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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19X RV

Hermetic Centrifugal Liquid Chillers

with PIC III Controls

50/60 Hz

HFC-134a

Start-Up, Operation, and Maintenance Instructions

SAFETY CONSIDERATIONS

Centrifugal liquid chillers are designed to provide safe

and reliable service when operated within design speci-

fications. 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 instruc-

tions as well as those listed in this guide.

DO NOT VENT refrigerant relief valves within a buikting. Outlet

from rupture disc or relief valve must be vented outdoors in accor-

dance with the latest edition of ANSI/ASHRAE 15 (American

National Standards Institute/American Society of Heating, Refrigera-

tion, and Air Conditioning Engineers). The accumulation of refriger-

ant 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 irregular-

ities, 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 pres-

sures on the equipment nameplate.

DO NOT USE air for leak testing. Use only refrigerant or dry

nitrogen.

DO NOT VALVE OFF any safety device.

BE SURE that all pressure relief devices are properly installed and

fimctioning before operating any chiller.

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 or eyebolt holes to rig chiller sections or the

entire assembly.

DO NOT work on high-voltage equipment unless yon are a qualified

electrician.

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 electrical circuits during servicing. IF

WORK IS INTERRUPTED, confirm that all circuits are deenergized

before resuming work.

AVOID SPILLING liquid refrigerant on skin or getting it into the

eyes. USE SAFETY GOGGLES. Wash any spills from the skin with

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 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

Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.

PC 211 Catalog No. 531-986 Printed in U.S.A. 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 ...................................... l l

• 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

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

(cont)

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)

Page

Optional Pumpout System Maintenance ......... 78

• OPTIONAL PUMPOUT COMPRESSOR OIL

CHARGE

• OPTIONAL PUMPOUT SAFETY CONTROL

SETTINGS

Ordering Replacement Chiller Parts ............. 78

TROUBLESHOOTING GUIDE ................ 79-I 26

Overview ........................................ 79

Checking Display Messages ..................... 79

Checking Temperature Sensors ................. 79

• RESISTANCE CHECK

• VOLTAGE DROP

•CHECK SENSOR ACCURACY

• DUAL TEMPERATURE SENSORS

Checking Pressure Transducers ................. 79

• COOLER CONDENSER PRESSURE TRANSDUCER

AND OPTIONAL WATERSIDE FLOW DEVICE

CALIBRATION

• TRANSDUCER REPLACEMENT

Control Algorithms Checkout Procedure ........ 80

Control Test ..................................... 81

Control Modules ................................. 97

•RED LED (Labeled as STAT)

• GREEN LED (Labeled as COM)

Notes on Module Operation ..................... 97

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 or defective boards

in anti-static shipping bag.

ABBREVIATIONS AND EXPLANATIONS

Frequently used abbreviations in this manual include:

CCM -- Chiller Control Module

CCN

CCW

ECDW

ECW

EMS

HGBP

I/O

ICVC

LCD

LCDW

LCW

LED

OLTA

PIC III

RLA

SCR

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, tempera-

tures, 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.).

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 of the 19XRV unit is

located on the back of the ICVC.

CHILLER FAMILIARIZATION

(Fig. 1 and 2)

Chiller Information Nameplate -- The information

nameplate is located on the right side of the chiller control

panel.

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 exter-

nal threads to enable each component to be plessure tested with

a thleaded pipe cap during factory assembly.

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 condenser operates at a higher

temperature/pressure than the cooler and has water flowing

through its internal tubes in order to remove heat fi_)m the

refrigerant.

Motor-Compressor- This component mainttfins sys-

tem temperature and pressure differences and moves the

heat-carrying refrigerant from the cooler to the condenser

19XRV -- High Efficiency Hermetic

Centrifugal Liquid Chiller with

Variable Frequency Drive

Unit-Mounted

19XRV 52 51 473

Cooler Size

10-12 (Frame 1 XR) 55-57 (Frame 5 XR)

15-17 (Frame 1 XR) 5F (Frame 5 XR)

20-22 (Frame 2 XR) 5G (Frame 5 XR)

30-32 (Frame 3 XR) 5H (Frame 5 XR)

35-37 (Frame 3 XR) 60-62 (Frame 6 XR)

40-42 (Frame 4 XR) 65-67 (Frame 6 XR)

45-47 (Frame 4 XR) 70-72 (Frame 7 XR)

50-52 (Frame 5 XR)

5A (Frame 5 XR)

5B (Frame 5 XR)

50 (Frame 5 XR)

Condenser Size

10-12 (F .... 1 XR /

15-17 (Frame 1

20-22 (Frame 2 XR)

30-32 (Frame 3 XR)

35-37 (Frame 3 XR)

40-42 (Frame 4 XR)

45-47 (Frame 4 XR)

50-52 (Frame 5 XR)

55-57 (Frame 5 XR)

60-62 (Frame 6 XR)

65-67 (Frame 6 XR)

70-72 (Frame 7 XR)

Compressor Code

(First Digit Indicates Compressor Frame Size) _

*Second digit will be a letter (example 4G3)

on units equipped with split ring diffuser.

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:

• 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 micropro-

cessor 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.

Variable Frequency Drive (VFD) -- The VFD al-

lows for the proper st_ut and disconnect of electrical energy for

the compressor-motor, oil pump, oil heater, and control panel.

Storage 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 con-

nection for the pumpout unit.

NOTE: If a storage vessel is not used at the jobsite, factory-

installed 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.

64 -

Special Order Indicator

- -- Standard

S -- Special Order

Motor Voltage Code

Code Volts-Phase-Hertz

62 -- 380-3-60

63 -- 416-3-60

64 -- 460-3-60

52 -- 400-3-50

Motor Efficiency Code

H -- High Efficiency

S -- Standard Efficiency

Motor Code

BD CD DB LB

BE CE DC LC

BF CL DD LD

BG CM DE LE

BH ON DF LF

BJ CP DG LG

CQ DH LH

OR DJ

MODELNUMBERNOMENCLATURE

27 99 Q 59843

Year of Manufacture Place of Manufacture

SERIAL NUMBER BREAKDOWN

Fig. 1 -- 19XRV Identification

FRONT VIEW

144

6LEGEND

1 -- Guide Vane Actuator

2 -- Suction Elbow

3 -- International Chiller Visual Control (ICVC)

4 -- Chiller Identification Nameplate

5 -- Cooler, Auto Reset Relief Valve

6 -- Cooler Pressure Transducer

7 -- Condenser In/Out Temperature Thermistors

8 -- Condenser Waterflow Device (Optional

ICVC Inputs available)

9 -- Cooler Waterflow Device (Optional ICVC

Inputs available)

10 -- Cooler In/Out Temperature Thermistors

11 -- Liquid Line Service Valve

12 -- Typical Flange Connection

13 -- Oil Level Sight Glasses

14 -- Refrigerant Oil Cooler (Hidden)

15 -- Oil Drain Charging Valve (Hidden)

16 -- Power Panel

17 -- Compressor Motor Housing

REAR VIEW

19 2O 21 22

29 27

24 31

LEGEND

-- 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)

Fig. 2 --Typical 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 refrigerant vapor is

compressed. Compression adds still more heat energy, and the

refrigerant is quite wmm (typic_flly 98 to 102 F [37 to 40 C])

when it is discharged t]om the compressor into the condensel:

Relatively cool (typically 65 to 90 F [18 to 32 C]) water

flowing into the condenser tubes removes heat from the refrig-

erant 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 cham-

ber between the FLASC chamber and cooler Here a float v_dve

forms a liquid seal to keep FLASC chamber vapor from enter-

ing 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 liq-

uid. The refrigerant is now at a temperature and plessure at

which the cycle began.

MOTOR AND LUBRICATING OIL

COOLING CYCLE

The motor and the lubricating oil are cooled by liquid re-

frigerant taken from the bottom of the condenser vessel

(Fig. 3). Refrigerant flow is maintained by the pressure differ-

ential that exists due to compressor operation. After the refrig-

erant 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 exchang-

er (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

DRIER

MOISTURE/

FLOW

INDICATOR

ORIFICE-

FITTING

VFD'

COOLING

ISOLATION

VALVE

THERMOSTATIC

EXPANSION

VALVE

(TXV)

UNIT

MOUNTED

VFD

(VARIABLE

FREQUENCY

DRIVE)

HEAT

EXCHANGER

SOLENOID

VALVE (OPTION)

DIFFUSER

VANE

MOTOR

COOLER ISOLATION

VALVE (OPTION)

Fig. 3 -- Refrigerant Motor Cooling and Oil Cooling Cycles

REFRIGERANT

LIQUID

REFRIGERANT

VAPOR

_ EFRIGERANT

LIQUID/VAPOR

F_ OIL

CHILLED

WATER

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 refdger-

ant. 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 opera-

tion, 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 Mainte-

nance 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 shut-

down (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 post-

lubricate 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 lubrica-

tion 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 recov-

ered by skimming it from the operating refrigerant level in the

cooler vessel.

