired for
display on the ICVC (e.g., US or METRIC).

CHANGE LANGUAGE--By
default, the ICVC displays
information in English. To change to another Language, access
the ICVC CONFIGURATION
screen:
1. Press the _
and [SERVICE[ softkeys. Enter the
password and highlight ICVC CONFIGURATION.
Press

PASSWORD -- When accessing the SERVICE tables, a password must be entered. All ICVC are initially set for a password
of 1- 1- 1- 1 in the ICVC CONFIGURATION
SCREEN.

the _

INPUT TIME AND DATE -- Access the TIME AND DATE
table on the SERVICE menu. Input the present time of chy,

2.
61

Use the _

softkey.
softkey to scroll to LID LANGUAGE.

3. Press
theINCREASE
or DECREASE
softkey
untilthe
desired
language
isdisplayed.
Press
_
toconfirm
desired
language.
MODIFYCONTROLLER
IDENTIFICATION
IF NECESSARY-- TheICVCmodule
ADDRESS can be changed from

Carrier
Mmq
uB
MACHINE

$_FI.Y

DATA

MACH_ ELEC_ICAL DATA
u_

the ICVC CONFIGURATION
screen. Change this adc_hess for
each chiller if there is more than one chiller at the jobsite. Write
the new adc_hess on the [CVC module for future reference.
INPUT EQUIPMENT
SERVICE
ESSARYiThe
EQUIPMENT
service tables.

NAMEPLATE

M_ r_Cl_CUsT _R_A_ER
_ZE

MACHINEELECINCAL DATA
_*o_

N_M

PLAXE

AG_

10AD SIDE

PARAMETERS
IF NECSERVICE
table has six

VERIFY
VFD
CONFIGURATION
AND
PARAMETERS
IF NECESSARY
(Fig. 35)

SIDE

CHANGE

IMPORTANT: The VFD controller has been factory configured for use and communications
to the International
Chiller Visual Controller (ICVC). Some parmneters ;ue
specific to the chiller configuration and will need to be verified prior to operation. All command functions must be
initiated from the [CVC.
VFD CHILLER

FIELD

SET UP AND VERIFICATION
sA,,,,

Label Ix_cations -- Verify the following labels have been
installed properly and match the chiller requisition:
• Surge Parameters
-- Located inside the control panel
(see Fig. 9).
• Refrigeration
Machine
Nameplate
-- Located on the
right side of the control panel (see Fig. 9).
• External Machine Electrical Data Nameplate -- Ix_cated
on the right side of the VFD as viewed from its front.
(See Fig. 35).
• Internal Machine Electrical Data Nameplate -- Ix_cated
on the inside of the left VFD enclosure
door. (See
Fig. 35).
• Record all nameplate information
on the Initial Start-up
Checklist at the end of this manual.

•
•

Check VFD CONFIG TABLE -- Enter
screen on the [CVC by entering
the
sequence when the chiller is not running:
• MENU
• SERVICE
• Password (default 1111)
• VFD CONFIG DATA
• Password (default 4444)
• VFD_CONF

NOTE: Some of the parameters
drive is stopped.

•
•
•
•
•
•
•
•

Electrical

Data Namoplato

Motor Nameplate kW i Motor nameplate rated power:
Inverter PWM Frequency -- Sets the carrier frequency
for the pulse width modulation output.

NOTE: Other pm'ameters on these screens me normally left at
the default settings; however, they may be changed by the
operator as _equired. The voltage and current imbalance level
and imbalance persistence time on the VFD_CONF table can
be adjusted to increase or decrease the sensitivity of these fault
conditions. Increasing time or pe_.sistence decreases sensitivity.
Decreasing time or persistence increases sensitivity to the fault
condition.

the VFD_CONF
following
screen

Confirm
that
the
following
parameters
VFD_CONF
screen match
the values on the
Machine Electrical Data Nameplate:

EXTERNAL

INTERNAL

Fig. 35 -- Machino

COOEce_I,I_,,o,

can be changed only when the

It is the operator's responsibility to distribute access to the
ICVC passwords. Carrier is not responsible for unauthorized access violations within the operator's organization.
Failure to observe this warning could result in bodily
injury.

in
the
Internal

Compressor 100% Speed -- Compressor speed required
to run at chiller design point.
Rated Line Voltage -- Nominal line voltage selected for
the job site.
Rated Line Amps -- Line current required for the chiller
to run at the design point.
Rated Line Kilowatts -- Line power required for the
chiller to run at the design point.
Motor Rated Load kW -- Power consumed by the motor
when running at the chiller design point.
Motor Rated Load Amps -- Motor current required for
the chiller to run at the design point.
Motor Nameplate
Amps -- Motor nameplate
full load
amps.
Motor Nameplate
RPM -- Rated speed of the motor
when running at motor nameplate rated frequency, rated
current, and rated voltage.

See the Initial Start-Up Checklist section for VFD Job Specific Configuration
table. For job specific pm'ameters see the
Machine Electrical Data Nameplate (Fig. 35) inside of the
VFD enclosure door
Modify Minimum and Maximum Load Points (ATI/PI: AT2/
P2) If-NecessaLy -- These pairs of chiller load points, located
on the OPTIONS screen, determine when to limit guide vane
travel or open the hot gas bypass valve when surge prevention
is needed. These points should be set based on individual
chiller operating conditions.
SET SURGE
LIMIT/HGBP
OPTION to 0 if the chiller is not equipped with an optional hot
gas bypass. Set SURGE LIMIT/HGBP
OPTION to 1 if a hot
gas bypass has been installed.

A labelthatliststheconfiguration
v_dues
ofthecontrols
is
located
ontheinside
oftheunit'scontrolpanel.
These
v_dues
arebased
upontheoriginalselection
ofthechillel:Jobsite
conditions
mayrequire
aslightmodification
tothese
parameters.
If afterconfiguring
avalueforthese
points,
surge
preventionis operating
toosoonor toolatefor conditions,
these
parameters
should
bechanged
byfileoperatol:
Anexmnple
ofsuchaconfiguration
isshown
below.
Refrigerant:
HCFC134a
Estimated

Minimum

Load Conditions:

44 F (6.7 C) LCW
45.5 F (7.5 C) ECW
43 F (6.1 C) Suction Temperature
70 F (21.1 C) Condensing Temperature
Estimated Maaimum Load Conditions:

Compressors wifll vmiable diflhser control have actuators
tested and stamped with the milliamp (mA) value that results in
100% actuator rotation. This v¢flue is configured
on the
SETUP2 screen. It is labeled DIFFUSER FULL SPAN mA.
MODIFY
EQUIPMENT
CONFIGURATION
IF NECESSARY -- The EQUIPMENT
SERVICE table has screens to
select, view, or modify parameters. Career's certified drawings
have the configuration values required for the jobsite. Modify
fllese values only if requested.
EQUIPMENT
SERVICE Screen Modifications
-- Change
the values on these screens according to specific job data. See
file certified drawings for the correct values. Modifications can
include:
• Chilled water reset (CHW SETPT RESET VALUE)
• Entering
chilled
water
control
(ECW
CONTROL
OPTION)
• 4 to 20 mA demand limit (DEMAND LIMIT AT 20 mA)
• AUTO RESTART OPTION (Enable/Disable)
• REMOTE CONTACT
OPTION (Enable/Disable)

120 - 37 = 83 psid (827 - 255 = 572 kPad)
add about 10 psid

AT2 = 10 ° F (5.5 ° C)
AP2 = 93 psid (642 kPad)
Calculate Minimum Load -- To calculate the minimum load
conditions, estimate the temperature difference the cooler will
have at 10% load, then estimate what the suction and condensing temperatures will be at this point. Use the proper saturated
pressure and temperature for the particular refrigerant used.

Owner-Modified
CCN Tables -- The following EQUIPMENT CONFIGURATION
screens me described for reference
only.
OCCDEFCSThe OCCDEFCS
screen contains the Ix_cal
trod CCN time schedules, which can be modified here or on the
SCHEDULE screen as described previously.

Suction Temperature:
43 F (6.1 C) = 38 psig (262 kPa) saturated
refrigerant pressure (HFC- 134a)

HOLIDAYS -- From file HOLIDAYS screen, file days of the
year that holidays are in effect can be configured. See the
holiday paragraphs in the Controls section for more details.
BRODEF
The BRODEF screen defines the start trod end of
&tylight savings time. By default this feature is enabled. Enter
file (kites for the start and end of daylight savings if required
for your location. Note that for Day of Week, 1 represents
Monday. Start Week and Stop Week refer to the instance of the
selected Day of Week during the selected month and yem: To
disable the feature, change "Stml Advance" and "Stop Back"
times to 0 (minutes). In the BRODEF table the user may also
identify a chiller as the time broadcaster for a CCN netwoN.
There should be only one device on a CCN network which is
designated as the Time Broadcastel:
ALARM ROUTING--This
is in the table SERVICE->
EQUIPMENT
CONFIGURATION->NET
OPT under the
heading Alarm Configuration.
Alarm Routing consists of tin
8-bit binary number Only bits 1, 2, and 4 (counting from the
left, first) are used. (The others do not mattel:) The bits can be
set by tiny device which can access and change configuration

Condensing Temperature:
70 F (21.1 C) = 71 psig (490 kPa) saturated
refrigerant pressure (HFC-134a)
Minimum Load ATI (at 20% Load): 2 F (1.1 C)
Minimum Load API :
71 - 38 = 33 psid (490 - 262 = 228 kPad)
Again, to avoid unnecesstuy surge prevention,
(140 kPad) at API from these conditions:
ATI = 2F(I.I
C)
API = 53 psid (368 kPad)
If surge prevention

LOAD
At low loads
(<50%)
At high loads
(>50%)

add 20 psid

occurs too soon or too late:

SURGE PREVENTION
OCCURS TOO SOON

SURGE PREVENTION
OCCURS TOO LATE

Increase Pl by
2 psid (14 kPad)
Increase P2 by
2 psid (14 kPad)

Decrease P1 by
2 psid (14 kPad)
Decrease P2 by
2 psid (14 kPad)

Further adjustments can be made if response to surge prevention or protection is not functioning as desired. VFD GAIN and
I/FD INCREASE
STEP can be adjusted to allow for more
agglessive changes in speed when surge prevention or protection is active.
CONFIGURE
DIFFUSER
CONTROL
IF
NECESSARYIf the compressor
is equipped with a variable
diflhser, (size 4 or 5 complessor) access the SETUP2 screen.
Scroll to DIFFUSER
CONTROL
and press the IENABLE]
softkey. Compare the diflhser and guide vane values (GUIDE
VANE 25% LOAD PT, GUIDE VANE 50% LOAD PT, GUIDE
VANE 75% LOAD PT, DIFFUSER
25% LOAD POINT,
DIFFUSER
50% LOAD POINT, DIFFUSER
7.5% LOAD
POINT) to the values located on the label inside the control
panel above the ICVC. See Fig. 9.

44 F (6.7 C) LCW
54 F (12.2 C) ECW
42 F (5.6 C) Suction Temperature
98 F (36.7 C) Condensing Temperature
Calculate Maximum Load -- To calculate the maximum load
points, use file design load condition <a. If the chiller full load
cooler temperature
difference is more than 15 F (8.3 C),
estimate the refrigerant suction and condensing temperatures at
this difference. Use file proper saturated pressure and temperature for the pmticular refrigerant used.
Suction Temperature:
42 F (5.6 C) = 37 psig (255 kPa) saturated
refrigerant pressure (HFC- 134a)
Condensing Temperature:
98 F (36.7 C) = 120 psig (1827 kPa) saturated
refrigerant pressure (HFC- 134a)
Maximum Load AT2:
54 - 44 = 10 ° F (12.2 - 6.7 = 5.5 ° C)
Maximum Load AP2:
To avoid unnecessmy surge prevention,
(70 kPad) to AP2 from these conditions:

The differential pressure (AP) and temperature (AT) can be
monitored
during chiller operation
by viewing ACTI1/E
DELTA P and ACTIVE
DELTA T (HEAT EX screen).
Compming SURGE/HGBP
DELTA T to ACTIVE DELTA T
will determine when the SURGE PREVENTION
function will
occur The smaller the difference between the SURGE/HGBP
DELTA T and the A CTI1/E DELTA T v_flues, the closer to surge
prevention.

tables.
If anyofthese
3 bitsis setto1,thecontroller
(ICVC,
forexample)
willbroadcast
any;darms
whichoccm:
• first bit = 1 indicates
thatthealarmshouldberead
and processed
by a "front end" device,suchas
•
•

Table 13 -- Control Test Menu Functions
TESTS TO BE
PERFORMED

ComfortWORKS®.
second bit = 1 indicates that the alarm should be read and
processed by a TeLINK TM or Autodial Gateway module.
fourth bit = 1 indicates that the alarm should be read and
processed
by an alarm printer interface
(an optional
module), ServiceLink TM, or a DataLINK TM modules.

1. CCM Thermistors

Entering Chilled Water
Leaving Chilled Water
Entering Condenser Water
Leaving Condenser Water
Evap Saturation Temp
Comp Discharge Temp
Comp Thrust Brg Temp
Oil Sump Temp
Comp Motor Winding Temp
Spare Temperature 1
Spare Temperature 2
Remote Reset Sensor

2. CCM Pressure
Transducers

Evaporator Pressure
Condenser Pressure
Oil Pump Delta P
Chilled Water Delta
Condenser Water Delta P
Transducer Voltage Ref
Humidity Sensor Input
Relative Humidity

3. Pumps

Oil Pump -- Confirm Pressure
Chilled Water -- Confirm Flow and Delta P
Condenser Water -- Confirm Delta P

4. Discrete
Outputs

Oil Heater Relay
Hot Gas Bypass Relay
Tower Fan Relay Low
Tower Fan Relay High
VFD Coolant Solenoid
Alarm Relay
Shunt Trip Relay

5. IGV & SRD
Actuator

Open/Close
If present, split ring diffuser will operate in
coordination with the guide vanes per configured schedule.

6. Head Pressure
Output
7. Diffuser Actuator*

Increase/Decrease

8. Pumpdown
Lockout

When using pumpdown/Iockout, observe
freeze up precautions when removing
charge:
Instructs operator which valves to close and
when.
Starts chilled water and condenser water
pumps and requests flow confirmation.
Monitors
Evaporator pressure
Condenser pressure
Evaporator temperature during
pumpout procedures
Turns pumps off after pumpdown.
Locks out compressor.

9. Terminate Lockout

Starts pumps and monitors flows.
Instructs operator which valves to
open and when.
Monitors
Evaporator pressure
Condenser pressure
Evaporator temperature during
charging process
Terminates compressor lockout.

10. Guide Vane
Calibration

Automatic, displays guide vane position signal voltage. This test is required before first
startup with new Actuator or Controller.

The Re-Alarm time is a time period after which, if a preexisting and previously broadcast ;darm has not been cleared, it
will be rebroadcast on the CCN network.
Other _ibles -- The
TIME screens contain
See the applicable CCN
screens. These tables
Building Supervisol:

CONSUME,
NET_OPT.
and RUNparameters used with a CCN system.
manual for more information on these
can only be defined from a CCN

ALARM CONTROL
ALARM ROUTING
This decision determines which CCN system elements will receive
and process alarms sent by the CSM. Input for the decision consists
of eight digits, each of which can be set to either 0 or 1. Setting a
digit to 1 specifies that alarms will be sent to the system element
that corresponds to that digit. Setting all digits to 0 disables alarm
processing. Digits in this decision correspond to CCN system
elements in the following manner:

Alarm

Printer

Autodail

Interface

Module

Gateway

Local Building Supervisors(s)
or ComfortWORKS

I
I
1

0
I

0
l
unused

NOTE: If your CCN does not contain ComfortWORKS®
controls or
a Building Supervisor, Autodial Gateway, or APIM to serve as an
alarm acknowledger, set all digits in this decision to 0 in order to
prevent unnecessary activity on the CCN Communication Bus.
Allowable Entries

00000000 to 11111111
0 = Disabled, 1 = Enabled

Default Value

11010000

Fig. 36 -- Alarm Control and Alarm Routing

Perform a Control Test -- Check the safety controls
status by performing
an
CONTROL
TEST
table
function
(Table 13).

automated
and select

control
a test

test. Access
the
to be performed

The Automated
Control
Test checks all outputs and inputs
for lunction.
In order to successfully
proceed with the controls
test, the compressor
should be off. no aimms showing,
and voltage should be within _+10% of Nmneplate
value. The complessot can be put in OFF mode by pressing the STOP push button
on the [CVC. Each test asks the operator
to confirm the operation is occurring
and whether or not to continue.
If an error occurs, the operator
can try to addless the problem
as the test is
being done or note the problem
and proceed to the next test.
NOTE:
Enter guide vane c;dibration
actuator feedback
potentiometer
input
terminals
9 and 10).

DEVICES TESTED

Open/Close

4-20 mA output

(independent

of guide vanes)

*Diffuser tests function only on size 4 and 5 compressor
control enabled.

to calibrate
guide vane
on CCM (Plug J4 upper

with diffuser

NOTE: During any of the tests, an out-of-range reading will have an
asterisk (*) next to the reading and a message will be displayed if
diffuser control is enabled.

NOTE:

[f during the control test the guide vanes do not open,
the low pressure
;dmm is not active.
(An active low
plessure
;dmm causes the guide vanes to close.)

verify

NOTE:
The oil pump test will not
cooler pressure
is below -5 psig (-35

energize
kPa).

the oil pump

When the control test is finished or the _
sollkey is
pressed, the test stops, and the CONTROL
TEST menu
displays. If a specific
automated
test procedure
is not
completed, access the particular control test to test the limction
when ready. The CONTROL
TEST menu is described in
Table 13.

PRESSURE
TRANSDUCER
CALIBRATION
-- Transducers
measuring
singlepressure
values
(suchascondenser
andevaporator
pressure)
arecalibrated
individually,
whilea
pairof transducers
measuring
a pressure
differential
(OIL/
PUMPDELTAR CONDENSER
WATERDELTAR
CHILLED
WATER
DELTAP)tuecalibrated
together
asadifferential.
Inunitswith[CVCcontrollers,
transducel.'s
forsensingwatersideflowarenotprovided
asstan&ud.
These
reading
canbe viewedandcalibrated
fromtheCOMPRESS
and
HEAT_EX
screens
ontheICVCcontrollel:
Eachtransducer
ortransducer
paircanbec_flibrated
attwo
points:
zero(0psigor0kPa)and"highend"(between
25and
250psig,or between
173and1724kPa).It is notusually
necess_uy
to calibrate
at initialstart-up.
Howevel,
at high
altitude
locations,
recalibration
maybenecessary
toensure
the
proper
refrigerant
temperature-pressure
relationship.
ZERO POINT CALIBRATION -- Shut down the compressor.
and cooler and condenser pumps. There must be no water flow
through the heat exchangers, but these systems must be tilled.
For differential pairs, leave the transducers installed. For single
vMue transducers, disconnect the transducer's
electrical cable,
remove the sensor from its Schmder fitting, then reconnect the
cable.
NOTE: If the cooler or condenser vessels tue at 0 psig (0 kPa)
or are open to atmospheric pressure, the transducers can be
calibrated for the zero point without removal.
Access the HEAT_EX or COMPRESS
screen under the
STATUS menu, and view the particular transducer reading.
(OIL PUMP DELTA P is in the COMPRESS screen; all others
are in HEAT_EX.)If
the displayed reading is not 0 psi (0 kPa),
press the SELECT key to highlight the associated line in the
display, then the ENTER key. (For zero point c_dibration, the
INCREASE and DECREASE keys have no effect.) The v_flue
should change to 0.0.

value can be changed
value.

to tiny value within _+15% of a nominal

NOTE: Prior calibrations
may have shilled the present
pre-c_flibration value from the center of this range. In this case,
the limit of acceptable new values will be less than 15% in one
direction.
If the [CVC fails to accept the high end calibration, the
value will not change and the display will show "Higher Force
In Effect". This indicates that the sensor voltage is out of the
acceptable range for the entered value. If this occm.s with a
differential pail: one possible remedy is to swap the high end
(inlet) and low end (outlet) transducers. In most cases this puts
the sensor voltage within the acceptable range.
Each transducer is supplied with 5 vdc power from the
CCM. Pressure transducer readings are derived from voltage
ratio, not absolute
voltage, which compensates
for any
reference
voltage variation. If this power supply fails, a
transducer voltage reference _darm is generated. If transducer
readings are suspected of being faulty, check the supply
voltage, measured between the high and low (that and third)
terminals of tiny transducer 3 terminal connection at the CCM.
This is _dso displayed
in CONTROL
TEST under CCM
PRESSURE TRANSDUCERS.

Check

Optional

Pumpout

System

Controls

and Compressor

-- Controls include an on/off switch,
a 0.5-amp fuse, the compressor overloads, an internal thermostat, a compressor contactor, refrigerant low pressure cut-out
and a refrigerant high pressure cutout. The high pressure cutout
is factory set to open at 185 psig (1276 kPa) and reset at
140 psig (965 kPa). The low pressure cutout is factory set to
open at 7 psia (-15.7 in. HG) and close at 9 psia (-11.6 in. HG).
Ensure the water-cooled condenser has been connected. Ensure
oil is visible in the compressor sight glass. Add oil if necesstuy.
See the Pumpout and Refrigerant Transfer Procedures and
Optional Pumpout System Maintenance sections, pages 71 and
78, for details on the transfer of refrigerant, oil specifications,
etc.

If the [CVC fails to accept the zero point calibration, the
value will not change to 0.0 and the display will show "Higher
Force In Effect". This indicates that the sensor voltage is out of
the acceptable range. For each single value transducer there are
3 terminals at the CCM: 0 vdc (low), "sensor" voltage, and
5.00 vdc (high). With a base supply voltage of 5.00 volts, the
acceptable range of voltage taken between the low and sensor
terminals for zero point c_flibration is 0.40 to 0.55 v. For each
transducer differential pair there are two 3-terminal sets at the
CCM. With a base supply voltage of 5.00 volts, the acceptable
range of voltage t_&en between the sensor terminal for the high
end transducer (water inlet or oil pump discharge) and the
sensor terminal for the low end transducer (water outlet or oil
sump) for zero point calibration is -0.065 to +0.085 v. If this
occurs with a differential pail: one possible remedy is to swap
the high end (e.g., inlet) and low end (e.g., outlet) transducers.
In most cases this puts the sensor voltage within the acceptable
range.
HIGH END CALIBRATION -- High end calibration can be
performed between 25 and 250 psig (173 and 1724 kPa),
comptu'ing the pressure readings in the ICVC display to an
accurate refrigeration
gage. While it normally will have a
negligible effect, it may improve transducer accuracy over the
full pressure range. High end c¢flibration is not recommended
for transducer differential pairs. Pressure can be provided by
attaching a regulated 250 psig (1724 kPa) pressure source, such
as from a nitrogen cylindel: to the transducel:

High Altitude

Locations -- Because the chiller is initi;dly calibrated at sea level, it is necess;uy to rec;dibrate the
pressure transducers if the chiller has been moved to a high
;altitude location. See the c;dibration procedure in the Troubleshooting Guide section.
Charge

Refrigerant

into Chiller

The transfel: addition, or removal of refrigerant in
isolated chillers may place severe stress on external
if springs have not been blocked in both up and
directions. Failure to block springs in both up and
directions could result in severe personal injury and
ment damage.

spring
piping
down
down
equip-

Always operate the condenser and chilled water pumps
during charging operations to prevent freeze-ups. Damage
could result to equipment if condenser and chilled water
pumps ;ue not operated during pumpdown or charging.

Access the HEAT EX screen under the STATUS menu,
and the CONDENSER
PRESSURE
or EVAPORATOR
PRESSURE to the reference pressure gage. To change the displayed reading, press the SELECT key to highlight the associated line in the display, then the INCREASE or DECREASE
key to set the new value, then the ENTER key. Generally, the

The standard 19XRV chiller is shipped with the refrigerant
_flready charged in the vessels. Howevel: the 19XRV chiller
may be ordered with a nitrogen holding charge of 15 psig
(103 kPa). Ewlcuate the nitrogen from the entire chillel: and
charge the chiller from refl'igerant cylinders.

CHILLEREQUALIZATION
WITHOUTA PUMPOUT
UNIT

The full refrigerant chmge on the 19XRV will vary with
chiller components and design conditions, as indicated on the
job data specifications. An approximate chtuge may be determined by adding the condenser charge to the cooler chmge as
listed in Table 14.

Whenequ_flizing
refrigerant
pressure
onthe19XRV
chiller
afterservice
workorduringtheinitialchillerstall-up,
do
not use the dischalig, e isolation valve to equali',.e. Eiflier the
motor cooling isolation valve or a charging hose (connected between the refrigerant charging valves on top of
the cooler and condenser) should be used as the equalization valve. Dmnage to the float valve could result.

Always operate the condenser and chilled water pumps
whenever charging, transferring, or removing refrigerant
from the chillel: Ftdlure to do so could result in serious
personal injury or equipment &image.

To equalize the pressure differential on a refrigerant isolated
19XRV chillek use the terminate lockout function of the
CONTROL TEST on the SERVICE menu. This helps to turn
on pumps and advises the operator on proper procedures.

Use the CONTROL TEST terminate lockout
monitor conditions and start the pumps.

IMPORTANT:
Turn on the chilled water
denser water pumps to prevent freezing.

and con-[

Slowly open the motor cooling isolation valve. The
chiller cooler and condenser pressures will gradually
equalize. This process takes approximately
15 minutes.

TRIMMING REFRIGERANT
CHARGE -- The 19XRV unit
is shipped with the correct charge for the design duty of the
chillel: On most 19XRV chillers the design LTD (Leaving
Temperature
Difference) between the leaving chilled water
temperature and the cooler refrigerant temperature is so low
that the traditional method of trimming the charge to achieve a
minimum LTD is not practical. In the case where leaks have
been found and corrected and the LTD is greater than about
4 ° F (2.2 ° C) above design, add refligemnt until the full load
design LTD is approached,
and then charge for proper oil
return at low load. (A high cooler LTD can also be caused by
dirty tubes, water box division plate bypass, a Du-tiafly closed
liquid isolation valve, or a sticking float valve.)

Once the pressures have equalized, the cooler isolation
v_dve, the condenser isolation valve, and the hot gas isolation valve may now be opened. Refer to Fig. 30 and 31,
for the location of the valves.

Whenever turning
reattach the valve
from opening or
chiller operation,
injury.

the discharge isolation valve, be sine to
locking device. This prevents the valve
closing during service work or during
which could result in serious pel.sonal

If low load oil loss is experienced, operate the chiller at low
load with the guide vanes nedy closed and observe the flow
through the sight glass in the oil skimmer line. Under low load
operation one should be able to see a flow of bubbly oil and
refrigerant in the sight glass. If there is no visible flow, add
refrigerant. If the sight glass shows a flow of nearly clear fluid,
remove refrigerant.

CHILLER EQUALIZATION
WITH PUMPOUT
UNIT -The following steps describe how to equalize refrigerant
pressure on an isolated 19XRV chiller using the pumpout unit.
1. Access the terminate lockout function on the CONTROL
TEST screen.
2.

IMPORTANT:
Turn on the chilled water
denser water pumps to prevent freezing.

and con-]

If the chiller has been shipped with a holding chmge, the
refrigerant is added through the pumpout charging connection
(Fig. 30 and 31, valve lb). First evacuate the nitrogen holding
chmge from file chiller vessels. Charge the refrigerant as a gas
until the system pressure exceeds 35 psig (141 kPa) for
HFC-134a. Aller the chiller is beyond this pressure the refrigerant should be charged as a liquid until all the recommended
refrigerant charge has been added. The charging valve (Fig. 30
and 31, v_flve I a or I b) can be used to charge liquid to the cooler or condenser Do not charge liquid through the liquid line
service valve.

The following steps describe how to equalize refrigerant
pressure in tin isolated 19XRV chiller without a pumpout unit.
1. Access terminate lockout function on the CONTROL
TEST screen.
2.

function

The preferred location at which refrigerant should be added
directly into the chiller is through file service valve at the top of
the condensel: If that valve is not accessible due to presence of
an attached pumpdown
unit which does not have a storage
tank, add charge through the valve connected to the side of the
condenser drain float sump. Adding charge through the di'ain
valve at the base of the chiller (off file liquid line) is NOT
recommended.

Open valve 4 on the pumpout unit and open valves la and
l b on the chiller cooler and condensek Fig. 30 and 31.
Slowly open valve 2 on the pumpout unit to equalize the
pressure. This process takes approximately
15 minutes.

Once the pressures have equalized, the dischmge isolation valve, cooler isolation valve, optional hot gas bypass
isolation valve, and the refrigerant isolation valve can be
opened. Close valves la and lb, and all pumpout unit
valves.

Table 14 lists file 19XRV chiller refrigerant charges for each
cooler and condenser code. Total refrigerant charge is the sum
of the cooler and condenser charge.

Table 14COOLER
CODE
10
11
12
15
16
17
20
21
22
30
31
32
35
36
37
40
41
42
45
46
47
50
51
52
55
56
57
6O
61
62
65
66
67
7O
71
72

Check Motor

Refrigerant (HFC-134a) Charge

REFRIGERANT
CHARGE
Ib
290
310
330
320
340
370
345
385
435
350
420
490
400
480
550
560
630
690
640
720
790
750
840
900
870
940
980
940
980
1020
1020
1060
1090
1220
1340
1440

CONDENSER
CODE

kg
132
141
150
145
154
168
157
175
197
159
190
222
161
218
250
254
266
313
290
327
358
340
361
408
395
426
445
426
445
463
463
461
494
553
608
653

INITIAL

1. Engage tile control power circuit breaker (CB2) located
inside the left hand side of the VFD enclosure.

REFRIGERANT
CHARGE
Ib
200
200
200
250
250
250
225
225
225
260
260
260
310
310
310
260
280
280
330
330
330
400
400
400
490
490
490
420
420
420
510
510
510
780
780
780

10
11
12
15
16
17
20
21
22
30
31
32
35
36
37
40
41
42
45
46
47
50
51
52
55
56
57
60
61
62
65
66
67
70
71
72

kg
91
91
91
113
113
113
102
102
102
118
118
118
141
141
141
127
127
127
150
150
150
161
161
181
222
222
222
190
190
190
231
231
231
354
354
354

The VFD checks for proper phase rotation as soon as
power is applied to the starter and the PIC III controls
power up. The controls do not permit a start if the phase
rotation is not correct.

An ahum message will appear on the ICVC if the phase
rotation is incorrect. If this occurs reverse any 2 of the 3
incoming power leads to the VFD and reapply powel:
The motor is now ready for a rotation check.

After the default screen status message states 'Ready to
Stmt' press the _
softkey. The PIC III control
performs start-up checks.

When the starter is energized and the motor begins
turn, check for clockwise motor rotation (Fig. 37).

Cooling tower water is at proper
design entering temperature.

Chiller is charged with refrigerant and all refi'igerant
oil valves are in their proper operating positions.

Oil is at the proper level in the reservoir

Oil reservoir temperature is above 140 F (60 C) or above
refrigerant temperature plus 50 ° F (28 ° C).

Vtdves in the evaporator
open.

are not automatic,

on the

and Compressor

Stop

Press the Stop button and listen for any unusual
from the compressor as it coasts to a stop.

Accidental

Start-Up

sounds

A chiller STOP

ovenide setting may be entered to prevent accident_d start-up
during service or whenever necessmy. Access the MAINSTAT
screen and using the _
or
highlight the CHILLER START/STOP

level and at-or-below

and condenser

(CBl)

When the motor is at full speed, note the OIL PRESSURE reading on the ICVC default screen. Normal
19XRV oil pressure readings are between 18 and 30 psid
(124 to 207 kPad). The oil pressure should be between 18
and 40 psid (124 to 276 kPad) on Frame 3 compressors
equipped with rolling element bearings.

To Prevent

Power is on to the main startel: oil pump relay, tower fan
stmter, oil heater relay, and file chiller control panel.

disconnect

START-UP

[PREVIOUS]
softkeys,
pammetel: Override the

current START value by pressing the _

and

softkey. Press

file _
softkey followed by the _
softkey. The
word SUPVSR! displays on the [CVC indicating the override
is in place.

sight glasses.

To restml

water circuits are

removed.

the chiller the STOP

Access

the MAINSTAT

override

setting

ensure water is

-- forces tile chiller ON

•

-- forces tile chiller OFF

•

]RELEASE
control.

] -- puts the chiller under remote or schedule

the

return

chiller

The default [CVC
command is in effect.

START/STOP.

•

normal

control,

]RELEASE]
softkey followed by the _
mole information, see Local Start-Up, page 50.

Access the CONTROL TEST screen. Scroll down on the
TERMINATE LOCKOUT option. Press the SELECT (to
enable the chiller to start) and answer YES to reset unit to
operating mode. The chiller is locked out at the factory in
order to prevent accidental start-up.

must be

screen and using

or ]PREVIOUS] softkeys highlight CHILLER
The 3 softkeys that appear represent 3 choices:

Do not permit water or brine that is wmmer than 110 F
(43 C) to flow through the cooler or condensel: Refrigerant
overpressure may discharge through the relief valves and
result in the loss of refrigerant charge, damaging the chillel:
7.

Finally close the main motor
front of the VFD enclosure.

Check Oil Pressure

Before stmting file chillel; verify:

NOTE: If the pumps
circulating properly.

Do not check motor rotation during coastdown. Rotation
may have reversed during equalization of vessel pressures.

the VFD is not stmted by a technician who has completed
Reliance LiquiFlo TM Tier 1 Training and whose name is
IMPORTANT:
Reliance VFD wmTanty will be void if
legi stered with The
Reliance.

Preparation

Rotation

screen

message

press

the

softkey.

For

line indicates

which

OPERATING
Operator

INSTRUCTIONS

Duties

Becolne falniliar with the chiller and related equiplnent
before operating the cNllel:

Prepare the system for start-up, start and stop the chiller.
and place the system in a shutdown condition.
Maintain a log of operating conditions and document any
abnormal readings.

CORRECT MOTOR ROTATION
IS CLOCKWISE WHEN VIEWED
THROUGH MOTOR SIGHT GLASS

3.
4.

Inspect the equipment, make routine adjustments,
fred
perform a Control Test. Maintain the proper oil and
refrigerant levels.

TO CHECK ROTATION, ENERGIZE COMPRESSOR MOTOR MOMENTARILY.
DO NOT LET MACHINE DEVELOP CONDENSER PRESSURE.
CHECK ROTATION IMMEDIATELY.

Protect the system from &image during shutdown periods.

Maintain the set point, time schedules,
functions.

ALLOWING CONDENSER PRESSURE TO BUILD OR CHECKING
ROTATION WHILE MACHINE COASTS DOWN MAY GIVE A FALSE
INDICATION DUE TO GAS PRESSURE EQUALIZING THROUGH COMPRESSOR.

Fig. 37 -- Correct

Motor

Prepare

Rotation

described

and other PIC HI

the Chiller for Start-Up -- Follow
in the Initial Start-Up section, page 67.

the steps

To Start the Chiller
Check

Chiller

Operating

Condition

-- Clleck to be
sure that chiller temperatures, pressures, water flows, find oil find
lefiigemnt levels indicate the system is functioning properly.

Instruct the Customer

Start the water pumps, if they are not automatic.

On the ICVC

-- Ensure the operator(s) understand all operating and maintenance procedures.
Point out the various chiller parts and explain their function as
pa-t of file complete system.
COOLER-CONDENSER--Float
chamber,
relief valves,
refrigerant charging valve, temperatme sensor locations, pressure transducer locations, Schmder fittings, waterboxes and
tubes, and vents find drains.
OPTIONAL
PUMPOUT
STORAGE
TANK AND PUMPOUT SYSTEM -- Transfer
vfdves find pumpout
system,
refrigerant
charging and pumpdown
procedme,
find relief
devices.

press

the _

stfu-t sequence will start. Follow the procedure described
in the Start-Up/Shutdown/Recycle
Sequence
section,
page 50.

Check the Running

System
-- After the compressor starts, the operator should monitor the ICVC display find
observe the parameters for normal operating conditions:
1. The oil reselaToir temperature
(49 C) during shutdown.