PRIMARY OIL RECOVERY MODE -- Oil is normally re-

covered 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 sec-

on&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 assem-

bly 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 compres-

sors using the alternate bearing design.

REAR MOTOR OIL SUPPLY TO

FORWARD HIGH

SPEED BEARING

(

FWD MOTOR

LABYRINTH

GAS LINE

MOTOR

COOLING LINE

PRESSURE

TRANSDUCER

OIL

ISOLATION PUMP

VALVES OIL

OIL HEATER

COOLER OILPUMP

MOTOR SIGHT

GLASS

FILTER

ISOLATION

VALVE

GLASS

ISOLATION

VALVE

Fig. 4- Lubrication System

t LINE

STARTING 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 ener-

gized 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 compres-

sor 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 rela-

tive 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 ptuame-

ters 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.

OPTIONAL

METER

PACKAGE

o./o

[]

I II II n11 I .

{t 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)

14,15 13 12 10,11 9

Fig. 6 -- Variable Frequency Drive Internal

1 m

2 --

3--

4 --

5 --

6 --

7--

8 --

9--

10 --

11 --

12 --

13 --

14 --

15 --

16 --

17 --

18 --

19 --

LEGEND

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

GUIDE VANE POWER PANEL CABLE

COOLER CHARGING CONTROL PANEL ACTUATOR CABLE

VALVE (HIDDEN)

WATER SEN_

CABLES

j cO2?s s'S 2

COOLER PRESSURE CABLE

TRANSDUCER

CONNECTION

SCHRADER

FITTING(HIDDEN)

CONDENSER

PRESSURE

TRANSDUCER

CONNECTION

CONDENSER CONDENSER

3-WAY SHUTOFF CHARGING

VALVE VALVE (HIDDEN)

COMPRESSOR

DISCHARGE

ELBOW JOINTS

Fig. 7 -- Chiller Controls and Sensor Locations

WATER

CABLES

CONTROLS

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 be-

cause its resistance changes in proportion to the temperature,

generating many values.)

DISCRETE SIGNAL --A discreW signal is a 2-position rep-

resentation 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.)

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 -- 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

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 regu-

lates 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.

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):

•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 and

Panel Locations*

PIC III COMPONENT

International Chiller Visual Controller

(ICVC) and Display

Chiller Control Module (CCM)

Oil Heater Contactor (1C)

Oil Pump Contactor (2C)

Hot Gas Bypass Relay (3C) (Optional)

Control Transformers (T1, T2, T3)

Temperature Sensors

Pressure Transducers

*See Fig, 5-10.

PANEL LOCATION

Control Panel

Power Panel

See Fig, 7.

INTERNATIONAL CHILLER VISUAL CONTROLLER

(ICVC) -- The ICVC is the "brain" of the PIC HI. This mod-

ule 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.

The viewing angle of the ICVC can be adjusted for opti-

mum 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:

English (default)

Chinese

Japanese

Kolean

NOTE: Plessing any one of the four softkey buttons will acti-

vate the backlight display without implementing a softkey

function.

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 Features of the ICVC

COLOR CEPL No.

CONTROLLER OF (hardware)

PLATE

ICVC Metallic CEPL

130445-02

SOFTWARE

CESR

131350-0X

OTHER

MARKINGS

"PIC IIr'

Marking

on back

of green

circuit

board

MOTOR TEMPERATURE

OIL RECLAIM

SIGHT GLASS_

COMPRESSOR OIL DISCHARGE

PRESSURE CABLE

BEARING TEMPERATURE

CABLE

AND DIFFUSER ACTUATOR

CABLE (FRAME 4 & 5

COMPRESSOR ONLY)

COMPRESSOR OIL SUMP

GUIDE

ACTUATOR CABLE

CABLE FROM

CONTROL PANEL

COMPRESSOR DISCHARGE

TEMPERATURE SENSOR

CABLE

HIGH PRESSURE

SWITCH LOCATION

OIL COOLER THERMOSTATIC

EXPANSION 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 Uto 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 lo-

cated 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.

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 transform-

ers convert incoming control voltage to 24 vac power for the

3 power panel contactor relays, CCM, and ICVC.

OPTIONAL TRANSFORMER (T3)--This transformer pro-

vides 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:

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 flintif one fails, the other can be connected external to the

machine. See NiNe 3 for a list of stan&trd instrumentation

sensors.

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 run-

ning, if the computed value for EVAPORATOR REFRIG

TEMP is greater than, or within 0.6° F (0.33° C) of the LEAV-

ING 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.

Table 3 -- Standard Instrumentation Sensors

TYPE LOCATION MONITORED REMARKS

Entering chilled water Cooler inlet nozzle

Leaving chilled water Cooler outlet nozzle

Entering condenser water Condenser inlet nozzle

Leaving condenser water Condenser outlet nozzle

Temperature Evaporator saturation 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 Relief valve tee

Condenser Relief valve tee

Oil sump Compressor oil sump

Oil sump discharge Oil pump discharge line

Pressure Diffuser (Compressor internal) 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

Angular Position Guide vane actuator Potentiometer inside of actuator

Pressure Switch High condenser (discharge) pressure Compressor volute, wired into the starter control circuit

Temperature Switch Oil pump motor winding temperature Wired into the oil pump control circuit

_÷

fo_m_,

0000

CONTROL PANEL

DISPLAY

(FRONT VIEW)

INTERNATIONAL

CHILLER

VISUAL

CONTROLLER

(ICVC)

FRONT VIEW

CARRIER COMFORT

NETWORK (CCN)

INTERFACE

HUMIDITY

SENSOR

CHILLER CONTROL

MODULE (CCM)

CONTROL POWER

CIRCUIT BREAKERS

@GG ( (

OPTIONAL

DATAPORT/DATAU NK

>CIRCUIT BREAKERS

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

PARAMETER

LABEL

CONTROL PANEL INTERNAL VIEW

CONTROl.

DIFFUSER

SCHEDULE

SETTINGS

(FRAME 5

COMPRESSOR

ONLY)

INTERNATIONAL

VISUAL

OONTRO_ER

REAR VIEW

CONTROL

PANEL

SIDE VIEW

REMOVABLE

BOLT

HINGE

CONTRAST

Fig. 9- Control Panel

CHILLER IDENTIFICATION NAMEPLATE

T1-24 VAC POWER TRANSFORMER

FOR HOT GAS BYPASS RELAY,

OIL PUMP CONTACTOR, AND

OIL HEATER CONTACTOR

T2-24 VAC POWER TRANSFORMER

FOR ICVC AND CCM T3-20 VAC POWER TRANSFORMER

FOR DATAPORT/DATALINK (OPTIONAL)

3C HOT GAS BYPASS

OIL HEATER CONDUIT CONTROL PANEL

POWER CONDUIT

Fig. 10 -- Power Panel

OPTIONAL HOT GAS

BYPASS CONDUIT

L,_ 3 00in ............ _-J CONNECTOR

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

NPT WATERPROOF SEAL

Fig. 11 -- Control Sensors (Temperature)

3.6" TUBE LENGTH

(90MM)

\EATSHR,NK\

2-CONDUCTOR CABLE

Fig. 12 -- Temperature Sensor Used

With Thermal Well

1/4" SAE FEMALE FLARE WITH

INTEGRAL SCHRADER DEFLATOR

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.

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 AP-

PROACH is defined as CONDENSER REFRIG TEMP

(derived from condenser pressure) minus LEAVING CON-

DENSER WATER temperature. When the chiller is running,

the displayed v_due for either approach will not be less than

0.2 ° F (0.1 oC). If either approach value exceeds the value con-

figured in the SETUPI screen, the corresponding Approach

Alert message will be entered into the Alert Histo Utable.

FLOW DETECTION- Flow 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.

Positive detemrination of flow on the evaporator side is

made if the following conditions ale true: (1) the EVAP SATU-

RATION 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

than the EVAP REFRIG TRIPPOINT. (If the unit is in Pump-

down or Lockout mode, conditions (1) and (2) ;ue not required

to establish flow.) On the condenser side, positive detemrina-

tion 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 differ-

entials (cooler and condenser) must exceed their respective

configured cutout thresholds.

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 PRES-

SURE exceeds the configured COND PRESS OVERRIDE

threshold by more than 5 psi (34.5 kPa). In addition, if the wa-

ter 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:

If No Flow (for either cooler or condenser) has been deter-

mined, and subsequently conditions change such that neither

conditions for Flow nor No Flow are _dl satisfied, the determi-

nation 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 pres-

sure transducers may be connected to the CCM at temrinals

J3 13-24 in place of the standard resistors and jumpers to deter-

mine 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 differ-

ential value of approximately 28.5 psi (197 kPa) will _flways be

displayed.)

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 CUT-

OUT) 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-of-

flow _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.

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 termi-

nals 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).

ICVC Operation and Menus (Fig. 14-20)

GENERAL

• 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 for SI metric units.

• 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 com-

pressor 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.

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.

When an alarm is detected, the ICVC default screen will

fieeze (stop up&_ting) at the time of alarm. The freeze enables

the operator to view the chiller conditions at the time of alarm.

The STATUS tables will show the updated information. Once

all aimms have been cleared (by pressing the _ soft-

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

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.

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.

Press the _ softkey to view the list of menu struc-

tures: _, [SCHEDULE], LSETPOINT], and

[SERVICEI.

• The STATUS menu allows viewing and limited calibra-

tion or modification of control points and sensors, relays

and contacts, and the options board.

PRIMARY STATUS

STATUS

MESSAGE

(ILLUMINATED

WHEN POWER ON)

• BLINKS CONTINUOUSLY

ON FOR AN ALARM

• BLINKS ONCE TO

CONFIRM A STOP

COMPRESSOR DATE

ON TIME

• HOLD FOR ONE

SECOND TO STOP

mmmm

SOFT KEYS

EACH KEY'S FUNCTION IS MENU

DEFINED BY THE MENU DESCRIPTION LINE

ON MENU LINE ABOVE

Fig. 14-- ICVC Default Screen

DEVICE NAME SCREEN NAME

mmm

Fig. 15 -- ICVC Service Screen

• 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 Con-

figuration 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

be viewed: _ ISCHEDULEI,[SE OINTI, or

[SERVICE]. To view or change parmneters within any of these

menu structures, use the _ 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.

BASIC ICVC OPERATIONS (Using the Softkeys) -- To per-

form any of the operations described below, the PIC III must be

powered up and have successfully completed its self test.

Press _ to leave tile selected decision or field with-

out saving any changes.

_, INCREASE DECREASE QUIT ENTER J

Press _ to leave tile selected decision or field and

save changes.

lINCREASE DECREASE QUIT ENTER J

71QD

Press _ to scroll tile cursor bar down in order to

highlight a point or to view more points below the cur-

rent screen.

_, NEXT PREVIOUS SELECT

Press [PREVIOUS[ to scroll tile cursor bar up in order to

highlight a point or to view points above tile current

screen.

NEXT PREVIOUS SELECT

Press _ to view tile next screen level (high-

lighted with the cursor bar), or to override (if allowable)

the highlighted point value.

_, NEXT PREVIOUS SELECT EXIT )

7] Q D

Press _ to return to tile previous screen level.

/ NEXTPREV,OUSSELECTEX,T )

Press ]INCREASE] or IDECREASEI

lighted point value.

INCREASE DECREASE QUIT

to change tile high-

ENTER

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 _ to view tile list of

point status tables.

/STATUS SCHEDULE SETPOINT SERVICE J

Press _ or IPREVIOUSI to highlight the desired

status table. The list of tables is:

•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

_, NEXT PREVIOUS SELECT ENTER ,_

Press _ to view the desired point status table.

t NEXT PREVIOUS SELECT ENTER ,_

On the point status table, press _ or [PREVIOUS]

until tile desired point is displayed on tile screen.

L NEXT PREVIOUS SELECT ENTER ,J

Q7!

mmmm

Fig. 16 -- Example of Status Screen

FORCING OPERATIONS

TD Force (manually ovelTide) a Value or Status

I. From any point status screen, press _ or

[PREVIOUS] to highlight the desired value.

lNEXT PREVIOUS SELECT EXIT )

Press _ to select tile highlighted v_due.

NEXT PREVIOUS SELECT EXIT

I CCN][

__I-

Start Chiller In CCN Control

DEFAULT SCREEN

LOCAL ] [ RESET II MENU ] (SOFTKEYS)

Start Chiller in Local Control

Clear Alarms _Access Main Menu

[ STATUS ][SCHEDULE] Es l I SERVICE ]

List the

Status Tables

•MAINSTAT

• STARTUP

• COMPRESS

• HEAT EX

• POWER

• VFD STAT

• ICV(_PSWD

Select a Statue Table

NEXT ]1PREVIOUS] [ SELECT ] [ EXIT

Select a Modification Point

NEXT ][ PREVIOUS] [ SELECT ] E EXIT

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

...... List the Service Tables

Display The Setpoint Table

List the Schedules

Modify aDiscrete Point

_,_ START ]ON STOP ] [ RELEASE ] [ ENTEROFF

Modify an Analog Point

INCREASE] IDECREASE] [ RELEASE ] E ENTER

Modify Control Options

ENABLE 11 DISABLE ] [ QUIT I [ ENTER

• Base Demand Limit

• LCW Setpoint

• ECW Setpoint

• Ice Build Setpoint

• Tower Fan High Setpcint

Select the Setpoint

[ N_ ][_-EVIOUS] [ SELECT I [

Modify the Setpoint

[INCREASEI[DECREASEII QUIT ] [

• OCCPC01S - LOCAL TIME SCHEDULE

• OCCPC02S - ICE BUILD TIME SCHEDULE

• OCCPC03S - CCN TIME SCHEDULE

Select a Schedule

1[ NEXT ][ PREVIOUS] I SELECT ] [ EXIT

Override

[NEXT

EXIT ]

EXIT ] (ANALOG VALUES)

EXIT ]

ENTER ]

Select a Time Period/Override

NEX T SELECT ][

e@ I ENTER][

aDay

[ DISABLE ]1 ENTER 1[ EXIT ] (DISCRETE VALUES)

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

[ NEXT ][ PREVIOUS] [

ALARM HISTORY

CONTROL TEST

CONTINUED

ON NEXT PAGE

SELECT ] [ EXIT I

Display Alarm History

(The table holds up to 25 alarms and

alerts with the most recent alarm

at the top of the screen.)

ALERT HISTORY !

Alert History

(The table holds up to 25 alarms and

alerts with the most recent alarm

at the top of the screen,)

List the Control Tests

CONTROL ALGORITHM 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)

• CCM Thermistors

• CCM Pressure Transducers

• Pumps

• Discrete Outputs

• IGV and SRD Actuator

• Head Pressure Output

• Diffuser Actuator

• Pumpdown/Lockout

• Terminate Lockout

Select a Test • Guide Vane Calibration

] NEXT I[PREVIOus]E SELECT][ EXIT ]• WSMDEFME (Water System Manager Control Status)

• OCCDEFCM (Time Schedule Status)

Select a Table

[NEXT ]EPREVIOUS]I SELECT ][ EXIT ]

OCCDEFM (Time Schedule Status)

Data Select Table

INEXT ][PREVIOus]E SELECT ] [ EXIT ]

OCCPC01S (Local Status)

OCCPC02S (CCN, ICE BUILD Status)

OCCPC03S (CCN Status)

• CAPACITY (Capacity Control Algorithm)

• OVERRIDE (Override Status)

• LLMAINT (LEADLAG Status)

• WSMDEFM2 (Water System Manager Control Status)

Maintenance Table Data

EQUIPMENT CONFIGURATION List the Equipment Configuration Tables

• NET OPT

• BRODEF

•OCCDEFCS

• HOLIDAYS

• CONSUME

• RUNTIME

Select a Table

E NEXT ][ PREVIOUS][ SELECT ] [ EXIT

Select a Parameter

[ NEXT ][PREVIOUS] [ SELECT ]

Modify a Parameter

[INCREASE] [DECREASE] [ QUIT ]

[ ENABLE ][ DISABLE ] [ QUIT ]

]

EXIT

ENTER

SELECT (USE ENTER) TO SCROLL DOWN

](ANALOG VALUES)

I (DISCRETE VALUES)

Fig. 18 -- 19XRV Service Menu Structure

SERVICE MENU CONTINUED

FROM PREVIOUS PAGE VFD CONFIG DATA

EQUIPMENT SERVICE

Service Tables:

•OPTIONS

• SETUPt

• SETUP2

• LEADLAG

• RAMP DEM

• TEMP CTL

--_ (ENTER A 4-DIGIT PASSWORD)

(VALUES SHOWN AT FACTORY DEFAULT)

Service Tables:

• VFD (STARTER) CONFIG PASSWORD

• VFD CONF

Select a Service Table

[NEXT ] IPREVIouslI SELECTI E EXIT l

Select a Service Table Parameter

[NEXT ] I PREVIOUS] I SELECT I E EXit ]

vice Table Parameter

I_AS_] I QUIT ] [ ENTER ] (ANALOG VALUES)