MOTOR COMPRESSOR
ASSEMBLY
-- Guide vane actuator: transmission, motor cooling system, oil cooling system,
temperature and pressure sensors, oil sight glasses, integral oil
pump, isolatable oil Iiltel; extra oil and motor temperature
sensol_, synthetic oil, find compressor serviceability.
MOTOR
COMPRESSOR
LUBRICATION
SYSTEM
-Oil pump, cooler filter, oil heatel: oil charge and specification,
operating and shutdown oil level, temperature and pressure,
and oil charging connections.
CONTROL SYSTEM--CCN
and LOCAL
start, reset,
menu, softkey functions, ICVC operation, occupancy schedule,
set points, safety controls, find auxiliay and optiomd controls.
sepmate

screen,

[_
soflkey to start the system. If the chiller is in the
OCCUPIED mode find the start timel_ have expired, the

Operator

AUXILIARY
EQUIPMENT-Disconnects,
trical sources, pumps, and cooling towel:

default

CHECK OPERATOR KNOWLEDGE-Stm-t, stop, and
shutdown procedures, safety and operating controls, refrigerant
and oil charging, and job safety.
REVIEW THE START-UP OPERATION,
AND MAINTENANCE MANUAL.
NOTE: Manufds find notebooks should not be stored under the
VFD power module as they will block airflow into the power
module cooling fan. Remove the manuals if they were placed
under the power module during shipping.
68

be above

120 F

The bearing oil temperature accessed on the COMPRESS
table should be 120 to 165 F (49 to 74 C) for compressors
using journal bemings, and up to 175 F (79 C) for Frame
3 compressors equipped with rolling element bemings. If
the bearing temperatme reads more than 180 F (83 C)
wifll the oil pump running, stop the chiller and determine
the cause of the high temperature. Do not restart the
chiller until corrected.

The oil level should be visible anywhere in one of the two
sight glasses. Foaming oil is acceptable as long as the oil
pressure and temperature are within limits.

The OIL PRESSURE should be between 18 and 30 psid
(124 to 207 kPad) differential, as seen on the ICVC
default screen. Typically the reading will be 18 to 25 psid
(124 to 172 kPad) at initial start-up. Typical values may
be up to 10 psid (69 kPad) higher for Frame 3 compressors equipped with rolling element bearings.

The moisture
motor cooling
dry condition.

The condenser pressure and temperature varies with the
chiller design conditions.
Typically the pressure will
range between 60 and 135 psig (390 to 950 kPa) with a
corresponding
temperature range of 60 to 105 F (15 to
41 C). The condenser entering water temperature should
be controlled
below the specified
design entering
water temperature
to save on compressor
kilowatt
requirements.

Cooler pressure and temperature also will vary with the
design conditions. Typical pressure range will be between
60 and 80 psig (410 and 550 kPa), with temperature
ranging between 34 find 45 F (1 and 8 C).

elec-

DESCRIBE CHILLER CYCLES -- Refi'igerant, motor cooling, lubrication, and oil reclaim.
REVIEW MAINTENANCEScheduled, routine, and extended shutdowns, importance of a log sheet, importance of
water treatment and tube cleaning, and importance of maintaining a leak-free chiller
SAFETY DEVICES AND PROCEDURES
-- Electrical disconnects, relief device inspection,
and handling refrigerant.

should

indicator sign glass on the refrigerant
line should indicate refrigerant flow and a

8. Thecompressor
mayoperate
atfull capacity
fora short
timeafterthepulldown
ramping
hasended,
eventhough
thebuilding
loadis sm_dl.
Theactiveelectric_d
demand
setting
canbeoveMdden
tolimitthecompressor
[kW.or
thepulldown
rotecanbedecreased
to avoida high
demand
chaisefor theshortperiodof highdemand
operation.
Pulldown
ratecanbebased
onloadrateor
temperature
rateandis accessed
ontheEQUIPMENT
SERVICEscreen,RAMPDEM table (N_ble4,
Example
21).
To Stop the Chiller
The occupancy
schedule starts and stops the chiller
automatically once the time schedule is configured.

By pressing the STOP button for one second, the alarm
light blinks once to confirm the button has been pressed.
The compressor will then follow the normal shutdown
in the Shutdown
Sequence,
Sequence section, page 50.

Manual

is diagnosed

After Limited

Shutdown-No speci_d preparations
should be necessary. Follow the regular preliminary checks and
starting procedures.
for Extended Shutdown -- The refrigerant should be transferred into the pumpout storage tank (if
supplied; see Pumpout and Refiigermlt Transfer Procedures) to
reduce chiller pressure and the possibility of leaks. Maintain a
holding ch;uge of 5 to 10 lb (2.27 to 4.5 kg) of refrigerant or
nitrogen to prevent air from leaking into the chillel:

It is possible to

NOTE: Manual control mode overrides the configured pulldown ramp rate during st;ut-up and permits the guide vanes to
open at a faster rate. The PIC lII controls will close the guide
vanes if the motor current exceeds the ACTIVE DEMAND
LIMIT or capacity override limits. The guide vanes will
_flso close if the chilled water temperature falls below the
CONTROL POINT. For descriptions of capacity overrides and
set points, see the Controls section.

If freezing temperatures
;u'e likely to occur in the chiller
area, drain the chilled watel: condenser watel; and the pumpout
condenser water circuits to avoid freeze-up. Keep the waterbox
drains open.
Leave the oil ch;uge in the chiller with the oil heater and
controls energized to maintain the minimum oil reservoir
temperature.

Refrigeration Log-

A refrigeration
log (as shown in
Fig. 38), is a convenient checklist for routine inspection and
maintenance
and provides a continuous
record of chiller
performance. It is also an aid when scheduling routine maintenance and diagnosing chiller problems.

-- Ensure the water sys-

tem drains ;u'e closed. It may be advisable to flush the water
circuits to remove any soft rust which may have formed. This
is a good time to brash the tubes and inspect the Schrader
fittings on the waterside flow devices for fouling, if necessary.
Check the cooler pressure on the ICVC default screen
compare it to the original holding charge that was left in
chillel: [f (after adjusting for ambient temperature changes)
loss in pressure is indicated, check for refrigerant leaks.
Check Chiller Tightness section, page 53.

Guide Vane Operation

Similarly. the TARGET VFD SPEED can be manu;dly set
in the COMPRESS screen. The target value is still limited to be
between configured
VFD MINIMUM
SPEED and VFD
MAXIMUM SPEED. Once speed is manually set in this mannel, capacity control changes are directed to modulate the
guide vanes.

Preparation

Shutdown

When the entering con-

manually operate the guide vanes in order to check control
operation or to control the guide vanes in an emergency. Manu;d operation is possible by overriding the tinget guide vane
position. Access the COMPRESS
screen on the ICVC and
scroll down to highlight TARGET GUIDE VANE POS. To
control the position, use the [INCREASE]
or [DECREASE]
softkey to adjust to the percentage of guide vane opening that is
desired. Zero percent is fully closed; 100% is fully open. To
release the guide vanes to automatic
control, press the
[RELEASEJ softkey.

l an
IMPORTANT:
isolating knifeDoswitch.
not attempt
High to
intensity
stop thearcing
chiller may
by opening
occm:
Do not restart the chiller until the problem
and corrected.

Operation-

denser water temperature drops very low. the operator should
automatically
cycle the cooling tower fans off to keep the
temperature up. Piping may ;dso be arranged to bypass the
cooling towel: The PIC llI controls have a low limit tower fan
output that can be used to assist in this control (terminals 5 and
6 on the TB2 haz;udous voltage field wiring terminal strip).

The chiller will not restmt until the _
or
softkey is pressed. The chiller is now in the OFF control
mode.

After Extended

C;uefully make all legular preliminary and running system
checks. Perform a Control Test before start-up. If the compressor oil level appears abnormally
high, the oil may have
absorbed refrigerant. Ensme that the oil temperatme is above
140 F (60 C) or above the cooler refrigerant temperature plus
50 ° F (27 ° C).

Cold Weather

sequence
as described
Start-Up/Shutdown/Recycle

Recharge the chiller by transferring refrigerant from the
pumpout storage tank (if supplied). Follow the Pumpout and
Refrigerant Transfer Procedures
section, page 71. Observe
freeze-up precautions.

Keep a record of the chiller pressmes, temperatures, and liquid levels on a sheet similar to the one in Fig. 38. Automatic
recording of PIC [II data is possible by using CCN devices
such as the Data Collection module and a Building Supervisol:
Contact a C_urier representative for more information.

and
the
any
See

REFRIGERATION
Plant

LOG CARRIER 19XRV HERMETIC CENTRIFUGAL

MODEL NO.

DATE

SERIAL NO.

COOLER

CONDENSER
Water

Refrigerant
TIME

Refrigerant

Temp

Out

InTemPout Press.

Temp

In PressUreout
GPM

VFD

Oil
Thrust

GPM

MACHINE

MOTOR RLA

COMPRESSOR
Water

Pressure
Press.

REFRIGERATION

InTemPout

BearingTemp
Pressure

SumPTemp
Level

Fig. 38 -- Refrigeration Log

Average
Line

Line

Average
Load

Current

Voltage

Kilowatts

Current

Inverter
Temp

Rectifier
Temp

VFD
Coolant
Flow

OPERATOR
INITIALS

REMARKS

PUMPOUT AND REFRIGERANT
TRANSFER
PROCEDURES
Preparation

-- The 19XRV chiller

TO READ
1.

COllie

equipped
wifll an optional pumpout storage tank, pumpout system, or
pumpout compressol: The refrigerant can be pumped for service work to either the chiller compressor vessel or chiller condenser vessel by using the optional pumpout system. If a
pumpout storage tank is supplied, the refrigerant can be isolaed in the storage tank. The following procedures describe
how to transfer refrigerant from vessel to vessel and perfonn
chiller evacuaions.
lllay

Pumpout

Unit

pumpout

To determine
pumpout
storage
vacuum
-0-400 psi (-101-0-2769
file storage tank.

Refer to Fig.
numbers.

30,

31,

and

vessel

(Fig.

for

valve

locations

_-::-_

CONTROL POWER
TRANSFORMER

PUMPOUT

COMPRESSOR
_
_

-- -- --HZ_'I
_ _

CRANKCASE

LEGEND
C
FU
GND
HTR
MTR
NC
OL
SS

6oVA

XFMR-1
HIGH PRESSURE
SAFETY

"_m

LOW

AUTO
-N-C-OP
SS-1
OFF ON _'_185-P

L_J'-I_|

PRESSURE

_9"-

NC_O-_SE-.>
OPEN 2 < _7 psia

HEATER

240-600v
27-40 WATT

CONTROL

E15.7
"6i_L

)<2

H.?Lin"
HG}jI

Fig. 39 -- Pumpout

and

PRESSURE
CHILLERS
WITH
STORAGE
In the Valve/Condition tables ilia accompany these
file letter "C" indicates a closed v_dve. Figures 9 and
locations of the valves.

20L

C_-----_-_-2 L ....

Always run chiller cooler and condenser waer pumps and
always charge or transfer refrigerant as a gas when chiller
vessel pressure is less than 35 prig (241 kPa). Below these
pressures, liquid refrigerant flashes into gas, resulting in
extremely low temperatures in the cooler/condenser
tubes
and possibly causing tube freeze-up.

--Oil

tank pressure,
a 30 in. Hg
kPa) gage is attached
to

should be visible in the pumpout unit compressor sight glass
under all operating conditions and during shutdown. If oil is
low. add oil as described under Optional Pumpout System
Maintenance
section, page 78. The pumpout unit control
wiring schematic is detailed in Fig. 39.

The ICVC dispkly on file chiller control panel is suitable
for determining
refrigerant-side
pressures
and low (soft)
vacuum.
To assure the desired range and accuracy
when
measuring
evacuation
and dehydration,
use a quality
vacuum
indicator
or manometel:
This can be placed on

POSITIVE
TANKS -instructions,
10 show the

Do not mix lefrigerants
from chillers that use different
compressor oils. Compressor &image can result.

Optional

during

Transfer. addition, or removal of refrigerant in springisolated chillers may place severe stress on external piping
if springs have not been blocked in both up and down
directions.

During transfer of refrigerant into and out of the optional
storage tank, carefully monitor the storage tank level gage.
Do not fill the tank more than 90% of capacity to _fllow for
refrigerant expansion. Overfilling may result in dmnage to
the tank or personal injury.

the

PRESSURES

file Schrader
connections
on each
removing
the pressure
transducel:

Always run the chiller cooler and condenser water pumps
and always charge or transfer refrigerant as a gas when the
chiller pressure is less than 35 psig (241 kPa). Below these
pressures, liquid refrigerant flashes into gas, resulting in
extremely low temperatures in the cooler/condenser
tubes
and possibly causing tube freeze-up.

Operating

REFRIGERANT

leak testing:

Unit Wiring
71

Schematic

---------

Contactor
Fuse
Ground
Heater
Motor
Normally Closed
Overload
Selector Switch

FRAME
ASSEMBLY

CONTROL
PANEL

Turn off tile pumpout

d.
e.

Turn off the chiller water pumps.
Close valves 3 and 4.

Open valves 2 and 5.

VALVE
CONDITION
VALVE
2_

VALVE
4_

_COMPRESSOR

VALVE /
5

ENTERING
WATER

/
LEAVING
WATER

Refrigerant

fiOl]l Pumpout

Equ_dize refligerant

Storage

Close pumpout and storage tank valves 2, 4, 5, and
10, and close refrigerant
charging valve 7; open
chiller isolation
valve 11 and any other chiller
isolation valves, if present.

water

pumps

and monitor

Open pumpout and storage tank
open chiller valves la and lb.
lb

2
C

4
C

5
C

valves

chiller

Transfer

watec

I a, I b, 2, 5, and 6.
lb
C

2
C

3
C

4
C

5
C

6
C

7
C

10
C

remaining

Turn off pumpout condenser watel:
the Refrigerant
from Chiller to Pumpout

Storage

pressure.

Valve positions:
la

2
C

4
C

5
C

7
C

10
C

water. Place valves in

3 and 6;

7
C

10
C

VALVE

Run the pumpout compressor
in automatic
mode
until vacuum switch is satisfied and compressor
stops. Close valves 7 and 10.

VALVE
CONDITION
c.
3.

3
C

Turn off the pumpout

Remove any remaining

4
C

7
C

10
C

compressor.

refrigerant.

a.
b.

Turn on chiller water pumps.
Turn on pumpout condenser watec

Place valves in the following

positions:

Run the pumpout compressor until the chiller pressure reaches 35 psig (241 kPa); then, shut off the
pumpout
compressor.
Warm
chiller
condenser
water will boil off any entrapped liquid refrigerant
and chiller pressure will rise.

refrigerant.
11

CONDITION

Close valve 5 and open valve 4. Turn off the
pumpout
condenser
water,
and turn
on the
pumpout
compressor
in manual
mode to push
liquid refrigerant out of the storage tank. Monitor
the storage tank level until the tank is empty.

Close refrigerant

charging

Transfer the remaining liquid.
a. Turn off pumpout condenser
the following positions:

b.
6

Slowly
open wflve 5 and refrigerant
charging
valves 7 and 10 to allow liquid refrigerant to drain
by gravity into the storage tank.

VALVE
CONDITION

Open valve 5 fully after the chiller pressure rises
above the freezing point of the refrigerant. Let the
storage tank and chiller pressure equalize. Open
refrigerant
charging
valve 7 and storage tank
charging valve 10 to let liquid refrigerant drain into
the chiller.

]la

Close valves

Gradually
crack open valve 5 to increase chiller
pressure to 35 psig (241 kPa). Slowly feed refrigerant to prevent freeze-up.

VALVE
CONDITION

10
C

VALVE
CONDITION

7
C

VALVE
CONDITION

pressure.

Turn on chiller
pressures.

la
C

condenser

Run the pumpout compressor in manual mode until
the storage tank pressure reaches 5 psig (34 kPa),
18 in. Hg vacuum (41 kPa absolute).
Turn off the pumpout compressor.

1. Equalize refrigerant

Tank to Chiller

4
C

Turn on pumpout

k.
Transfer
Tank

During transfer of refrigerant into and out of the 19XR
storage tank, carelhlly monitor the storage tank level gage.
Do not fill the tank more than 90% of capacity to allow for
refrigerant expansion. Overfilling may result in &image to
the tank and personal injury.

VALVE
CONDITION

3
C

CONDENSER

Fig. 40 -- Pumpout Unit
Transfer

VALVE
CONDITION

OIL
SEPARATOR

compressor.

When chiller pressure rises to 40 psig (276 kPa),
turn on the pumpout compressor
until the pressure
again reaches 35 psig (241 kPa), then, turn off the
pumpout compressor.
Repeat this process until the
chiller pressure no longer rises; then, turn on the
pumpout compressor and pump out until the chiller
pressure reaches 18 in. Hg vacuum (41 kPa absolute). This can be done in On or Automatic mode.

valves 7 and 10.

Close valves

VALVE
CONDITION
4.

la
C

I a, I b, 3, 4, and 6.
lb
C

2
C

3
C

4
C

5
C

6
C

7
C

10
C

g. Turn off the pumpout condenser water.
Establish vacuum for service. To conserve refrigerant,
operate the pumpout compressor as described in Step 3e
until the chiller pressure is reduced to 18 in. Hg
vacuum (41 kPa absolute).

All Refrigerant

1. Push lefrigemnt

to Chiller

Condenser

into chiller condenser

Turn on the chiller
chiller pressure.

Valve positions:

water

Vessel

Valve positions:

and monitor

the

11
in the chiller

Equalize the refrigerant
condenseE

Turn off chiller water
denser water supply.

Turn on pumpout compressor
the chiller cooler vessel.

When all liquid has been pushed into the chiller
condenser vessel, close the cooler refrigerant isolation valve (11 ).

Turn on the chiller water pumps.

Turn off the pumpout

pumps

cooler

and pumpout

and

Turn on pumpout compressor
out of the chiller condenser.

When all liquid is out of the chiller condenser.
close valve 11 and any other liquid isolation valves
on the chiller.

Turn off the pumpout

Run pumpout compressor
until the chiller cooler
vessel pressure reaches 18 in. Hg vacuum (41 kPa
absolute). Monitor pressures on the chiller control
panel and on refrigerant gages.
This operation can be done in Automatic
or On
mode. In Automatic
mode, the compressor
will
stop automatically
at approximately
15 in. Hg
vacuum (51 kPa absolute).

water.

Turn off pumpout
Turn off chiller
compressoc

Transfer

All Refrigerant

1. Push lefiigemnt

condenser
water

pumps

to Chiller

vessel.

3 and 4

11
C

Tnrn on pumpout

Run the pumpout compressor
until the chiller condenser reaches 18 in. Hg vacuum (41 kPa absolute)
in Manual or Automatic mode. Monitor pressure at
the chiller control panel and refrigerant gages.
Close valve lb.

Turn off pumpout

Close valves

condenser

water.

compressor.

la, 2, and 5.

11
C

Turn off pumpout

condenser

water.

Turn off chiller water pumps and lock out chiller
compressoE
Refrigerant to Normal Operating Conditions

Turn on chiller water pumps.

Open valves la, lb, and 3.
_

11
C

Crack open valve 5, gradually increasing pressure in the
evacuated chiller vessel to 35 psig (241 kPa). Feed refiigerant slowly to prevent tube freeze-up.

Leak test to ensure chiller vessel integrity.

Open v_dve 5 fully.
CONDITION
VALVE

11
C

compressol:

e. Turn off pumpout compressor.
f. Close valves lb, 3, and 4.

con-

to push refrigerant

Make sure that liquid line service valves
are closed and valves 2 and 5 are open.

CONDITION
VALVE

d. Close valve la.

and

1. Be sure that the chiller vessel that was opened has been
evacuated.

11
c

Turn on pumpout

and pumpout

Return

VALVE
CONDITION

pumps

cooler

Turn on chiller water pumps.

5; open

VALVE

condenser

water

in the chiller

CONDITION

Turn off chiller
denser water.

h.
2 and

the

CONDITION
VALVE

compressor.

and monitor

Equalize the refrigerant
condensel:

con-

to push liquid out of

Evacuate gas from chiller cooler vessel.
a. Close liquid line service valves
valves 3 and 4.

pumps

CONDITION
VALVE
CONDITION
VALVE

water

Evacuate gas from chiller condenser

vessel.

pumps

Turn on the chiller
chiller pressure.

VALVE
CONDITION

This operation can be done in Automatic or On mode.
In Automatic mode, the compressor will stop automatically at approximately
15 in. Hg vacuum (51 kPa
absolute).
CH[LLERS WITH ISOLATION VALVES -- Tile valves referred to in the following instructions are shown in Fig. 31 and
40. Valve 7 remains closed.
Transfer

11
C

Close valves la, lb, 3, and 5.

Open chiller isolation
valves, if present.

valve

11 and any other isolation

watel:
and lock out chiller

CONDITION
VALVE
Turn off chiller

Cooler Vessel

into the chiller cooler vessel.

11
water

pumps.

DISTILLING THE REFRIGERANT

Adding

2. Equalize the refl'igerant pressure.
a. Turn on chiller water pumps and monitor chiller
pressures.
b. Close pumpout and storage tank valves 2, 4, 5, and
10, and close chiller charging valve 7; open chiller
isolation valve 11 and any other chiller isolation
valves, if present.
c. Open pumpout and storage tank valves 3 and 6;
open chiller valves la and lb.
VALVE
CONDITION

2
C

4
C

5
C

7
C

10
C

Gradually
crack open valve 5 to increase chiller
pressure to 35 psig (241 kPa). Slowly feed refrigerant to prevent freeze-up.

Open valve 5 fully after the chiller pressure rises
above the freezing point of the refrigerant. Let the
storage tank and chiller pressure equalize.

the procedures
Charge section, page 75.

de-

Always
use the compressor
pumpdown
function
in the
Control
Test table to turn on the cooler pump and lock out
the compressor
when transfen'ing
refrigerant.
Liquid refligemnt may flash into a gas and cause water in the heater
exchanger
tubes
to freeze
when
the chiller
pressure
is
below 35 psig (241 kPa) for HFC-134a,
resulting
in equipment damage.

Removing Refrigerant -- If the optional pumpout system is used, the 19XRV refrigerant charge may be transferred
to a pumpout storage tank or to the chiller condenser or cooler
vessels. Follow the procedures in the Pumpout and Refrigerant
Transfer Procedmes section when transferringrefrigerant from
one vessel to another:

Adjusting the Refrigerant Charge -- If the addition or removal of refrigerant is required to improve chiller
performance,
follow the procedures
Refrigerant Chmge section, page 75.

given

under

the Trim

Transfer remaining refrigerant.
a. Close valve 3.

Refrigerant Leak Testing -- Because HFC-134a refrigerantis above atmospheric pressure at room temperature,

b. Open valve 2.

leak testing can be performed with refrigerant in the chillel:
Use an electronic halide leak detector, soap bubble solution, or
ultrasonic leak detectol: Ensure that the room is well ventilated
and free from concentration of refrigerant to keep false readings to a minimum. Before making aW necessguy repairs to a
leak, transfer all refrigerant from the leaking vessel.

c.
d.

Turn on
Run the
pressure
(41 kPa

Turn off the pumpout

Close valves

Turn off pumpout

VALVE
CONDITION
4.

Refrigerant--Follow

scribed in Trim Refrigerant

1. Transfer the refligerant flom the chiller to the pumpout
storage tank as described in the Transfer the Refligerant
from Chiller to Pumpout Storage Tank section.

pumpout condenser water.
pumpout compressor
until the storage tank
reaches 5 psig (34 kPa), 18 in. Hg vacuum
absolute) in Manual or Automatic mode.

la
C

Leak Rate

-- It is recommended by ASHRAE that chillers
be taken off line immediately and repaired if the refrigerant
leak rate for the entire chiller is more than 10% of the operating
refrigerant charge per yegu:

compressor.

la, lb, 2, 5, and 6.

lb
C

condenser
2
C

3
C

4
C

In addition, Carrier recommends
that leaks totalling less
than the above rate but more than a rate of 0.1% of the total
chguge per yegu should be lepaired during annu_d maintenance
or whenever the refrigerant is transferred for other service
work.

water.
5
C

6
C

7
C

10
C

Test After Service,

Drain the contaminants
from the bottom of the storage
tank into a containel: Dispose of contaminants safely.

GENERAL

Repair,

or Major

Leak-

all the refrigerant has been lost or if the chiller has been opened
for service, the chiller or the affected vessels must be pressure
tested and leak tested. Refer to the Leak Test Chiller section to
perform a leak test.

MAINTENANCE

Refrigerant
Properties -- The standard refrigerant for
the 19XRV chiller is HFC-134a. At normal atmospheric
pressure, HFC-134a refrigerant will boil at -14 F (-25 C) and
must, therefore, be kept in pressurized containel.s or storage
tanks. The refrigerant is practically odorless when mixed with
air and is noncombustible at atmospheric pressure. Read the
Material Safety Data Sheet and the latest ASHRAE Safety
Guide for Mechanical Refrigeration to learn more about safe
handling of this refrigerant.

HFC-134a refrigerant
should not be mixed with air or
oxygen and pressurized for leak testing. In general, this
refrigerant should not be present with high concentrations
of air or oxygen above atmospheric pressures, because the
mixture can undergo combustion, which could result in
serious personal injury or death.

TESTING WITH REFRIGERANT TRACER -- Use an environmentally acceptable refrigerant as a tracer for leak test
procedures. Use dry nitrogen to raise the machine pressure to
leak testing levels.
TESTING WITHOUT REFRIGERANT TRACER -- Another method of leak testing is to pressurize with nitrogen only and
to use a soap bubble solution or an ultrasonic leak detector to
determine if leaks are present.

Refrigerant HFC-134a will dissolve oil and some nonmetallic materials, dq the skin, and, in heavy concentrations,
may displace enough oxygen to cause asphyxiation. When
handling this refrigerant, protect the hands and eyes and
avoid breathing fumes.

TO PRESSURIZE WITH DRY NITROGEN

Trim Refrigerant
Charge -- To reraove any excess refrigerant, follow the procednm in Transfer Refrigerant from
Chiller to Pumpout Storage Tank section, Steps la and b,
page 72.
Refer to the Trimming Refligerant Charge section on
page 66.

NOTE: Pressurizing with dU nitrogen for leak testing should
not be done if the full refiigerant charge is in the vessel
because purging file nitrogen is veU dill]cult.
1. Connect a copper tube fiom the pressure regulator on the
cylinder to the refligemnt charging valve. Never apply
full cylinder pressure to the pressurizing line. Follow the
listed sequence.
2. Open file charging valve fully.
3. Slowly open the cylinder regulating valve.
4. Observe the pressure gage on the chiller and close the
regulating valve when the pressure reaches test level. Do
not (,.w_,ed 140 psig (965 kPa).
5. Close the charging valve on the chiller. Remove the
copper tube if it is no longer mquimdi

WEEKLY

Check the Lubrication System -- Mark the oil level
on the reservoir sight glass, and observe the level each week
while the chiller is shut down.
If the level goes below the lower sight glass, check the oil
reclaim system for proper operation. If additional oil is
required, add it through the oil di'ain ch_u'gingwdve (Fig. 2). A
pump is required when adding oil against refrigerant pressure.
The oil charge for the 19XRV compressor depends on the
compressor Frmne size:
• Frame 2 compressor-8 gal (30 L)
• Frame 3 compressor-8 gal (30 L)
• Frame 4 compressor-10 gal (37.8 L)
• Frame 4 compressor with split ring diffuser -- 12 gal
(45 L)
• Frame 5 compressor -- 18 gal (67.8 L)
The added oil must meet Career specifications for the
19XRV. Refer to Changing Oil Filter and Oil Changes section
on page 76. Any additional oil that is added should be logged
by noting the amount and date. Any oil that is added due to oil
loss that is not related to service will eventually return to the
sump. It must be removed when the level is high.
An oil heater is controlled by the PIC III to maintain oil
temperature (see the Controls section) when the compressor is
off. The ICVC COMPRESS screen displays whether the heater
is energized or not. The heater is energized if the OIL HEATER
RELAY p_umneter reads ON. [f the PIC III shows that the
heater is energized and if the sump is still not heating up, the
power to the oil heater may be off or the oil level may be too
low. Check the oil level, the oil heater contactor voltage, and oil
heater resistance.

Repair

the Leak, Retest, and Apply Standing
After pressurizing tile chiller, test for
leaks with an electronic halide leak detectok soap bubble
solution, or an ultrasonic leak detector. Bring the chiller back to
atmospheric pressure, repair a W leaks found, and retest.
After retesting and finding no leaks, apply a standing
vacuum test. Then dehydrate the chiller. Refer to the Standing
Vacuum Test and Chiller Dehydiation section (pages 55 and
58) in the Before [nitial Start-Up section.

Vacuum Test-

Checking Guide Vane Linkage -- When the chiller
is off. the guide vanes are closed and the actuator mechanism is
in the position shown in Fig. 41. [f slack develops in the diive
chain, do the following to eliminate backlash:
1. With the chiller shut down and the actuator fl.dly closed,
remove the chain guard and loosen the actuator bracket
holddown bolts.
2. Loosen guide vane sprocket adjusting bolts.
3. PU bracket upwards to remove slack, then mtighten the
bracket holddown bolts.
4. Retighten the guide vane sprocket adjusting bolts. Ensure
that the guide vane shaft is rotated fully in the clockwise
direction in order close it fully.

The PIC 1II does not permit compressor start-up if the oil
temperature is too low. The PIC III continues with start-up only
after the temperature is within allowable limits.

3
ACT
SPROCKET

VANE
ACTUATOR

SCHEDULED

CHAIN
GUARD

Service
Ontime
-- The [CVC will display a SERVICE
ONTIME value on the MAINSTAT screen. This value should
be reset to zero by the service person or the operator each time
major service won is completed so that the time between
service can be viewed and tracked.

VANE
SPROCKET

GUIDE VANE SPROCKET
ADJUSTING BOLTS

Fig. 41 --Guide

MAINTENANCE

Establish a regular maintenance
schedule based on actual
chiller requirements such as chiller load, run hours, and water
quality. The time inteia'als listed in this section an" o_'red as
guides to sem'i_z" onh"

BRACKET
HOLDDOWN
BOLTS

VANE
SHAFT

MAINTENANCE

Vane Actuator Linkage

Inspect the Control

Panel -- Maintenance consists of
general cleaning and tightening of connections. Vacuum the
cabinet to eliminate
dust build-up. If the chiller control
malfunctions,
refer to the Troubleshooting
Guide section for
control checks and adjustments.

Oil Specification

-- If oil is added, it must meet the following Carrier specifications:
Oil Type for units using R-134a

..................
Inhibited
polyolester-based
synthetic
compressor oil formatted for
use with HFC, gear-driven,
hermetic compressors.

ISO Viscosity Grade .................................

Ensure power to the control center is off when cleaning and
tightening connections inside the control p_mel. Failure to
disconnect power could result in electrocution.

The polyolester-based
oil (P/N: PP23BZI03)
ordered from a local Carrier representative.

68
may

Oil Changes--Cmrier
Check

Safety

and

Operating

recommends
changing the oil
after the first year of operation and every three to five years
thereafter as a minimum in addition to a yedy oil amdysis.
Howevel: if a continuous oil monitoring system is functioning
and a yearly oil analysis is performed, file time between oil
changes can be extended.
TO CHANGE THE OIL

Controls

Monthly
Table
tion,
least
Table

-- Check values of monitored
parameters
(see
6 for safety control settings). To ensure chiller protecthe Automated
Control Test should be performed at
once per month (with machine in OFF mode). See
12 for Control Test functions.

1. Transfer the refrigerant into the chiller condenser vessel
(for isolatable vessels) or to a pumpout storage tank.

Changing

Oil Filter--Change
the oil filter on a
yearly basis or when the chiller is opened for repairs. The
19XRV chiller has an isolatable oil filter so that the filter
may be changed
with the refrigerant
remaining
in the
chiller. Early 19XRV compressors
were designed with the
oil filter housing attached to the oil pump. The following
procedure applies to later 19XRV compressors
which have
the oil filter separate flom the oil pump.
1. Ensure the compressor
compressor is open.

is off and the disconnect

Disconnect

Close the oil filter isolation valves located behind power
panel on top of oil pump assembly.
Close the isolation valves located on both ends of the oil
filtel: Have rags and a catch basin available to collect oil
spillage.

the power to the oil pump.

Equfdize the filter's higher internal pressure to ambient
by connecting an oil charging hose to the Schmder valve
on the oil filter housing. Collect the oil-refrigerant
mixture which is dischm'gedi

Remove the oil filter assembly by loosening the hex nuts
on both ends of the filter assembly.

Insert the replacement tilter assembly with the rerow on
the housing pointing away from the oil pump.

Rotate the assembly so that the schraeder drain vfflve is
oriented fit the bottom, and tighten the connection nut on
each end to a torque of approximately 30 ft-lb (41 N-m)

Evacuate the filter housing by placing a vacuum pump on
the charging valve. Follow the normal evacuation procedures. Shut the charging valve when done and reconnect
the valve so that new oil can be pumped into the filter
housing. Fill with the stone amount that was removed;
then close file charging valve.

10.

Remove the hose from the chmging valve, open the isolation valves to the filter housing, and turn on the power to
the pump and the motol:

Open file control and oil heater circuit breakel:

Change the oil filter fit this time. See Changing
section.

Oil Filter

Change the refrigerant filter fit this time, see the next
section, Refrigerant Filtec

Charge the chiller with oil. Chmge until the oil level is
equal to the oil level marked in Step 2. Turn on the power
to the oil heater and let file PIC [II warm it up to fit least
140 F (60 C). Operate the oil pump manually, using the
Control Test function, for 2 minutes. For shutdown conditions, the oil level should be full in the lower sight glass.
If the oil level is above 1/2 full in the upper sight glass,
remove the excess oil. The oil level should now be equal
to the amount shown in Step 2.

Refrigerant Filter

-- A refrigerant filter/driel, located on
the refrigerant cooling line to the motol; should be changed
once a ye;u or more often if filter condition indicates a need for
more frequent replacement. Change the filter by closing the
filter isolation valves (Fig. 4) and slowly opening the flare
fittings with a wrench and back-up wrench to relieve the pressure. A moisture indicator sight glass is located beyond this
filter to indicate the volume and moisture in the refrigerant. If
the moisture indicator indicates moisture, locate the source of
water immediately by performing a thorough leak check.

The oil filter housing is at a high pressure. Relieve this
pressure slowly. Failure to do so could result in serious personal injury.
9.

Mark the existing oil level.

4. When the chiller pressure is 5 psig (34 kPa) or less, drain
the oil reservoir by opening the oil charging vfdve
(Fig. 2). Slowly open the valve against refrigerant
pressure.

for the

Oil Reclaim Filter--The

oil reclaim
system has a
strainer on file eductor suction line, a strainer on the discharge
pressure line, and a filter on the cooler scavenging
line.
Replace file filter once per year or more often if tilter condition
indicates a need for more frequent replacement. Change the
filter by closing the filter isolation valves and slowly opening
the flare fitting with a wrench and back-up wrench to relieve
the pressure. Change the stminel_ once every 5 yeal_ or whenever refrigerant is evacuated from the coolel:

VFD Refrigerant

Strainer -- A t_efiigerant strainer is
located in the 5/8 in. line that supplies refiigerant to the VFD.
The strainer should be replaced once a year or more often if the
str;dner condition indicates a need for mote ft_equent replacement. Change the filter by closing the refrigerant cooling line
isolation valves. Refiigerant pressure can be relieved through
access valves on the strainer housing. Tighten 5/8 flare nuts to
55 to 66 ft-lb (75 to 89 Nm).
Inspect
inspection
service.

Refrigerant

Float System -every 5 years or when the condenser

1. Transfer the refrigerant into the cooler
pumpout storage tank.
2. Remove the float access covet:

signs of corrosion or scale. Replace a sensor or Schmder fitting
if corroded or remove any scale if found.
CONDENSER
AND OPTIONAL
FLOW DEVICES
-Since this water circuit is usually an open-type system, the
tubes may be subject to contamination
and scale. Clean the
condenser tubes with a rotmy tube cleaning system at least
once per yetu and more often if the water is contaminated.
Inspect the entering and leaving condenser water sensors and
flow devices for signs of corrosion or scale. Replace the sensor
or Schrader fitting if corroded or remove any scale if foundi

Perforln this
is opened for

Higher than normal condenser pressures, together with the
inability to reach full refiigeration load, usually indicate ditty
tubes or air in the chillet: If the refiigeration log indicates a rise
above normal condenser pressures, check the condenser refiigerant temperature against the leaving condenser water temperature. If this reading is more than what the design difference is
supposed to be, the condenser tubes may be ditty or water flow
may be incorrect. Because HFC-134a is a high-pressure refiigetant, air usually does not enter the chiller

vessel or into a

Clean the chamber and valve assembly thoroughly.
sure the valve moves fieely. Ensure that all openings
fiee of obstructions.

Examine the cover gasket and replace if necessmy.

Be
are

During the tube cleaning process, use brushes specially
designed to avoid scraping and scratching
the tube wall.
Contact a Carrier representative to obtain these brushes. Do not
use wire brushes.

See Fig. 42 for a view of the float v_dve design. For linear
float valve designs, inspect the orientation of the float slide pin.
It must be pointed toward the bubbler tube for proper operation.

Inspect Relief Valves and Piping -- The relief v_dves
on this chiller protect the system against the potentially dangerous effects of overpressure. To ensure against dalnage to the
equipment and possible injury to personnel, these devices must
be kept in peak operating condition.
As a minimum, the following maintenance is required.

Hard scale may require chemic_d treatment for its prevention or removal. Consult a water treatment specialist for
proper treatment.

1. At least once a yeat: disconnect the vent piping at the
valve outlet and catefttlly inspect the valve body and
mechanism for any evidence of interned corrosion or rest,
dirt, sc_de, leakage, etc.
2.

If corrosion or foreign material is found, do not attempt to
repair or recondition. Replace the valve.

If the chiller is installed in a corrosive atmosphere or the
relief v_dves ate vented into a corrosive atmosphere,
inspect the relief valves at more fiequent intervals.

Compressor

Bearing

and Gear Maintenance

Water Leaks -- The refiigerant

moisture indicator on the
refiigetant motor cooling line (Fig. 2) indicates whether there
is water leakage during chiller operation. Water leaks should be
repaired immediately.

The chiller must be dehydi'ated after repair of water leaks.
See Chiller Dehydi'ation section, page 58.

The key to good bearing and gear maintenance
is proper
lubrication.
Use the proper grade of oil, maintained
at
recommended
level, temperature,
and pressure. Inspect the
lubrication system regularly and thoroughly.
Excessive beating were can sometimes be detected through
increased vibration or increased beating temperature. Gears
and babbitted joumal and thrust bearings should be exalnined
approximately every five years for signs of wear based on the
results of the annual oil analysis. To inspect the bearings, a
complete compressor teatdown is required. Only a trained setvice technician should remove and examine the bearings. The
fiequency of exalnination is determined by the hours of chiller
operation, load conditions during opetafion, and the condition
of the oil and the lubrication system. Rolling element bearings
(Frmne 3 compressor high speed shaft only) cannot be field inspected; excessive vibration is the primary sign of wear or
damage. If either symptom appems, contact an experienced
and responsible service organization for assistance.

Inspect the Heat
Devices

Exchanger

Tubes

and Flow
8
LEGEND

COOLER AND OPTIONAL FLOW DEVICES -- Inspect and
clean the cooler tubes at the end of the first operating season.
Because these tubes have internal ridges, a rotary-type tube
cleaning system is needed to fully clean the tubes. Inspect
the tubes' condition to determine the scheduled frequency for
future cle_ming and to determine whether water treatment in the
chilled water/brine circuit is adequate. Inspect the entering and
leaving chilled water temperature sensors and flow devices for

1
2
3
4
5
6
7
8

---------

Refrigerant Inlet from FLASC Chamber
Linear Float Assembly
Float Screen
Bubble Line
Float Cover
Bubble Line Connection
Refrigerant Outlet to Cooler
Gasket

Fig. 42 -- 19XRV Float Valve Design
77

Water Treatment--Untreated

or improperly
treated
water may result in corrosion, scaling, erosion, or algae. The
services of a qu_dified water treatment specialist should be
obtained to develop and monitor a treatment program.

fittings. Comptue the two readings. If there is a difference in
readings, the transducer can be calibrated as described in the
Troubleshooting
Guide section. Oil differential pressure (OIL
PUMP DELTA P on the COMPRESS
screen) should be zero
whenever the compressor is off.

Optional

Pumpout System Maintenance
-- For
pumpout unit colnpressor
maintenance
details, refer to the
19XR Positive Pressure Stolage System Installation, Start-Up,
and Service Instructions.

Water must be within design flow limits, clean, and treated
to ensure proper chiller performance and reduce the potential of tube &image due to corrosion, scaling, erosion, and
algae. CtuTier assumes no responsibility for chiller &image
resulting from untreated or improperly treated watec

Inspect

OPTIONAL PUMPOUT COMPRESSOR
OIL CHARGE -Use oil conforming to Carrier specifications
for reciprocating compressor
usage. Oil requirements
are as follows:
ISO Viscosity ................................
Cturier Pfut Number. ...........

the VFD

68 or 220
PP23BZ 103 or PP23BZ104

The total oil chtuge is 13 oz. (0.5 L)
Oil should be visible in the pumpout compressor sight glass
both during operation and at shutdown. Always check the oil
level before operating the pumpout compressol: Before adding
changing oil, relieve the refrigerant pressure through the access
valves.

The motor leads must be disconnected from the starter
before an insulation test is performed. The voltage
generated from the tester can &_mage the starter o1 drive
components.

Relieve refrigerant
follows:

pressure and add oil to the pumpout unit

1. Close service v_dves 2and4.

Before working on tiny st_uter or drive, shut off the chillel:
open and tag all disconnects supplying power to the stfulec
After disconnecting
input power to a VFD and before
touching tiny internal components,
wait five minutes for
the DC bus capacitors to discharge, then check the voltage
with a voltmetel: Failure to observe this precaution could
result in sever bodily injury or death.

Run the pumpout compressor in Automatic mode for one
minute or until the vacuum switch is satisfied and compressor shuts off.

Move the pumpout selector switch to OFE Pumpout
compressor shell should now be under vacuum.

Oil can be added to the shell with a hand oil pump
through the access valve in the compressor base.

NOTE: The compressor access valve has a self-sealing fitting
which will require a hose connection with a depressor to open.
OPTIONAL
PUMPOUT SAFETY CONTROL
SETTINGS
(Fig. 43)--The
optional pumpout
system high-pressure
switch opens fit 185 psig (1276 kPa) and closes fit 140 psig
(965 kPa). Check the switch setting by operating the pumpout
compressor
and slowly throttling the pumpout condenser
water

The disconnect on the st_uter fiont panel does not deenergize all internal circuits. Open all internal and remote
disconnects before servicing the sttutel:

Never open isolating knife switches while equipment is
operating. Electrical arcing can cause serious injury.

Ordering

Replacement

Chiller

Parts

When

ordering Carrier specified parts, the following information
must accompany tin order:
• chiller model number and serial number
• name, quantity, and part number of the part required
• delivery address and method of shipment.

Periodically vacuum or blow off accumulated debris on internal VFD enclosure components with a high-velocity, lowpressure blowec
Power connections
on newly installed VFDs may relax
and loosen after a month of operation. Turn power off and
retighten. Recheck annually thereafter.

CONTACTOR

TERMINAL
STRIP

SWITCH
FUSES

\
Loose power connections can cause voltage spikes,
heating, m¢fllimctioning, or failures.

over-

Recalibrate

Pressure Transducers -- Once a yea1,
the pressure transducers should be checked against a pressure
gage reading. Check all eight transducers: the 2 oil differenti_fl
pressure transduco_,
the condenser pressure transducer, the
cooler pressure transduce1: the diffuser pressure transducer
(only for compressors equipped with split ring diffusers), and
the optional wato_ide pressure transducer pairs (consisting of
4 flow devices: 2 cooler. 2 condenser).
Note the evaporator and condenser pressure readings on the
HEAT EX screen on the ICVC (EVAPORATOR PRESSURE
and CONDENSER
PRESSURE).
Attach an accurate set of
refrigeration
gages to the cooler and condenser
Schmder

TRANSFORMER

Fig. 43 --

Pumpout

Control

Box (Interior)

TROUBLESHOOTING
GUIDE
(Tables 15-18B)

RESISTANCE
CHECK -- Turn off the control power and,
fi_)m the module, disconnect the terminal plug of the sensor in
question. With a digital ohmmetel: measure sensor resistance
between receptacles as designated by the wiring diagram. The
resistance
and corresponding
temperature
are listed in
Table 18A or 18B. Check the resistance of both wires to
ground. This resistance should be infinite.

Overview-

The PIC III has many features to help tile
operator and technician troubleshoot a 19XRV chiller
•
•

The ICVC shows the chiller's
actual operating conditions and can be viewed while the unit is running.
The ICVC default screen freezes when an alarm occurs.

VOLTAGE DROP -- The voltage drop across any energized
sensor can be measured with a digital voltmeter while the
control is energized. Table 18A or 18B lists the relationship
between temperature
and sensor voltage drop (volts dc
measmed across the energized sensor). Exercise ctue when
measuring voltage to prevent damage to the sensor leads,
connector plugs, and modules. Sensors should also be checked
at the sensor plugs. Check the sensor wire at the sensor for
5 vdc if the control is powered on.

The freeze enables the operator to view the chiller conditions at the time of alarm. The STATUS screens continue
to show current information.
Once all alarms have been
cleared

•

(by correcting
the problems
and pressing the
softkey), the ICVC default screen returns to
normal operation.
The CONTROL ALGORITHM
STATUS screens (which
include
the CAPACITY.
OVERRIDE,
LL_MAINT.
VFD_HIST.
LOADSHED,
CUR_ALARM,
WSMDEFME, and OCCDEFCM
screens) display information
that helps to diagnose
problems
with chilled
water
temperature
control, chilled water temperature
control
overrides,
hot gas bypass, surge algorithm
status, and
time schedule operation. See Table 15.
The control test feature facilitates the proper operation
and test of temperature
sensors, pressure transducers, the
guide vane actuator,
oil pump, water pumps, tower
control, and other on/off outputs while the compressor
is
stopped. It also has the ability to lock off the compressor
and turn on water pumps for pumpout operation.
The
ICVC shows the temperatures
and pressures
required
during these operations.
From other SERVICE tables, the operator/technician
can
access configured
items, such as chilled water resets,
override set points, etc.
If an operating fault is detected, an alarm message is generated and displayed on the ICVC default screen. A more
detailed message -- along with a diagnostic message -is also stored into the ALARM HISTORY and ALERT
H[STORY tables.
Review the ALERT HISTORY table to view other less
critical events and abnormal conditions which may have
occurred. Compare timing of relevant alerts and alarms.

Checking

Display Messages--The

Relieve
all refrigerant
pressure
or &'ain the water before
replacing
temperature
sensors or thermowells
threaded
into
the refrigerant
pressure
boundary.
Failure to do so could
result in persomd injmy and equipment
damage.

CHECK SENSOR ACCURACY-Place the sensor in a
medium of known temperature and compare that temperatme
to the measured reading. The thermometer used to determine
the temperature of the medium should be of laboratory qu_flity
with 0.5 ° F (.25 ° C) graduations. The sensor in question should
be accurate to within 2 ° F (1.2 ° C).
See Fig. 7 for sensor locations. The sensors are immersed
directly in the refrigerant or water circuits. The wiring at each
sensor is easily disconnected
by unlatching the connectol:
These connectors allow only one-way connection to the sensol:
When installing a new sensor, apply a pipe sealant or thread
sealant to the sensor threads.
DUAL TEMPERATURE
SENSORS -- For servicing convenience, there are 2 sensol_ each on the beming and motor
temperature sensors. If one of the sensors is &_maged, the other
can be used by simply moving a wire. The number 2 terminal
in the sensor terminal box is the common line. To use the
second sensol: move the wire from the number I position to the
number 3 position.

first area to

check when troubleshooting the 19XRV is the ICVC display. If
the alarm light is flashing, check the primary and secon&wy
message lines on the ICVC default screen (Fig. 14). These
messages will indicate where the fault is occurring. These
messages contain the alarm message with a specified code.
This code or state appears with each alarln and alert message.
The ALARM and ALERT HISTORY tables on the [CVC
SERVICE menu also contains a message to further expand on
the fault description.
NOTE: The &_te format in these tables is MM/DD/YY.

Checking

Pressure
Transducers-There
are 6
factoly-installed
pressure transducers, with inputs available for
optional cooler and condenser watel.side differential pressure
transducers. The ICVC softwm'e will display a default reading
of 26 psi during start-up and operation. An additional transducer. factory inst;_lled in the bottom of the cooler barrel, will read
as EVAPORATOR
SATURATION TEMP on the HEAT_EX
DISPLAY screen. This provides additional protection against a
loss of water flow condition.
These pressure transducers can be calibrated if necessary. It
is not usually necessary
to calibrate at initial start-up.
However. at high altitude locations, it is necessmy to calibrate
the transducel.'s to ensure the proper refrigerant temperature/
pressure relationship. Each transducer is supplied with 5 vdc
power from the CCM. If the power supply fifils, a transducer
voltage reference alarm occurs. If the transducer reading is
suspected of being faulty, check the TRANSDUCER
VOLTAGE REF supply voltage. It should be 5 vdc _+.5v displayed in
CONTROL
TEST under CCM PRESSURE
TRANSDUCERS. If the TRANSDUCER
VOLTAGE REF is correct, the
transducer should be recalibrated or replaced.

For a complete list of possible _darm and alert messages, see
Table 15. If the alarm light starts to flash while accessing a
menu screen, press the _
softkey to return to the defimlt
screen to read the almm message. The STATUS screen can also
be accessed to determine where an alarm exists.
A "C" to the right ofa pammeter's value means that there is
a communications
fault on that channel.

Checking

Temperature Sensors --All
temperature
sensors are thermistor-type
sensors. This means that the
resistance of the sensor varies with temperature. All sensors
have the same resistance characteristics. If the controls m'e on,
determine sensor temperature by measuring voltage diop; if the
controls are powered off, detemfine
sensor temperature by
measuring resistance. Compare the readings to the values listed
in Table 18A or 18B.

Also check that inputs on CCM J5-1 through J5-6 have not
been grounded and are not receiving anything other than a 4 to
20 mA signal.

COOLER
CONDENSER
PRESSURE
TRANSDUCER
AND OPTIONAL
WATERSIDE
FLOW DEVICE CALIBRATION -- Calibration can be checked by compming the
plessme leadings from file transducer to an accurate refrigeration gage leading. These readings can be viewed or calibrated
from the HEAT_EX screen on the ICVC. The transducer can
be checked grad calibrated fit 2 pressure points. These calibration points me 0 psig (0 kPa) and between 25 and 250 psig
(173 and 1724 kPa). To calibrate these transducers:
1. Shut down the compressor,
NOTE: There
exchangers.

should

coolek and condenser

be no flow

through

high altitude

pumps.

Disconnect the transducer in question from its Schmder
fitting for cooler or condenser transducer calibration. For
oil pressure or flow device calibration keep transducer in
place.
NOTE: If the cooler or condenser
vessels are at
0 psig (0 kPa) or are open to atmospheric pressure, the
transducers can be calibrated for zero without removing the transducer from the vessel.

Access the HEAT_EX scleen and view the particular
transducer reading (the EVAPORATOR
PRESSURE
or
CONDENSER
PRESSURE parameter on the HEAT EX

Control

Table

15-

TABLE

If the transducer
value is not within the calibration
range, the transducer returns to the original reading. If
the pressure is within the allowed range (noted above),
check the voltage ratio of the transducer. To obtain the
voltage ratio, divide the voltage (dc) input from the
transducer
by the TRANSDUCER
VOLTAGE REF
supply voltage signal (displayed in CONTROL
TEST
menu in the PRESSURE
TRANSDUCERS
screen) or
measure
across the positive
(+ red) and negative
(- black) leads of the transducer.
For example,
the
condenser
transducer
voltage reference
is measured
fit CCM terminals J2-4 and J2-6, the condenser transducer voltage input. The input to reference
voltage
ratio must be between 0.80 and 0.11 for the software to
allow calibration.
Pressurize
the transducer
until the
ratio is within range. Then attempt calibration again.
between

Checkout

Procedure

-- One

These maintenance
screens are very useful in helping to
determine how the control temperature is calculated and guide
vane positioned and also for observing the leactions from load
changes, control point overrides, hot gas bypass, surge prevention, etc. The tables are:

softkey. The value will now go to zero. No high end
calibration is necessary for OIL PRESSURE DELTA P or
flow devices.

point can fdso be calibrated

Algorithms

of the tables on the [CVC SERVICE menu is CONTROL
ALGORITHM
STATUS. The maintenance
screens may be
viewed from the CONTROL ALGORITHM
STATUS table to
see how a particulm control algorithm is operating.

HEAT_EX screen, and OIL PUMP DELTA P on the
COMPRESS
screen). It should read 0 psi (0 kPa). If the
reading is not 0 psi (0 kPa), but within _+5 psi (35 kPa),
the value may be set to zero by pressing the
softkey while the appropriate
transducer ptuameter
is
highlighted on the ICVC screen. Then press the

A high pressure

fok so the

is correct.

Be sure to use a back-up wrench on the Schrader fitting
whenever removing a transducek since the Schmder fitting
may back out with the transducek causing an uncontrolled
loss of refrigerant and possible injury to personnel.

screen). To calibrate oil pressure or liquidside flow
device, view the particular reading (CHILLED WATER
DELTA P and CONDENSER
WATER DELTA P on the

relationship

The PIC III does not allow calibration if the transducer is
too far out of calibration. In this case, a new transducer must be
installed and re-calibrated. If calibration problems are encountered on the OIL PRESSURE DELTA P channel, sometimes
swapping the compressor oil discharge pressure transducer and
the oil sump pressure transducer will offset an adverse transducer tolerance stack up and allow the calibration to proceed.
TRANSDUCER
REPLACEMENT
-- Since the transducers
are mounted on Schrader-type
fittings, there is no need to
remove refrigerant from the vessel when replacing the transducers. Disconnect the transducer winng. Do not pull on the
transducer wires. Unscrew the transducer from the Schmder
fitting. When instfdling a new transducer, do not use pipe sealer
(which can plug the sensor). Put the plug connector back on the
sensor and snap into place. Check for refi'igerant leaks.

the heat

locations must be compensated

chiller temperature/pressure

Capacity
Control

OVERRIDE

Override
Status
LEAD/LAG
Status
Time
Schedules
Status

OCCDEFCM

WSMDEFME

Water
System
Manager
Status

VFD HIST

VFD Alarm
History
Loadshed
Status

LOADSHED
CURALARM

calibrated by accessing the appropriate transducer pmameter on the HEAT_EX screen, highlighting the pm'ametek
pressing the _
softkey, and then using the

EXPANDED
NAME

CAPACITY

LL MAINT

and 250 psig (172.4 and 1723.7 kPa) by attaching a regulated 250 psig (1724 kPa) pressure (usually from a
nitrogen cylinder).
The high pressure point can be

Control

Current
Alarm Status

Algorithm

Status

Tables

DESCRIPTION
This tableshows all values used to
calculate the chilled water/brine
control point.
Details of all chilled water control
override values.
Indicates LEAD/LAG operation
status.
The Local and CCN occupied
schedules are displayed here to
help the operator quickly determine whether the schedule is in
the "occupied" mode or not.
The water system manager is a
CCN module that can turn on the
chiller and change the chilled water
control point, This screen indicates
the status of this system.
Displays VFD values at last fault.
DisplaysLeadshed (Demand Limit)
status.
Displays current chiller alarms.

Surge and hot gas bypass parameters may be observed in
the HEAT_EX screen. The surge and hot gas bypass control
algorithm status is viewed from tiffs screen. All values defiling
wifll this control are displayed.

[INCREASE 1 or [DECREASE]
softkeys to adjust the
vfdue to the exact pressure on the refrigerant gage. Press
the _
softkey to finish the calibration. Pressures fit

Control

Test -- The Control Test feature can check all the
thermistor temperature
sensors, pressure transducel_,
pumps
and their associated flow devices, the guide vane actuatol: and
other control outputs such as tower fans, VFD cooling
solenoid, shunt trip relay, oil heaters, alarm relay and hot gas
bypass. The tests can help to determine whether a switch is
defective or a pump relay is not operating, as well as other
useful n_ubleshooting
issues. During pumpdown operations,
the pumps _ue energized to prevent fieeze-up and the vessel
pressures and temperatures
ale displayed. The Pumpdown/
Lockout feature prevents compressor start-up when there is no
refiigerant in the chiller or if the vessels are isolated. The

Terminate Lockout feature ends the Pumpdown/Lockout
after
the pumpdown procedure is reversed and refrigerant is added.

LEGEND
CCN
CCM
DPI
ICVC
PIC III
TXV
VFD
VFG

---------

TO TABLES

16A-16J

Carrier Comfort Network
Chiller Control Module
Drive Peripheral Interface
International Chiller Visual Control
Product Integrated Controls III
Thermostatic Expansion Valve
Variable Frequency Drive
Variable Frequency (Drive) Gateway

Table 16 -- Alarm and Alert Messages
A. MANUAL STOP
PRIMARY MESSAGE

SECONDARY

MESSAGE

PROBABLE

CAUSE/REMEDY

MANUALLY STOPPED -- PRESS
TERMINATE PUMPDOWN MODE

CCN OR LOCAL TO START
TO SELECT CCN OR LOCAL

PIC III in OFF mode, press CCN or LOCAL softkey to start unit.
Enter the CONTROL TEST table and select TERMINATE LOCKOUT
to unlock compressor.

SHUTDOWN

IN PROGRESS

COMPRESSOR

UNLOADING

Chiller unloading before shutdown due to soft!stop feature.

SHUTDOWN

IN PROGRESS

COMPRESSOR

DEENERGIZED

Chiller compressor is being commanded
deenergized within one minute.

ICE BUILD
SHUTDOWN

READY

OPERATION
IN PROGRESS

COMPLETE

to stop. Water pumps are

Chiller shutdown from Ice Build operation.

RECYCLE RESTART PENDING

Chilled water temperature below recycle set point. Cooling load is
less than chiller minimum capacity.

TO START

PRIMARY MESSAGE

SECONDARY

MESSAGE

PROBABLE

UNOCCUPIED

READY TO START IN XX MIN

REMOTE CONTACT OPEN

Remote contacts are open. Close contacts to start.

READY TO START IN XX MIN

STOP COMMAND

Chiller START/STOP on MAINSTAT manually forced to stop. Release
SUPERVISOR force to start.

READY TO START IN XX MIN

OCCUPIED

READY TO START IN XX MIN

REMOTE CONTACT CLOSED

Chiller timer countdown complete. Unit will proceed to start. Remote
contact Enabled and Closed.

READY TO START IN XX MIN

START COMMAND

Chiller START/STOP on MAINSTAT manually forced to start. Release
SUPERVISOR force to start under normal control.

READY TO START IN XX MIN

RECYCLE RESTART PENDING

Chiller is recycle mode.

READY TO START

UNOCCUPIED

Time schedule for PIC III is unoccupied in OCCPC01S screen.
Chiller will start when state changes to occupied. Make sure the time
and date are correct in the TIME AND DATE screen.

READY TO START

REMOTE CONTACT OPEN

Remote contacts have stopped the chiller. Close contacts to start.

READY TO START

STOP COMMAND

Chiller START/STOP on MAINSTAT manually forced to stop. Release
SUPERVISOR force to start.

READY TO START

OCCUPIED

READY TO START

REMOTE CONTACT CLOSED

Chiller timer counting down. Unit ready to start.

READY TO START

START COMMAND

Chiller START/STOP on MAINSTAT has been manually forced to
start. Chiller will start regardless of time schedule or remote contact
status.

STARTUP INHIBITED

LOADSHED

IN RECYCLE

MODE

CAUSE/REMEDY

READY TO START IN XX MIN

Time schedule for PIC III is unoccupied. Chillers will start only when
occupied. Check OCCPCnnS and Holidays screens.

IN EFFECT

MODE

Chiller timer counting down. Unit ready to start.

IN EFFECT

MODE

IN EFFECT

MODE

Chiller timers countdown
IN EFFECT

IN EFFECT

is complete. Unit will proceed to start.

CCN Ioadshed module commanding

chiller to stop.

SHUTDOWN

PRIMARY MESSAGE

SECONDARY

RECYCLE RESTART

PENDING

OCCUPIED

RECYCLE RESTART

PENDING

RECYCLE RESTART
RECYCLE RESTART

MESSAGE

PROBABLE

MODE

CAUSE/REMEDY

Unit in recycle mode, chilled water temperature
above Setpoint to start.

is not sufficiently

REMOTE CONTACT CLOSED

Unit in recycle mode, chilled water temperature
above Setpoint to start.

is not sufficiently

PENDING

START COMMAND

Chiller START/STOP on MAINSTAT manually forced to start, chilled
water temperature is not sufficiently above Setpoint to start.

PENDING

ICE BUILD MODE

IN EFFECT

Chiller in ICE BUILD mode. Chilled water temperature
ICE BUILD conditions.

is satisfied for

Table

16 -- Alarm

and Alert Messages

(cont)

D. PRE-START ALERTS: These alerts only delay start-up. When alert is corrected, the start-up will continue. No reset is
necessary.
ICVC FAULT
STATE

PRIMARY
MESSAGE

SECONDARY
MESSAGE

PRIMARY CAUSE
compressor

ADDITIONAL
starts

CAUSE/REMEDY

100

PRESTART
ALERT

STARTS LIMIT
EXCEEDED

100_Excessive
(8 in 12 hours),

101

PRESTART
ALERT

HIGH BEARING
TEMPERATURE

101_Comp Thrust Brg Temp [VALUE]
exceeded limit of [LIMIT]*.

Check oil heater for proper operation.
Check for low oil level, partially closed oil supply valves, clogged oil filters.
Check the sensor wiring and accuracy.
Check Comp Thrust Brg Alert setting in
SETUP1 screen.

102

PRESTART
ALERT

HIGH MOTOR
TEMPERATURE

102-_Comp Motor Winding Temp
[VALUE] exceeded limit of [LIMIT]*.

Check motor sensors for wiring and accuracy.
Check motor cooling line for proper operation,
or restrictions.
Check for excessive starts within a short time
span.
Check Comp Motor Temperature Override
setting in SETUP1 screen.

103

PRESTART
ALERT

HIGH
DISCHARGE
TEMP

103_Comp
Discharge Temp [VALUE]
exceeded limit of [LIMIT]*.

Allow discharge sensor to cool.
Check sensor wiring and accuracy.
Check for excessive starts.
Check Comp Discharge Alert setting in
SETUP1 screen.

104

PRESTART
ALERT

LOW
REFRIGERANT
TEMP

104-_Evaporator Refrig Temp [VALUE]
exceeded limit of [LIMIT]*.

Check transducer wiring and accuracy.
Check for low chilled fluid supply
temperatures.
Check refrigerant charge.
Check Refrig Override Delta T in SETUP1
screen.

105

PRESTART
ALERT

LOW OIL
TEMPERATURE

105_Oil Sump Temp [VALUE]
exceeded limit of [LIMIT]*.

Check oil heater contactor/relay and power.
Check oil level and oil pump operation.

106

PRESTART
ALERT

HIGH
CONDENSER
PRESSURE

106_Condenser
Pressure [VALUE]
exceeded limit of [LIMIT]*.

Check transducer wiring and accuracy.
Check for high condenser water
temperatures.
Check high condenser pressure switch wiring.

107

PRESTART
ALERT

LOW LINE
VOLTAGE

107-_Percent Line Voltage [VALUE]
exceeded limit of [LIMIT]*.

Check voltage supply.
Check voltage transformers and switch gear.
Consult power utility if voltage is low.

108

PRESTART
ALERT

HIGH LINE
VOLTAGE

108_Percent
Line Voltage [VALUE]
exceeded limit of [LIMIT]*.

Check voltage supply.
Check power transformers.
Consult power utility if voltage is high.

109

PRESTART
ALERT

GUIDE VANE
CALIBRATION

109_Actual Guide Vane Pos
Calibration Required Before Startup.

Press STOP button on ICVC and perform
Guide Vane Calibration in Controls Test
screen.
Check guide vane actuator feedback
potentiometer.

110

PRESTART
ALERT

HIGH
RECTIFIER
TEMP

110_Rectifier
Temperature
exceeded limit of [LIMIT]*.

Check that VFD refrigerant isolation valves
are open.
Check VFD refrigerant cooling solenoid and
refrigerant strainer.
Check for proper VFD cooling fan operation
and blockage.

111

PRESTART
ALERT

HIGH
INVERTER
TEMP

111-_lnverter Temperature [VALUE]
exceeded limit of [LIMIT]*.

[VALUE]

Depress the RESET softkey if additional start
is required. Reassess start-up requirements.

Check that VFD refrigerant isolation valves
are open.
Check VFD refrigerant cooling solenoid and
refrigerant strainer.
Check for proper VFD cooling fan operation
and blockage.

*[LIMIT] is shown on the ICVC as temperature, pressure, voltage, etc., predefined or selected by the operator as an override or an alert. [VALUE] is
the actual pressure, temperature, voltage, etc., at which the control tripped.
E. START-UP

IN PROGRESS

PRIMARY MESSAGE

SECONDARY

MESSAGE

MODE

CAUSE/REMEDY

STARTUP IN PROGRESS

OCCUPIED

Chiller is starting. Time schedule is Occupied.

STARTUP IN PROGRESS

REMOTE CONTACT CLOSED

Chiller is starting. Remote contacts are Enabled and Closed.

STARTUP IN PROGRESS

START COMMAND

Chiller is starting. Chiller START/STOP
start.

AUTORESTART
PROGRESS

OCCUPIED

AUTORESTART
PROGRESS

REMOTE CONTACT CLOSED

Chiller is starting after power failure. Remote contacts are Enabled and
Closed.

AUTORESTART
PROGRESS

START COMMAND

Chiller is starting after power failure. Chiller START/STOP
screen manually forced to start.

IN EFFECT

MODE

in MAINSTAT manually forced to

Chiller is starting after power failure. Time schedule is Occupied.

IN EFFECT

on MAINSTAT

Table 16 -- Alarm and Alert Messages (cont)
R NORMALRUN
PRIMARY MESSAGE

SECONDARY

MESSAGE

CAUSE]REMEDY

RUNNING -- RESET ACTIVE

BY 4-20 mA SIGNAL

Auto chilled water reset active based on external input.

RUNNING -- RESET ACTIVE
RUNNING -- RESET ACTIVE

REMOTE TEMP SENSOR
CHW TEMP DIFFERENCE

Auto chilled water reset active based on external input.
Auto chilled water reset active based on CHW Delta T in
TEMP CTL screen.

RUNNING -- TEMP CONTROL

LEAVING CHILLED WATER

Default method of temperature

RUNNING -- TEMP CONTROL

ENTERING CHILLED WATER

Entering Chilled Water control enabled in TEMP

RUNNING -- TEMP CONTROL

TEMPERATURE

Ramp Loading in effect. Use RAMP DEM screen to modify.

RUNNING -- DEMAND LIMITED

BY DEMAND RAMP LOADING

Ramp Loading in effect. Use RAMP DEM screen to modify.

RUNNING -- DEMAND LIMITED

BY LOCAL DEMAND SETPOINT

Demand limit set point is less than actual demand.

RUNNING -- DEMAND LIMITED

BY 4-20 mA SIGNAL

Demand limit is active based on external auto demand limit option.

RUNNING -- DEMAND LIMITED

BY CCN SIGNAL

Demand limit is active based on control limit signal from CCN.

RUNNING -- DEMAND LIMITED

BY LOADSHED/REDLINE

Demand limit is active based on LOADSHED screen set-up.

RUNNING -- TEMP CONTROL

HOT GAS BYPASS

Hot gas bypass valve is energized
description.

RUNNING -- DEMAND LIMITED

BY LOCAL SIGNAL

Active demand limit manually overridden on MAINSTAT table.

RUNNING -- TEMP CONTROL

ICE BUILD MODE

Chiller is running under Ice Build temperature

RUNNING -- DEMAND LIMITED

MOTOR LOAD CURRENT

Chiller has reached 100% of Load Current Rating during normal
operation.

RUNNING -- DEMAND LIMITED

VFD LINE CURRENT

Chiller has reached 100% of Line Current Rating during normal
operation.

G. NORMAL
ICVC FAULT
STATE

RUN WITH

RAMP LOADING

control.
CTL screen.

(open). See Surge prevention

control.

OVERRIDES

PRIMARY
MESSAGE

SECONDARY
MESSAGE

PRIMARY CAUSE

ADDITIONAL

CAUSE]REMEDY

120

RUN CAPACITY
LIMITED

HIGH CONDENSER
PRESSURE

120-_Condenser Pressure
[VALUE] exceeded limit of
[LIMIT]*.

121

RUN CAPACITY
LIMITED

HIGH MOTOR
TEMPERATURE

121_Comp
Motor Winding
Temp [VALUE] exceeded
limit of [LIMIT]*.

122

RUN CAPACITY
LIMITED

LOW EVAP REFRIG
TEMP

122_-_Evaporator Refrig
Temp [VALUE] exceeded
limit of [LIMIT]*.

Check refrigerant charge.
Check that optional cooler liquid line isolation
valve is fully open.
Check for excessive condenser flow or low
chilled water flow.
Check for low entering cooler temperature.
Check that condenser inlet and outlet water
nozzles are piped correctly.
Check for waterbox division plate gasket bypass.

123

RUN CAPACITY
LIMITED

HIGH COMPRESSOR
LIFT

123-_Surge Prevention
Override: Lift Too High For
Compressor

Check for high condenser water temperature
low suction temperature.
Check for high Evaporator or Condenser
approaches.
Check surge prevention parameters in
OPTIONS screen.

124

RUN CAPACITY
LIMITED

MANUAL GUIDE VANE
TARGET

124_Run Capacity Limited:
Manual Guide Vane Target.

Target Guide Vane Position has been forced in
the COMPRESS screen. Select and RELEASE
force to return to normal (automatic) operation.

125

RUN CAPACITY
LIMITED

LOW DISCHARGE
SUPERHEAT

No Alert message.

Check for oil loss or excess refrigerant charge.
Verify that the valves in the oil reclaim lines are
open.

126

RUN CAPACITY
LIMITED

HIGH RECTIFIER

126_Rectifier
Temperature
[VALUE] exceeded limit of
[LIMIT]*.

Check Rectifier Temp Override in SETUP1
screen.
Check that VFD refrigerant isolation valves are
open.
Check VFD refrigerant cooling solenoid.
Check for proper VFD cooling fan operation and
blockage.

127

RUN CAPACITY
LIMITED

MANUAL SPEED
CONTROL

No Alert message.

Chiller is not in automatic temperature

128

RUN CAPACITY
LIMITED

HIGH INVERTER TEMP

128-qnverter Temperature
[VALUE] exceeded limit of
[LIMIT]*.

Check Inverter Temp Override in SETUP1
screen.
Check that VFD refrigerant isolation valves are
open.
Check VFD refrigerant cooling solenoid.
Check for proper VFD cooling fan operation and
blockage.

TEMP

Check condenser water pump operation.
Check for high condenser water temperatures or
low flow rate. Verify that isolation valves are
open.
Check Cond Press Override setting in SETUP1.
Check for closed valves or restriction in motor
cooling lines.
Check for closed refrigerant isolation valves.
Check Comp Motor Temp Override setting in
SETUP1.

control.

*[LIMIT] is shown on the ICVC as the temperature, pressure, voltage, etc., set point predefined or selected by the operator as an override, alert, or
alarm condition. [VALUE] is the actual pressure, temperature, voltage, etc., at which the control tripped.