[ ENABLE ] E DISABLE ] IQUIT ] E ENTER ](DISCRETE VALUES)

TIME AND DATE

A'I-rACH TO NETWORK DEVICE

List NetJrk Devices

• Local • Device 6

• Device 1 • Device 7

• Device 2 • Device 8

• Device 3 • Attach to any Device

• Device 4

• Device 5

Display Time and Date Table:

• To Modify -- Current Time -- Day of Week

-- Current Date -- Holiday Today

[INCREASEI[DECREASE]I ENTER ] I EXIT I(ANALOG VALUE)

[ YES I[ NO ] IENTER ] I EXIT I(DISCRETE VALUE)

Select a Device

[ NEXT ]1PREVIOUSI[ SELECT I I ATTACH ]

Modify Device Address _ [

[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 ]1 LOCAL I[ RESET II MENU l

ICVC CONFIGURATION

ICVC Configuration Table I[ENTER ] [ EXIT ]

• To Modify -- ICVC CCN Address • To View -- ICVC Software Version

(last 2 digits of part number

indicate software version)

-- Baud Rate (Do not change this)

-- English (U.S. IMP.) or S.I. Metric Units

-- Password

-- LID Language

LEGEND

CCN -- Carrier Comfort Network

ICVC -- International Chiller Visual Controller

PIC III -- Product Integrated Control III

VFD -- Variable Frequency Drive

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

For Discrete Poin_ -- Press _ or _ to se-

lect the desired state.

lSTART STOP RELEASE ENTER )

For Analog Poin_ -- Press IINCREASEI

[DECREASE] to select tile desiled value.

_, INCREASE DECREASE RELEASE ENTER )

3. Press _ to legister the new value.

INCREASE DECREASE RELEASE ENTER

NOTE: When forcing or changing metric values, it is neces-

salTto hold down the sollkey for a few seconds in order to see

a value change, especially on kilopascal values.

To Remove a Force

I. On tile point status table press _ or IPREVIOUS]

to highlight the desired value.

lNE_ PREVIOUSSELECT EX. )

2. Pless _ to access tile highlighted value.

NEXT PREVIOUS SELECT EXIT

3. Pless [RELEASE] to remove tile force and return tile

point to the PIC III's automatic control.

t INCREASE DECREASE RELEASE ENTER ,]

DD D

Force Indication -- A forced value is indicated by

"SUPVSR," "SERVC," or BEST fla. hmg next to the point

value on the STATUS table.

TIME SCHEDULE OPERATION (Fig. 19)

I. On tile Menu screen, press ]SCHEDULE].

STATUS SCHEDULE SETPOINT SERVICE

2. Pless _ or [PREVIOUS] to highlight tile desired

schedule.

OCCPC01S -- LOCAL Time Schedule

OCCPC02S -- ICE BUILD Time Schedule

OCCPC03S -- CCN Time Schedule

NEXT PREVIOUS SELECT EXIT

Press _ to view the desired time schedule.

_, NEXT PREVIOUS SELECT EXIT .)

Press _ or IPREVIOUSI to highlight the desired

period or oveMde to change.

[, NEXT PREVIOUS SELECT EXIT .)

Press _ to access tile highlighted PERIOD or

OVERRIDE.

_, NEXT PREVIOUS SELECT EXIT .J

Press IINCREASE I or [DECREASE] to change tile

time values. OVERRIDE values are in one-hour

increments, up to 4 hours.

_INCREASE DECREASE ENTER EXIT .J

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

fields. Press IDISABLEI to eliminate days from the

period.

t ENABLED,SA_LEENTER EXIT )

Fig. 19 -- Example of Time Schedule

Operation Screen

Press _ to register tile values and to move holi-

zontally (left to right) within a pedod.

ENABLE DISABLE ENTER EXIT

Press _ to leave the PERIOD or OVERRIDE.

NEXT PREVIOUS SELECT EXIT

DQQ

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.

tNEXT PREVIOUS SELECT EXIT ,J

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 screen

pless ISETPOINT 1.

STATUS SCHEDULE SETPOINT SERVICE )

mmmm

2. 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.

3. Press _ or [PREVIOUS] to highlight the desired

set point entry.

NEXT PREVIOUS SELECT EXIT )

4. Press _ to modify the highlighted set point.

t PREV,OUSSELECT EX,T )

5. Press IINCREASEI or IDECREASEI to change the select-

ed set point value.

_, INCREASE DECREASE QUIT ENTER )

6. Press _ to save the changes and return to the pre-

vious screen.

_, INCREASE DECREASE QUIT ENTER )

SERVICE OPERATION- To view the menu-&iven pro-

grams available for Service Operation, see Service Operation

section, page 48. For examples of ICVC display screens, see

Table 4.

Fig. 20 -- Example of Set Point Screen

Table 4 -- ICVC Display Data

IIMPORTANT: The following notes apply to all Table 4

examples.

1. Only 12 lines of information 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 _ softkey to page forward; press

the IPREVIOUS] softkey twice to page back.

2. To access the information shown in Examples 10 through 22,

enter a 4-digit password after pressing the _ 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.

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 pro-

grams. For more information, see the 19XRV CCN literature.

6. Reference Point Names shown in these tables in all capital let-

ters 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 Refer-

ence 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.

7. Alarms and Alerts: An asterisk in the far right field of a ICVC sta-

tus screen indicates that the chiller is in an alarm state; an excla-

mation 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

CCN -- Carrier Comfort Network

CHW -- Chilled Water

CHWR -- Chilled Water Return

CHWS -- Chilled Water Supply

CT -- Current Transformer

ECW -- Entering Chilled Water

HGBP -- Hot Gas Bypass

ICVC -- International Chiller Visual Controller

LOW -- Leaving Chilled Water

LRA -- Locked Rotor Amps

mA -- Milliamps

P -- Pressure

PIC III -- Product Integrated Controls III

SS -- Solid State

T-- Temperature

VFD -- Variable Frequency Drive

WSM -- Water System Manager

EXAMPLE 1 -- CHILLER DISPLAY DEFAULT SCREEN

The following data is displayed in the Default screen.

DESCRIPTION STATUS UNITS REFERENCE POINT NAME DISPLAY

(ALARM HISTORY)

(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

0-500000.0

-40-245

0-420

40-245

0-999

0-1

HOURS

DEG F

PSI

DEG F

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.

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 UNITS

Control Mode NOTE 2 NOTE 2

Run Status NOTE 3 NOTE 3

Start Inhibit Timer 0-15 rain

Occupied'?. 0/1 NO/YES

System Alert/Alarm 0-2 NOTE 4

*Chiller Start/Stop 0/1 STOP/START

*Remote Start Contact 0/1 OPEN/CLOSE

POINT

MODE

STATUS

T START

O-CO

SYS_ALM

CHIL_S_S

REMCON

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

-30-30

10-120

-40-245

40-100

0-999

4-20

-40-245

0-99999

0-8

0-500000.0

0-32767

DEG F

HOURS

T RESET

LCW STPT

CHW_TMP

DEM LIM

LNAMPS P

LINEKW P

AUTODEM

AUTORES

R RESET

c starts

S-TARTS

c hrs

S-HRS

Ice Build Contact 0-1 OPEN/CLOSE lEE CON

Emergency Stop 0/1 ENABLE/EMSTOP EMSTOP

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

0-100

0-1

-6.7-200

-6,7-200

0-1

0,0-100.0

0-1

UNITS

OFF/ON

NO/YES

OFF/ON

NO/YES

OFF/ON

^PSI

DEG F

NO/YES

FALSE/TRUE

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

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.

STATUS

0.0-100.0

0-100

-40-245

-6.7-200

-40-245

0/1

0-100

0-5

UNITS

DEG F

^PSI

DEG F

OFF/ON

POINT

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

-6.7-420

-40-245

-20-20

-40-245

-6.7-420

0-99

-6.7-420

-40-245

-6.7-420

0-99

0.0-I00.0

0/I

0-200

0-100

-40-245

UNITS

PSI

DEG F

PSI

DEG F

PSI

OFF/ON

NO/YES

PSI

DEG F

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

0.0-999.0

0.0-99999.0

0.0-999.0

0.0-99999.0

0.00-2.00

0.0-99999.0

0.00-2.00

0-99999

0.0-999.0

0.0-99.0

0.0-100.0

0-99999

0.0-300.0

0.0-5.0

0.0-100.0

UNITS

AMPS

VOLTS

AMPS

kWH

AMPS

VOLTS

AMPS

VOLTS

AMPS

DEG F

VOLTS

POINT

LNAMPS P

LNAMPS A

LNVOLT -P

LNVOLT A

LINE_PF-

LINE 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

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.