8.3

Table 16 -- Alarm and Alert Messages (cont)
H. OUT-OF-RANGE

SENSOR

ICVC FAULT
STATE

PRIMARY
MESSAGE

SECONDARY
MESSAGE

260

SENSOR FAULT

LEAVING CHILLED WATER

260-+Sensor Fault: Check
Leaving Chilled Water Sensor.

Check sensor resistance or voltage drop.
Check for proper wiring.
Check for disconnected or shorted wiring.

261

SENSOR FAULT

ENTERING
WATER

261 -+Sensor Fault: Check
Entering Chilled Water
Sensor.

Check sensor resistance or voltage drop.
Check for proper wiring.
Check for disconnected or shorted wiring.

262

SENSOR FAULT

CONDENSER

262-+Sensor Fault: Check
Condenser Pressure Sensor.

Check sensor wiring.
Check for disconnected
Check for condensation
connector.

or shorted wiring.
in transducer

263-+Sensor Fault: Check
Evaporator Pressure Sensor.

Check sensor wiring.
Check for disconnected
Check for condensation
connector.

or shorted wiring.
in transducer

263

SENSOR FAULT

PRIMARY CAUSE

CHILLED

PRESSURE

EVAPORATOR
PRESSURE

ADDITIONAL

CAUSE/REMEDY

264

SENSOR FAULT

COMPRESSOR
TEMP

BEARING

264-+Sensor Fault: Check
Comp Thrust Brg Temp Sensor.

Check sensor resistance or voltage drop.
Check for proper wiring.
Check for disconnected or shorted wiring.

265

SENSOR FAULT

COMPRESSOR
TEMP

MOTOR

265-+Sensor Fault: Check
Comp Motor Winding Temp
Sensor.

Check sensor resistance or voltage drop.
Check for proper wiring.
Check for disconnected or shorted wiring.

266

SENSOR FAULT

COMP DISCHARGE

266-+Sensor Fault: Check
Comp Discharge Temp Sensor.

Check sensor resistance or voltage drop.
Check for proper wiring.
Check for disconnected or shorted wiring.

267

SENSOR FAULT

OIL SUMP TEMP

267-+Sensor Fault: Check Oil
Sump Temp Sensor.

Check sensor resistance or voltage drop.
Check for proper wiring.
Check for disconnected or shorted wiring.

268

SENSOR FAULT

COMP OIL PRESS DIFF

268-+Sensor Fault: Check Oil
Pump Delta P Sensor.

Check sensor resistance or voltage drop.
Check for proper wiring.
Check for disconnected or shorted wiring.

269

SENSOR FAULT

CHILLED WATER FLOW

269-+Sensor Fault: Check
Chilled Water Delta P Sensor.

Check sensor wiring and accuracy.
Check for disconnected or shorted wiring. If
3ressure transducers are not installed,
check for presence of resistors and jumpers
on lower CCM terminal block J3.

270

SENSOR FAULT

COND WATER FLOW

270-+Sensor Fault: Check
Cond Water Delta P Sensor.

Check sensor wiring and accuracy.
Check for disconnected or shorted wiring. If
3ressure transducers are not installed,
check for presence of resistors and jumpers
on lower CCM terminal block J3.

271

SENSOR FAULT

EVAP SATURATION TEMP

271-+Sensor Fault: Check
Evap Saturation Temp Sensor.

Check sensor resistance or voltage drop.
Check for proper wiring.
Check for disconnected or shorted wiring.

TEMP

Table 16 -- Alarm and Alert Messages (cent)
I. CHILLER PROTECTIVE LIMIT FAULTS
ICVC FAULT
STATE

PRIMARY
MESSAGE

SECONDARY
MESSAGE
POWER

PRIMARY CAUSE

CAUSE/REMEDY

200

PROTECTIVE

LIMIT

RECTIFIER
FAULT

201

PROTECTIVE

LIMIT

INVERTER POWER FAULT 201_lnverter
Power Fault:
Check VFD Status.

Malfunction within VFD Power Module.
Call Carrier Service.

202

PROTECTIVE

LIMIT

MOTOR AMPS NOT
SENSED

202-_Motor Amps Not
Sensed -- Average Load
Current [VALUE].

Check main circuit breaker for trip. Increase
Current % Imbalance in VFD CONF screen.

203

FAILURE TO START

MOTOR ACCELERATION
FAULT

203_Motor Acceleration Fault
-- Average Load Current
[VALUE].

204

FAILURE TO STOP

VFD SHUTDOWN

204_VFD Shutdown Fault:
Check Inverter Power Unit.

Check that inlet guide vanes are fully closed at
start-up.
Check Motor Rated Load Amps in VFD CONF
screen. Reduce unit pressure if possible.
VFD Circuit Board malfunction.
Call Carrier Service.

205

PROTECTIVE

LIMIT

HIGH DC BUS VOLTAGE

205_High
DC Bus Voltage:
[VALUE] exceeded limit of
[LIMIT]*.

Verify phase to phase and phase to ground line
voltage. Monitor AC line for high transient voltage conditions. VFD Circuit Board malfunction.
Call Carrier Service.

206

PROTECTIVE

LIMIT

VFD FAULT

206-_VFD Fault Code:
[VALUE]; Check VFD Fault
Code List.

See VFD Fault Code description
action.

207

PROTECTIVE

LIMIT

HIGH CONDENSER
PRESSURE

207-_High Cond Pressure
trip. [VALU E] exceeded Switch
Trippoint.

Check Compressor Discharge High Pressure
switch wiring and accuracy.
Check for high condenser water temperatures,
low water flow, fouled tubes.
Check for division plate/gasket bypass.
Check for noncondensables in refrigerant.

208

PROTECTIVE

LIMIT

EXCESSIVE
AMPS

208_Percent
Load Current
[VALUE] exceeded limit of
[LIMIT]*.

Check Motor Rated Load Amps in VFD CONF
screen. Percent Load Current > 110%.
Check Motor Rated Load Amps setting.

209

PROTECTIVE

LIMIT

LINE CURRENT
IMBALANCE

209_Line Current Imbalance: Check VFD Fault History for Values.

Check phase to phase and phase to ground
)ower distribution bus voltage.
Check Line Current % Imbalance in VFD_CONF
screen. Consult power company.

210

PROTECTIVE

LIMIT

LINE VOLTAGE DROPOUT

210-_Single Cycle Line Voltage Dropout.

Temporary loss of voltage. Disable Single Cycle
Dropout in VFD CONF screen.

211

PROTECTIVE

LIMIT

HIGH LINE VOLTAGE

211_High
Percent Line Voltage [VALUE].

Check phase to phase and phase to ground distribution bus voltage. Consult power company.

212

PROTECTIVE

LIMIT

LOW LINE VOLTAGE

212_Low
Percent Line Voltage [VALUE].

Check phase to phase and phase to ground distribution bus voltage. Consult power company.

213

PROTECTIVE

LIMIT

VFD MODULE RESET

213_VFD Module Power-On
Reset When Running.

Temporary loss of VFD control voltage. Check
VFD control power breaker, transformer and
fuses.

214

PROTECTIVE

LIMIT

POWER LOSS

214_Control
Power Loss
When Running.

Check phase to phase and phase to ground distribution bus voltage.
Check VFD fuses.
Check 24 vac power supply to ICVC.
Consult power company.

215

PROTECTIVE

LIMIT

LOW DC BUS VOLTAGE

215-cLew DC Bus Voltage:
[VALUE] exceeded limit of
[LIMIT]*.

Verify phase-to-phase and phase-to-ground
voltage. VFD Circuit Board malfunction.
Call Carrier Service.

216

PROTECTIVE

LIMIT

LINE VOLTAGE
IMBALANCE

216-_Line Voltage Imbalance. Check VFD Fault History for Values.

Check phase-to-phase and phase-to-ground
distribution bus voltage. Increase Line Voltage
% Imbalance in VFD CONF screen.

217

PROTECTIVE

LIMIT

MOTOR OVERLOAD TRIP

217-+Motor Overload Trip;
Check VFD configurations,

Any phase current > 106% RLA. Can result from
significant load side current imbalance when
running at full load.
Check entering condenser water temperature
and water flow rate.
Check Motor Rated Load Amps in VFD CONF
screen.

218

PROTECTIVE

LIMIT

VFD RECTIFIER
OVERTEMP

218_VFD Rectifier Temp
Exceeded: Check Cooling and
VFD Cenfig.

Check that VFD refrigerant isolation valves are
open.
Check VFD refrigerant cooling solenoid and
refrigerant strainer.
Check for proper VFD cooling fan operation and
blockage.

219

PROTECTIVE

LIMIT

VFD INVERTER
OVERTEMP

219-_VFD Inverter Temp
Exceeded: Check Cooling and
VFD Cenfig.

Check that VFD refrigerant isolation valves are
open.
Check VFD refrigerant cooling solenoid and
refrigerant strainer.
Check for proper VFD cooling fan operation and
blockage.

FAULT

MOTOR

200_Rectifier
Power Fault:
Check VFD Status.

ADDITIONAL

Malfunction within VFD Power Module.
Call Carrier Service.

and corrective

line

Table 16 -- Alarm and Alert Messaged (cont)
I. CHILLER PROTECTIVE LIMIT FAULTS(cont)
ICVC FAULT
STATE

PRIMARY
MESSAGE

SECONDARY
MESSAGE

220

PROTECTIVE

LIMIT

221

PROTECTIVE

LIMIT

UNUSED

222

PROTECTIVE

LIMIT

LINE FREQUENCY

223

LOSS OF
COMMUNICATION

224

PROTECTIVE

225

PRIMARY CAUSE

GROUND FAULT

220-_Ground Fault Trip;
Check Motor and Current
Sensors.

ADDITIONAL

CAUSE/REMEDY

Check for condensation on motor terminals.
Check motor power leads for phase to phase or
phase to ground shorts. Disconnect motor from
VFD and megger motor.
Call Carrier Service.

221_UNUSED
TRIP

222-_Line Frequency -[VALUE] exceeded limit of
[LIMIT]; Check Power Supply.

If operating from a generator, check generator
size and speed.

WITH VFD GATEWAY
MODULE

223_Loss
of SIO Comm with
VFD Gateway: Check VFG
Module and Power.

Check VFD communication wiring and
connectors on VFD Gateway and DPI board.
Check for compatibility between ICVC and
Gateway software.

LIMIT

VFD COMMUNICATIONS
FAULT

224_Loss
of DPI Comm with
VFD Gateway: Check VFG to
VFD Comm.

Check VFD communication wiring and
connectors.
Check status lights on DPI Communications
Interface Board.
Call Carrier Service.

PROTECTIVE

LIMIT

MOTOR CURRENT
IMBALANCE

Check Motor Current % Imbalance in
VFD CONF screen.

226

PROTECTIVE

LIMIT

LINE PHASE REVERSAL

225_Motor
Current Imbalance: Check VFD Fault
History for Values.
226-_Line Phase Reversal:
Check Line Phases.

227

PROTECTIVE

LIMIT

OIL PRESS SENSOR
FAULT

227_Oil Pressure Delta P
[VALUE] (Pump Off): Check
Pump/Transducers.

Check
Check
Check
Check

transducer wiring and accuracy.
power supply to pump.
pump operation.
transducer calibration.

228

PROTECTIVE

LIMIT

LOW OIL PRESSURE

228-_Low Operating Oil
Pressure [VALUE]: Check Oil
Pump and Filter.

Check
Check
Check
Check
Check
Check
Check
Check

transducer wiring and accuracy.
power supply to pump.
pump operation.
oil level.
for partially closed service valves.
oil filters.
for foaming oil at start-up.
transducer calibration.

229

PROTECTIVE

LIMIT

LOW CHILLED WATER
FLOW

229_Low Chilled Water Flow;
Check Switch/Delta P Config
& Calibration.

230

PROTECTIVE

LIMIT

LOW CONDENSER
WATER FLOW

230-_Low Condenser Water
Flow; Check Switch/Delta P
Config & Calibration.

231

PROTECTIVE

LIMIT

HIGH DISCHARGE

Perform pump control test.
Check optional transducer calibration and
wiring.
Check Evaporator Refrigerant Temperature
sensor.
Check chilled water valves.
Check for evaporator saturation temperature
< 34 deg. F if not in Pumpdown Lockout mode.
Place unit in Pumpdown mode before removing
charge.
Perform pump control test.
Check optional transducer calibration and
wiring.
Check condenser water valves.
Check for condenser pressure > 130 PSlG.
Check for closed compressor discharge isolation valve.
Check if chiller was operating in surge.
Check sensor resistance or voltage drop.
Check for proper wiring.
Check for proper condenser flow and
temperature.
Check compressor discharge isolation valve.
Check for proper inlet guide vane and optional
diffuser actuator operation.

232

PROTECTIVE

LIMIT

LOW REFRIGERANT
TEMP

TEMP

231_Comp
Discharge Temp
[VALUE] Exceeded Limit of
[LIMIT]*.

232_Evaporator
Refrig Temp
[VALUE] exceeded limit of
[LIMIT]*.

Reverse connections
to circuit breaker.

of any two line conductors

Check for proper refrigerant charge.
Check float valve operation.
Check for closed condenser liquid line isolation
valve. If problem occurs at high load, check for
low condenser pressure which causes inadequate flasc orifice differential pressure.
Check for proper water flow and temperature.
Confirm that condenser water enters bottom row
of condenser tubes first.
Check Evaporator Refrigerant Temperature
sensor.
Check for division plate gasket bypass.
Check for fouled tubes.

Table 16 -- Alarm and Alert Messages (cent)
I. CHILLER PROTECTIVE LIMIT FAULTS(cent)
ICVC FAULT
STATE

PRIMARY
MESSAGE

SECONDARY
MESSAGE

PRIMARY CAUSE

ADDITIONAL

CAUSE/REMEDY

233

PROTECTIVE

LIMIT

HIGH MOTOR
TEMPERATURE

233->Comp Motor Winding
Temp [VALUE] exceeded limit
of [LIMIT]*.

234

PROTECTIVE

LIMIT

HIGH BEARING
TEMPERATURE

234_Comp
Thrust Brg Temp
[VALUE] exceeded limit of
[LIMIT]*.

235

PROTECTIVE

LIMIT

HIGH CONDENSER
PRESSURE

235_Condenser
Pressure
[VALUE] exceeded limit of
[LIMIT]*.

Check for high condenser water temperatures,
low water flow, fouled tubes.
Check for division plate/gasket bypass.
Check for noncondensables.
Check transducer wiring and accuracy.

236

PROTECTIVE

LIMIT

COMPRESS
SPEED

236_Compressor
Surge:
Check condenser water temp
and flow.

Check for high condenser water temperatures,
low water flow, fouled tubes.
Check for division plate/gasket bypass.
Check for noncondensables.
Check surge prevention parameters in
OPTIONS screen. Increase VFD Increase Step
in SETUP2.
Check VFD Minimum Speed in SETUP2 screen.

237

PROTECTIVE

LIMIT

SPARE SAFETY DEVICE

237_Spare

Spare safety input has tripped or factory
installed jumper is not present on Terminal
Block 1 (TB1).

238

PROTECTIVE

LIMIT

EXCESSIVE
SURGE

238->Compressor
Surge:
Check condenser water temp
and flow.

Check for high condenser water temperatures,
low water flow, fouled tubes.
Check for division plate/gasket bypass.
Check for noncondensables.
Check surge prevention parameters in
OPTIONS screen.
Check cooling tower control settings and performance to design/selection temperatures across
the entire operating range of the chiller.
Check cooler approach and water flow.

239

PROTECTIVE

LIMIT

TRANSDUCER
VOLTAGE FAULT

239-->Transducer Voltage Ref
[VALUE] exceeded limit of
[LIMIT]*.

Check that CCM transducer voltage reference is
between 4.5 v and 5.5 v.
Check that pressure transducers are not
shorted to ground. This fault is normally
declared the first time an ICVC is powered up if
it was downloaded with software when it was not
connected to a CCM.
Call Carrier Service.

24O

PROTECTIVE

LIMIT

LOW DISCHARGE
SUPERHEAT

240_Check
Overcharge

Check for oil loss or excessive refrigerant. If oil
level is low, refrigerant charge may be too low
resulting in ineffective oil reclaim. Excessive
refrigerant charge may cause liquid carryover
into compressor.
Check calibration of evaporator pressure and
condenser pressure sensors.
Check calibration of compressor discharge tem)erature sensor.

241

PROTECTIVE

LIMIT

RECTIFIER
OVERCURRENT

241 ->Rectifier Overcurrent
Fault: Check VFD Status.

Check for high water temperatures
in water flow rates.

242

LOSS OF
COMMUNICATION

WITH CCM MODULE

242-_Loss of Communication
With CCM, Check Comm.
Connectors.

Check wiring and control power to CCM.

243

POTENTIAL
FREEZE-UP

EVAP PRESS/1-EMP TOO
LOW

243->Evaporator
Refrig Temp
[VALUE] exceeded limit of
[LIMIT]*.

Check for proper refrigerant charge.
Check float valve operation.
Check for proper fluid flow and temperature.
Confirm that condenser water enters bottom row
of condenser tubes first.
Check Evaporator Refrigerant Temperature
sensor.
Check for division plate gasket bypass.
Check for fouled tubes.

244

POTENTIAL
FREEZE-UP

COND PRESS/TEMP
LOW

244->Condenser
Refrig Temp
[VALUE] exceeded limit of
[LIMIT]*.

Condenser water too cold or chiller shut down
with brine below 32 F in cooler so equalization
temperature in chiller approached 32 E
Check condenser pressure transducer.
Check refrigerant charge.

SURGE/LOW

COMPR

TOO

Safety Device.

for Oil in Or
of Refrigerant.

Check motor sensors wiring and accuracy.
Check motor cooling line and spray nozzle for
proper operation, or restrictions.
Check for excessive starts within a short time
span.
Check oil heater for proper operation.
Check for low oil level, partially closed oil supply
valves, or clogged oil filter.
Check oil cooler refrigerant thermal expansion
valves.
Check for sensor wiring and accuracy.
This fault can result from extended operation at
low load with low water flow to the evaporator or
condenser.

or changes

Table 16 -- Alarm and Alert Messages (cont)
I. CHILLER PROTECTIVE LIMIT FAULTS(cont)
ICVC FAULT
STATE

PRIMARY
MESSAGE

SECONDARY
MESSAGE

245

PROTECTIVE

LIMIT

HIGH VFD SPEED

246

PROTECTIVE

LIMIT

INVALID DIFFUSE
CONFIG.

247

PROTECTIVE

LIMIT

DIFFUSER
FAULT

248

PROTECTIVE

LIMIT

249

PROTECTIVE

250

UNUSED

251

PRIMARY CAUSE

ADDITIONAL

CAUSE/REMEDY

245--_Actual VFD Speed
exceeded limit of Target VFD
Speed + 10%.
246_Diffuser
Control Invalid
Configuration: Check SETUP2
Entries.

Actual VFD Speed on COMPRESS screen must
not exceed Target VFD Speed by more than
10%.

247-+Diffuser Position Fault:
Check Guide Vane/Diffuser
Actuator.

Confirm that Diffuser Option in SETUP 2 screen
has not been Enabled if compressor does not
have a split ring diffuser. May indicate rotating
stall condition.
Check rotating stall transducer wiring accuracy
and sealing.
Check diffuser schedule and guide vane schedule in SETUP2 screen.
Check for proper operation of diffuser and inlet
guide vane actuators including inlet guide vane
calibration.
Check diffuser actuator coupling for rotational
slip.
Check resistor between CCM terminals J3-7
and J3-8.
Check for electrical noise in CCM Diffuser Pressure wiring. Do not continue to operate com3ressor except for diagnostic purposes.

SPARE TEMPERATURE
#1

248-_Spare Temperature #1
[VALUE] exceeded limit of
[LIMIT]*.

Check Spare Temperature Enable and Spare
Temperature Limit in SETUP1 Screen.

LIMIT

SPARE TEMPERATURE
#2

249_Spare
Temperature #2
[VALUE] exceeded limit of
[LIMIT]*.
250-_Unused State.

Check Spare Temperature Enable and Spare
Temperature Limit in SETUP1 Screen.

PROTECTIVE

LIMIT

VFD CONFIG CONFLICT

251_VFD Config Conflict
(VFD Uploaded): Verify to
Reset Alarm.

The VFD CONF table in the Gateway does not
match that which is in the ICVC. This is a normal
fault if an ICVC has been uploaded with software when it was not attached to the CCM
Enter VFD CONF screen and then exit
VFD CONF screen by pressing EXIT then
CANCEL. Re-enter the VFD CONF screen,
3ress EXIT then SAVE. Parameters stored in
the Gateway will be uploaded into the ICVC.
Confirm valid settings in VFD CONF screen.

252

PROTECTIVE

LIMIT

VFD CONFIG CONFLICT

The VFD CONF table in the Gateway does not
match that which is in the ICVC.

253

PROTECTIVE

LIMIT

GUIDE VANE
CALIBRATION

252-+VFD Config Conflict
VFD Downloaded): Verify to
Reset Alarm.
253_Guide
Vane Fault
[VALUE]. Check Calibration.

254

PROTECTIVE

LIMIT

VFD CHECKSUM

255

PROTECTIVE

LIMIT

VFD DEW PREVENTION

256

PROTECTIVE

LIMIT

INDUCTOR OVERTEMP

257

PROTECTIVE

LIMIT

VFD START INHIBIT

258

UNUSED STATE

POSITION

UNUSED

ERROR

254_Checksum
Error:
Press Reset to Restore
Configuration.
255-_Dew Prevention - Coolant Too Cold. Check Solenoid
& Cond T.

256-+Inductor Overtemp Trip Check Temp Switch and Cooling Fans.
257_VFD Start Inhibit: Check
VFD Diagnostic Parameters
212/214.

Check 25%, 50%, and 75% Guide Vane and Diffuser Load Point entries in SETUP2 screen.

Enter CONTROL TEST and execute Guide
Vane Calibration.
Check CCM guide vane feedback terminals J4-9
and J4-10.
Check guide vane feedback potentiometer.
Alarm before start indicates guide vane opening
is not less than 4%. Alarm running indicates
guide vane position is < -1% or > 103%, or feedback voltage is < .045 or > 3.15 VDC.
Actual VFD checksum does not match calculated value.
VFD COLDPLATE TEMP is too close to dew
_oint based on VFD ENCLOSURE TEMP and
RELATIVE HUMIDITY in POWER screen.
Check for moisture in VFD enclosure.
Check Humidity Sensor in CONTROLS TEST.
Check for contamination on CCM J3-7 and J3-9
Humidity Sensor.
Check that VFD refrigerant cooling modulating
valve is closing.
Check for cooling fan air flow obstructions.

The VFD Start Inhibit is derived from the Alarm
bit being set in the VFD. The conditions causing
the alarm must be corrected in the VFD to
enable subsequent starts and operation. See
VFD parameters 212/214.

258_Unused.

*[LIMIT] is shown on the ICVC as the temperature, pressure, volta e, etc., set point predefined or selected by the operator as an override, alert, or
alarm condition. [VALUE] is the actual pressure, temperature, voltage, etc., at which the control tripped.

Table 16 -- Alarm and Alert Messages (cont)
I. CHILLER PROTECTIVE
ICVC FAULT
STATE

LIMIT FAULTS (cont)

PRIMARY
MESSAGE

SECONDARY
MESSAGE

259

PROTECTIVE

LIMIT

CCN OVERRIDE

282

PROTECTIVE

LIMIT

283

PROTECTIVE

LIMIT

284

PRIMARY CAUSE

STOP

ADDITIONAL

CAUSE/REMEDY

259_CCN Emergency/
Override Stop.

CCN has signaled the chiller to stop.This fault
must be manually reset from the default screen
of the ICVC.

INVALID VFD CONFIG

282-+Line Frequency
[VALUE] Exceeded Configuration Range.

INVALID VFD CONFIG

283_Compressor
100%
Speed Config Ranges: 50=Hz
45-52; 60 Hz=55-62.

LINE FREQUENCY in POWER screen must be
maintained between 45-52 Hz if LINE
FREQ=60Hz? is set to NO(50 Hz). LINE FREQUENCY must be maintained between
55-62 Hz if LINE FREQ=60Hz? is set to YES
(60 Hz).
COMPRESSOR 100% SPEED in VFD CONF
screen must be set between 45-52 Hz [{ LINE
FREQ=60Hz? is set to NO(50 Hz). COMPRESSOR 100% SPEED must be set between
55-62 Hz if LINE FREQ=60Hz? is set to YES
(60 Hz).

VFD GATEWAY

COMPATIBILITY
CONFLICT

284_VFD Gateway Compatibility Conflict: Check VFG/
VFD Versions.

VFD Gateway and VFD software versions are
not compatible. Call Carrier Service.

285

VFD GATEWAY

COMPATIBILITY
CONFLICT

285-_VFD Gateway Compatibility Conflict: Check VFG/
ICVC Versions.

VFD Gateway and ICVC software versions are
not compatible. Call Carrier Service.

286

PROTECTIVE

INVERTER
OVERCURRENT

286_lnverter
Overcurrent
Fault: Check VFD Status.

Check for high entering water temperature or
low condenser water flow.
Check current settings in VFD CONF screen.

LIMIT

J. CHILLER ALERTS
ICVC FAULT
STATE

PRIMARY
MESSAGE

SECONDARY
MESSAGE

PRIMARY CAUSE

140

SENSOR ALERT

LEAVING COND WATER
TEMP

141

SENSOR ALERT

ENTERING COND WATER
TEMP

142

LOW OIL
PRESSURE

CHECKOILFI_ER
ALERT

143

AUTORESTART
PENDING

LINECURRENT
IMBALANCE

144

AUTORESTART
PENDING

LINEVOLTAGE
DROPOUT

145

AUTORESTART
PENDING

HIGH LINE VOLTAGE

146

AUTORESTART
PENDING

LOW LINE VOLTAGE

147

AUTORESTART
PENDING

VFD MODULE RESET

148

AUTORESTART
PENDING

POWER LOSS

149

SENSOR ALERT

HIGH DISCHARGE

150

SENSOR ALERT

HIGH BEARING
TEMPERATURE

TEMP

ADDITIONAL

CAUSE/REMEDY

140-_Sensor Fault: Check
Leaving Cond Water Sensor.
141_Sensor Fault: Check
Entering Cond Water Sensor.
142_Low Oil Pressure Alert.
Check Oil Filter.

Check sensor resistance
Check for proper wiring.

143-_Line Current Imbalance: Check VFD Fault History for Values.
144-+Single Cycle Line
Voltage Dropout.

Power loss has been detected in any phase.
Chiller automatically restarting.

145_High Percent Line
Voltage [VALUE].
146_Low Percent Line
Voltage [VALUE].
147->VFD Module Power-On
Reset When Running.

Check phase
)ower.

148_Control
Power-Loss
When Running.
149_Comp Discharge Temp
[VALUE] Exceeded Limit of
[LIMIT]*.

Check 24 vac control power supply to ICVC.

150_Comp Thrust Brg Temp
[VALUE] exceeded limit of
[LIMIT]*.

Check
Check
Check
Check
Check

Check
Check
Check
Check
Check
Check
Check
Check

or voltage drop.

sensor resistance or voltage drop.
for proper wiring.
for partially or closed shut-off valves.
oil filter.
oil pump and power supply.
oil level.
for foaming oil at start-up.
transducer wiring and accuracy.

A drop in line voltage has been detected within
2 voltage cycles.
Chiller automatically
restarting if Auto Restart is
enabled in OPTIONS screen.
to phase

and phase

to ground

line

Check phase to phase and phase to ground line
)ower.
VFD Module has detected a hardware fault due
to electrical noise, power loss or software and
has reset. Chiller automatically
restarting.
Check for power loss and sources of electromagnetic interference.

Check sensor resistance or voltage drop.
Check for proper wiring.
Check for proper inlet guide vane and optional
diffuser actuator operation.
Check for proper condenser flow and
temperature.
Check for high lift or low load.
Check for fouled tubes or noncondensables in
the chiller.
sensor resistance or voltage drop.
for proper wiring.
for partially closed service valves.
oil cooler TXV.
oil level and oil level.

Table 16 -- Alarm and Alert Messages (cont)
J. CHILLER

ALERTS

(cont)

ICVC FAULT
STATE

PRIMARY
MESSAGE

SECONDARY
MESSAGE

PRIMARY CAUSE

151

CONDENSER
PRESSURE ALERT

PUMP RELAY
ENERGIZED

151_High Condenser Pressure [VALUE]: Pump Energized to Reduce Pressure.

Check sensor wiring and accuracy.
Check condenser flow and water temperature.
Check for fouled tubes.
This alarm is not caused by the High Pressure
Switch.

152

RECYCLE ALERT

EXCESSIVE
STARTS

152_Excessive
starts,

Chiller load is too low to keep compressor on
line and there has been more than 5 starts in
4 hours.
Increase chiller load, adjust hot gas bypass,
increase RECYCLE RESTART DELTA T from
SETUP1 Screen.

153

no message:
ALERT
only

no message; ALERT only

153_Lead/Lag
DisabledConfig: Duplicate Chiller
Address.

Illegal chiller address configuration in Lead/Lag
screen. Both chillers require a different address.

154

POTENTIAL
FREEZE=UP

COND PRESS/TEMP
TOO LOW

154_Condenser
)revention.

The condenser pressure transducer is reading a
3ressure that could freeze the condenser tubes.
Check for condenser refrigerant leaks.
Check fluid temperature.
Check sensor wiring and accuracy.
Place the chiller in PUMPDOWN mode if the
vessel is evacuated.

155

OPTION SENSOR
FAULT

REMOTE RESET
SENSOR

155-_Sensor Fault/Option
Disabled: Remote Reset
Sensor.

Check sensor resistance or voltage drop.
Check for proper wiring to CCM connector J4.

156

OPTION SENSOR
FAULT

AUTO CHILLED WATER
RESET

156_-_Sensor Fault/Option
Disabled: Auto Chilled Water
Reset.

Check sensor resistance or voltage drop.
Check for proper wiring to CCM connector J5.

157

OPTION SENSOR
FAULT

AUTO DEMAND LIMIT
INPUT

157-_Sensor Fault/Option
Disabled: Auto Demand Limit
Input.

Check sensor resistance or voltage drop.
Check for proper wiring to CCM connector J5.

158

SENSOR ALERT

SPARE TEMPERATURE
#1

158_-_Spare Temperature 1
[VALUE] exceeded limit of
[LIMIT]*.

Check sensor resistance or voltage drop.
Check for proper wiring to CCM connector J4.
Check Spare Temp #1 Limit in SETUP1 screen.

159

SENSOR ALERT

SPARE TEMPERATURE
#2

Check sensor resistance or voltage drop.
Check for proper wiring to CCM connector J4.
Check Spare Temp #2 Limit in SETUP1 screen.

161

LOSS OF
COMMUNICATION

WITH WSM

159_Spare Temperature 2
[VALUE] exceeded limit of
[LIMIT]*.
161_-_WSM Cool Source -Loss of Communication.

162

SENSOR ALERT

EVAPORATOR
APPROACH

162-_ Evaporator Approach
[VALUE] Exceeded Limit of
[LIMIT]*.

Check that refrigerant charge level is adequate,
waterbox division plate gaskets are sealing,
evaporator tubes are not fouled and that oil
reclaim system is working.
Check sensor resistance or voltage drop.
Check for proper wiring.
Check Evap Approach Alert setting in SETUP1
screen.

163

SENSOR ALERT

CONDENSER

163-_Condenser Approach
[VALUE] Exceeded Limit of
[LIMIT]*.

Check sensors resistance or voltage drop.
Check for proper wiring.
Check Cond Approach Alert setting in SETUP1
screen.
Check for noncondensable gas in the
condenser.
Check that the condenser tubes are not fouled.

164

VFD SPEED ALERT

LOW VFD SPEED

164_Actual VFD Speed
exceeded limit of Target VFD
Speed -10%.

Actual VFD Speed on COMPRESS screen must
be at least 90% of Target VFD Speed.

165

AUTORESTART
PENDING

LOW DC BUS VOLTAGE

165_Low DC Bus Voltage:
[VALUE] Exceeded Limit of
[LIMIT]*.

Verify phase to phase and phase to ground line
voltage.

166

AUTORESTART
PENDING

HIGH DC BUS VOLTAGE

166_High DC Bus Voltage:
[VALUE] Exceeded Limit of
[LIMIT]*.

Verify phase to phase and phase to ground line
voltage. Monitor AC line for high transient voltage conditions.

167

SYSTEM ALERT

HIGH DISCHARGE

167_Comp Discharge Temp
[VALUE] exceeded limit of
[LIMIT]*.

Check sensor resistance or voltage drop.
Check for proper wiring.
Check for excessive starts.
Check Comp Discharge Alert setting in SETUP1
screen.

168

SENSOR ALERT

HUMIDITY
INPUT

RECYCLE

APPROACH

SENSOR

TEMP

recycle

freeze up

ADDITIONAL

Check
Check
(Water
Check

CAUSE/REMEDY

settings in WSMDEFME screen.
CCN communications link with WSM
System Manager) Module.
Supervisory Part of WSM.

168-_Sensor Fault: Check
Check humidity sensor wiring on CCM connecHumidity Sensor Input Sensor. tots J3 and J5.
Check Humidity Sensor Input in Controls Test.

Table 17 -- Fault Code Descriptions and Corrective Actions
Fault Type indicates if the fault is:
1 -- Auto-resettable
2 -- Nomresettable
3User-configurable
4 -- Normal Fault
VFD FAULT
CODE

FAULT TYPE

DESCRIPTION

ACTION

ICVC FAULT
STATE

Auxiliary Input 1

Input is open.

Check remote wiring.

Power Loss 1, 3

DC bus voltage remained below 85% of
nominal for longer than Power Loss Time
(185).
Enable/disable with Fault Config 1 (238).

Monitor the incoming AC line for low voltage or
line power interruption.

215

UnderVoltage

DC bus voltage fell below the minimum
value of 407V DC at 400/480V input
Enable/disable with Fault Config 1(233).

Monitor the incoming AC line for low voltage or
)ower interruption.

215

OverVoltage

DC bus voltage exceeded maximum value.

Monitor the AC line
transient conditions.
be caused by motor
decel time or install

205

Current reg saturated
for > timeout

Motor Overload

Invtr Base Temp 1

Base temperature

Invtr IGBT Temp 1

HW OverCurrent

1,3

1, 3

for high line voltage or
Bus overvoltage can also
regeneration. Extend the
dynamic brake option.

206
Internal electronic overload trip.

An excessive motor load exists. Reduce load
so drive output current does not exceed the
current set by Motor NP FLA (42).

217

Check for proper temperature
coolant.

and flow rate of

219

Output transistors have exceeded their
maximum operating temperature,

Check for proper temperature
coolant.

and flow rate of

219

The drive output current has exceeded the
hardware current limit,

Check programming. Check for excess load,
improper DC boost setting, DC brake volts set
too high or other causes of excess
cu rrent.

286

Ground Fault 1

A current path to earth ground in excess of
7% of drive rated amps has been detected
at one or more of the drive output termF
nals.

Check the motor and external wiring to the
drive output terminals for a grounded
condition.

220

Decel Inhibit 3

The drive is not following a commanded
deceleration because it is attempting to
limit bus voltage.

1. Verify input voltage is within drive specified
limits.
2. Verify system ground impedance follows
proper grounding techniques.
3. Disable bus regulation and/or add dynamic
brake resistor and/or extend deceleration
time.

204

OverSpeed Limit 1

Functions such as slip compensation or
bus regulation have attempted to add an
output frequency adjustment greater than
that programmed in Overspeed Limit (83).

Remove excessive load or overhauling condF
tions or increase Overspeed Limit (83).

206

Analog In Loss 1,3

An analog input is configured to fault on
1. Check parameters.
signal loss. A signal loss has occurred.
2. Check for broken/loose connections
Configure with Anlg In 1,2 Loss (324, 327).
inputs.

Enable/disable

with Fault Config 1 (238).
exceeded limit.

206
at

Auto Rstrt Tries 3

Drive unsuccessfully attempted to reset a Correct the cause of the fault and manually
fault and resume running for the proclear.
grammed number of Auto Rstrt Tries (174).
Enable/disable with Fault Config 1 (238).

206

Current FBK Lost 4

The magnitude of motor current feedback
Verify connection of current feedback device
was less than 5% of the configured Motor
and motor terminals. If fault repeats replace
Nameplate Amps for the time configured in current feedback devices and/or power supply.
the Motor Imbalance Time. Detection of
this fault is disabled when the Motor Imbalance Time is set to the maximum value of
10.0 seconds.

206

SW OverCurrent

The drive output current has exceeded the
software current,

Check for excess load, improper DC boost setting. DC brake volts set too high.

286

Motor I Imbalance

Phase current displayed in Imbalance Display (221) > percentage set in Imbalance
Limit (49) for time set in Imbalance Time
(50).

Clear fault.

225

LEGEND
DPI/I/O
EPROM
FLA
IGBT
NP

------

Drive Peripheral Interface Inputs/Outputs
Erasable, Programmable, Read-Only
Full Load Amps
Insulated Gate Bipolar Transistor
Nameplate

Table 17 -- Fault Code Descriptions and Corrective

Actions (cont)

Fault Type indicates if the fault is:
1 -- Auto-resettable
2 -- Nomresettable
3 -- User-configurable
4 -- Normal Fault
VFD FAULT
CODE

FAULT TYPE

Phase U to Grnd

Phase V to Grnd

Phase W to Grnd

Phase UV Short

Phase VW Short

Phase UW Short

DESCRIPTION

ACTION

ICVC FAULT
STATE
22O

A phase-to-ground fault has been detected
between the drive and motor in this phase.

• Check the wiring between the drive and
motor.
2. Check motor for grounded phase.
3. Replace drive•

Excessive current has been detected
between these two output terminals•

• Check the motor and drive output terminal
wiring for a shorted condition•
2. Replace drive•

246

Params Defaulted

The drive was commanded
values to EPROM.

• Clear the fault or cycle power to the drive•
2. Program the drive parameters as needed.

206

Shear Pin 3

Programmed Current Lint Val (148) has
been exceeded.
Enabled/disable with Fault Config 1 (238)•

Check load requirements
(148) setting.

206

Drive OverLoad

Drive rating of 110% for 1 minute or 150%
for 3 seconds has been exceeded•

Reduce load or extend Accel Time (140)•

DB Resistor Out of
Range
Port 1-5 Net Loss

71- 75

to write default

and Current Lmt Val

286
206

The network card connected to DPI port
stopped communicating.
The fault code indicates the offending port
number (71 = port 1, 72 = port 2, etc.).

• Check communication board for proper
connection to external network.
2. Check external wiring to module on port.

206

Peripheral Fault at
DPI Port 6

IR Volts Range

The drive autotuning default is Calculate,
and the value calculated for IR Drop Volts
is not in the range of acceptable values.

Re-enter motor nameplate data.

206

FluxAmpsRef

The value for flux amps determined by the
autotune procedure exceeds the programmed Motor NP FLA (42).

• Reprogram Motor NP FLA (42) with the correct motor nameplate value.
2. Repeat Autotune (61).

206

Excessive Load

Motor did not come up to speed in the allot• Uncouple load from motor.
ted time.
2. Repeat Autotune (61).

206

AutoTune Aborted

The autotune procedure was canceled by
the user.

Restart procedure.

206

81- 85

Port 1-6 DPI Loss

DPI port stopped communicating•

• If module was not intentionally disconnected, check wiring to the port. Replace
wiring, port expander, modules, Main Control board or complete drive as required•
2. Check OIM connection•

206

Rang

206

An attached peripheral with control capabilities via Logic Source Sel (89) (or OIM
control) was removed.
The fault code indicates the offending port
number (81 = port 1, etc.).
86

DPI Port 6 Communication Loss

Autotune: Ixo too
Ixo voltage calculated from motor namelarge 4
)late data is too high.
Parameter Chksum 2 The checksum read from the board does
not match the checksum calculated•

Re-enter motor nameplate data.

206

• Restore defaults.
2. Reload user set if used.

206

101

UserSetl

206

UserSet2 Chksum 2

The checksum read from the user set does
not match the checksum calculated•

Re-save user set.

102
103
104

UserSet3 Chksum 2
Pwr Brd Chksuml

The checksum read from the EPROM does
not match the checksum calculated from
the EPROM data.

Clear the fault or cycle power to the drive•

206

105

Pwr Brd Chksum2

The checksum read from the board does
not match the checksum calculated•

• Cycle power to the drive•
2. If problem persists, replace drive•

206

100

Chksum 2

206

LEGEND
DPI/I/O
EPROM
FLA
IGBT
NP

------

Drive Peripheral Interface Inputs/Outputs
Erasable, Programmable, Read-Only
Full Load Amps
Insulated Gate Bipolar Transistor
Nameplate

Table 17 -- Fault Code Descriptions and Corrective Actions (cont)
Fault Type indicates if the fault is:
1 -- Auto-resettable
2 -- Non-resettable
3User-configurable
4 -- Normal Fault
VFD FAULT
CODE

FAULT TYPE

DESCRIPTION

106

Incompat MCB-PB 2

Drive rating information stored on the
3ower board is incompatible with the Main
Control board.

107

Replaced MCB-PB k Main Control board was replaced and
3arameters were not programmed,
I/O Board Check
Sum Non-Resettable

109

ACTION

110

I/O Board Failure
Non-Resettable

121

Loss of communication

122

I/O Board Comm
Loss k
I/O Board Fail

2O0

Inverter Dsat

u,v,w

High current was detected in an IGBT.

201

205
206
207
208

to I/O board,

206

1, Verify proper motor data is entered.
2. Reduce current limit.

286

Inverter Unused Bit 4 Inverter section of power structure hardware reported unexpected fault.
Invtr Gate Kill
Inverter gate kill contact is open.
Rectifier Dsat
High current was detected in an IGBT.

Check wiring harness.

206

Rectifier IOC

Rectifier overcurrent.

1, Verify proper motor data is entered.
2, Reduce current limit.

241

206

High current was detected in an IGBT.

u,v,w

212
213

206

1. Cycle power,
2. If fault repeats, replace I/O board,
1. Check for loose connection in IGBT wire
harness,
2 Check IGBTs.
3. Check precharge resistors and fuses.
4. Check precharge contactor.

Board failure.

210
211

1. Restore defaults,
2. Reprogram parameters.

206

u,v,w

209

206

Cycle power.

Inverter
OverCurrent
u,v,w

204

Load compatible version files into drive.

206

202
203

ICVC FAULT
STATE

Close gate kill contact.
1. Check for loose connection
harness,
2, Check IGBTs.

201

207, 235
in IGBT wire

200

214

Reactor Temp

Temperature switch in reactor opened,

Check for proper temperature
operation.

215

Rectifier Unused Bit
4

Rectifier section of power structure hareware reported unexpected fault.

Check wiring harness.

206

216

Rectifier Ground
Fault

Excessive ground current measured.

Check for grounded input wiring.

220

217

Rectifier Base Temp

Excessive rectifier temperatured
measured,

Check for proper temperature
coolant.

and flow rate of

218

Rectifier IGBT Temp

Excessive calculated IGBT temperature.

Check for proper temperature
coolant.

and flow rate of

218

219

Rectifier IT
Overload

Short-term current rating of rectifier
exceeded,

Low input voltage can result in increased current load. Provide proper input voltage to the
drive.

212

220

Rectifier 12T
Overload

Long-term current rating of rectifier
exceeded,

Low input voltage can result in increased current load. Provide proper input voltage to the
drive.

212

221

Ride Thru Abort

Input power loss timed out.

1. Verify input power and connections.
2, Check Line Sync board.
3. Check AC Line I/O board.

210

222

High AC Line

Input line voltage is too high.

Reduce input voltage to meet specification
480 _+10%.

223

Low DC Bus

The bus voltage is too low.

Verify proper input voltage.

215

224

Rctfr Over Volt

The bus voltage is too high.

Monitor the AC line
transient conditions,
be caused by motor
decel time or install

205

LEGEND
DP1/1/O
EPROM
FLA
IGBT
NP

------

Drive Peripheral Interface Inputs/Outputs
Erasable, Programmable, Read-Only
Full Load Amps
Insulated Gate Bipolar Transistor
Nameplate

and fan

for high line voltage or
Bus overvoltage can also
regeneration. Extend the
dynamic brake option.

211

Table 17 -- Fault Code Descriptions and Corrective

Actions (cont)

Fault Type indicates if the fault is:
1 -- Auto-resettable
2 -- Non-resettable
3 -- User-configurable
4 -- Normal Fault
VFD FAULT
CODE

FAULT TYPE

DESCRIPTION

ACTION

ICVC FAULT
STATE

225

Input Amp
Imbalance

Input phase current imbalance exceeded
limits,

Check for loose connection
wiring.

226

Input Volt
Imbalance

Input voltage imbalance exceeded limits.

Check for problem in input power
distribution.

216

227

AC Line Lost

Input power Lost.

.
2.
3.
4.

210

228

Line Frequency

Line frequency not in the range of
47-63 Hz.

Verify connection between AC Line Sync and
AC Line I/O boards.

222

229

Rectifier
Checksum

The checksum read from the board does
not match the checksum calculated.

. Restore defaults.
2. Reload user set if used.

206

230

Inverter HW
Detected a Fault Bit
Non Was Found 4

Inverter section of power structure hareware reported unexpected fault.

Check wiring harness.

206

231

Recyifier HW
Detected a Fault Bit
Non Was Found 4

Rectifier portion of pwoer structure hareware reported unexpected fault.

Check wiring harness.

206

232

Rctfr Not OK

A fault was detected in the rectifier other
than one specifically decoded,

Look at rectifier parameter 243 to see fault
code.

200

233

Precharge closed

Precharge was closed when it should be
open.

. Check AUX contacts on precharge.
2. Check input bit 0 in rectifier parameter
to view status of input.
3. Check wiring.
4. Check precharge resistors and fuses.

206

Precharge was open when it should be
closed.

. Check AUX contacts on precharge.
2. Check input bit 0 in rectifier parameter
to view status of input.
3. Check wiring.
4. Check precharge resistors and fuses.

234

Precharge open

Verify
Check
Check
Verify

in input power

209

proper input voltage.
line sync board and fuse.
AC line I/O board.
connection between boards.

216

206
216

235

Rctfr Pwr Board

Drive rating information stored on the
)ower board is incompatible with the Main
Control board.
The checksum read from the board does
not match the checksum calculated.

Load compatible version files into drive.
. Cycle power to the drive.
2. If problem persists, replace drive.

206

236

Rctfr I/O Board

Loss of communication
Board failure.

Cycle power.
. Cycle power.
2. If fault repeats, replace I/O board.

206

237

Rectifier Start Timed
Out 4

The rectifier did not regulate to the desired
bus voltage within the defined time.

Replace rectifier power board and/or rectifier
control board.

206

238

Rectified Not Logged
In 4

Rectifier took too long to connect to
inverter,

. Check the cabling between the communications interface and the two control boards.
2. Connect one DPI device at a time to see if
one of the DPI devices is causing the
problem.
3. Replace the communications interface.
4. Replace the rectifier control board.

206

239

Rectifier Power
Phased ACB 4

Input power is phased ACB rather than
ABC.

Switch two of the input power phases.

206

to I/O board.

LEGEND
DPI/I/O
EPROM
FLA
IGBT
NP

------

Drive Peripheral Interface Inputs/Outputs
Erasable, Programmable, Read-Only
Full Load Amps
Insulated Gate Bipolar Transistor
Nameplate

Table 18A -- Thermistor Temperature (F) vs. Resistance/Voltage
TEMPERATURE

-25
-24
-23
-22
-21
-20
-19
-18
-17
-16
-15
-14
-13
-12
-11
-10
-9
-8
-7
-6
-5
-4
-3
-2
-1
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
58
57
58
59

PIC III
VOLTAGE
DROP (V)

RESISTANCE
(Ohms)

4.700
4.690
4.680
4.670
4.659
4.648
4.637
4.625
4.613
4.601
4.588
4.576
4.562
4.549
4.535
4.521
4.507
4.492
4.477
4.461
4.446
4.429
4.413
4.396
4.379
4.361
4.344
4.325
4.307
4.288
4.269
4.249
4.229
4.209
4.188
4.167
4.145
4.123
4.101
4.079
3.056
4.033
4.009
3.985
3.960
3.936
3.911
3.886
3.861
3.835
3,808
3.782
3.755
3.727
3.700
3.672
3.644
3.617
3.588
3.559
3.530
3.501
3.471
3.442
3.412
3.382
3.353
3.322
3.291
3.260
3.229
3.198
3.167
3.135
3.104
3.074
3.042
3.010
2.978
3.946
2.914
2.882
2.850
2.819
2.788

98,010
94,707
91,522
88,449
85,486
82,627
79,871
77,212
74,648
72,175
69,790
67,490
65,272
63,133
61,070
59,081
57,162
55,311
53,526
51,804
50,143
48,541
46,996
45,505
44,066
42,679
41,339
40,047
38,800
37,596
36,435
35,313
34,231
33,185
32,176
31,202
30,260
29,351
28,473
27,624
26,804
26,011
25,245
24,505
23,789
23,096
22,427
21,779
21,153
20,547
19,960
19,393
18,843
18,311
17,796
17,297
16,814
16,346
15,892
15,453
15,027
14,614
14,214
13,826
13,449
13,084
12,730
12,387
12,053
11,730
11,416
11,112
10,816
10,529
10,250
9,979
9,717
9,461
9,213
8,973
8,739
8,511
8,291
8,076
7,868

TEMPERATURE

(F)
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
119
120
121
122
123
124
125
126
127
128
129
130
131
132
133
134
135
136
137
138
139
140
141
142
143
144

PIC III
VOLTAGE
DROP (V)

RESISTANCE
(Ohms)

2.756
2.724
2.692
2.660
2.628
2.596
2.565
2.533
2.503
2.472
2.440
2.409
2.378
2.347
2.317
2.287
2.256
2.227
2.197
2.167
2.137
2.108
2.079
2.050
2.021
1.993
1.965
1.937
1.989
1.881
1.854
1.827
1.800
1.773
1.747
1.721
1.695
1.670
1.644
1.619
1.595
1.570
1.546
1.523
1.499
1.476
1.453
1.430
1.408
1.386
1.364
1.343
1.321
1.300
1.279
1.259
1.239
1.219
1.200
1.180
1.161
1.143
1.124
1.106
1.088
1.070
1.053
1.036
1.019
1.002
0.986
0.969
0.953
0.938
0.922
0.907
0.893
0.878
0.864
0.849
0.835
0.821
0.808
0,795
0.782

7,665
7,468
7,277
7,091
6,911
6,735
6,564
6,399
6,238
6,081
5,929
5,781
5,637
5,497
5,361
5,229
5,101
4,976
4,855
4,737
4,622
4,511
4,403
4,298
4,196
4,096
4,000
3,906
3,814
3,726
3,640
3,556
3,474
3,395
3,318
3,243
3,170
3,099
3,031
2,964
2,898
2,835
2,773
2,713
2,655
2,597
2,542
2,488
2,436
2,385
2,335
2,286
2,239
2,192
2,147
2,103
2,060
2,018
1,977
1,937
1,898
1,860
1,822
1,786
1,750
1,715
1,680
1,647
1,614
1,582
1,550
1,519
1,489
1,459
1,430
1,401
1,373
1,345
1,318
1,291
1,265
1,240
1,214
1,190
1,165

9.5

TEMPERATURE

(F)
145
146
147
148
149
150
151
152
153
154
155
156
157
158
159
160
161
162
163
164
165
166
167
168
169
170
171
172
173
174
175
176
177
178
179
180
181
182
183
184
185
186
187
188
189
190
191
192
193
194
195
196
197
198
199
200
201
202
203
204
205
206
207
208
209
210
211
212
213
214
215
216
217
218
219
220
221
222
223
224
225

Drop
PIC III
VOLTAGE
DROP (V)
0.769
0.756
0.744
0.731
0.719
0.707
0.696
0.684
0.673
0.662
0.651
0.640
0.630
0.619
0.609
0.599
0,589
0.579
0.570
0.561
0.551
0.542
0.533
0.524
0.516
0.508
0.499
0.491
0,484
0.476
0.468
0.460
0.453
0.445
0,438
0,431
0,424
0.418
0.411
0,404
0.398
0.392
0.385
0.379
0.373
0.367
0.361
0.356
0.350
0.344
0.339
0.333
0.328
0.323
0.318
0.313
0.308
0.304
0.299
0.294
0.290
0.285
0.281
0.277
0.272
0.268
0.264
0.260
0.256
0.252
0.248
0.245
0.241
0.237
0.234
0.230
0.227
0.224
0.220
0.217
0.214

RESISTANCE
(Ohms)
1,141
1,118
1,095
1,072
1,050
1,029
1,007
986
965
945
925
906
887
868
850
832
815
798
782
765
75O
734
719
7O5
690
677
663
650
638
626
614
602
591
581
570
561
551
542
533
524
516
5O8
501
494
487
48O
473
467
461
456
45O
445
439
434
429
424
419
415
410
4O5
401
396
391
386
382
377
372
367
361
356
35O
344
338
332
325
318
311
3O4
297
289
282

Table 18B -- Thermistor Temperature
TEMPERATURE

(c)
-33
-32
-31
-30
-29
-28
-27
-26
-25
-24
-23
-22
-21
-20
-19
-18
-17
-16
-15
-14
-13
-12
-11
-10
-9
--8
-7
-6
-6
-4
--3
-2
-1
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
2O
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37

PIC III
VOLTAGE DROP (V)
4.722
4.706
4.688
4.670
4.650
4.630
4.608
4.586
4.562
4.538
4.512
4.486
4.458
4.429
4.399
4.368
4.336
4.303
4.269
4.233
4.196
4.158
4.119
4.079
4.037
3.994
3.951
3.906
3.861
3.814
3.765
3.716
3.667
3.617
3.565
3.512
3.459
3.406
3.353
3.298
3.242
3.185
3.129
3.074
3.016
2.959
2.901
2.844
2.788
2.730
2.672
2.615
2.559
2.503
2.447
2.391
2.335
2.280
2.227
2.173
2.120
2.067
2.015
1.965
1.914
1.865
1.816
1.768
1.721
1.675
1.629

RESISTANCE
(Ohms)
106 880
100 260
94 165
88 480
83170
78125
73 580
69 250
65 205
61 420
57 875
54 555
51 450
48 536
45 807
43 247
40 845
38 592
38 476
34 489
32 621
30 866
29 216
27 633
26 202
24 827
23 532
22 313
21 163
20 079
19 058
18 094
17 184
16 325
15 515
14 749
14 026
13 342
12 696
12 085
11 506
10 959
10 441
9 949
9 485
9 044
8 627
8 231
7 855
7 499
7 161
6 840
6 536
6 246
5 971
5 710
5 461
5 225
5 000
4 786
4 583
4 389
4 204
4 028
3 861
3 701
3 549
3 404
3 266
3 134
3 008

(c)
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
101
102
103
104
105
106
107

Drop

PIC III
VOLTAGE DROP (V)
1.585
1.542
1.499
1.457
1.417
1.377
1.338
1.300
1.263
1.227
1.192
1.158
1.124
1.091
1.060
1.029
0.999
0.969
0.941
0.913
0.887
0.861
0.835
0.811
0.787
0.764
0.741
0.719
0.698
0.677
0.657
0.638
0.619
0.601
0.583
0.566
0.549
0.533
0.518
0.503
0.488
0.474
0.460
0.447
0.434
0.422
0.410
0.398
0.387
0.376
0.365
0.355
0.344
0.335
0.325
0.316
0.308
0.299
0.291
0.283
0.275
0.267
0.260
0.253
0.246
0.239
0.233
0.227
0.221
0.215

RESISTANCE
(Ohms)
2 888
2 773
2 663
2 559
2 459
2 363
2 272
2 184
2 101
2 021
1 944
1 871
1 801
1 734
1 670
1 609
1 550
1 493
1 439
1 387
1 337
1 290
1 244
1 200
1 158
1 116
1 079
1 041
1 006
971
938
906
876
836
8O5
775
747
719
693
669
645
623
6O2
583
564
547
531
516
5O2
489
477
466
456
446
436
427
419
410
4O2
393
385
376
367
357
346
335
324
312
299
285

Control

Modules

the ICVC. Communications
between the [CVC and the
CCM is accomplished
through the SIO (Sensor Input/
Output) bus, which is a phone cable. The communication
between the CCM and VFD is accomplished through the
sensor bus, which is a 3-wire cable.

Turn controller power off before servicing controls. This
ensures safety and prevents &image to the controllec

The ICVC and CCM modules perform continuous diagnostic evaluations of the hmdware to determine its condition.
Proper operation
of all modules
is indicated
by LEDs
(light-emitting diodes) located on the circuit board of the ICVC
and CCM.

All system operating intelligence resides in the ICVC.
Some safety shutdown logic resides in the Gateway in
case communications
are lost between the VFD and
ICVC. Outputs are controlled by the CCM and VFD as
well.

There is one green LED located on the CCM board, and one
red LED located on the ICVC and CCM boards respectively.
RED LED (Labeled as STAT) --If the red LED:
•
•
•
•

Blinks continuously
at a 2-second interval, the module is
operating properly
Is lit continuously,
there is a problem
that requires
replacing the module
Is off continuously,
the power should be checked
Blinks 3 times per second, a software error has been
discoveled and the module must be replaced

on Module

Power is supplied to the modules within the control panel
via the 24-vac TI and T2 transformers. The transformers
_u'e located within the power panel.
In the power panel, TI supplies power to the compressor
oil heatel: and optional hot gas bypass, and T2 supplies
power to both the ICVC and CCM.
T3 provides 24V power to the optiomd
DataLINK TM modules.

If there is no input powel, check the luses and circuit breaker
If the fuse is good, check for a shorted secondary of the transformer or. if power is present to the module, replace the module.
GREED LED (Labeled as COM)-These
LEDs
indicate
the communication
status between different paris of the controller and the network modules and should blink continuously.
Notes

If a green LED is on continuously, check the communication wiring. If a green LED is off. check the red LED
operation. If the red LED is normal, check the module
address switches (SWI) (Fig. 44 and 45). Confirm _dl
switches _ue in OFF position.

Power is connected

Chiller Control

DataPort

to Plug Jl on each module.

Module

(CCM) (Fig

45)

INPUTS -- Each input channel has 2 or 3 terminals. Refer to
individual chiller wiring diagrams for the con'ect terminal
numbers for a specific application.
OUTPUTSOutput is 24 vac. There are 2 termimds per
output. Refer to the chiller wiring diagram for a specific
application for the correct terminal numbel_.

Operation

1. The chiller operator monitors and modifies configurations in the microprocessor
by using the 4 softkeys and

MODULE
PART NUMBER
SOFTWARE
PART NUMBER

CCN INTERFACE
CONNECTION

DATALINK
DATAPORT

/
We

• /

OR
MODULE

(OPTION)

•

m
o

o @

ICVC

[]CB1

[

@
CONTRAST
ADJUSTMENT

/
BACK OFICVC

J7 SIO

/
J1 POWER/
CCN

\
J8 SERVICE

SWl

Fig 44 -- Rear of ICVC (International Chiller Visual Controller)

J1
24 VAC

° ©

ANA' OUT

SIO
J6 "------.-

SW2

Fig. 45 -- Chiller Control Module (CCM)

Replacing

Defective

Processor

Modules

The module replacement pan number is printed on a sm_dl
label on the rear of the ICVC module. The chiller model and
serial numbers tue printed on the chiller nameplate located on
an exterior corner post. The proper software is factory-installed
by Carrier in the replacement
module. When ordering a
replacement chiller visual control (ICVC) module, specify the
complete replacement part number, lilll chiller model numbek
and chiller serial numbel: The installer must configure the new
module to the original chiller data. Follow the procedures
described in the Software Configuration section on page 61.

Electrical shock can cause pel,sonal injm 7. Disconnect
electrical power before servicing.

all

INSTALLATION
1. Verify the existing ICVC module is defective by using the
procedure
described
in the Troubleshooting
Guide
section, page 79, and the Control Modules
section,
page 97. Do not select the ATTACH TO NETWORK
DEVICE table if the [CVC indicates a communication
failure.
2.

Power off the controls.

Remove the old ICVC.

Install the new ICVC module.
back on.

The [CVC now
network device.

Data regarding the ICVC configuration should have been
recorded and saved. This data must be reconfigured into
the new ICVC. If this data is not available, follow the
procedures
described
in the Software
Configuration
section. If the module to be replaced is functional, configurations may also be copied manually. The &{ta sheets on
pages CL-3 and CL-II _u'e provided for this purpose.
Default values are shown so that only deviations from
these need to be recorded.
98

If a CCN Building Supervisor or Service Tool is available, the module configuration should have already been
uploaded
into memory. When the new module is
installed, the configuration can be downloaded from the
computec
Any communication
wires from other chillers or CCN
modules should be disconnected
to prevent the new
ICVC module from uploading incorrect run hours into
memw 7.
Record wdues for the TOTAL COMPRESSOR
STARTS,
SERVICE ONTIME and the COMPRESSOR
ONTIME
from the MAINSTAT screen on the ICVC.

automatically

Turn the control
attaches

to the

power
local

Set the current time and &tie in the SERVICE/TIME
AND DATE screen. Set the CCN Bus and Address in the
SERVICE / ICVC CONFIGURATION
screen. Press the
alarm RESET softkey (from the default screen). Upload
via Service Tool or manually reenter all non-default
configuration
values. (Refer to pages CL-3 through
CL-II.)
If the correct VFD Configuration
values are
displayed in the VFD_CONF
table when that table is
viewed, simply press EXIT then SAVE to reload all
of them. Use Service Tool or manually reenter TOTAL
COMPRESSOR
STARTS,
SERVICE
ONTIME
and
COMPRESSOR
ONTIME. [f forced using Service Tool,
release the force on SERVICE ONTIME after the desired
v_due has been set.

9. Perform
theguidevane
calibration
procedure
(inControl
Test).
Check
andrecalibrate
pressure
transducer
leadings
(refertopage64).Check
thattheCURRENT TIME and
DATE in the TIMEAND

DPI RIBBON
CABLE CONNECTOR

DATE screen are correct.

DPI Communications
Interface Board Status LEDs -- VFD
status can be determined
from the status LEDs on the DPI
Communications
Interface Board shown in Fig. 46. The DPI
Board is mounted on file fiont of the VFD power module in a
vertical orientation.

Gateway
provides
SIO bus
The SIO
connector

Status
LEDsThe RS485 VFD Gateway
a communication
link between the CCM and ICVC
to the VFD Drive Peripheral Interface (DPI) board.
bus communicates
with the Gateway through VFD
A32. See Fig. 47.

The Gateway has four status indicators on the top side of the
module.
DRIVE STATUS INDICATOR
-- The DRIVE status indicator is on the right side of the Gateway. See Table 19.

A32
TERMINAL BLOCK

NUMBER

STATUS
INDICATOR

DRIVE

NET A

NET B

DESCRIPTION
DPI Connection

Status

Module Status
Serial Communication
Serial Communication

NOTE: If all status indicators
power.

Status

Traffic Status

are off, the Gateway is not receiving

Fig. 47 -- Gateway Status LEDs

,7.110

T=0
° =°-°

Ill =

N
RECTIFIER LED

COLOR
G teen
Yellow
Red
Red Inverter
Green Rectifier

INTVERTER LED

STATE
Flashing

DESCRIPTION
Drive ready, but not running and no faults are present

Steady

Drive running, no faults are present.

Flashing
Steady

The drive is not ready. A VFD start inhibit is in effect.
An alarm condition exits. Check VFD Fault Code in ICVC VFD

Flashing

A fault has occurred. Check VFD Fault Code in ICVC VFD STAT screen.

Steady

A non-resettable

Steady

VFD Gate Kill circuit has opened due to a normal shutdown command or because the
compressor high pressure switch has opened. This status LED combination is normal
when the chiller is not running.

Fig. 46-

STAT screen.

fault has occurred. Check VFD Fault Code in ICVC VFD STAT screen.

DPI Communications

Interface Board Status LEDs

Table 19 -- DRIVE Status Indicator
STATE
Off

CAUSE

Flashing
Red
Solid
Red

Orange

Flashing
Green

Solid
Green

LED

Table

STATE
Off

ACTION

The Gateway is not
powered or is not connected properly to the
drive.

• Securely connect the
Gateway to the drive using
the DPI ribbon cable.
• Apply power to the drive.

The Gateway is not
receiving a ping message from the drive.
The drive has refused
an I/O connection from
the Gateway.

• Verify that cables are
securely connected.
• Cycle power to the drive.
IMPORTANT: Cycle power
after making the following
correction:
• Verify that all DPI cables
on the drive are securely
connected and not damaged. Replace cables if
necessary.

The Gateway is connected to a product that
does not support Rockwell Automation DPI
communications.

• Check wires leading to the
A32 terminal block.
• Check that A32 terminal
block is fully engaged.

The Gateway is establishing an I/O connection to the drive or the
I/O has been disabled.

Normal behavior.

The Gateway is properly connected and is
communicating with the
drive.

No action required.

MS STATUS
second

CORRECTIVE

Table 21 -- NET A Status Indicator:
State Definitions

INDICATOR
from
--

The MS status

Indicator:

CAUSE

Off

The module is not powered or is not properly
connected to the
network.

• Securely connect the
Gateway ribbon cable to
the drive DPI board.
• Attach the RS485 cable in

First incoming network
command not yet recognized.

Gateway to the connector.
• Apply power to the drive.

Flashing
Green

Online to network, but
not producing or consuming I/O information,

No action required. The LED
will turn solid green when
communication resumes.

Solid
Green

The module is properly
connected and communicating on the network.

No action required.

Off

indicator

Solid
Green

is the

CAUSE

CORRECTIVE

ACTION

Gateway not receiving
data over the network.

• Check wires leading to
A32 terminal block.
• Check that A32 terminal
block is fully engaged.

Gateway is transmitting data.

No action required.

20.

Physical

Data -- Tables 23A-29 and Fig. 48-57 provide
additional information on component weights, compressor fits
and clearances, physical and electrical &Lta, and wiring schematics for the operator's convenience during troubleshooting.

Definitions

CORRECTIVE

ACTION

Table 22 -- NET B Status Indicator:
State Definitions

See Table
State

CORRECTIVE

NET B STATUS INDICATOR -- Tile NETB status indicator
is the left LED on file Gateway. See Table 22.

STATE

the fight of the Gateway.

MS Status

STATE

ACTION

The Gateway is not
)owered.

• Securely connect the
Gateway to the drive using
the ribbon cable.
• Apply power to the drive.

Flashing
Green

The Gateway is operational. No I/O data is
being transferred.

Normal behavior during SIC
configuration initialization
3rocess.

Solid
Red

The Gateway is operational and transferring
I/O data.

No action required.

Do not attempt to disconnect flanges while the machine is
under pressure. Failure to relieve pressure can result in persomd injury or damage to the unit.

NET A STATUS INDICATOR
-- The NET A status indicator is tile third LED from the right of the Gateway. See
Table 21.

Before rigging the compressor,
ing the power panel.

100

disconnect

all wires enter-

Table 23A -- Heat Exchanger Data (English)
ENGLISH

NUMBER OF TUBES
Dry (Rigging) Weight (Ib)

SIZE
Cooler

Condenser

Cooler Only

Condenser

Chiller
Only

Refrigerant Weight (Ib)
Cooler
Condenser

Charge
Water Volume (gal)
Cooler
Condenser

10
11
12

142
161
180

180
200
225

2,707
2,777
2,848

2,704
2,772
2,857

290
310
330

200
200
200

34
37
40

42
45
49

15
16
17

142
161
180

180
200
225

2,968
3,054
3,141

2,984
3,068
3,173

320
340
370

250
250
250

39
43
47

48
52
57

20
21
22

200
240
282

218
266
315

3,407
3,555
3,711

3,373
3,540
3,704

345
385
435

225
225
225

48
55
62

48
55
63

30
31
32

200
240
280

218
267
315

4,071
4,253
4,445

3,694
3,899
4,100

350
420
490

260
260
260

56
64
72

56
65
74

35
36
37

200
240
280

218
267
315

4,343
4,551
4,769

4,606
4,840
5,069

400
480
550

310
310
310

61
70
80

62
72
83

40
41
42

324
364
400

370
417
463

4,908
5,078
5,226

8,039
5,232
5,424

560
630
690

280
280
280

104
112
119

110
119
129

45
46
47

324
364
400

370
417
463

5,363
5,559
5,730

5,602
5,824
6,044

640
720
790

330
330
330

112
122
130

120
130
141

50
51
52

431
485
519

509
556
602

8,713
5,940
6,083

6,090
6,283
6,464

750
840
900

400
400
400

132
143
150

147
156
165

5A
5B
50

225
241
258

----

5,124
5,177
5,243

500
520
550

----

123
126
129

----

55
56
57

431
485
519

509
556
602

6,257
6,517
6,682

870
940
980

490
490
490

144
156
164

161
171
182

5F
5G
5H

225
241
258

----

5,577
5,640
5,716

550
570
600

----

133
137
141

----

60
61
62

557
599
633

648
695
741

6,719
6,895
7,038

6,764
6,949
7,130

940
980
1020

420
420
420

168
176
183

182
191
200

65
66
67

557
599
633

648
695
741

7,392
7,594
7,759

7,682
7,894
8,102

1020
1060
1090

510
510
510

183
193
201

200
210
220

70
71
72

644
726
790

781
870
956

9,942
10,330
10,632

10,782
11,211
11,612

1220
1340
1440

780
780
780

241
259
274

267
286
305

NOTES:
1. Cooler data: based on a
150 psig, nozzle-in-head
includes suction elbow,
Weight does not include

---6,785
7,007
7,215
----

2. Condenser data: based on a condenser with standard wall tubing, 2-pass, 150 psig, nozzle-in-head waterbox with victaulic
grooves. Weight includes the float valve, discharge elbow, and
distribution piping. Weight does not include unit-mounted starter,
isolation valves, and pumpout unit.

coolerwith standard wall tubing, 2-pass,
waterbox with victaulic grooves. Weight
control panel, and distribution piping,
compressor,

101

Table 23B -- Heat Exchanger Data (Sl)
NUMBER OF TUBES

Sl
Dry (Rigging) Weight (kg)

SIZE

Condenser

Only

Chiller
Refrigerant
Cooler

Weight(kg)
Condenser

Charge
Water
Cooler

Volume (L)
Condenser

Cooler

Condenser

Cooler Only

10
11
12

142
161
180

180
200
225

1228
1260
1292

1227
1257
1296

132
141
150

91
91
91

129
140
151

159
170
185

15
16
17
20
21
22

142
161
180
200
240
282

180
200
225
218
266
315

1346
1385
1425
1545
1613
1683

1354
1392
1439
1530
1606
1680

145
154
168

113
113
113

148
163
178

182
197
216

156
175
197

102
102
102

182
208
235

182
208
238

30
31
32

200
240
282

218
266
315

1847
1929
2016

1676
1769
1860

159
191
222

118
118
118

212
242
273

212
246
280

35
36
37

200
240
282

218
266
315

1970
2064
2163

2089
2195
2299

181
218
249

141
141
141

231
265
303

235
273
314

40
41
42
45
46
47

324
364
400
324
364
400

366
415
464
366
415
464

2226
2303
2370
2433
2522
2599

2286
2373
2460
2541
2642
2742

254
286
313

127
127
127

394
424
450

416
450
488

290
327
358

150
150
150

424
462
492

454
492
534

50
51
52

431
485
519

507
556
602

2591
2694
2759

2762
2850
2932

340
381
408

181
181
181

500
541
568

556
591
625

5A
5B
50

225
241
258

----

2324
2348
2378

----

227
236
249

55
56
57
5F
5G
5H

431
485
519
225
241
258

507
556
602
----

2838
2956
3031
2530
2558
2593

3078
3178
3273
----

395
426
445

60
61
62

557
599
633

648
695
741

3048
3128
3192

3068
3152
3234

426
445
463

191
191
191

636
666
693

689
723
757

65
66
67

557
599
633

648
895
741

3353
3445
3519

3485
3581
3675

463
481
494

231
231
231

693
731
761

757
795
833

70
71
72

644
726
790

781
870
956

4510
4686
4823

4891
5085
5267

553
608
653

354
354
354

912
980
1037

1011
1083
1155

NOTES:
1. Cooler data: based on a cooler with standard wall tubing, 2-pass,
1034 kPa, nozzleqn-head
waterbox with victaulic grooves.
Weight includes suction elbow, control panel, and distribution piping. Weight does not include compressor.