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

HU_]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 STATUS UNITS POINT

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 #

0-223

0/1

0-255

0-1000

NORMAL/ALARM

NORMAL!ALARM

NORMAL/ALARM

NORMAL!ALARM

FALSE/TRUE

NORMAL!ALARM

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 PWD].

4. Press [_T_T].

DESCRIPTION

Disable Service Password

**Remote Reset Option

Reset Alarm?

CCN Mode?

STATUS

0-1

UNITS POINT

DSABLE/ENABLE PSWD DiS

DSABLE/ENABLE RESE]_OPT

NO/YES REMRESET

NO/YES 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 UNITS POINT DEFAULT

40-100 % DLM 100

10-120 DEG F Icwsp 50.0

15-120 DEG F ecwsp 60.0

15-60 DEG F ice sp 40.0

55-105 DEG F TFH SP 75

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

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

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

STATUS

-40-245

10-120

-99-99

-2-2

0-100

0-110

0-100

40-100

NOTE: All variables with CAPITAL LETTER point names are available for CCN read

screen.

UNITS

DEC F

POINT

ECW

LCW

ctrlpt

cperr

ecwdt

ecwres

Icwres

error

gvd

GV TRG

GV POS

VF[3_OUT

VFD_ACT

DEM INH

DMDLIM

operation; forcing shall not be supported on maintenance

EXAMPLE 11 -- OVERRIDE 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

-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

UNITS

DEC F

PSI

DEC F

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

NOTE: All variables with CAPITAL LETTER point names are available for CCN read operation; forcing shall not be supported on maintenance

screens.

Table 4 -- ICVC Display Data (cont)

EXAMPLE 12- LL_MAINT 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 [SELECT].

5. Scroll down to highlight ILL_MAINT.I

6. Press [S_EC_.

DESCRIPTION STATUS

LeadLag Control

LEADLAG: Configuration NOTE 1

Current Mode NOTE 2

Load Balance Option 0/1

LAG START Time 2-60

LAG STOP Time 2-60

Prestart Fault Time 2-30

Pulldown: Delta T/Min x.xx

Satisfied? 0/1

LEAD CHILLER in Control 0/1

LAG CHILLER: Mode NOTE 3

Run Status NOTE 4

Start/Stop NOTE 5

Recovery Start Request 0/1

STANDBY CHILLER: Mode NOTE 3

Run Status NOTE 4

Start/Stop NOTE 5

Recovery Start Request 0/1

Spare Temperature 1 -40-245

Spare Temperature 2 -40-245

NOTES:

1. DISABLE, LEAD, LAG, STANDBY, INVALID

2. DISABLE, LEAD, LAG, STANDBY, RECOVERY, CONFIG

3. Reset, Off, Local, CCN

UNITS POINT

DSABLE/ENABLE

MIN

NO/YES

DEG F

leadlag

Ilmode

Ioadbal

lagstart

lagstop

preflt

pull dt

pull_sat

leadctrl

lagmode

lagstat

lag_s_s

lag_rec

stdmode

stdstat

Std s_s

std rec

SP,_RE_T1

SPARE_T2

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 13 -- VFD_HIST DISPLAY SCREEN

To access this display from the ICVC default screen:

1. Press [MEN0].

2. Press _.

3. Scroll down to highlight [CONTROL ALGORITHM STATUS].

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

STATUS UNITS POINT

0.0-99999.0

0.0-999.0

0.0-99.0

0.00-2.00

0.0-100.0

0.00-2.00

0.0-100.0

0.0-99999.0

0.0-300.0

0.0-100.0

200-225

AMPS

VOLTS

AMPS

VOLTS

AMPS

DEG F

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

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 STATUS UNITS POINT

WSM Active'?. 0/1 NO/YES WSMSTAT

Chilled Water Temp 0.0-99.9 DEG F CHWTEMP

Equipment Status 0/1 OFF/ON CHWRST

Commanded State XXXXXXXX TEXT CHWRENA

CHW setpt Reset Value 0.0-25.0 ^F CHWRVAL

Current CHW Set Point 0.0-99.9 DEG F CHWSTPT

NOTE: All variables with CAPITAL LETTER point names are available for CCN read operation; forcing shall not be supported on maintenance

screens.

EXAMPLE 15-- 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 I.

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

0-16

0-60

0-480

3-99

0-1

0-1440

xxxxxxxx

UNITS

MIN

DSABLE/ENABLE

MIN

POINT

Idsgrp

Idsdlta

maxshed

occ num

occbrcst

retime

routing

DEFAULT

DSABLE

10000000

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

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)

STATUS

346-480

45.0-62.0

0/1

346-480

10-1500

0-7200

10-1500

1500-3600

0-5600

O/1

UNITS

VOLTS

NO/YES

VOLTS

AMPS

POINT

motornv

comp 100

line frq

vfd volt

vfd amps

vfd rlkw

mot rlkw

mot rla

motorni

motorpm

motorkw

pwm freq

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

0.0-102.0

1-10

5-40

1-10

5-40

1-10

5-60

0/1

SEC

DSABLE/ENABLE

skipfrql

skipfrq2

skipfrq3

skipband

v unbal

v time

lineim i

lineim t

motim i

motim t

ramp Tnc

rampdec

cycdrop

DEFAULT

460

60.0

YES

46O

2OO

100

2OO

100

3456

100

102.0

0.0

DSABLE

NOTE: Those parameters marked with a * shall not be downloaded to the VFD, but shall be used in other calculations and algorithms in the ICVC.

EXAMPLE 17 -- OPTIONS 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

40-100

0/1

0.5-20

30-170

0.5-20

50-170

0.5-3

5-20

7-10

0/1

0-2

0/1

20-85

0-100

UNITS

DSABLE/ENABLE

PSI

MIN

DSABLE/ENABLE

PSI

POINT

astart

modes

strtstop

srg hgbp

hgbdtl

hgbdpl

hgbdt2

hgb dp2

hgb db

surge_a

surge t

ibopt

ibterm

ibrecyc

HPDPO

HPDP100

HPDPMIN%

DEFAULT

DSABLE

100

1.5

DSABLE

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

Comp Motor Temp Override

Cond Press Override

Rectifier Temp Override

Inverter Temp Override

Comp Discharge Alert

Comp Thrust Brg Alert

Chilled Medium

Chilled Water Deadband

Evap Refrig Trippoint

Refrig Override Delta T

Evap Approach Alert

Cond Approach Alert

Condenser Freeze Point

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

Spare Alert/Alarm Enable

Disable=0, Lo=1/3,Hi=2/4

Spare Temp #1 Enable

Spare Temp #1 Limit

Spare Temp #2 Enable

Spare Temp #2 Limit

STATUS

150-200

90-165

155-170

125-200

165-185

0/1

0.5-2.0

0.0-40.0

2.0-5.0

0.5-15

-20 - 35

0-1

0.5 - 50.0

0.5-5

UNITS

DEG F

PSI

DEG F

WATER/BRINE

DEG F

DSABLE/ENABLE

PSI

MIN

POINT

MT_OVER

CP OVER

REC OVER

INV -OVER

CD _,LERT

TB ALERT

MEDIUM

CWDB

ERT TRIP

REF OVER

EVAP AL

CONE) AL

CDFRt_EZE

FLOWDISP

EVAP CUT

CONE) CUT

WFLO_/ T

15-300 SEC

2.0-10.0 DEG F

0.5-4.0 DEG F

0-4

-40-245 DEG F

0-4

-40-245 DEG F

OILPR T

rcycr dt

rcycs dt

splen

spllim

sp2_en

sp21im

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

Capacity Control

Proportional Inc Band

Proportional DEC Band

Proportional ECW Band

Guide Vane Travel Limit

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

DEFAULT

20O

125

160

200

175

WATER

1.0

DSABLE

5.0

245

STATUS UNITS POINT DEFAULT

DSABLE/ENABLE

gv_inc

gv_dec

gw_ecw

gv_ctrl

diff_opt

gv25

df 25

gv 50

df 50

gv_75

df 75

diff ma

vfd gain

vfd step

vfd min

vfd_max

2-I0

I-3

30- I O0

0/1

0-78

0-100

0-78

0-10o

0-78

0-10o

15-22

0.1-1.5

1-5

65-100

90-100

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

6.5

6.0

DSABLE

0.75

100

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 I.