466
477
488
222
222
222

249
259
272

545
591
621

609
647
689

503
519
534

2. Condenser data: based on a condenser with standard wall tubing, 2-pass, 1034 kPa, nozzle-in-head waterbox with victaulic
grooves. Weight includes the float valve, discharge elbow, and
distribution piping. Weight does not include unit-mounted starter,
isolation valves, and pumpout unit.

102

Table 24A -- 19XRV Additional Data for Cooler Marine Water Boxes*
ENGLISH
COOLER
FRAME
FRAME
FRAME
FRAME
FRAME
FRAME
FRAME
FRAME
FRAME
FRAME
FRAME
FRAME
FRAME
FRAME
FRAME
FRAME
FRAME
FRAME
FRAME
FRAME
FRAME
FRAME
FRAME
FRAME
FRAME
FRAME
FRAME
FRAME

FRAME,

2, 1 AND 3
2, 2 PASS
3_ 1 AND 3
3, 2 PASS
4, 1 AND 3
4, 2 PASS
5, 1 AND 3
5, 2 PASS
6, 1 AND 3
6, 2 PASS
7, 1 AND 3
7, 2 PASS
8, 1 AND 3
8, 2 PASS
2, 1 AND 3
2, 2 PASS
3, 1 AND 3
3, 2 PASS
4, 1 AND 3
4, 2 PASS
5, 1 AND 3
5, 2 PASS
6, 1 AND 3
6, 2 PASS
7, 1 AND 3
7, 2 PASS
8, 1 AND 3
8, 2 PASS

PASS

PASS
PASS
PASS
PASS
PASS
PASS
PASS
PASS
PASS
PASS
PASS
PASS
PASS
PASS

peig
150
150
150
150
150
150
150
150
150
150
150
150
150
150
300
300
300
300
300
300
300
300
300
300
300
300
300
300

Rigging Weight
(Ib)
730
365
730
365
1888
944
2448
1223
2860
1430
3970
1720
5048
2182
860
430
860
430
2162
1552
2655
1965
3330
2425
5294
4140
6222
4952

SI
Water Volume
(gal)
84
42
84
42
109
54
122
61
139
69
309
155
364
182
84
42
84
42
109
47
122
53
139
58
309
146
364
161

*Add to heat exchanger data for total weights or volumes.
NOTES:
1. Weight adder shown is the same for cooler and condenser of equal frame
size.

kPa
1034
1034
1034
1034
1034
1034
1034
1034
1034
1034
1034
1034
1034
1034
2068
2068
2068
2068
2068
2068
2068
2068
2068
2068
2068
2068
2068
2068

Rigging Weight
(kg)
331
166
331
166
856
428
1109
555
1297
649
1801
780
2290
990
390
195
390
195
981
704
1204
891
1510
1100
2401
1878
2822
2246

Water Volume

(L)
318
159
318
159
412
2O5
462
231
524
262
1170
585
1376
688
318
159
318
159
412
178
462
199
524
218
1170
553
1376
609

2, For the total weight of a vessel with a marine waterbox, add these values to
the heat exchanger weights (or volumes),

Table 24B -- 19XRV Additional Data for Condenser Marine Water Boxes*
ENGLISH
CONDENSER
FRAME
FRAME
FRAME
FRAME
FRAME
FRAME
FRAME
FRAME
FRAME
FRAME
FRAME
FRAME
FRAME
FRAME
FRAME
FRAME
FRAME
FRAME
FRAME
FRAME
FRAME
FRAME
FRAME
FRAME
FRAME
FRAME
FRAME
FRAME

2,
2,
3,
3,
4,
4,
5,
5,
6,
6,
7,
7,
8,
8,
2,
2,
3,
3,
4,
4,
5,
5,
6,
6,
7,
7,
8,
8,

FRAME, PASS

1 AND 3
2 PASS
1 AND 3
2 PASS
1 AND 3
2 PASS
1 AND 3
2 PASS
1 AND 3
2 PASS
1 AND 3
2 PASS
1 AND 3
2 PASS
1 AND 3
2 PASS
1 AND 3
2 PASS
1 AND 3
2 PASS
1 AND 3
2 PASS
1 AND 3
2 PASS
1 AND 3
2 PASS
1 AND 3
2 PASS

PASS
PASS
PASS
PASS
PASS
PASS
PASS
PASS
PASS
PASS
PASS
PASS
PASS
PASS

psig
150
150
150
150
150
150
150
150
150
150
150
150
150
150
300
300
300
300
300
300
300
300
300
300
300
300
300
300

Rigging Weight
!lb)
N/A
365
N/A
365
N/A
989
N/A
1195
N/A
1443
N/A
1561
N/A
1751
N/A
430
N/A
430
N/A
1641
N/A
1909
N/A
2451
N/A
4652
N/A
4559

SI
Water Volume
N/A
42
N/A
42
N/A
54
N/A
60
N/A
69
N/A
123
N/A
141
N/A
42
N/A
42
N/A
47
N/A
50
N/A
58
N/A
94
N/A
94

*Add to heat exchanger data for total weights or volumes.
NOTES:
1. Weight adder shown is the same for cooler and condenser of equal frame
size.

kPa
1034
1034
1034
1034
1034
1034
1034
1034
1034
1034
1034
1034
1034
1034
1034
2068
2068
2068
2068
2068
2068
2068
2068
2068
2068
2068
2068
2068

Rigging

Weight

N/A
166
N/A
166
N/A
449
N/A
542
N/A
655
N/A
708
N/A
794
N/A
195
N/A
195
N/A
744
N/A
866
N/A
1112
N/A
2110
N/A
2068

Water Volume

tL)
N/A
159
N/A
159
N/A
2O5
N/A
226
N/A
262
N/A
465
N/A
532
N/A
159
N/A
159
N/A
178
N/A
190
N/A
218
N/A
386
N/A
385

2, For the total weight of a vessel with a marine waterbox, add these values to
the heat exchanger weights (or volumes),

103

Table 25A -- 19XRV Motor Weights -- Standard
MOTOR
CODE

Motors

ENGLISH
StatorWeight*(Ib)
60 Hz
50 Hz

Rotor Weightt (Ib)
60 Hz
50 Hz

End Bell
Cover(Ib)

Stator Weight* (kg)
60 Hz
50 Hz

Rotor Weightt (kg)
60 Hz
50 Hz

End Bell
Cover(kg)

900

915

190

205

185

408

415

915

965

200

220

185

415

438

100

975

1000

215

230

185

442

454

104

BG
BH

1000
1030

1060

230

250

185

454

481

104

113

1175

240

265

185

467

501

109

120

1105

185

501

120

1154

1188

236

255

274

523

539

107

116

125

1182

1196

243

260

274

536

542

110

118

125

CD
CE

1220
1253

1258

252

270

274

553

571

114

122

125

1272

261

281

274

568

577

118

127

125

1261

1328

265

284

274

572

602

120

129

125

1294

1353

273

293

274

587

614

124

133

125

1321

1386

280

303

274

599

629

127

137

125

1343

1413

282

308

274

609

641

128

140

125

1419

1522

300

336

274

644

690

136

152

125

1567

274

711

152

125

1570

1725

324

347

236

712

782

147

157

107

1580

1737

326

354

236

717

788

148

161

107

DD
DE

1919
1939

2069

423

458

318

870

938

192

208

144

2089

428

463

318

880

948

194

210

144

1989

2139

448

478

318

902

970

203

217

144

2054

1998

473

422

318

932

906

215

191

144

2099

2056

488

443

318

952

933

221

201

144

2159

2101

508

464

318

979

953

230

210

144

2380

318

1080

237

145

2700

2770

651

701

414

1388

1415

295

341

188

2760

2890

670

701

414

1408

1474

325

341

188

2760

2890

670

718

414

1442

1474

325

348

188

2800

2960

685

751

414

1442

1529

334

363

188

2800

2960

685

751

414

1483

1529

334

363

188

2960

3110

751

801

414

1483

1597

363

386

188

2960

3110

780

801

414

1515

1597

376

386

188

3110

414

1411

363

188

265

335

522

801

*Stator weight includes stator and shell.
tRotor weight includes rotor and shaft.

NOTE: When different voltage
largest weightis given.

104

motors

have different weights

the

Table 25B -- 19XRV Motor Weights -- High-Efficiency
MOTOR
CODE

Motors
SI

ENGLISH

Stator Weight*(Ib)
60 Hz
50 Hz

Rotor Weightt
(Ib)
60 Hz
50 Hz

End Bell
Cover (Ib)

StatorWeight*(kg)
60 Hz
50 Hz

Rotor Weightt (kg)
60 Hz
50 Hz

End Bell
Cover (kg)

1030

240

185

467

109

1070

250

185

485

113

1120

265

185

508

120

BG
BH

1175
1175

1175

290

185

533

132

1175

290

185

533

132

1175

185

533

1235

1290

242

255

274

560

585

110

116

125

1260

1295

249

259

274

572

587

113

117

125

CD
CE

1286
1305

1358

258

273

274

583

616

117

124

125

1377

265

279

274

592

625

120

127

125

1324

1435

280

296

274

601

651

127

134

125

1347

1455

303

298

274

611

660

137

135

125

1358

1467

316

274

616

665

143

125

1401

1479

329

316

274

635

671

149

143

125

1455

1479

329

274

660

671

149

125

1567

274

711

1950

406

318

885

184

144

1950

2025

406

429

318

885

919

184

195

144

DD
DE

2150
2150

2250

536

546

318

975

1021

243

248

144

2250

550

318

975

1021

249

144

2250

2380

575

567

318

1021

1080

261

257

144

2250

2380

599

318

1021

1080

272

144

2380

604

318

1080

274

144

2380

614

318

1080

279

144

2380

318

1080

1873

1939

364

389

318

850

880

165

176

144

1939

2023

389

406

318

850

918

176

184

144

2023

2043

406

417

318

880

927

184

189

144

2043

2096

417

434

318

918

951

189

197

144

2096

2133

434

444

318

927

968

197

201

144

2133

2199

444

458

318

951

997

201

2O8

144

2199

318

968

3060

3120

701

751

414

1388

1415

318

341

188

EJ
EK

3105
3180

3250

716

751

414

1408

1474

325

341

188

3250

716

768

414

1442

1474

325

348

188

3180

3370

737

801

414

1442

1529

334

363

188

3270

3370

737

801

414

1483

1529

334

363

188

3270

3520

801

851

414

1483

1597

363

386

188

3340

3520

830

851

414

1515

1597

376

386

188

3520

414

1597

290

335

614

458

851

*Stator weightincludes
stator and shell.
tRotor weightincludesrotor
and shaft.

132

152

125

279

144

2O8

386

NOTE: When different voltage
largest weight is given.

105

motors

144

188
have different weights

the

Table 26A -- 19XRV Waterbox
HEAT
EXCHANGER

COOLER/
CONDENSER

WATERBOX

DESCRIPTION

Cover Weights -- English (Ib)

FRAME 1
Standard
Nozzles
Flanged

COOLER/
CONDENSER

HEAT
EXCHANGER

COOLER/
CONDENSER

HEAT
EXCHANGER

COOLER/
CONDENSER

177

204

320

350

32O

35O

NIH, 2 Pass Cover, 150 psig

185

218

320

350

32O

35O

NIH, 3 Pass Cover, 150 psig

180

196

310

340

310

34O

NIH Plain End Cover, 150 psig

136

300

3OO

300

3OO

3OO
486

MWB End Cover, 150 psig
NIH, 1 Pass Cover, 300 psig

248

301

411

486

411

NIH, 2 Pass Cover, 300 psig

255

324

411

518

411

518

NIH, 3 Pass Cover, 300 psig

253

288

433

468

433

468

NIH Plain End Cover, 300 psig

175

400

4OO

400

4OO

FRAME 4
WATERBOX

DESCRIPTION

Standard
Nozzles

FRAME 5

FRAME

Flanged

NIH, 1 Pass Cover, 150 psig

148

185

168

229

187

223

NIH, 2 Pass Cover, 150 psig

202

256

224

298

257

330

NIH, 3 Pass Cover, 150 psig

473

489

629

655

817

843

NIH Plain End Cover, 150 psig
MWB End Cover, 150 psig

138

154

172

317

393

503

NIH, 1 Pass Cover, 300 psig

593

668

764

839

959

1035

NIH, 2 Pass Cover, 300 psig

594

700

761

878

923

1074

NIH, 3 Pass Cover, 300 psig

621

656

795

838

980

1031

NIH/MWB End Cover, 300 psig

569

713

913

FRAME 7 COOLER
WATERBOX

DESCRIPTION

Standard
Nozzles

Flanged

Standard
Nozzles

Flanged

329

441

329

NIH, 2 Pass Cover, 150 psig

426

541

426

541

NIH, 3 Pass Cover, 150 psig

1202

1239

1113

1171

315

789

7O3

NIH, 1 Pass Cover, 300 psig

1636

1801

1472

1633

NIH, 2 Pass Cover, 300 psig

1585

1825

1410

1644

NIH, 3 Pass Cover, 300 psig

1660

1741

1496

1613

NIH/MWB End Cover, 300 psig

1451

1440

FRAME 8 COOLER
WATERBOX

DESCRIPTION

Standard
Nozzles

Flanged

FRAME 7 CONDENSER

NIH, 1 Pass Cover, 150 psig

NIH Plain End Cover, 150 psig
MWB End Cover, 150 psig

Standard
Nozzles

441

FRAME 8 CONDENSER
Standard
Nozzles

Flanged

NIH, 1 Pass Cover, 150 psig

417

494

417

NIH, 2 Pass Cover, 150 psig

531

685

531

685

NIH, 3 Pass Cover, 150 psig

1568

1626

1438

1497

NIH Plain End Cover, 150 psig
MWB End Cover, 150 psig

404

1339

898

NIH, 1 Pass Cover, 300 psig

2265

2429

1860

2015

NIH, 2 Pass Cover, 300 psig

2170

2499

1735

2044

NIH, 3 Pass Cover, 300 psig

2273

2436

1883

1995

NIH/MWB End Cover, 300 psig

1923

1635

LEGEND
NIH
-MWB --

FRAME 3
Standard
Flanged
Nozzles

NIH, 1 Pass Cover, 150 psig

MWB End Cover, 300 psig

HEAT
EXCHANGER

FRAME 2
Standard
Nozzles
Flanged

494

NOTE:Weightfor
NIH 2-Pass Cover, 150 psigisincludedinthe
exchanger weights showninTable
23A.

Nozzle-lmHead
Marine Waterbox

106

heat

Table 26B -- 19XRV Waterbox
HEAT
EXCHANGER

COOLER/
CONDENSER

WATERBOX

DESCRIPTION

Cover Weights -- Sl (kg)

FRAME1
Standard
Nozzles
Flanged

HEAT
EXCHANGER

COOLER/
CONDENSER

HEAT
EXCHANGER

COOLER/
CONDENSER

145

159

145

159

NIH, 2 Pass Cover, 1034 kPa

145

159

145

159

NIH, 3 Pass Cover, 1034 kPa

141

154

141

154

NIH Plain End Cover, 1034 kPa

136

MWB End Cover, 1034 kPa
NIH, 1 Pass Cover, 2068 kPa

112

137

186

220

186

22O

NIH, 2 Pass Cover, 2068 kPa

116

147

186

235

186

235

NIH, 3 Pass Cover, 2068 kPa

115

131

196

212

196

212

181

FRAME 5

FRAME4

WATERBOX

DESCRIPTION

Standard
Nozzles

Flanged

Standard
Nozzles

FRAME 6

Flanged

Standard
Nozzles

Flanged

NIH, 1 Pass Cover, 1034 kPa

104

101

NIH, 2 Pass Cover, 1034 kPa

116

102

135

117

150

NIH, 3 Pass Cover, 1034 kPa

215

222

285

297

371

382

MWB End Cover, 1034 kPa
NIH, 1 Pass Cover, 2068 kPa

144

178

228

269

303

347

381

435

469

NIH, 2 Pass Cover, 2068 kPa

269

318

345

398

419

487

NIH, 3 Pass Cover, 2068 kPa

282

298

361

380

445

468

NIH/MWB End Cover, 2068 kPa

258

323

414

NIH Plain End Cover, 1034 kPa

FRAME 7 COOLER
WATERBOX

DESCRIPTION

Standard
Nozzles

Flanged

FRAME 7 CONDENSER
Standard
Nozzles

Flanged

NIH, 1 Pass Cover, 1034 kPa

149

200

149

2OO

NIH, 2 Pass Cover, 1034 kPa

193

245

193

245

NIH, 3 Pass Cover, 1034 kPa

545

562

5O5

531

NIH Plain End Cover, 1034 kPa

143

MWB End Cover, 1034 kPa
NIH, 1 Pass Cover, 2068 kPa

358

319

742

817

668

741

NIH, 2 Pass Cover, 2068 kPa

719

828

640

746

NIH, 3 Pass Cover, 2068 kPa

753

790

679

732

NIH/MWB End Cover, 2068 kPa

658

653

FRAME 8 COOLER
WATERBOX

DESCRIPTION

Standard
Nozzles

Flanged

FRAME 8 CONDENSER
Standard
Nozzles

Flanged

NIH, 1 Pass Cover, 1034 kPa

189

224

189

224

NIH, 2 Pass Cover, 1034 kPa

241

311

241

311

NIH, 3 Pass Cover, 1034 kPa

711

738

652

679

NIH Plain End Cover, 1034 kPa

183

MWB End Cover, 1034 kPa
NIH, 1 Pass Cover, 2068 kPa

607

407

1027

1102

844

914

NIH, 2 Pass Cover, 2068 kPa

984

1134

787

927

NIH, 3 Pass Cover, 2068 kPa

1031

1105

854

905

872

742

NIH/MWB End Cover, 2068 kPa
LEGEND
NIH
-MWB --

Flanged

MWB End Cover, 2068 kPa

COOLER/
CONDENSER

FRAME 3
Standard
Nozzles

NIH, 1 Pass Cover, 1034 kPa

NIH Plain End Cover, 2068 kPa

HEAT
EXCHANGER

FRAME 2
Standard
Nozzles
Flanged

NOTE:Weightfor
NIH 2-Pass Cover, 1034 kPa is included in the
heatexchanger
weights showninTable
23B.

Nozzle-In-Head
Marine Waterbox

107

Table 27 -- Optional Pumpout Electrical Data
PUMPOUT UNIT
19XR04026501

VOLTS-PH-Hz

19XR04026501

MAX

RLA

LRA

208/230-3-60

15.8

105

208/230-3-50

15.8

105

19XR04026502

460-3-60

7.8

19XR04026503

400-3-50

7.8

LEGEND
LRA
RLA

---

Locked Rotor Amps
Rated Load Amps

Table 28 -- Additional Miscellaneous
FRAME 2
COMPRESSOR

ITEM
CONTROL CABINET
OPTIONAL

DISCHARGE

OPTIONAL COOLER
UNIT-MOUNTED

ISOLATION VALVE

FRAME 3
COMPRESSOR

Ib
34

kg
15

INLET ISOLATION VALVE

VFD

1600

Weights

726

FRAME 4
COMPRESSOR

Ib
34

kg
15

Ib
34

kg
15

108

726

1600

726

1600

726

1600

LEGEND
VFD

Variable Frequency Drive

Table 29 -- Motor Voltage Code
MOTOR CODE

VOLTS

FREQUENCY

62
63
64
52

380
416
460
400

60
60
60
50

108

FRAME 5
COMPRESSOR

19XRV COMPRESSOR
COMPRESSOR

FITS AND CLEARANCES

FRAME 2

FRAME 3

(in.)
FRAME 4

FRAME 4

FRAME 5

Code

201-299

321-390, 3ZZ

421-490

4B1-4W8

501-600

DESCRIPTION

Fixed Diffuser

With Rolling
Element
Bearings

Fixed Diffuser

Split Ring
Diffuser

ITEM

Low Speed Journal-Gear

End

.0050/.0040

.0055/.0043

.0069/.0059

Low Speed Journal-Motor

End

.0050/.0040

.0053/.0043

.0065/.0055

.0115/.0055

N/A

.010/-.005

N/A

Low Speed Labyrinth to Thrust Disk

Labyrinth to Low Speed Shaft

N/A

.010/.005

.0095/.0055

.013/.009

Low Speed Shaft Thrust Float

.020/.008

.023/.008

.020/.008

Impeller Eye to Shroud

Impeller Bore to Shaft-Rear

Impeller Bore to Shaft-Front

Impeller Discharge to Shroud

Impeller Spacer to Shaft

Slinger to Shaft

-.0020/-.0005

-.0021/-.0006

-.0019/-.0005

N/A

-.0014/.0000

.0025/.0010

.0024/.0010

.0013/.0005

.0012/.0004

Labyrinth to Slinger

.013/.009

.010/.006

Labyrinth to Impeller

.012/.008

High Speed Journal-Impeller

.0047/.0037

N/A

.0040/.0028

.0048/.0038

Thrust Assembly Seal Ring Axial Clearance

Thrust Assembly Seal Ring to Shaft

High Speed Shaft Thrust Float

High Speed Journal-Gear

N/A

End

-.0025/-.0010

.006/.002

N/A

.006/.002

.0045/.0015

N/A

.0045/.0015

.014/.008

0 Float

.014/.008

.0050/.0040

N/A

.0048/.0038

.0062/.0052

*Depends on impeller size, contact your Carrier Service Re 3resentative for more information.

must be removed from the high speed shaft and bearing assembly before the high speed shaft and bearing assembly can be
separated from the transmission.
4.
If any components within the Frame 3 rolling element high speed
shaft and bearing assembly are damaged it is recommended that
the entire high speed shaft and bearing assembly be replaced.
5. Impeller spacing should be performed in accordance with the
most recent Carrier Impeller Spacing Service Bulletin.

NOTES:
1. All clearances for cylindrical surfaces are diametrical.
2. Dimensions shown are with rotors in the thrust position.
3. Frame 3 rolling element style high speed shaft and bearing
assembly cannot be pulled from impeller end. The transmission
assembly must be removed from the compressor casting (after
the impeller is removed) and the bearing temperature sensor

Fig. 48 -- Compressor

109

Fits and Clearances

SEE VIEW A10RA2

COMPRESSOR, TRANSMISSION
AREA (FRAME
1) OIL HEATER RETAINING NUT (NOT SHOWN)
2) BULLGEAR
RETAINING BOLT
3) DEMISTER BOLTS (NOT SHOWN)
4) IMPELLER BOLT

COMPRESSOR,

TRANSMISSION

5 COMPRESSOR

SEE VIEW B

SHOWN)

AREA

THRUST

Cl
VIEW A1
LOW SPEED SHAFT THRUST DISK

VIEW A2
LOW SPEED SHAFT THRUST DISK

Fig. 48 -- Compressor Fits and Clearances (cont)

110

NOTE5

IMPELLER SHIMMING
TO BE DETERMINED
AT ASSEMB_

SEE VIEW C

VIEW B -- HIGH SPEED SHAFT (FRAME 2, 4, OR 5)

+0.0007
0.025

+0.0007
-0.0007-

0.0011
0.0013
INTERFERENCE
0.0011
0.0013
INTERFERENCE
0.0012
0.0004

VIEW B -- HIGH SPEED
Fig. 48 --

Compressor

SHAFT (FRAME 3)

Fits and

III

Clearances

(cont)

\
VIEW C -- HIGH SPEED SHAFT RING SEAL

A CAUTION

CAUTION

USE COPPER CONDtJC'I'0RS
0NY
UTII,]SEZ

DES

ALWAYS
• TERM

USE

NUT

• ADAPTOR
Insulate

T0
TO

BOLTS

WRENCHES

INSULATOR

• BRASS
• LUG

CONDUCTEURS

ft.

ALWAYS USE 2 WRENCHES TO T]GHTEN,
o TERM INSULATOR TO MOTOR
15 35 ft Ib
o CABLE LUG NUTS .....
ft.lb.

ft. lb. max
[b,

[b.

with

cable

it+

....3

3035

+,ntir'r
+ cnnnection

including
1 inch
term
insulator.

15+35

INSULATOR
STUD

(1/2")

USE COPPER CONDUCTORS ONLY
UTII,ISEZ
DES CONDUCTEUBS EN CUIVRE SEUI,MENT

SEU,MENT

TIGHTEN,

M0'10R

TERM

CUIVRE

eler_Ir]eai

insulation

and

Insulate

iz_slllation
1

inch

entire

connection

including
1 inch
term
insulator.

@Je

with

electrical

(¸:able insula±,io_

insulation

and

i_ch

the

TAPETO EXTENDTO AND OVER
TERMINAL

STUD-

r.......

1©

_-INSULATION
-'\4---I

2@
3©

LEAD

}_TRE |NS[H,A

lCN

@6
@4

8@
A DAD'p]_N?

........

_A_NSS NU]" ]

L'-TERMINAL

INSIJLATOR

<-_-'A?+[ER ATTACHrNE

@,5

LEAD, 'tHiS

AREA

TO BE WRAPPED?_THONELAYFROF
TIIERNAL
INSULATION
PUTTY AND AT
I[,EAS']

FOUR

ELECTRICAL

LAYERS

INSULATING

APPROPRIATE

TAPE

MOTOR LEAD INSTALLATION LABELS

19XRV COMPRESSOR
COMPRESSOR

ITEM

ASSEMBLY TORQUES
FRAME 4

FRAME 4

FRAME 5

Code

FRAME 2
201-299

321=390, 3ZZ

FRAME 3

421-490

4B1-4W8

501-600

DESCRIPTION

Fixed Diffuser

With Rolling
Element
Bearings

Fixed Diffuser

Split Ring

Diffuser

Oil Heater Retaining Nut-

ft-lb (N'm)

N/A

18-22 (25-30)

Bull Gear Retaining Bolt--

ft-lb (N'm)

80-90 (108-122)

Demister

15-19 (20-26)

Impeller bolt Torque -- ft-lb (N'm)

32-48 (43-65)

55-60 (75-81)

160-225 (217-305)

Bolts -- ft Ib (N'm)

Fig. 48 -- Compressor Fits and Clearances (cont)
ll2

LEGEND
AUX
CB
CCM
CCN
COM
COMM
DUDP
GRD
GVA
HGBP
HPS
ICVC
IGV
J
RHS
T
TB
VFD

--------------

Auxiliary
Circuit Breaker
Chiller Control Module
Carrier Comfort Network
Common
Communications
Data Link/Data Port
Chassis Ground
Guide Vane Actuator
Hot Gas Bypass
High Pressure Switch
International Chiller Visual Controller
Inlet Guide Vane
Junction

-- Relative Humidity Sensor
Transformer
Terminal Block
-- Variable Frequency Drive

1C
2C
3C

FOR FIG. 49-54

Compressor Oil Heater Contactor
Oil Pump Contactor
Hot Gas Bypass Relay
Field Control Wiring
Field Power Wiring
Factory Wiring
Shielded Cable

>--I

I
•

<_
@

Male/Female

Potentiometer
Pressure Switch

A
o-Aro

Compr Oil Pump Terminal
Cartridge
Resistor

Fuse

Chassis Ground

Connector

Terminal Block Connection

Temperature Switch

Wire Splice or Junction

Common Potential

Component Terminal

VFD Terminal

Thermistor
Transducer

113

Transformer
IGBT

DE_OTE_ COND_=CTO_
_ALE/F_E_4_L_ ¢ON_ECTOR

Fig. 49 -- Electronic PIC III Control Panel Wiring Schematic (Frame 2, 3, 4 Compressor, Standard Diffuser)

lEGEND

DENOTES OIL

ABBREV

PUMP TERMINA

C RCUIT

BREAKER

DDM

(:HILLER

CONTROL

ON LISTING

MODULE

HGBP

HOT GAS BYPASS

TERMINAL

BOARD

_v_ INE
GD,OE
V ACP_',TGU__t__
. -GUIDE

DENOTES POWER PANEL TERMINAL
0

VANE

ACTUAI©R

D_NOTES COMPONLNT TERMINAL
W_RE SP_CE

i i

COMPONENTi

O_T_ON W_R_NG
_

LAYOUT

DENOTES MALE/F_MALE
DENOTES MACH,
•_

COMPR OiL

_,C,

CONTROL PANEL CONN,

(BLK)

K) _N
(WHT)

YEL

VBLi_ABE _
PER JOB
REGMT

22
-- O_

2B
_
'

12
0

BL_
(BLK) -(BLK)
COMPR OiL
PUMP MOTOR
(1 i/2
HP)

GVA L2

GVA L

(BLU)

[.............................

(RED)

..................

(WHT)
(W_T)

(BLK)

230

(W_T)

(RED)
L_

(WHI}

p
I

II I
i

I
COMPR DISCH
HIGH PRES5

TO VFD/AB2/2_

VFD/A32/4m_

(BLK)

I
TO CB/_
TO CB2_

HGBP

TO VFD/A32/3_

I I
(CLR)

TO STARTER

(OPTIONAL)

(BLU)

(RED)

TO CCH J7_2_

(BLK)

_
_

(LU)

•
I

{ D)
(YL) _

HD_P
SOLENOID
I
3C

2sc)
VWIBNG
(_R_,)

_ (BLU)

{CLR)

POWER

PANEL W1RING 5CHENATIC

(RE_)I

(YE)

HGBP l

SOL

NOID

CCM

,'_,

Fig. 50 -- Power Panel Wiring Schematic

I
I

(BI I K)

_
I///

1
I

I os

o I

I
I

co,,i I

I iI
° BGBP
II I
I

iiiii

_R)

I, '_,_I
I_L)

I
•
I

._LL)_

TO CCM
Ji2
4m

)

I (LK)
i_)
(Y) " -_eK)--III

(GRN)

( U)

_:0

(Oi

J12-5_
VFD COOLANT
SOLENOID

OPTIONAL

_A/\

ODIFC_FION
i
i

ORD

TO CCM J?_3_

TO CCH J?_i_

_ K)

WIRING
i--i'i

IIIIII

TO CCM J12

c ii
/_

DENOTES VFD PANE_ CONN,

HEALER

CB_K)
I

LIA#_A_DRI
I '

IlBV

CONIRO

_V_'ABB

ONY
I

PDWER
VFD

ENCLOSURE

OIL

PUMP

PANEL
COHPRESSI]R OIL PUNP
3BDI4161480V-3-60
(1 t12 H, P.) 400-3-._0

CDNTACTOR

(_-12_[J_-

--(

Y EL.)

I
I _

BLK)

I-___J

(l15v ONLY}
COMPRESSOR

[:_30wArTs-D2XR£

OILHEA_

tmO varr_-mxR_.0Z_R4

FiGDP

FR_IE

115V

ONLY

-(WHT)

(RZD)

7 HX

<
115V
HO_P

J<)

ONLY
FR,_HE

1 [HRU

HGBP

< WHT)

(BLK)

(B_K>------l

T
_(B

(BLK)

=tXTE

(RED)

T
"_
(SEE _4 VKD

(RED

(WHT)

>lc

IIHT)-

[_HINAL
I'_'---HSBP

FR,_IE 1 THRU 7 HX tl_V

II.K)---- 1

,c<>
F

_LI<)

L(WHT>-_

_-----------(
RE O_>--_

(WHT)

SEE _4V
FOR C_rTROL$
_C
-(BLK) -<_

FRAME

I THRU

(RED)

(I).-K)
----e-----(BLK )--

g71a

_'_

(YZL)----e-----< YEL)--

115V

ONLY

(I]PTIONAL)

(BLU)

l*IGgP SE]L£NO]D

W HI">.-

(BLK)

] (/_L_)I

Fig. 51 -- 19XRV Chiller Control Schematic

ACTUATOR
7 HX ONLY

6 HX

-(RED)

HGBP
_FRAME

SOLENOI

CHILLER

CBe

CONTROL PANEL

_+_c.i
'IC

_JI2

--(DL

24 V_£
VA

C_I
2A
IEVC-Jt

_yi--J

I_RN)

+d_ZS)

(_I_Y)

_/_L_RM

ICVC
CB1 q

((_RY)

CB]

F-_T_

-k

s'_op

CcM
J6
_UIO _E_ND

L[MIIZZZSZZZZ

....
.... r-'V--i

(_HIELIO/._--J

EvaPm_r_ rm, V---_'_

RED)--

E_CA_RATCIR LV& _)---(
uaTm T_:Np,
_)----<

RED)+---+
_I.I<)-_

CORI_ZN_

Bl,

SEE CHART _EU]W

_>----< _LFO_

VATER TEMP,

_>---(

IseI-I_I÷Ir_

I F '_"

_-r

_ ' _

(C_)--

+a,e.
REm+E+E++

(_K_ I
C_4

I _---_oml ---I

I I

iLI

]_li._=
ii,

+°i+
_

_DLIDP

SL.KZ_-_
I

G,V+ _S[TION
FEE]JI_C_K

(R_>
_VER

EVAP,,SATUma_TION_>_(

_mN>_

(S_4"I)
+

¢_: I_

_REII_

wATERIZNP.