6. Press [SEL_T].

DESCRIPTION

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

STATUS

0-3

0/1

25-75

1-236

2-60

2-30

0/1

25-75

1-236

UNITS

DSABLE/ENABLE

MIN

DSABLE/ENABLE

POINT

leadlag

Ioadbal

commsens

lag_per

lagadd

lagstart

lagstop

preflt

stndopt

stnd_per

stnd_add

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

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

DEFAULT

DSABLE

STATUS UNITS DEFAULT

0/1 1

DSABLE/ENABLE

MIN

POINT

rampslct

dem_src

kw ramp

dem_app

dem_20ma

dem sel

dw_i_t

0/1

5-20

3-15

40-100

0/1

5-60

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].

STATUS

0/1

2-10

-30- 30

-40-245

-30-30

0-15

-30-30

UNITS

DSABLE/ENABLE

DEG F

POINT

ecw_opt

trap ramp

deg_20ma

res_rtl

res rt2

deg- rt

restd_l

restd 2

deg_chw

res_sel

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 0-3

DSABLE

DEFAULT

DSABLE

PIC III System 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 let-

ters and in a box represent sollkeys on the ICVC (e.g.,

and _ ). See Table 4 for exmnples of the type

of information that can appeguon the ICVC screens. Figures

14-20 give an overview of ICVC operations and menus.

CAPACITY CONTROL -- Generally the chiller adjusts ca-

pacity in response to deviation of leaving or entering chilled wa-

ter 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.

Minor adjustments to the rate of capacity adjustment can be

made by changing PROPORTIONAL INC (Increase) BAND,

PROPORTIONAL DEC (Decrease) BAND, and PROPOR-

TIONAL ECW (Entering Chilled Water) GAIN in the Service/

Equipment Service/SETUP2 screen. Increasing the PROPOR-

TIONAL [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.

Factors and variables used in the capacity control determi-

nation 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 devia-

tion 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 cal-

culate 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 in-

clude: (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) AC-

TUAL GUIDE VANE POSITION, (3) ACTUAL VFD

SPEED, and (4) surge prevention mode. Generally the control-

ler will maintain the highest inlet guide vane setting at the low-

est speed to maximize efficiency while avoiding surge.

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 posi-

tion 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 rel-

ative 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 sec-

ond output is modulated. See Table 5.

Table 5 -- Guide Vane Delta Modes

NORMAL SURGE

GUIDE VANE CONTROL PREVENTION

DELTA MODE MODE

IGV VFD IGV VFD

Increase

only if VFD

speed =

From +0,2 to Increase Increase max and if Increase

+2.0 1st when IGV hot gas 1st

= max bypass is

present

and open

Decrease

From -0.2 to when VFD Decrease Decrease --

-2.0 speed = 1st

rnin

Normal Control mode occurs when ACTIVE DELTA T >

SURGE/HGBP DELTA T_

Surge Prevention Mode occurs when ACTIVE DELTA T

<SURGE/HGBP DELTA T_

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 volt-

age (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.

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 modi-

fied in the SETUP2 display screen. TARGET and ACTUAL

VFD SPEED can be viewed in the COMPRESS screen.

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 DEAD-

BAND, the PIC III opens or closes the guide vanes until the tem-

perature 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 DEAD-

BAND may be viewed or modified on the SETUPI screen,

which is accessed from the EQUIPMENT SERVICE table.

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 com-

pmssol.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 dif-

fuser 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.

c£

rJ.

2mA

(O%)

Full 4 mA

Open (0.2%

Full --

Closed

approx,

4rnA*

(_00%) 0 %

surge more likely

75 % Load Point

surge less likely

50 % Load Point

rotating stall

less likely

25 % Load Point

50 % 78 %

* Diffuser full Span mA. GUIDE VANE OPENING (%)

Fig. 21 -- Diffuser Control

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 great-

er 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.

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 propor-

tion 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.

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.

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 PROPOR-

TIONAL 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 PRO-

PORTIONAL DEC BAND, and it can slow or quicken the ca-

pacity 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

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).

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.

If the DEMAND LIMIT SOURCE (percent line current)

exceeds the ACTIVE DEMAND LIMIT by 5% or less, in-

creases in guide vane opening will be prevented. If the DE-

MAND 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 (con-

figumble in the RAMP_DEM table).

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 Qegard-

less 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.

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.

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 SER-

VICE /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 oppor-

tunity, 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.

Thechilleralsomaintainsa start-to-stmttimer 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.

OCCUPANCY SCHEDULE--The chiller schedule, de-

scribed in the Time Schedule Operation section (page 21 ), deter-

mines 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 MAIN-

STAT 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 OCCU-

PIED? is YES, unless an unoccupied time period is in effect.

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.

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.

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. SCHED-

ULE 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 up-

load the new number into the SCHEDULE screen. See Fig. 17.

Safety Controls -- _n_e PIC III monitors all safety con-

trol 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

• 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:

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 qmessage, 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.

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 pro-

vided in the Troubleshooting Guide section, page 79.

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 com-

pressor 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.

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.

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.

Table 6 -- Protective Safety Limits and Control Settings

MONITORED PARAMETER LIMIT COMMENTS

Temperature Sensors Out of Range .O6>Voltage Ratio>.98 or - 40 F>

Temperature>245 F for 3 seconds

Pressure Transducers Out of Range .06>Voltage Ratio>.98 for 3 seconds

High Compressor Discharge Temperature

High Motor Temperature

Compressor Thrust Bearing Temperature

Low Evaporator Temperature

Freeze Protection)

Transducer Voltage Fault

High Condenser Pressure --Control

Switch

Prestart

Low Condenser Pressure

Freeze Protection)

Oil-- Low Pressure

Low Pressure

Pressure Sensor Fault

Low Temperature

Line Voltage--High

High

Low

Imbalance

Line Current -- Single Cycle Dropout

Imbalance

Power -- Line Frequency Out of Range

ICVC Power on Reset

ALARM/

ALERT

260-271,

140,141

260-271

231

167

103

233

102

101

234

243

232

1o4

239

235

207

106

244

154

228

142

227

105

211/145

108

212/146

107

216

210/144

209/143

222

214/148

COMP DISCHARGE TEMP > 220 F

(104.4 C)

COMP DISCHARGE TEMP > COMP DISCHARGE

ALERT

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 REFRIG TRIPPOINT + 1 F

EVAP REFRIG TEMP < 33 F (water) and

EVAP APPROACH > EVAP APPROACH ALERT

0° F (-17.8 C)<EVAP REFRIG TEMP

<40 F (4.4 C) (brine) and EVAP APPROACH

> EVAP APPROACH ALERT

EVAPORATOR REFRIG TEMP < 33 F

+ REFRIG OVERRIDE DELTA T (water)

EVAPORATOR REFRIG TEMP < EVAP REFRIG

TRIPPOINT (brine)

5.5 VDC< Voltage Reference<4.5 VDC

CONDENSER PRESSURE > 165 PSI

High Pressure Switch Open(165 _+5 PSIG) &

VFD START = YES

CONDENSER PRESSURE > COND PRESS

OVERRIDE - 20 PSI

CONDENSER PRESSURE > 145 PSI

Chiller in PUMPDOWN mode and CONDENSER

REFRIG TEMP < CONDENSER FREEZE POINT

Energizes condenser pump relay if CONDENSER

REFRIGTEMP<CONDENSER FREEZEPOINT.

Deenergizes condenser pump relay when

CONDENSER REFRIG TEMP > CONDENSER

FREEZE POINT + 5° F (2.8 ° C) and ENTERING

COND LIQUID > CONDENSER FREEZE POINT

OIL PRESSURE DELTA P < 13 PSlD and

VFD START = TRUE

OIL PRESSURE DELTA P < 18 PSlD and startup

complete after OIL PRESS VERIFY TIME elapsed

OIL PRESSURE DELTA P < 18 PSlD and startup

complete

OIL PRESSURE DELTA P > 4 PSI immediately

before oil pump turned on

OILSUMPTEMP < 150 Fand OILSUMPTEMP <

EVAP REFRIG TEMP + 50 F (27.8 C)

Line voltage > approximately 528 V, limits are

calculated by VFD

PERCENT LINE VOLTAGE > Overveltage

threshold

DC BUS VOLTAGE < approximately 408 V,

limits are calculated by a VFD

PERCENT LINE VOLTAGE < Undervoltage

threshold

LINE VOLTAGE IMBALANCE > LINE VOLTAGE

% IMBALANCE

Line Voltage on 2 Phases < 50% for 1 Cycle

LINE CURRENT IMBALANCE>LINE CURRENT

% IMBALANCE

47 Hz < LINE FREQUENCY < 63 Hz

Loss of control power to ICVC for excessive time

_eriod

Preset Alarm, Voltage Ratio=Input Voltage/

Voltage Reference(5 Volts)

Preset Alarm, Voltage Ratio=Input Voltage/

Voltage Reference(5 Volts)

Preset Alarm, Configure COMP DISCHARGE

ALERT in SETUP1 screen

Configure COMP DISCHARGE ALERT in SETUP1

screen

Prestart Alert, Configure COMP DISCHARGE

ALERT in SETUP1 screen

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 BRG

ALERT in SETUP1 screen

Preset Alarm

Preset Alarm, configure EVAP REFRIG

TRIPPOINT in SETUP1 screen

Preset Alarm, Configure EVAP APPROACH

ALERT in SETUP1 screen

Configure EVAP REFRIG TRIP POINT and

CHILLED MEDIUM in SETUP1 screen

Prestart Alert, Configure REFRIG OVERRIDE

DELTA T in SETUP1 screen

Prestart Alert, Configure EVAP REFRIG TRIP-

POINT and CHILLED MEDIUM in SETUP1 screen

Preset Alarm

Preset Alarm, Configure COND PRESS

OVERRIDE in SETUP1 screen

Preset Alarm, Switch closes at 110 _+- PSIG

Prestart Alert, Configure COND PRESS

OVERRIDE in SETUP1 screen

Prestart Alert

Preset Alarm, Configure CONDENSER FREEZE

POINT in SETUP1 screen.