II"I

'_ISLO)

R{I))_

_----1_------(
REl))
_

(OPTION)

P_
(REIi)--VF_ IA3 _/3

_
ELK>--F_.--->_ v#_>--

@
COMPRESSB_
_>---<
DI$CHN_GE I[MI:+_>----(

RZ_>----BLK)----

tHRUST ]_F_AR
[NO
CIIMP_SOR
_
r_P_r_g

SPARE)

_'(SHIELII

@
-@
BLK)--..@
C LR_.....--

FEED

P_i
++

"fZN_RAI'UR[ L_>--.-(

MI]'fl]R
TEMP+
'_-'_:_(
SPARE "TEMP.#]

BACK

TZNTI_TERC(<
ONH

+LK)----_LK _--'--"
SPARD

F --i>>--'(VHT)-_>--<
BLK)---

Jll

FEE-->>--<
v_-INFERNAL VARIABLE
GUIDE V#C_E CONTROL
SEE I15/230V FOR R3WER

/
CONTINLEI)

SHEEI

CONTINUE_

ZI_ SHEET

Fig. 51 -- lgXRV Chiller Control Schematic (cont)

CONTINUED

"x
ON

SI_EE'T6

_INUED

FROM

_EET

CONTINUED

FROM

SHET

FROM SHEET 5
J12

(BLK)
(3RN)

C_E

B531

(gLK)

C_
OIL
SUMP
PRESSURE

_-.-._>---<
[_>---<
_>---<

_LK_
CLR)---RED>----

OIL PUMP
_>--"(
I_LK)----DISCH. PRESSURE [_'_>-'------

D_19D_
OIL PUMP MOll]R

-i1

YF11OODLANT SOLENOID
(BB',_

(BLK)------_,

"-PT-[4-_o_.,

VFD

ENCLOSURE

VFO

PDWER

>IC

MODULE

LOAD RESIS]OR
SIAND_RD]/0
LOAD

]

RESISTOR

B31_
JUMPER
_c aux
LOAD

HPS

ET_D

RESISTOR

CLOSE:110_7 PSIG.

r--_ _ 8_I--

SWI

JUMPER

-----<_-----

>ic
EVAP_ATOR
REFI_IOER_NT
PESSURE

_
_>---(

BLK)----CLF_
R_

CONDENSER
REFR
]6ERANT
PRESSURE

t-_>__<
_>---(

CLR)..
_
REI)>----

Fig. 51 -- 19XRV Chiller Control Schematic

(cont)

CARRIER 19XRV LF2 VFD WIRING DIAGRAM
_z_e
_e_

_osz__, c.

oll _M_

CR_D_
_SLK_
_Z_C

--:,4]
iAe_ec--

Fig. 52 -- 19XRV Chiller VFD Schematic

I1_:;;:,:::::::)'_......
J

_N_OL

NOTE_

pANEL

1. THIS FEATURE IS STANDARD IN THE PIC II OONTROLS,
BUT REQUIRE5 A CONIROLIJZR Y_TH A NON--GROUNDED
OR 1-5Vdc
OUTI_UT SIONAL NOT BY CARRIE_

.... ,7,

¢CM MCOLAJ_
----r"r-p-----"IAUIO
-_-_-_---

4-2OmA

DEMAND RESE1

\\
_CONIROLLER

2. _IS FEA_RE
IS SIANDARD
IN THE PIC II_ONTROLS,
BUT REOUIRES A SENSOR PACKAGE
OPTION, BY CARRIER.
(ITEM #3, SEE OPTION LISTINO)

INPUT (SEE NOTE #I)

__----IT--IAUm
C_fLLEO
_ATER
RESE_
---,_--JCON_OLLER
INPUT
(SEE
NOTE
_)

3. PINS SHOWN FOR REFERENCE ONLY.
ACTUAL PIN LAYOUT NOT SHOWN,

]
I

____

t___

4--20r.A
(O-IOOXkw)
DATAUNK OR
TRANSFORMER
(OPIION)

_--(_) ....
4s_

SPARE _EMP #1 SmSOR
(COMMON SUPPLY] CSEE NOTE

C l(/h(//l

#2)

RELAY

(oRno.}

SPARETEMP12 SENSOR
(COMMONREIURN)(SEENOTE#2)

REMOIE 1EMP RESEI SENSOR
(_
N01Z /2)
OATAUNK 13_
DATAPOR'[ MOOULE

ITI_ 1 OR2)
_E

oPnON

]S_NO BELOW)

PROIECTIVEDATA
TRANSMW
G_ID 1
D-SHELLI

_ I
RECEIVE DATA

RS-2Z2 PORT
fO BAS
CONIRQ__'_CE
(SEENOTE _)

POWER PANEL
(_OWN _
÷

CONTROL PANEL OPTIONAL W1RING

COMPONENT

LAYOUT

COVERREMOVED)

03NTRCL pANEL j
TD_MINAL BLOCK

OPTION
ITE_

USTING

DESCRIPTION

DAIAPORT

MOOULE

DAIAUNK

MOOULE

SENSOR PA_KA(_£

CHECK TO
ORDER

°°°i
Icvc

INSIDE PANEL COVER

Fig. 53 -- 19XRV Chiller Control

CONTROL PANEL COMPONENT

Panel Component

Layout

LAYOUT

NOTES:
I

GENERAL
1,0

CONTROL

VFD SHALL BE DESIGNED AND MANUFACTURED

IN ACCORDANCE

WITH

CARRIER ENGINEERING REQUIREMENT Z-420o
1,1

1.2

MUST HAVE

24VAC RATING. MAX

WITH ALL APPUCABLE

SWI'[CHES WITH C43LI)PLATED BIFURCATED C:ONIAC'ISARE RECX3MMENDED.

CODES

AND JOB SPECIFICATION&

EQUIPMENT INSIALLATION AND

CONrACIS

ARE SHOWN

3.2

REMOVE

COMPONENT,

AND

3,_

TME VF'D CONTACT
ANNUNCIATOR
277VAC.

ASSUME

FAN

AND THE CHILLER SHUII]OYvN.

NARNING - DO NOT USE ALUMINUM
_RING

TO VFD

DR ANT
3.4

AND

AND
2,3

POWER

CONDUCTOR

CHILLER FULL LOAD AMPS

UNE LUG ADAPTORS
(# CONDUCTORS)

VFD
MAX INPUT
AMPS.

RATING MUST

MEET VFD NAMEPLATE

TOWER FAN
MEANS

STANDARD 65KAIC
# CONDUCTORS

RANGE)

SPARE

$-20mA

NON--GROUNDEO
OF 500

VOLTAGE

CABLES PER PHASE

3.6

OP_ONAL

CONDUCTOR RANGE

405A

3/0

608A

3/0-

BY CARRIER.

WIRINI_CARRYING

OUTPUT
4-20mA

SIGNAL

FOR COOLER AND
COIL AND

ALARM

UP TO 3 AMPS

TO START PUMPS

MACHINE

PROTECTION,

AND

TOWER

IF PRIMARY

MEANS. ALSO PROVIDE

DD NOT USE STARTER

FOR CONTACTOR

CONTROL

COIL, ACTUATOR

MOTOR

3DV OR LESS WIIHIN A CONDUIT "NHICH

AND

FOR

CONTROLLERS

A MAXIMUM

WITH A

INPUT IMPEDANCE

OHMS.

REMOVE JUMPER

WIRE TB1/19

TO TB1/20

IOOKAIC LUG CAPACITY (PER PHASE)

# CONDUCTORS

IS DESIGNED

INPUT SIGNAL

AS FI_I_I.OWS:

LUG CAPACITY (PER PHASE)

AUXILLIARY

LOADS.

(MINIMUM CIRCUIT AMPACITY),

SIZE (CONDUCTOR

AT 115VAC

TO ASSURE

AS THE POWER SOURCE

OTHER

(VA)

MOTOR CONTROL IS BY OTHER

FOR DDNTROL

ARE REQUIRED AT INSTALLATION. MINIMUM QUANTITY

AND

LOADS

MOTOR CONTACTOR

WIRING REOUIRED FOR CARRIER

DO NOT ROUTE CONTROL

3.5

UNE S@E

IS 10mA.

HAS WIRES 'CARRYING 50V OR HIGHER OR ALONG SIDE WIRES CARR'fING 50V OR HIGHER,

Z,1 METAL CONDUII MUST BE USED FGR IHE POI_ER WIRES, FROVI VFD TO BRANCH
FEEDER.
2,2

CAN CONTROL

TOWER FAN

DEVICES IS RATED 5 AMPS

TRANSFORMER

PROVIDE A LOCAL MEANS OF DISODNNEGTINO POWER TO VFD, PROVIDE SHORT
CIRCUIT PROTECTION FOR THE CHILLER AND INIERCONNECTING WIRE AT THE
BRANCH FEEDER. IHE SHOR'[ CIRCUIT PROfE'_:TION SHALL BE FUSED TYPE
OR EQUiVALEN'f CIRCUIT BREAKDR PER SHEEI 3 OF 4 OF THIS DOCUMEN'f.

OUTPUTS

PUMP,

CONTROL

PARALLEL

IS BOrnA. NOMINAL CURRENT

TBI-Ig AND "fBI-20 BEFORE CDNNECI]N_

MOTORS MUST BE PROVIDED

PUMP

CONDUCTORS,

CURRENT

BY CARRIER],

THESE TERMINALS.

FOR CONDENSER

UTERATURE.

IN THE POSITION IHEY WOULD

,.LIMPERWIRE BETWEEN

SAFETIES BETV_

CONTROL DEVICES. MUST

_lll DEIAILS IN EQUIPMENT SUBMITTAL DRA_NOS
AND S_TCHES

AND THE LOCA]ION

INTERFERE WITH EQUIPMENT ACCESS

ALL STARIINO AND

WITH THE CIRCUIT DE-ENERGIZED

2,0

DEVICE CONTACTS

WIRING, TI'3:_MINAIlON GF CONDUCTORS AND DEVICES, MUS'f 8E IN COMPUANCE

THE ROUTING OF FIELD-INS'[ALLEDCONDUIT AND CONDUCTORS

POWER

OR LAROEP,.

START/STOP

SAFELY DEVICE CONTAC:TS_ (DEVICES NOI SUPPUED

COMPLY

1,5

TO BE AT LEAST 18 A_

DEVICE CONTACTS, REMOTE

AND SPARE

OR THE READING. AOdUSIlNG OR SERVICING OF ANY

1,4

CONDUCTORS

3.1 ICE BUILD START/ERMINATE

ALL FIELD-SUPPUED CONDUCTORS, DEVICES AND 'THE FIELD-INSTALLATION

OF FIELD-INSTALLED DEVICES, MUST NOT

1,3

_RI N(3

FIELD SUPPLIED CONTROL

CONDUCTOR RANGE

500MCM

40D

- 500MCM

500MCM

3/0

2.4- COMPRESSOR
MOTOR AND CONTROLS MUST BE GROUND[I) BY USING EGUIPM[NT
GROUNDING LUGS PROVIDED INSIDE UNIT MOUNTED VFD ENCLOSURE,

Fig. 54 -- 19XRV Field Wiring

400MCM

IF INSTALLING

SPARE

SAFETY" CONTACT.

INCOMING
POWER

WATER-PUMPS
AND FANS

AMp,

CLASS

J, TIME DELAY,

6DD VOLT

AMP.

_LA$S

600

'lIME DELAY.

VOL1

VARIABLE
FREQUENCY
DRIVE

[

V-1PH-50/60HZ

]
L_J
Z

CUSTOMER

SUPPLIED RE_IOTE ALARM
SEE NO_ ;5,3

I
-......
.......

(OPTIONAL)

REQUIRED POWER WIRING
REQUIRED CONTROL WIRING
OPTIONAL WIRINC
FIELD WIRING

Fig. 54 -- 19XRV Field Wiring (cont)

122

:1=

P3
F,-

T"
-VOLTS

-VOLTS

EVAPORATOR
U CdJID
PUMP MOTOR

CONDENSE]R LIQUID
PUMP MOTOR

{NOT

(NOT

BY CARRIER)

PRIMARY
COOLING TOWER FAN
Full Reset

STATUS
SERVICE

CHW Delta T->No Reset

SERVICE

CHW Setpt Reset Value
Commanded
State

SERVICE
SERVICE

Common

Option

SERVICE

Comp Discharge

Sensor

Alert

SERVICE

Comp Discharge

Alert

SERVICE

Comp Discharge

Temp

STATUS

Comp Discharge

Temp

SERVICE

Comp Discharge

Temp

SERVICE

Comp Motor Temp Override

SERVICE

Comp Motor Temp Override

SERVICE

Comp Motor Winding

Temp

STATUS

Comp Motor Winding

Temp

SERVICE

Comp Motor Winding

Temp

SERVICE

2 ICVC PARAMETER INDEX (cont)

TABLE

SCREEN NAME
MAINSTAT

CONTROL ALGORITHM
CONTROL ALGORITHM

STATUS
STATUS

EQUIPMENT

SERVICE

EQUIPMENT

SERVICE

CONTROL ALGORITHM
CONTROL ALGORITHM
EQUIPMENT

SERVICE

CONTROL ALGORITHM
EQUIPMENT

STATUS
STATUS

STATUS

SERVICE

CONTROL ALGORITHM

STATUS

CONTROL TEST

MAINSTAT
TEMP CTL

X
X

TEMP

CTL

WSMDEFME
WSMDEFME
LEADLAG

OVERRIDE
SETUP1

CONTROL ALGORITHM
EQUIPMENT

OVERRIDE
THERMITORS

STATUS

SERVICE

OVERRIDE
SETUP1

COMPRESS
CONTROL ALGORITHM

STATUS

CONTROL TEST
CONTROL ALGORITHM

Brg Alert

SERVICE

Brg Alert

SERVICE

Comp Thrust

Brg Temp

STATUS

Comp Thrust

Brg Temp

SERVICE

Comp Thrust

Brg Temp

SERVICE

CONTROL TEST

Compressor

100% Speed

SERVICE

VFD CONFIG DATA

Compressor

Ontime

Compressor

Ontime

EQUIPMENT

OVERRIDE
THERMITORS

Comp Thrust

STATUS

SERVICE

OVERRIDE
SETUP1

COMPRESS
CONTROL ALGORITHM

STATUS

OVERRIDE
THERMITORS

STATUS

VFD

CONF

MAINSTAT
DEFAULT SCREEN

Cond Approach Alert
Cond Flow Delta P Cutout
Cond Press Override

SERVICE
SERVICE
SERVICE

Cond Press Override

SERVICE

Condenser
Condenser

Approach
Freeze Point

STATUS
SERVICE

Condenser
Condenser

High Pressure
Pressure

Condenser

Pressure

SERVICE

Condenser

Pressure

SERVICE

Condenser

Refrig Temp

STATUS

Condenser

Refrig Temp

SERVICE

Condenser
Condenser
Condenser

Refrigerant Temperature
Water Delta P
Water Delta P

STATUS
SERVICE

Condenser
Condenser

Water Delta P
Water Flow

SERVICE
STATUS

CONTROL TEST

Condenser

Water Flow

SERVICE

CONTROL TEST

Condenser

Water Pump

STATUS

Condenser Water Pump
CONSUME
Control Mode

SERVICE
SERVICE
STATUS

Control

Point

SERVICE

Control

Point

STATUS

Control

Point

SERVICE

Control
Control

Point
Point Error

SETPOINT
SERVICE

TEST

WSMDEFME
VFD HIST

COMPRESS

Comp Thrust

CONTROL

CONFIGURABLE

EQUIPMENT SERVICE
EQUIPMENT SERVICE
CONTROL ALGORITHM STATUS
EQUIPMENT
EQUIPMENT

SETUP1
SETUP1
OVERRIDE

X
X

SERVICE

SETUP1

SERVICE

HEAT EX
SETUP1

STATUS
STATUS

VFD STAT
HEAT EX
CONTROL ALGORITHM

STATUS

CONTROL TEST

OVERRIDE
PRESSURE TRANSDUCERS
HEAT EX

CONTROL ALGORITHM

STATUS

OVERRIDE
DEFAULT SCREEN
HEAT EX
PRESSURE TRANSDUCERS

CONTROL TEST

PUMPS
STARTUP
PUMPS
STARTUP

CONTROL TEST
EQUIPMENT CONFIGURATION
CONTROL ALGORITHM

STATUS

PUMPS
CONSUME
MAINSTAT
CAPACITY
MAINSTAT

EQUIPMENT

SERVICE

CONTROL ALGORITHM

STATUS

TEMP

CTL

SETPOINT
CAPACITY

SERVICE

Current
Current

CHW Setpoint
Date

SERVICE
SERVICE

CONTROL ALGORITHM

STATUS

WSMDEFME
TIME AND DATE

Current
Current

Mode
Time

SERVICE
SERVICE

CONTROL ALGORITHM

STATUS

LL MAINT
TIME AND DATE

128

APPENDIX -- 19XRV LIQUlFLO
MENU
SOFTKEY

PARAMETER
Date

2 ICVC PARAMETER

TABLE

SCREEN NAME

SERVICE

Day of Week

SERVICE

Daylight

SERVICE

Savings

DC Bus Voltage

CONFIGURATION

STATUS

DC Bus Voltage

SERVICE

DC Bus Voltage

Reference

STATUS

DC Bus Voltage

Reference

SERVICE

Decrease

EQUIPMENT

Ramp Time

CONFIGURABLE

TIME AND DATE

BRODEF

POWER
CONTROL ALGORITHM

STATUS

VFD HIST

CONTROL ALGORITHM

STATUS

VFD HIST

POWER
VFD CONF

Degrees Reset

SERVICE

EQUIPMENT

SERVICE

TEMP

CTL

Degrees Reset

SERVICE

EQUIPMENT

SERVICE

TEMP

CTL

Degrees Reset At 20 mA

SERVICE

EQUIPMENT

SERVICE

TEMP

CTL

Delta P at 0% (4 mA)

SERVICE

EQUIPMENT

SERVICE

OPTIONS

Delta P at 100% (20 mA)
Demand Kilowatts

SERVICE
STATUS

EQUIPMENT

SERVICE

OPTIONS
POWER

Demand Limit and kW Ramp
Demand Limit At 20 mA

SERVICE
SERVICE

EQUIPMENT
EQUIPMENT

SERVICE
SERVICE

RAMP DEM
RAMP DEM

Demand Limit
Demand Limit

Decrease
Inhibit

SERVICE
SERVICE

Demand Limit
Demand Limit

Prop Band
Source

SERVICE
SERVICE

EQUIPMENT
EQUIPMENT

SERVICE
SERVICE

Demand Watts Interval

SERVICE

EQUIPMENT

SERVICE

Description
Device Name

SERVICE
SERVICE

Diffuser

25% Load Point

SERVICE

EQUIPMENT

SERVICE

SETUP2

Diffuser

50% Load Point

SERVICE

EQUIPMENT

SERVICE

SETUP2

Diffuser
Diffuser

75% Load Point
Actuator

SERVICE
STATUS

EQUIPMENT

SERVICE

SETUP2
COMPRESS

Diffuser

Actuator

SERVICE

Diffuser

Actuator

SERVICE

Diffuser

Actuator

SERVICE

Diffuser

Control

SERVICE

EQUIPMENT

SERVICE

SETUP2

Diffuser

Full Span mA

SERVICE

EQUIPMENT

SERVICE

SETUP2

SERVICE
STATUS

EQUIPMENT

SERVICE

SETUP2
ICVC PWD

X
X

Diffuser Option
Disable Service
Discharge
Discrete

SERVICE

INDEX (cont)

Password

Pressure
Outputs

SERVICE

Control

Test

SERVICE
SERVICE
SERVICE

ECW Setpoint
Stop

Enable Reset Type

X
X

RAMP DEM

ICVC CONFIGURATION
ICVC CONFIGURATION

CONTROL TEST
CONTROL TEST

IGV & SRD ACTUATOR

CONTROL TEST

DIFFUSER

CONTROL TEST

ACTUATOR

PRESSURE TRANSDUCERS
CONTROL TEST

SETPOINT

STATUS

MAINSTAT

TEMP

Water

STATUS

Entering

Chilled

Water

STATUS

Entering

Chilled

Water

Entering

Chilled

Water

Entering

Cond Water

Entering

Condenser

Water

Entering

Condenser

Water

EQUIPMENT SERVICE
CONTROL ALGORITHM STATUS
CONTROL ALGORITHM STATUS

EQUIPMENT

SERVICE

CTL

HEAT EX
CONTROL ALGORITHM

STATUS

CAPACITY
DEFAULT SCREEN

SERVICE

CONTROL TEST

THERMITORS

SERVICE

CONTROL TEST

THERMITORS

STATUS

HEAT EX
DEFAULT SCREEN

SERVICE

Alert

RAMP DEM
RAMP DEM

SETPOINT
SERVICE

Status

Chilled

Evap Approach

NET OPT
CAPACITY

TEMP CTL
CAPACITY
CAPACITY

Entering

Equipment

EQUIPMENT CONFIGURATION
CONTROL ALGORITHM STATUS

SERVICE

ECW Control Option
ECW Delta T
ECW Reset

Emergency

VFD CONFIG DATA

CONTROL ALGORITHM

STATUS

WSMDEFME

SERVICE

EQUIPMENT

SERVICE

SETUP1

Evap Flow Delta P Cutout

SERVICE

EQUIPMENT

SERVICE

SETUP1

Evap Ref Override

SERVICE

Temp

Evap Refrig Trippoint

SERVICE

Evap Saturation

Temp

STATUS

Evap Saturation

Temp

SERVICE

Evaporator

Approach

STATUS

Evaporator

Pressure

STATUS

Evaporator

Pressure

SERVICE

CONTROL ALGORITHM
EQUIPMENT

STATUS

SERVICE

OVERRIDE
SETUP1
HEAT EX

CONTROL TEST

THERMITORS
HEAT EX
HEAT EX

CONTROL TEST

129

PRESSURE TRANSDUCERS

APPENDIX -- 19XRV LIQUlFLO
MENU
SOFTKEY

PARAMETER
Evaporator

Refrig Temp

STATUS

Evaporator

Refrig Temp

SERVICE

Evaporator

Refrigerant

2 ICVC PARAMETER INDEX (cont)

TABLE

SCREEN NAME

STATUS

Flux Current

SERVICE

EQUIPMENT

SERVICE

CONTROL ALGORITHM

STATUS

STATUS
SERVICE
STATUS
STATUS

Ground Fault Current

SERVICE

Group Number
Guide Vane 25% Load Pt

SERVICE
SERVICE

Guide Vane 50% Load Pt

SERVICE

EQUIPMENT

Guide Vane 75% Load Pt
Guide Vane Calibration

SERVICE
SERVICE

EQUIPMENT

Guide Vane Control
Guide Vane Delta

SERVICE
SERVICE

EQUIPMENT

SERVICE

CONTROL ALGORITHM

STATUS

EQUIPMENT CONFIGURATION
EQUIPMENT SERVICE

SERVICE

Head Pressure
Head Pressure

Output Control
Reference

Head Pressure
Head Pressure

Reference
Reference

Test

VFD HIST
STAT

OPTIONS
VFD STAT
POWER
VFD HIST
X
X

SERVICE

SETUP2

SERVICE

SETUP2
CONTROL TEST

IGV & SRD ACTUATOR
CAPACITY

CONTROL TEST
CONTROL ALGORITHM STATUS

COMPRESS
EQUIPMENT

SERVICE

SERVICE
STATUS
SERVICE
SERVICE

EQUIPMENT SERVICE
CONTROL TEST

SETUP2

CONTROL TEST
HEAT EX

OPTIONS
HEAD PRESSURE OUTPUT

High DC Bus Voltage

STATUS

VFD

STAT

High Line Voltage

STATUS

VFD

STAT

Holiday
HOLIDAYS

SERVICE
SERVICE

Hot Gas Bypass

Relay

Hot Gas Bypass

Relay Test

Humidity

EQUIPMENT

CONFIGURATION

STATUS
SERVICE

NET OPT
SETUP2

STATUS

Guide Vane Travel Limit

SETUP1
POWER

VFD

Full Load Point (T2, P2)
Ground Fault
Ground Fault Current

Guide Vane Delta

OVERRIDE
DEFAULT SCREEN

SERVICE
STATUS

Fault

CONFIGURABLE

HEAT EX
CONTROL ALGORITHM

Temperature

Flow Delta P Display
Flux Current

Frequency

TIME AND DATE
HOLIDAYS

X
X

HEAT EX
CONTROL TEST

DISCRETE OUTPUTS

Sensor Input

STATUS

Humidity Sensor Input
Ice Build Contact

SERVICE
STATUS

Ice Build Control

SERVICE

EQUIPMENT

SERVICE

OPTIONS

Ice Build Option

SERVICE

EQUIPMENT

SERVICE

OPTIONS

Ice Build Recycle

SERVICE

EQUIPMENT

SERVICE

OPTIONS

SERVICE

SETPOINT
OPTIONS
OCCP02S

X
X
X

CONFIGURATION

OCCDEFCS

Ice Build Setpoint
Ice Build Termination
Ice Build Time Schedule
Ice Build Time Schedule
ICVC CONFIGURATION
IGV & SRD Actuator
Incompatibility

SETPOINT
SERVICE
SCHEDULE
(OCCPC02S)

SERVICE
SERVICE

STATUS

Increase Ramp Time
Inverter Overcurrent
Inverter Overload

SERVICE
STATUS
STATUS

Overtemp
Power Fault

CONTROL TEST

EQUIPMENT
EQUIPMENT

PRESSURE TRANSDUCERS
MAINSTAT

SERVICE

Fault

Inverter
Inverter

POWER

CONTROL TEST
VFD
VFD CONFIG DATA

STATUS
STATUS

VFD
VFD

STAT
STAT

VFD

CONF

Inverter

PWM Frequency

SERVICE

Inverter

Temp Override

SERVICE

Inverter

Temp Override

SERVICE

Inverter

Temperature

STATUS

Inverter

Temperature

SERVICE

CONTROL ALGORITHM

STATUS

OVERRIDE

Inverter

Temperature

SERVICE

CONTROL ALGORITHM

STATUS

VFD HIST

LAG % Capacity
LAG Address
LAG CHILLER:

SERVICE
SERVICE
Mode

VFD CONFIG DATA

STAT

VFD CONF
VFD STAT
POWER

CONTROL ALGORITHM
EQUIPMENT

STATUS

SERVICE

OVERRIDE
SETUP1

POWER

EQUIPMENT
EQUIPMENT

SERVICE
SERVICE

LEADLAG
LEADLAG

SERVICE

CONTROL ALGORITHM

STATUS

LL MAINT

LAG Start Time

SERVICE

CONTROL ALGORITHM

STATUS

LL MAINT

LAG START Timer

SERVICE

LAG Stop Time
LAG STOP Timer

SERVICE
SERVICE

EQUIPMENT

SERVICE

CONTROL ALGORITHM STATUS
EQUIPMENT SERVICE

130

X
X

LEADLAG

LL MAINT
LEADLAG

APPENDIX -- 19XRV LIQUlFLO
PARAMETER
LCW Reset

MENU
SOFTKEY

2 ICVC PARAMETER

TABLE

INDEX (cont)
SCREEN NAME

SERVICE

CONTROL ALGORITHM

STATUS

CAPACITY

SETPOINT
SERVICE

CONTROL ALGORITHM

STATUS

SETPOINT
LLMAINT

Lead Lag Control

SERVICE

CONTROL ALGORITHM

STATUS

LLMAINT

Lead Lag Control

SERVICE

LEAD/LAG: Configuration

SERVICE

LEAD/LAG:

SERVICE

LCW Setpoint
LEAD CHILLER

in Control

Configuration

EQUIPMENT

SERVICE

CONTROL ALGORITHM
EQUIPMENT

STATUS

SERVICE

LEADLAG
LEADLAG

Chilled Water

STATUS

Leaving

Chilled Water

SERVICE

Leaving

Chilled Water

Leaving

Chilled Water

SERVICE

CONTROL TEST

THERMITORS

Leaving

Cond Water

SERVICE

CONTROL TEST

THERMITORS

Leaving

Condenser

Water

Leaving

Condenser

Water

HEAT EX
CONTROL ALGORITHM

STATUS

CAPACITY
DEFAULT SCREEN

STATUS

HEAT EX
DEFAULT SCREEN

LID Language
Line Active Current

SERVICE
STATUS

Line Active Current

SERVICE

Line Active Voltage

STATUS

ICVC CONFIGURATION
POWER
CONTROL ALGORITHM

STATUS

VFD HIST

SERVICE
SERVICE

CONTROL ALGORITHM STATUS
VFD CONFIG DATA

VFD HIST
VFD CONF

Line Current
Line Current

Imbal Time
Imbalance

SERVICE
STATUS

VFD CONFIG DATA

VFD CONF
POWER

Line Current

Imbalance

STATUS

Line Current

Imbalance

SERVICE

Line Current

Phl (R)

STATUS

Line Current

Phl (R)

SERVICE

Line Current

Ph2 (S)

STATUS

Line Current

Ph2 (S)

SERVICE

Line Current

Ph3 (T)

STATUS

Line Current

Ph3 (T)

SERVICE
SERVICE

Line Frequency

STATUS

Line Frequency
Line Kilowatts

SERVICE
STATUS

POWER

Line Active Voltage
Line Current % Imbalance

Line Phase Reversal
Line Power Factor

LLMAINT

Leaving

Line Freq=60 Hz? (No=50)

CONFIGURABLE

X
X

VFD STAT
CONTROL ALGORITHM

STATUS

VFD HIST

CONTROL ALGORITHM

STATUS

VFD HIST

CONTROL ALGORITHM

STATUS

VFD HIST

CONTROL ALGORITHM

STATUS

VFD HIST

POWER
POWER
POWER
VFD CONFIG DATA

VFD CONF

POWER
CONTROL ALGORITHM

STATUS

STATUS
STATUS

VFD HIST
POWER
VFD STAT
POWER

Line Power Factor

SERVICE

CONTROL ALGORITHM

STATUS

VFD HIST

Line Reactive
Line Reactive

Current
Current

STATUS
SERVICE

CONTROL ALGORITHM

STATUS

POWER
VFD HIST

Line Reactive

Voltage

STATUS

POWER

Line Reactive Voltage
Line Volt Imbalance Time

SERVICE
SERVICE

CONTROL ALGORITHM STATUS
VFD CONFIG DATA

VFD HIST
VFD CONF

Line Voltage % Imbalance

SERVICE

VFD CONFIG DATA

VFD CONF

Line Voltage

Imbalance

STATUS

Line Voltage

Imbalance

STATUS

Line Voltage

Imbalance

SERVICE

Line Voltage

Phl (RS)

STATUS

Line Voltage

Phl (RS)

SERVICE

Line Voltage

Ph2 (ST)

STATUS

Line Voltage

Ph2 (ST)

SERVICE

Line Voltage

Ph3 (TR)

STATUS

Line Voltage

Ph3 (TR)

POWER
VFD STAT
CONTROL ALGORITHM

STATUS

VFD HIST

CONTROL ALGORITHM

STATUS

VFD HIST

CONTROL ALGORITHM

STATUS

VFD HIST

SERVICE

CONTROL ALGORITHM

STATUS

VFD HIST

Load Balance Option

SERVICE

CONTROL ALGORITHM

STATUS

LL MAINT

Load Balance Option

SERVICE

Load Current

Phl (U)

STATUS

Load Current

Phl (U)

SERVICE

Load Current

Ph2 (V)

STATUS

Load Current

Ph2 (V)

SERVICE

Load Current

Ph3 (W)

STATUS

Load Current

Ph3 (W)

SERVICE

POWER
POWER
POWER

EQUIPMENT

SERVICE

LEADLAG
POWER

CONTROL ALGORITHM

STATUS

VFD HIST

CONTROL ALGORITHM

STATUS

VFD HIST

CONTROL ALGORITHM

STATUS

VFD HIST

POWER
POWER

131

APPENDIX -- 19XRV LIQUlFLO
PARAMETER
Loadshed

MENU
SOFTKEY

2 ICVC PARAMETER INDEX (cont)

TABLE

SCREEN NAME

SERVICE

CONTROL ALGORITHM

STATUS

LOADSHED

Loadshed
Loadshed

Function
Function

SERVICE
SERVICE

EQUIPMENT CONFIGURATION
CONTROL ALGORITHM STATUS

NET OPT
LOADSHED

Loadshed

Timer

SERVICE

CONTROL ALGORITHM

STATUS

LOCAL

CONFIGURABLE

LOADSHED
DEFAULT SCREEN

Local Network

Device

SERVICE

Local Time Schedule

ATTACH TO NETWORK

SCHEDULE

Local Time Schedule (OCCPC01 S)
LOG OUT OF DEVICE

SERVICE
SERVICE

Low DC Bus Voltage

STATUS

Low Line Voltage
Maximum Loadshed

STATUS
SERVICE

Time

EQUIPMENT

CONFIGURATION

X
X

OCCP01S

OCCDEFCS

VFD
EQUIPMENT

DEVICE

STAT

VFD STAT
NET OPT

Min. Load Point (T1, P1)

SERVICE

EQUIPMENT

SERVICE

OPTIONS

Minimum Output
Model Number

SERVICE
SERVICE

EQUIPMENT

SERVICE

OPTIONS
ICVC CONFIGURATION

Motor
Motor

Amps Not Sensed
Current % Imbalance

STATUS
SERVICE

Motor
Motor

Current
Current

Imbal Time
Imbalance

SERVICE
STATUS

Motor

Current

Imbalance

STATUS

Motor
Motor

Current Imbalance
Kilowatt Hours

SERVICE
STATUS

Motor

Kilowatts

Motor

Nameplate

Amps

SERVICE

VFD CONFIG DATA

VFD

CONF

Motor

Nameplate

SERVICE

VFD CONFIG DATA

VFD

CONF

Motor

Nameplate

RPM

SERVICE

VFD CONFIG DATA

VFD

CONF

Motor
Motor

Nameplate
Overload

Voltage

SERVICE
STATUS

VFD CONFIG DATA

VFD CONF
POWER

Motor
Motor

Overload
Overload

Motor

Power Factor

STATUS

Motor

Power Factor

SERVICE

Motor
Motor

Rated Load Amps
Rated Load kW

SERVICE
SERVICE

VFD CONFIG DATA
VFD CONFIG DATA

VFD CONF
POWER
VFD

CONTROL ALGORITHM

STATUS

STATUS
SERVICE

VFD STAT
VFD CONF

X
X

STAT

VFD HIST
POWER
POWER

CONTROL ALGORITHM

STATUS

VFD STAT
VFD HIST

CONTROL ALGORITHM

STATUS

VFD HIST

POWER

VFD CONFIG DATA
VFD CONFIG DATA

VFD
VFD

CONF
CONF

X
X

OCCPC01S

(Local Time Schedule)

SCHEDULE

OCCP01S

OCCPC02S

(Ice Build Time Schedule)

SCHEDULE

OCCP02S

OCCPC03S

(CCN Time Schedule)

SCHEDULE

OCCP03S

OCCPC01S

(Local Time Schedule)

SERVICE

EQUIPMENT

CONFIGURATION

OCCDEFCS

OCCPC02S

(Ice Build Time Schedule)

SERVICE

EQUIPMENT

CONFIGURATION

OCCDEFCS

OCCPC03S

(CCN Time Schedule)

SERVICE

EQUIPMENT

CONFIGURATION

OCCDEFCS

Occupied?

STATUS

Oil Heater Relay

STATUS

Oil Heater Relay Test

SERVICE

Oil Press Verify Time
Oil Pressure

SERVICE

Oil Pressure

SERVICE

Acceptable?

MAINSTAT
COMPRESS
CONTROL TEST
EQUIPMENT

SERVICE

CONTROL TEST

DISCRETE OUTPUTS

SETUP1
DEFAULT SCREEN

PUMPS

Oil Pump Delta P

STATUS

STARTUP

Oil Pump Delta P

STATUS

COMPRESS

Oil Pump Delta P

SERVICE

CONTROL TEST

Oil Pump Delta P

SERVICE

CONTROL TEST

Oil Pump Relay

STATUS

Oil Pump Relay

SERVICE

Oil Sump Temp

STATUS

Oil Sump Temp

STATUS

PRESSURE TRANSDUCERS
PUMPS
STARTUP

CONTROL TEST

PUMPS
STARTUP
COMPRESS

Oil Sump Temp

DEFAULT SCREEN

Oil Sump Temp

SERVICE

Password

(VFD CONFIG DATA)

SERVICE

CONTROL TEST

VFD CONFIG DATA

Password

(SERVICE)

SERVICE

ICVC CONFIGURATION

132

THERMITORS

APPENDIX -- 19XRV LIQUlFLO
MENU
SOFTKEY

PARAMETER

2 ICVC PARAMETER

TABLE

INDEX (cont)
SCREEN NAME

Percent Line Current

STATUS

MAINSTAT

Percent Line Current
Percent Line Current

STATUS

POWER
DEFAULT SCREEN

Percent Line Kilowatts

STATUS

MAINSTAT

Percent Line Kilowatts

STATUS

POWER

Percent Line Voltage
Percent Load Current
Percent Motor Kilowatts

STATUS
STATUS
STATUS

POWER
POWER
POWER

Pressure

Transducers

Control

Test

PRESTART FAULT Time
PRESTART FAULT Timer

SERVICE
SERVICE
SERVICE

CONFIGURABLE

CONTROL TEST
CONTROL ALGORITHM STATUS
EQUIPMENT SERVICE

PRIMARY MESSAGE

LL MAINT
LEADLAG

DEFAULT SCREEN

Proportional

Dec Band

SERVICE

EQUIPMENT

SERVICE

SETUP2

Proportional

ECW Gain

SERVICE

EQUIPMENT

SERVICE

SETUP2

Proportional

Inc Band

SERVICE

EQUIPMENT

SERVICE

SETUP2

Pulldown Ramp Type:
Pulldown: Delta T/Min

SERVICE
SERVICE

RAMP DEM
LL MAINT

CONTROL TEST

Pumpdown/Lockout

Control

Test

SERVICE

Pumpdown/Lockout

Control

Test

SERVICE

Pumps Control

Test

SERVICE

Rated Line Amps
Rated Line Kilowatts

SERVICE
SERVICE

Rated Line Voltage
Re-alarm Time

SERVICE
SERVICE

Recovery Start Request
Rectifier Overcurrent

SERVICE
STATUS

EQUIPMENT SERVICE
CONTROL ALGORITHM STATUS
CONTROL TEST

CONTROL TEST
CONTROL TEST

VFD CONFIG DATA
VFD CONFIG DATA
VFD CONFIG DATA
EQUIPMENT CONFIGURATION
CONTROL ALGORITHM

STATUS

VFD CONF
VFD CONF

X
X

VFD CONF
NET OPT

X
X

LLMAINT
VFD STAT

Rectifier

Overload

STATUS

POWER

Rectifier
Rectifier

Overtemp
Power Fault

STATUS
STATUS

VFD STAT
VFD STAT

Rectifier Temp Override

SERVICE

Rectifier

Temp Override

SERVICE

Rectifier

Temperature

STATUS

Rectifier

Temperature

SERVICE

CONTROL ALGORITHM

STATUS

OVERRIDE

Rectifier

Temperature

SERVICE

CONTROL ALGORITHM

STATUS

VFD HIST

Recycle
Redline

Control

SERVICE
SERVICE

EQUIPMENT SERVICE
CONTROL ALGORITHM STATUS

SETUP1
LOADSHED

Reference

Number

Refrig Override

Humidity

Relative

Humidity

Remote Contacts

SERVICE
SERVICE
SERVICE
STATUS
STATUS
SERVICE

Remote Start Contact

STATUS

Remote Temp->No
RESET
Reset Alarm?