Configure CONDENSER FREEZE POINT in

SETUP1 screen

Preset Alarm

Preset Alarm, Configure OIL PRESS VERIFY

TIME in SETUP1 screen

Preset Alert

Preset Alarm

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

Configure LINE CURRENT % IMBALANCE and

LINE CURRENT IMBALANCE TIME in

VFD CONF screen

Preset Alarm

Table 6 -- Protective Limits and Control Settings (cont)

MONITORED PARAMETER

Motor- Surge

Surge

Current Imbalance

Overload Trip

Excessive Amps

Acceleration Fault

Amps Not Sensed

Starts Limit Exceeded

Low Chilled Water Flow

Low Cond Water Flow

High Approach--Evaporator

Condenser

VFD--High VFD Speed

Failureto Stop

Rectifier-- High Temperature

Overcurrent

Power Fault

Inverter-- High Temperature

Power Fault

Inductor -- Overtemperature Switch

DC Bus Voltage -- High

Low

Ground Fault

Optional Limits -- Spare Temperature

Guide Vane Position

Low Discharge Superheat

ALARM/ALERT

236

225

217

206

2O3

202

100

229

230

162

163

245

204

218

110

241

2OO

219

111

286

201

256

205/166

215

22O

158,159,

248,249

253

240

LIMIT

> 5 surge events within SURGE TIME PERIOD

and VFD SPEED > 90%

> 5 surge events within SURGE TIME PERIOD

and VFD SPEED < 90%

MOTOR CURRENT IMBALANCE>MOTOR

CURRENT % IMBALANCE

Any LOAD CURRENT PHASE > 108% for

Excessive Time Period

PERCENT LOAD CURRENT > 110% for 30 sec.

PERCENT LOAD CURRENT > 95% and

VFDSTART = TRUE for 5 to 40 sec

PERCENT LOAD CURRENT < 5% for 3 seconds

and VFD START=TRUE for 20 sec

More than 8 starts in 12 hours

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%

PERCENT LOAD CURRENT >15% and

VFDSTART = NO for 20 sec

RECTIFIER TEMPERATURE limit exceeded

RECTIFIER TEMPERATURE > RECTIFIER TEMP

OVERRIDE -20 F (11.1 C)

Rectifier current limit exceeded

IGBT current limit exceeded or a fault was detected

in the rectifier

INVERTER TEMPERATURE limit exceeded

INVERTER TEMPERATURE > INVERTER TEMP

OVERRIDE-20 F (11.1 C)

Inverter current limit exceeded

IGBT current limit exceeded

Inductor temperature limit exceeded

DC BUS VOLTAGE Limit Exceeded

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

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

COMMENTS

Preset Alarm, Configure SURGE DELTA% AMPS

and SURGE TIME PERIOD in OPTIONS screen

Preset Alarm, Configure SURGE DELTA% AMPS

and SURGE TIME PERIOD in OPTIONS screen

Configure MOTOR CURRENT % IMBALANCE and

MOTOR CURRENT IMBAL TIME in VFD CONF

screen

Preset Alarm, Configure MOTOR LOAD ACTIVE

DEMAND LIMIT in MAINSTAT screen

Preset Alarm

Preset Alarm, PERCENT LOAD CURRENT =

AVERAGE LOAD CURRENT/MOTOR RATED

LOAD AMPS

Preset Alarm, PERCENT LOAD CURRENT =

AVERAGE LOAD CURRENT/MOTOR RATED

LOAD AMPS

Preset Prestart Alert

Optional Alarm, Configure WATER FLOW VERIFY

TIME in SETUP1 screen

Optional Alarm, Configure WATER FLOW VERIFY

TIME in SETUP1 screen

Configure EVAP APPROACH ALERT in SETUP1

screen

Configure COND APPROACH ALERT in SETUP1

screen

Preset Alarm, Must be outside +10% threshold for

75 sec.

Preset Alarm, PERCENT LOAD CURRENT =

AVERAGE LOAD CURRENT/MOTOR RATED

LOAD AMPS

Preset Alarm, Configure RECTIFIER TEMP

OVERRIDE in SETUP1 screen

Prestart Alert, Configure RECTIFIER TEMP

OVERRIDE in SETUP1 screen

Preset Alarm

Preset Alarm, Configure INVERTER TEMP

OVERRIDE in SETUP1 screen

Prestart Alert, Configure INVERTER TEMP

OVERRIDE in SETUP1 screen

Preset Alarm

Preset Alarm, Temperature switch in reactor has

opened

Preset Alarm/Alert

Preset Alarm

Optional Alarm/Alert, Configure SPARE TEMP

ENABLE and SPARE TEMP LIMIT in SETUP1

screen

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 pre-

vent 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.

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.

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. Motor load ramp loading (AMPS OR KW RAMP %/

MINI limits the rate at which tile compressor motor cur-

rent 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 (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.)

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).

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.

High Discharge Temperature 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.

Oil Sump Temperature and Pump Con-

trol -- 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 com-

pressor 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 be-

ing heated (for 30 seconds at the end of every 30 minutes).

The oil pump will not operate if the EVAPORATOR PRES-

SURE is less than -5 psig (-34.5 kPa).

Oil Cooler -- The oil must be cooled when the compres-

sor 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 tem-

perature 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).

NOTE: The TXVs me not adjustable. The oil sump tempemtme

may be at a lower temperature during compressor operation.

Table 7 -- Capacity Overrides Table

FIRST STAGE SET POINT SECOND STAGE SET POINT OVERRIDE TERMINATION

OVERRIDE

CONDITION View/Modify on Override Default Configurable Value Value

ICVC Screen Value Range

CONDENSER CONDENSER PRESSURE CONDENSER PRESSURE

High Condenser Pressure SETUP1 PRESSURE 90 to 165 psig > COND PRESS OVERRIDE < CONDENSER PRESS

(COND PRESS OVERRIDE) >125 psig (862 kPa) (621 to 1138 kPa) + 2.4 psig (16.5 kPA) OVERRIDE - 1 PSI (6.9 kPa)

High Motor Temperature COMP MOTOR 150 to 200 F COMP MOTOR WINDING TEMP COMPR MOTOR WINDING

(COMP MOTOR TEMP SETUP1 WINDING TEMP > COMP MOTOR TEMP OVER- TEMP < COMP MOTOR TEMP

OVERRIDE) > 2OO F (93 C) (66 to 93 C) RIDE + 10 F (5.6 C) OVERRIDE- 2 F (1.1 C)

EVAPORATOR REFRIG TEMP

EVAPORATOR < EVAP REF OVERRIDE TEMP

Low Evaporator Temperature REFRIG TEMP 2 to 5 F - 1 F (.6 C) EVAP REFRIG TEMP

(REFRIG OVERRIDE SETUP1 < EVAP REFRIG (1.1 to 2.8 C) NOTE: EVAP REF OVERRIDE > EVAP REF OVERRIDE TEMP

DELTA T) TRIPPOINT + 3 F TEMP = EVAP REFRIG TRIP- +2F(1.1C)

(1.7 C) POINT + REFRIG OVERRIDE

DELTA T

Min TI: 1.5 F (0.8 C) 0.5 - 2.0 F

(0.3- 1.1 C)

Min PI: 50 psid 30 - 170 psid ACTIVE DELTA T > SURGE/

High Compressor Lift OPTIONS (345 kPa) (207 - 1172 kPad) None HGBP DELTA T + SURGE/HGBP

(SURGE/HGBP DELTA T,P) Max T2:10 F (5.6 C) 0.5 - 20 F DEADBAND

(0.3- 11,1 C)

Max P2:85 psid 50 - 170 psid

(586 kPad) (345 - 1172 kPad)