STATUS

SERVICE

Reset
Reset

OVERRIDE
SETUP1

EQUIPMENT

SERVICE

CONTROL TEST

SETUP1
POWER

EQUIPMENT

SERVICE

CONTROL TEST

SERVICE

EQUIPMENT

SERVICE

EQUIPMENT

SERVICE

STATUS

OPTIONS

ICVC PWD
MAINSTAT
THERMITORS

MAINSTAT

TEMP

CTL

TEMP CTL
DEFAULT SCREEN
ICVC

PWD

EQUIPMENT

SERVICE

TEMP

CTL

RESET TYPE 2

SERVICE

EQUIPMENT

SERVICE

TEMP

CTL

RESET TYPE 3

SERVICE

EQUIPMENT

SERVICE

TEMP

CTL

Restart

SERVICE

EQUIPMENT

SERVICE

SERVICE
STATUS

PRESSURE TRANSDUCERS

SERVICE

Run Status
Run Status

ICVC CONFIGURATION

RESET TYPE 1

Delta T

POWER

STATUS
Option

Remote Reset Option
Remote Reset Sensor
Remote Reset Sensor

Remote Temp->Full

EQUIPMENT

SERVICE

Delta T

Relative

CONTROL ALGORITHM

133

STATUS

SETUP1
LL MAINT
MAIN STAT

X
X
X

APPENDIX -- 19XRV LIQUlFLO
PARAMETER

MENU
SOFTKEY

2 ICVC PARAMETER INDEX (cont)

TABLE

SCREEN NAME

CONFIGURABLE

RUNTIME

SERVICE

EQUIPMENT

CONFIGURATION

RUNTIME

Schedule Number
SECONDARY MESSAGE

SERVICE

EQUIPMENT

CONFIGURATION

NET OPT
DEFAULT SCREEN

Serial

SERVICE

Service

Number
Ontime

ICVC CONFIGURATION

STATUS

Shunt Trip Relay

MAINSTAT

STATUS

Shunt Trip Relay Test
Shutdown Delta T

SERVICE
SERVICE

STARTUP
CONTROL TEST
EQUIPMENT SERVICE

DISCRETE OUTPUTS
SETUP1
VFD

X
X

Single

Cycle Dropout

STATUS

Single

Cycle Dropout

SERVICE

VFD CONFIG DATA

VFD_CONF

STAT
X
X

Skip Frequency

SERVICE

VFD CONFIG DATA

VFD

Skip Frequency

SERVICE

VFD CONFIG DATA

VFD_CONF

Skip Frequency

SERVICE

VFD CONFIG DATA

VFD

CONF

Skip Frequency

Band

SERVICE

VFD CONFIG DATA

VFD

CONF

Soft Stop Amps Threshold
Software Part Number

SERVICE
SERVICE

EQUIPMENT

SERVICE

Spare Alert/Alarm

SERVICE

EQUIPMENT

SERVICE

Enable

Spare Safety Input

STATUS

CONF

OPTIONS
ICVC CONFIGURATION

SETUP1
STARTUP

Spare Temp #1 Enable

SERVICE

EQUIPMENT

SERVICE

SETUP1

Spare Temp #1 Limit

SERVICE

EQUIPMENT

SERVICE

SETUP1

Spare Temp #2 Enable

SERVICE

EQUIPMENT

SERVICE

SETUP1

Spare Temp #2 Limit

SERVICE

EQUIPMENT

SERVICE

SETUP1

Spare Temperature

STATUS

Spare Temperature

SERVICE

Spare Temperature

SERVICE

Spare Temperature

STATUS

Spare Temperature

SERVICE

Spare Temperature

SERVICE

STANDBY % Capacity
STANDBY Address

SERVICE
SERVICE

STANDBY Chiller Option
STANDBY CHILLER: Mode

SERVICE
SERVICE

Start Acceleration
Start Advance

STATUS
SERVICE

Fault

Start Complete

COMPRESS
CONTROL ALGORITHM

STATUS

CONTROL TEST

COMPRESS
CONTROL ALGORITHM

STATUS

CONTROL TEST
EQUIPMENT
EQUIPMENT

SERVICE
SERVICE

EQUIPMENT SERVICE
CONTROL ALGORITHM STATUS
EQUIPMENT

CONFIGURATION

STATUS
EQUIPMENT

CONFIGURATION

EQUIPMENT

Start Time
Start Week

SERVICE
SERVICE

EQUIPMENT
EQUIPMENT

Start/Stop
Starts In 12 Hours

SERVICE
STATUS

Stop Back

SERVICE

VFD_STAT
BRODEF

CONFIGURATION
CONFIGURATION
CONFIGURATION

BRODEF
BRODEF

X
X

CONTROL ALGORITHM
EQUIPMENT

STATUS

CONFIGURATION

LL MAINT
MAINSTAT
BRODEF

STARTU P

STATUS
SERVICE

LEADLAG
LL_MAINT

BRODEF
MAINSTAT
BRODEF

STATUS

Stop Day of Week

X
X

VFD_STAT

SERVICE
STATUS
SERVICE

Stop Complete

LEADLAG
LEADLAG

STARTU P

Start Day of Week
Start Inhibit Timer
Start Month

Stop Complete

LL MAINT
THERMITORS

STATUS

Start Complete

LL MAINT
THERMITORS

VFD_STAT
EQUIPMENT

CONFIGURATION

BRODEF

Stop Fault

STATUS

Stop Month

SERVICE

EQUIPMENT

CONFIGURATION

BRODEF

Stop Time

SERVICE

EQUIPMENT

CONFIGURATION

BRODEF

Stop Week

SERVICE

EQUIPMENT

CONFIGURATION

BRODEF

Superheat
Surge/HGBP

Required

SERVICE

VFD_STAT

CONTROL ALGORITHM

STATUS

OVERRIDE

Active?

STATUS

Gas Bypass

SERVICE

EQUIPMENT

SERVICE

OPTIONS

Surge Delta % Amps

SERVICE

EQUIPMENT

SERVICE

OPTIONS

Surge Limit/HGBP

SERVICE

EQUIPMENT

SERVICE

OPTIONS

SERVICE

EQUIPMENT

SERVICE

OPTIONS

EQUIPMENT

SERVICE

Surge/Hot

Option

Surge Protection
Surge Protection
Surge Time Period

Counts

HEAT_EX

STATUS
SERVICE

COMPRESS

134

OPTIONS

APPENDIX -- 19XRV LIQUlFLO

2 ICVC PARAMETER

PARAMETER

MENU
SOFTKEY

Surge/HGBP

Deadband

SERVICE

EQUIPMENT

SERVICE

OPTIONS

Surge/RGBP

Delta P1

SERVICE

EQUIPMENT

SERVICE

OPTIONS

Surge/RGBP

Delta P2

SERVICE

EQUIPMENT

SERVICE

OPTIONS

Surge/RGBP

Delta T

STATUS

Surge/RGBP

Delta T1

SERVICE

EQUIPMENT

SERVICE

OPTIONS

Surge/RGBP

Delta T2

SERVICE

EQUIPMENT

SERVICE

OPTIONS

System

Alert/Alarm

TABLE

INDEX (cont)
SCREEN NAME

HEAT EX

STATUS

Target Guide Vane Pos

STATUS

Target Guide Vane Pos

SERVICE

MAINSTAT
COMPRESS
CONTROL ALGORITHM

STATUS

COMPRESS

Target VFD Speed

STATUS

STARTUP

Target VFD Speed

SERVICE

Temp Pulldown

SERVICE

Temperature

Reset

STATUS

Temperature
Reset
Terminate Lockout

SERVICE
SERVICE

Thermistors
Control
TIME AND DATE
Time Broadcast

Test

Enable

CONTROL ALGORITHM
EQUIPMENT

STATUS

SERVICE

CAPACITY
TEMP

CTL

EQUIPMENT
EQUIPMENT

SERVICE
SERVICE

TEMP CTL
CONTROL TEST

EQUIPMENT

CONFIGURATION

Torque Current

SERVICE

CONTROL ALGORITHM

STATUS

VFD HIST

Total Compressor
Starts
Total Error + Resets

STATUS
SERVICE

CONTROL ALGORITHM

STATUS

MAINSTAT
CAPACITY

Tower Fan High Setpoint

SETPOINT

STATUS

STARTUP

Tower Fan Relay Low

SERVICE

POWER

CONTROL TEST

DISCRETE OUTPUTS

STATUS
SERVICE

CONTROL TEST

DISCRETE OUTPUTS

Transducer

SERVICE

CONTROL TEST

PRESSURE TRANSDUCERS

Ref

US Imp / Metric
Values at Last Fault:
VFD Checksum

SERVICE
SERVICE

Error

STATUS

VFD Cold Plate Temp

STATUS

VFD Cold Plate Temp
VFD Comm Fault
VFD CONFIG PASSWORD
VFD Coolant

Flow

VFD Coolant
VFD Coolant

Flow
Solenoid

SERVICE
STATUS
SERVICE

CONTROL ALGORITHM

STATUS

STATUS
SERVICE

VFD Enclosure

Temp

STATUS

VFD Enclosure
VFD Fault

temp

SERVICE
STATUS

ICVC CONFIGURATION
VFD HIST

STATUS

VFD HIST
VFD STAT
VFD CONFIG DATA
POWER
DISCRETE OUTPUTS

CONTROL TEST

CONTROL ALGORITHM

STATUS

VFD HIST
VFD STAT

STATUS
CONTROL ALGORITHM

STATUS

VFD HIST

VFD FAULT HISTORY

SERVICE

CONTROL ALGORITHM

STATUS

VFD HIST

VFD Gain

SERVICE

VFD Increase Step
VFD Inverter Version

POWER

SERVICE

HEAT EX

VFD Fault Code

Version

POWER
CONTROL ALGORITHM

VFD Fault Code

VFD Gateway

VFD STAT

STATUS
Test

STARTUP

Tower Fan Relay Low Test
Voltage

BRODEF

STATUS

Tower Fan Relay High Test

CONTROL TEST
TIME AND DATE

Torque Current

Tower Fan Relay High

MAINSTAT

SERVICE
SERVICE
SERVICE

CAPACITY

Target VFD Speed

Deg/Min.

CONFIGURABLE

VFD STAT

EQUIPMENT

SERVICE

STATUS

SETUP2

VFD STAT

SERVICE
STATUS

EQUIPMENT

SERVICE

SETUP2
VFD STAT

VFD Maximum Speed

SERVICE

EQUIPMENT

SERVICE

SETUP2

VFD Minimum Speed
VFD Power On Reset

SERVICE
STATUS

EQUIPMENT

SERVICE

SETUP2
VFD STAT

EQUIPMENT

SERVICE

VFD Rectifier

Version

VFD Speed Control
VFD Start
VFD Start Inhibit
Water Flow Verify Time
WSM Active?

STATUS
SERVICE
STATUS

VFD STAT

STATUS
SERVICE
SERVICE

SETUP2
STARTUP
VFD STAT

EQUIPMENT SERVICE
CONTROL ALGORITHM STATUS

135

SETUP1
WSMDEFME

INDEX
Abbreviations and explanations
4, 5
Adding refrigerant
74
Adjusting the refrigerant charge
74
After extended shutdown
69
Alter limited shutdown
69
Alarm (trip) output contacts 40
Attach to network device control 47
Automatic soft stop amps threshold
51
Auto. restart alter power failure 42
Bearings 8
Before initial start-up .52-67
Capacity override
.;9
Carrier Comfort Network interface
60
Changing oil filter 76
Charge refrigerant into chiller 65
Chilled water recycle mode
51
Chiller control module (CCM)
97
Chiller dehydration
58
Chiller familiarization
5, 6
Chiller information nameplate
5
Chiller operating condition (check) 68
Chiller tightness (check)
53
Chillers with isolation valves 73
Chillers with storage tanks
71
Cold weather operation 69
Compressor bearing and gear maintenance
77
Condenser
5
Condenser freeze prevention 41
Condenser pump control 41
Control algorithms checkout procedure
80
Controlpanel
5
Control modules
97
Control test 64, 81
Controls
11-49
Cooler 5
Defimlt screen freeze .;6
Definitions (controls)
11
Design set points, (input) 61
Details (lubrication cycle) 8
Display messages (check)
79
Equipment required .52
Evaporator freeze protection
41
Extended shutdown (preparation for) 69
General (controls)
11
General maintenance
74, 75
Ground fault troubleshooting
60
Guide vane linkage (check)
7.5
Head pressure reference output 44
Heat exchanger tubes and
flow devices (inspect)
77
High altitude locations
65
High discharge temperature control .;9
Ice build control 46
ICVC operation and menus
16
Initial start-up
6Z 6_5'
Initial start-up checklist for 19XRV hermetic
centrifugal liquid chiller
CL-lro CL-12
Input power wiring 59
Inspect the control panel
76
Instruct the customer operator
68
Introduction
4
Job data required
.52
Kilowatt output 41
Lead/lag control
44
Leak rate
74
Leak test chiller .5.5
Local occupied schedule (input) 61
Local start-up
50
Lubrication cycle 8, 9
Lubrication system (check)
7.5
Manual guide vane operation 69
Motor and lubricating oil cooling cycle
7
Motor-compressor
5
Motor rotation (check)
67

Notes on module operation 97
Oil changes
76
Oil charge .52
Oil cooler 39
Oil pressure _mdcompressor stop (check)
67
Oil reclaim filter 76
Oil reclaim system 8
Oil specification
76
Oil sump temperature and pump control 39
Open oil circuit valves .52
Operating instructions
68-70
Operating the optional pumpout unit 71
Operator duties 68
Optional pumpout compressor
water piping (check)
5_5'
Optional pumpout system controls and
compressor(check)
65
Optional pumpout system maintenance
78
Ordering replacement chiller parts 78
Overview (troubleshooting guide)
79
Perform a control test 64
Physical data 99
PIC III system components
11
PIC III system functions
.;4
Power up the controls and check
the oil heater 61
Preparation (initialstart-up)
67
Preparation (pumpout and refrigerant
transfer procedures)
71
Prepare the chiller for start-up
68
Pressure transducers (check)
79
Prevent accidental start-up 67
Pumpont and refrigerant transfer
procedures
71-74
Ramp loading 39
Recalibmte pressure transducers
7,5'
Refrigerant filter 76
Refrigerant float system (inspect)
77
Refrigerant leak testing
74
Refrigerant properties
74
Refrigerant (removing)
74
Refrigerant tracer 53
Refrigeration cycle 7
Refrigeration log 69
Relief valves (check)
58
Relief valves and piping (inspect)
77
Remote reset of alarms 41
Remote start/stop controls
40
Repair the leak, retest, and
apply standing vacuum test 7.5
Replacing defective processor modules
98'
Running system (check) 68
Safety and operating controls
(check monthly)
76
Safety considerations
1
Safety controls
.;6
Safety shutdown 52
Scheduled maintenance
75-78
Service configurations (input) 61
Ser_.ice ontime 7.5
Seta.'ice operation 48'
Shipping packaging (remove) .52
Shunt trip (option) 36
Shutdown sequence
51
Software configuration
61
Spare safety and space temperature inputs 40
Standing vacuum test 55
Starting equipment
9-11
Start-up/shutdown/recycle sequence
50-.52
Start the chiller 68
Stop the chiller 69
Storage vessel 5
Sunnnary (lubrication cycle) 8
Surge prevention algorithm 42

Surge protection
43
System components
5
Temperature sensors (check)
79
Test after service, repair, or m:tior leak
Tighten all gasketed joints and
guide vane packing
.52
Tower fan relay low and high 41
Trim refrigerant charge 7.5
Troubleshooting guide
79-126
Unit-mounted VFD
9
Using the optional storage tank and
pumpout system 52
Variable frequency drive 5
VFD cooling cycle 8
VFD (identify)
58
VFD (inspect)
78
Water/brine reset 42
Water leaks
77
Water piping (inspect)
58
Water treatment
78
Weekly nmintenance
7.5
Wiring (inspect)
60

Catalog No. 531-986

or change at any time, specifications
Printed in U.S.A.

or designs without notice and without incurring obligations.

Form 19XRV-1SS

Pg 136

4-05

Replaces:

New

INITIAL START-UP CHECKLIST
FOR 19XRV HERMETIC CENTRIFUGAL
LIQUID
(Remove and use for job file.)

CHILLER

MACHINE INFORMATION:
NAME

JOB NO.

ADDRESS

MODEL

CITY

STATE

ZIP

S/N

DESIGN CONDITIONS:
TONS

(kW)

BRINE

FLOW
RATE

TEMPERATURE
IN

TEMPERATURE
OUT

PRESSURE
DROP

PASS

SUCTION
TEMPERATURE

CONDENSER
TEMPERATURE

COOLER
CONDENSER

COMPRESSOR:

Volts

RLA

OLTA

STARTER:
OIL PUMP:

Mfg
Volts

Type
RLA

S/N
OLTA

REFRIGERANT:

Type: __

CARRIER OBLIGATIONS:

Charge __
Assemble ...................
Leak Test ...................

Yes []
Yes []

No []
No []

Dehydrate ..................
Charging ...................
Operating Instructions

Yes []
Yes []

No []
No []
Hrs.

START-UP TO BE PERFORMED IN ACCORDANCE WITH APPROPRIATE MACHINE START-UP INSTRUCTIONS
JOB DATA REQUIRED:
1. Machine Installation Instructions ..................
Yes []
No []
2.
3.
4.
5.

Machine Assembly, Wiring and Piping Diagrams ......
Starting Equipment Details and Wiring Diagrams ......
Applicable Design Data (see above) ................
Diagrams and Instructions for Special Controls .......

Yes
Yes
Yes
Yes

[]
[]
[]
[]

No
No
No
No

[]
[]
[]
[]

INITIAL MACHINE PRESSURE:
YES

Was Machine Tight?
If Not, Were Leaks Corrected?
Was Machine Dehydrated After Repairs?
CHECK OIL LEVEL AND RECORD:

3/4
1/2 Top sight glass
1/4

ADD OIL:

Yes []

No []

Amount:

3/4
1/2 Bottom sight glass
1/4

RECORD PRESSURE DROPS:
CHARGE REFRIGERANT:

Book
Tab

Cooler
Initial Charge

Condenser
Final Charge After Trim

Manufacturer reserves the right to discontinue, or change at any time_ specifications or designs without notice and without incurring obligations.
h2
PC 211
Catalog No, 531-986
Printed in U.S,A.
Form 19XRV-1SS
CL-1
4-05
Replaces:

New

INSPECT WIRING AND RECORD ELECTRICAL
RATINGS:
Motor Voltage
Line Voltages:

DATA:

Motor(s) Amps
Motor

FIELD-INSTALLED

Oil Pump Voltage

Oil Pump

Starter LRA Rating

Controls/Oil Heater

STARTERS ONLY:

Check continuity T1 to T1, etc. (Motor to starter, disconnect motor leads T1, T2, T3.) Do not megger VFD;
disconnect leads to motor and megger the leads.
"PHASE TO PHASE ....
MEGGER MOTOR
10-Second

Readings:

60-Second

Readings:

Polarization

T1 -T2

T1 -T3

PHASE TO GROUND"

T2-T3

T1-G

T2-G

T3-G

Ratio:

VFD Manufacturer
VFD Serial Number

VFD Date Code

c_
U3

CONTROLS: SAFETY, OPERATING, ETC.
c_

Perform Controls Test (Yes/No)

PIC III CAUTION
COMPRESSOR MOTOR AND CONTROL PANEL MUST BE PROPERLY AND INDIVIDUALLY
CONNECTED BACK TO THE EARTH GROUND IN THE STARTER (IN ACCORDANCE WITH
CERTIFIED DRAWINGS).
RUN MACHINE:

q
I-

Yes

Do these safeties shut down machine?
Condenser Water Flow
Chilled Water Flow

Yes []
Yes []

No []
No []

Pump Interlocks

Yes []

No []

INITIAL START:
Line Up All Valves in Accordance With Instruction Manual:
Start Water Pumps and Establish Water Flow

Oil Level OK and Oil Temperature OK

Check Oil Pump Rotation-Pressure

tm
LU

Check Compressor Motor Rotation (Motor End Sight Glass) and Record:

I-

Clockwise

Restart Compressor, Bring Up To Speed. Shut Down. Any Abnormal Coastdown Noise?
*If yes, determine cause.

Yes* []

No []

c_
Z

o,
I-

START MACHINE AND OPERATE. COMPLETE THE FOLLOWING:
A:
B:
C:
D:
E:
F:

Trim charge and record under Charge Refrigerant Into Chiller section on page 65.
Complete any remaining control calibration and record under Controls section (pages 11-49).
Take at least two sets of operational log readings and record.
After machine has been successfully run and set up, shut down and mark shutdown oil and refrigerant levels.
Give operating instructions to owner's operating personnel. Hours Given:
Hours
Call your Carrier factory representative to report chiller start-up.

SIGNATURES:
CARRIER
TECHNICIAN

CUSTOMER
REPRESENTATIVE

DATE

CL-2

CO/WO
19XRV PIC III SETPOINT
DESCRIlrrlON
Base Demand

3ABLE

CONFIGURATION

RANGE

Limit

40 to 100

StIEET

UNITS

DEFAULT

100

LCW

Setpoint

10to 120
(- 12.2 to 48.9)

DEG F (C)

50.0 (10)

ECW

Setpoint

15to 120
(-9.4 to 48.9)

DEG F (C)

60.0 (15.6)

Ice Build Setpoint

15 to 60
(-9.4 to 15.6)

DEG F (C)

40.0 (4.4)

Tower Fan Itigh Setpoint

55 to 105
(13 to 41 )

DEG F (C)

75 (24)

Upload all control configuration
ICVC Softwme
ICVC Controller

tables via service tool'?

Yes

[]

Version Number:
Identification:

BUS:

ADDRESS:

CL-3

VALUE

19XRV PIC III TIME SCHEDULE

M
Period

Period

CONFIGURATION

Day Flag
T F S

SHEET

Occupied
Time

OCCPC01S

Unoccupied
Time

zm
c_

NOTE: Default setting is OCCUPIED 24 hours/day.

ICE BUILD

19XRV PIC III TIME SCHEDULE

CONFIGURATION

SHEET

OCCPC02S

o,
Io

M
Period

Period

Day Flag
T F S

Occupied
Time

Unoccupied
Time

zm
tm
LU

I-

NOTE: Default setting is UNOCCUPIED

24 hours/day.
Z

19XRV PIC III TIME SCHEDULE

CONFIGURATION

Day Flag
T F S

Period 1:
Period 2:
Period 3:
Period 4:
Period 5:
Period

Period

NOTE: Default setting is OCCUPIED 24 hours/day.

CL-4

SHEET

OCCPC03S

Occupied
Time

Unoccupied
Time

19XRV PIC III VFD_CONF
DESCRIIrFION
Motor

Nameplate

CONFIGURATION

RANGE

SIIEET

UNITS

DEFAULT

380-460

VOLTS

460

45.0-62.0

60.0

0/l

NO/YES

YES

346-480

VOLTS

460

* Rated Line Amps
* Rated Line Kilowatts
* Motor Rated Load KW

l 0-1500
0-7200
0-7200

AMPS
kW
kW

200
100
100

* Motor

10-1500

AMPS

200

l 0-1500

AMPS

100

Compressor

100% Speed

Line Freq=60
* Rated

Voltage

TABLE

Hz? (No=50)

Line Voltage

Rated

Load Amps

Motor

Nameplate

Amps

Motor

Nameplate

RPM

1500-3600

Motor

Nameplate

0-5600

3456
kW

100

Inverter PWM Frequency
(0=4 k Hz, 1=2 k Hz)

0/l

Skip Frequency

0.0-102.0

102.0

Skip Frequency

0.0-102.0

102.0

Skip Frequency

0.0-102.0

102.0

Skip Frequency

Band

0.0-102.0

0.0

Line Voltage % Imbalance
Line Volt Imbalance Time

l - l0
l - l0

%
SEC

l0
l0

Line Current

5-40

l-l0

SEC

5-40

Line Current

% Imbalance
Imbal

Time

Motor

Current

% Imbalance

Motor

Current

Imbal

l - l0

SEC

Increase

Ramp Time

5-60

SEC

Decrease

Ramp

5-60

SEC

DSABLE/ENABLE

DSABLE

Time

Single Cycle Dropout

Time

0/l

NOTE: Those parameters marked with a * shall not be downloaded

VALUE

to the VFD, but shall be used in other calculations

CL-5

and algorithms in the ICVC.

O
19XRV PIC HI OIq'IONS

DESCRIF1TON
Auto Restart Option
Remote Contacts Option
Soft Stop Amps Threshold
Surge/llot Gas Bypass
Surge Limit/HGBP Option
Select: Surge=0, HGBP=I
Min. Load Point (T1, P1)
Surge/ItGBP

Delta T1

Surge/ItGBP

Delta P1

Full Load Point

TABLE

RANGE
0/1
0/1
40 to 100

CONFIGURATION

SIIEET

UNITS
DSABLE/ENABLE
DSABLE/ENABLE
%

DEFAULT
DSABLE
DSABLE
100

^F fie)

1.5(0.8)

PSI (kPa)

50 (344.8)

0/1

0.5 to 20
(.3to 11.1)
30 to 170
(206.9 to 1172.2)

LI3

(T2, P2)

Surge/ltGBP

Delta T2

Surge/IR_BP

Delta P2

Surge/liGBP

Deadband

Surge Protection
Surge Delta% Amps
Surge Time Period

VALUE

0.5 to 20
(.3to 11.1)
50 to 170
(344.8 to 1172.2)
0.5 to 3
(.3 to 1.7)

^F fie)

10 (5.6)

PSI (kPa)

85 (586.1)

^F (^C)

1 (0.6)

S
.<
D

7to 10

%
MIN

10
8

Ice Build Option
Ice Build Termination
0=Temp, l=Contacts, 2=Both

0/1

DSABLE/ENABLE

DSABLE

Ice Build Recycle

0/1

5 to 20

LI3

Ice Build Control

Oto 2

0
DSABLE/ENABLE

DSABLE
HA

Iiead Pressure

Reference

C3
HA

Delta P at 0% (4 mA)

Delta P at 100% (20 mA)
Minimum Output

20 to 85
(138 to 586)
20 to 85
(138 to 586)
0 to 100

psi (kPa)

25 (172)
C3
(9

psi (kPa)

50 (344.8)

o,
<
D

CL-6

CO/WO
19XRV PIC IIl SETUP1

DESCRHrl'ION

TABLE

CONFIGURATION

RANGE

Comp Motor Temp Override

150 to 200
(66 to 93)

Cond Press Override

Comp Discharge Alert

90 to 165
(621 to 1138)
155 to 170
(68 to 77)
155 to 170
(68 to 77)
125 to 200
(52 to 93)

Comp Thrust Brg Alert

165 to 185
(74 to 85)

Chilled Medium

0/1

Rectifier Temp Override
Inverter Temp Override

Chilled Water Deadband
Evap Refrig Trippoint
Refrig Override Delta T
Evap Approach Alert
Cond Approach Alert

.5 to 2.0
(0.3 to 1.1)
0.0 to 40.0
(-17.8 to 4.4)
2.0 to 5.0
(1.1 to 2.8)
0.5 to 15
(0.3 to 8.3)
0.5 to 15
(0.3 to 8.3)

UNITS

SttEET

DEFAULT

°F (°C)

200 (93)

PSI (kPa)

125 (862)

°F (°C)

160 (71)

°F (°C)

160 (71)

°F (°C)

200 (93)

°F (°C)

175 (79)

WATER/
BRINE

WATER

T (_C)

1.0 (0.6)

°F (°C)

33 (0.6)

T (_C)

3 (1.7)

T CC)

5 (2.8)

T (_C)

6 (3.3)

°F (°C)

34(1.1)

DSABLE/
ENABLE

DSABLE

Condenser Freeze Point

-20 to 35
(-28.9 to 1.7)

Flow Delta P Display

0 to 1

Evap Flow Delta P Cutout

0.5 to 50.0
(3.4 to 344.8)

PSI (kPa)

5.0 (34.5)

Cond Flow Delta P Cutout

0.5 to 50.0
(3.4 to 344.8)

PSI (kPa)

5.0 (34.5)

Water Flow Verify Time
Oil Press Verify Time
Recycle Control

0.5 to 5
15 to 300

MIN
SEC

5
40

Restart Delta T

2.0 to 10.0
(1.1 to 5.6)

°F (°C)

5 (2.8)

Shutdown Delta T

0.5 to 4.0
(0.3 to 2.2)

°F (°C)

1 (.0.6)

Spare Alert/Alarm Enable
Disable=0, Lo=l/3, Iii=214
Spare Temp #1 Enable

0 to 4

Spare Temp #1 Limit

_40 to 245
(_40 to 118)

Spare Temp #2 Enable

0 to 4

Spare Temp #2 Limit

_40 to 245
(_40 to 118)

NOTE:Novariablesareavailablefor CCNreadoperation.

Forcing

0
°F (°C)

245 (118)
0

°F (°C)

shallnotbe supported

CL-7

245 (118)
servicescreens.

VALUE

O
19XRV PIC IH SETUP2
DESCRIPFION
Capacity

TABLE

STATUS

CONFIGURATION
UNITS

SIIEET
DEFAULT

VALUE

Control

Proportional

Inc Band

2 to 10

6.5

Proportional

DEC Band

2 to 10

6.0

Proportional

ECW

I to 3

2.0

Guide Vane Travel

Gain

Limit

30 to 100

Diffuser Option
Guide Vane 25% Load Pt
Diffuser 25% Load Point

0/1
0 to 78
0 to 100

DSABLE/ENABLE
%
%

DSABLE
25
0

Guide Vane 50% Load Pt

0 to 78

Diffuser 50% Load Point

0 to 100

Guide Vane 75% Load Pt

0 to 78

Diffuser 75% Load Point

0 to 100

Diffuser Full Span mA

15 to 22

Diffuser Control

zm
u3

q
D

VFD Speed Control
VFD Gain
VFD Increase

0.1 to 1.5

Step

0.75

1 to 5

VFD Minimum

Speed

65 to 100

VFD Maximum

Speed

90 to 100

100

zm
u3

q
L)

CL-8

CO/WO
19XRV PIC HI LEADLAG
DESCRIF1TON

TABLE

CONFIGURATION

RANGE

UNITS

StlEET
DEFAULT

Lead Lag Control
LEAD/LAG:
Configuration
DSABLE=0,
LEAD=l,
LAG=2, STANDBY=3

0 to 3

Load Balance

0/1

DSABLE/ENABLE

DSABLE

0/1

DSABLE/ENABLE

DSABLE

LAG% Capacity
LAG Address

25 to 75
1 to 236

50
92

LAG START Timer

2 to 60

MIN

LAG STOP Timer

2 to 60

MIN

2 to 30

MIN

0/1

DSABLE/ENABLE

DSABLE

25 to 75
I to 236

50
93

Common

PRESTART
STANDBY

Option

Sensor

Option

FAULT
Chiller

Timer
Option

STANDBY%
Capacity
STANDBY Address

CL-9

VALUE

O
19XRV PIC III RAMP_DEM
DESCRIFI'ION

RANGE

Pulldown Ramp Type:
Select: Temp=0, Load=l
Demand

Limit

CONFIGURATION
UNITS

SIIEET
DEFAULT

0/1

VALUE

and kW Ramp

Demand Limit Source
Select: Amps=0, kW= 1
Amps or kW Load Ramp%
Demand
Demand

TABLE

Limit Prop Band
Limit At 20 mA

20 mA Demand Limit Opt
Demand Watts Interval

Min

5 to 20

3 to 15
40 to 100

%
%

10
40

0/1
5 to 60

DSABLE/ENABLE
MIN

DSABLE
15

lad

19XRV PIC Ill TEMP_CTL

TABLE

CONFIGURATION

SIIEET

lad

DESCRIlrl'ION

RANGE

UNITS

DEFAULT

Control Point

VALUE
_3

ECW Control Option

DSABLE/ENABLE

DSABLE

^F (^C)

3 (1.7)

-30 to 30
(-17 to 17)

^F (_C)

10 (6)

Temp -> No Reset

-40 to 245
(-40 to 118)

DEG F (C)

85 (29)

Temp -> Full Reset

-40 to 245
(-40 to 118)

DEG F (C)

65 (18)

-30 to 30
(-17 to 17)

^F (^C)

10 (6)

Temp Pulldown

Deg/Min

0/1
2to 10
(1.1 to 5.6)

o,
<

Temperature
Reset
RESET TYPE 1
Degrees Reset At 20 mA
RESET TYPE 2
Remote
Remote

Degrees Reset
RESET

TYPE

lad

CIIW

Delta T -> No Reset

0 to 15 (0 to 8)

^F (_C)

10 (6)

CIIW

Delta T -> Full Reset

0 to 15 (0 to 8)
-30 to 30
(-17 to 17)

_F (_C)

0 (0)

^F (_C)

5 (3)

Degrees Reset
Enable

Reset Type

0 to 3

CL-10

CO/WO
BROADCAST
DESCRIF1TON
Time Broadcast

Enable

(BRODEF)

CONFIGURATION

RANGE

StlEET

UNITS

DEFAULT

DSABLE/ENABLE

DSABLE

I to 12

Start Day of Week
Start \¥eek

1 to 7
1 to 5

7
1

Start Time
Start Advance

00:00 to 24:00
0 to 360

Stop Month

1 to 12

Stop Day of Week

1 to 7

Stop Week

1 to 5

Stop Time

00:00 to 24:00

Stop Back

0 to 360

Daylight Savings
Start Month

HH:MM
MIN

02:00
0

02:00
MIN

CL-II

VALUE

CO/_O_
ICVC DISPLAY AND ALARM SItUTDOWN

fPRIMARY

STATE RECORD SIIEET

MESSAGE:

SECONDARY

DATE:

MESSAGE:

TIME:

COMPRESSOR

ONTIME:

CHW IN

CHW OUT

EVAP REF

CDW IN

CDW OUT

COND REF

z
u

C3
LU
tm
Z

o,
<
io

OILTEMP

OILPRESS

COMMUNICATION

AMPS %IN

MESSAGE
LU

CCN

LOCAL

RESET

IS
c_
Z

o,
<
io

Copyright 2005 Carrier Corporation
Manufacturer reserves the right to discontinue, or change at any time, specifications
Book 2J2
Tab

PC 211

Catalog No. 531-988

Printed in U.SA.

or designs without notice and without incurring obligations.

Form 19XRV-1SS

CL-12

4-05

Replaces:

New

Source Exif Data:

File Type                       : PDF
File Type Extension             : pdf
MIME Type                       : application/pdf
PDF Version                     : 1.2
Linearized                      : No
Page Count                      : 148
Page Layout                     : SinglePage
Page Mode                       : UseNone
Producer                        : Goby Monitor Application version 3, 2, 1, 4
Create Date                     : Wed Apr 04 20:26:28 2007
Author                          : 
Title                           : 
Subject                         :

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CARRIER Package Units(both Units Combined) Manual L0522671

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