Manual Guide Vane Target Press RELEASE softkey after

(TARGET GUIDE VANE POS) COMPRESS Automatic 0 to 100% None selecting TARGET GUIDE VANE

POS

Forced TARGET VFD SPEED

Manual Speed Control VFD MINIMUM cannot override either a Press RELEASE softkey after

capacity inhibit or a capacity selecting TARGET VFD SPEED

(TARGET VFD SPEED) COMPRESS Automatic SPEED to 100% decrease command generated by

the PIC III

Motor Load MAINSTAT Automatic 40 to 100% ACTIVE DEMAND LIMIT ACTIVE DEMAND LIMIT

(ACTIVE DEMAND LIMIT) > Set Point + 5% < Set Point - 2%

ACTUAL SUPER- ACTUAL SUPERHEAT ACTUAL SUPERHEAT

HEAT< SUPERHEAT None < SUPERHEAT REQUIRED > SUPERHEAT REQUIRED

Low Discharge Superheat OVERRIDE REQUIRED for

conditions - 1.25 F (0,7 C) + 1 F (0.56 C)

High Rectifier Temperature RECTIFIER 155 to 170 F RECTIFIER TEMP RECTIFIER TEMP

(RECTIFIER TEMP SETUP1 TEMPERATURE> (66 to 77 C) > RECTIFIER TEMP OVERRIDE < RECTIFIER TEMP OVERRIDE

OVERRIDE) 160 F (71 C) + 10 F (5,6 C) - 5 F (2.8 C)

High Inverter Temperature INVERTER 155 to 170 F INVERTER TEMP INVERTER TEMP

(INVERTER TEMP SETUP1 TEMPERATURE > > INVERTER TEMP OVERRIDE < INVERTER TEMP OVERRIDE

OVERRIDE) 160 F(71 C) (66 to 77 C) + 10 F(5,6C) -5 F(2.8C)

Remote Start/Stop Controls -- A remote device, such

as a timeclock that uses a set of contacts, may be used to stmt

and stop the chillel: Howevel; the device should not be pro-

gmmmed 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

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

chiller from starting. Tile operator 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

the _ softkey followed by the _ or _ soft-

key. This ensures that, if the automatic system is m_dfunction-

ing, 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

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

the certified drawings for further details on contact ratings. The

contacts must have 24 vac dry contact rating.

Spare Safety and Spare Temperature Inputs --

Norln_dly closed (NC) discrete inputs for addition_d field-

supplied 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.

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 config-

ured 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 Cto 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).

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.

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 Trouble-

shooting 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

(IeVC).

Condenser Pump Control -- The chiller will moni-

tor the CONDENSER PRESSURE and may turn on the con-

denser 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 CON-

DENSER 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 _dgo-

rithm 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 pump-

down or in pumpdown/lockout with the fieeze prevention

disabled.

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 chill-

er is in Recycle Shutdown Mode when the condition occurs,

the controls will transition to a non-recycle shutdown.

Evaporator Freeze Protection -- When the EVAP-

ORATOR REFRIG TEMP is less than the EVAP REFRIG

TRIPPOINT plus the REFRIG OVERRIDE DELTA T (config-

urable 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 ° Cfor 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 condens-

er 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 deener-

gize as the pressure differential between cooler and condenser

vessels changes. This prevents low condenser water tempera-

turn 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 condens-

er 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]).

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 PRES-

SURE and CONDENSER PRESSURE is less than 28 Psid

(193 kPa), and ENTERING CONDENSER WATER tempera-

ture 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.

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 con-

denser 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 automati-

cally 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 start-

up, and the STARTS IN 12 HOURS counter is not incremented.

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.

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 elimi-

nate 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.

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.

To activate a reset type, access the TEMP_CTL scleen and

input all configuration information for that reset type. Tilen,

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 appropri-

ately configured. Reset Type 1 permits up to _+30° F (_+16.7° C)

of reset to the chilled water set point. Inputs are wired to terlni-

nals 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.

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 tempera-

ture difference (the difference between entering and leaving

chilled water) at which no temperature reset occurs (CHW

DELTA T-> NO RESET). Tills chilled water temperature dif-

ference 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 RE-

SET). Finally. enter the amount of reset (DEGREES RESET).

Reset Type 3 can now be activated.

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 particu-

lar impeller wheel can perform varies with the gas flow

through the impeller and the dialneter of the impellec

Tile lift capability (surge line) of a v_uiable speed compres-

sor 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 operat-

ing 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 DEL-

TA T2, and SURGE/HBBP DELTA P2 values is applied to the

full speed condition only. These surge characteristics are facto-

ry 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 al-

gorithm, some field adjustments may be necessary.

A chiller equipped with a VFD can adjust inlet guide posi-

tion 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

thecontrol'smodelof thesurgepreventionlineup.Guide

vanesarenotpermittedtoopenfurtherwhensurgeprevention

ison.Oncespeedhasbeenincreasedtomaximum,if stilloper-

atinginthesurgepreventionregionandif theHotGasBypass

optionisinstalled,thehotgasbypassvalvewillopen.Whenin

SurgePreventionmode,withacommandtodecreasecapacity

theguidevaneswillclosebutspeedwillnotdecrease.

NOTE:If uponromp-upachillerwithVFDtendstogotofull

speedbeforeguidevanesopenfully,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, investi-

gate 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.

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 surge prevention algorithm first determines if correc-

tive 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.

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.

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.

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.

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.

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 the

surge count (SURGE PROTECTION COUNTS).

19XRV DEFAULTS:ATt =1.5= F

AP1 =50 psid

AT2 = llY" F

AP2 = 85 psid

(psi)

85-

50-

HGBP/SURGE PREVENTION (lo, 85)

DEADBAND REGION ,

1 2 3 4 5 6 7 8 9 10 1 1

AT (F)

LEGEND

ECW -- Entering Chilled Water

HGBP -- Hot Gas Bypass

LOW -- Leaving Chilled Water

AP = (Condenser Psi) -(Cooler Psi)

AT = (ECW) - (LCW)

Fig. 22-- 19XRV Not Gas Bypass/Surge

Prevention with Default English Settings

zxp

(kPa)

19XRV DEFAULTS: AT1 =.8° C

APt = 345 kPad

AT2 = 5.6° C

AP2 = 586 kPad

HGBP/SURGE PREVENTION (&6, 586)

DEADBAND REGION

500-

400-

300-

.2 A.6 .81,0 2.0 3.0 4.0 5.0 6.0

&T (C)

LEGEND

ECW -- Entering Chilled Water

RGBP -- Hot Gas Bypass

LOW -- Leaving Chilled Water

AP = (Condenser kPa) - (Cooler kPa)

AT = (ECW) - (LCW)

Fig. 23 i 19XRV Hot Gas Bypass/Surge

Prevention with Default Metric Settings

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 ta-

ble. When configuring this output ensure that minimum re-

quirements for oil pressure and proper condenser FLASC on-

lice 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 us-

able to control any specific piece of equipment (that is, without

further control elements or signal conditioning), although it

may be.

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.

Lead/Lag Control -- The lead/lag control system auto-

matically 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.

NOTE: The lead/lag function can be configured on the LEAD-

LAG 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.

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

DELTA P

DELTA P__

AT0%

lNON-ZERO

',EXAMPLE OF

' M N MUM

',REFERENCE

',OUTPUT

s" a"

i t

===7 = ..........

0mA 2 mA4mA

(O%) 4T0 20 mA OUTPUT

Fig. 24- Head Pressure Reference Output

]11

20 mA

(100%)

• 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

COMMON POINT SENSOR USAGE AND INSTALLA-

TION- Lead/lag operation does not require a common

chilled water point sensor However. common point sensors

(Spare Temp #1 and #2) may be added to the CCM module, if

desired.

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).

If the entering chilled water control option (ECW CON-

TROL 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).

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.

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:

CHILLER COMMUNICATION WIRING -- Refer to the

chiller's Installation Instructions, Cmrier Comfort Network

Interface section for infommtion on chiller communication

wiring.

LEAD/LAG OPERATION- The 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.

Lead/Lag Chiller Configuration and Operation

• A chiller is designated the lead chiller when its

LEADLAG: CONFIGURATION value on the LEAD-

LAG 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).

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.

If 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) dis-

plays 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.

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.

Standby Chiller Configuration and Operation -- A chiller is

designated as a standby chiller when its LEADLAG: CONFIG-

URATION wdue on the LEADLAG screen is set to "3." The

standby chiller can operate as a replacement for the lag chiller

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. 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.

3. Lead chiller ACTIVE DEMAND LIMIT (see the MAIN-

STAT screen) value must be greater than 95% of lhll load

mnps.

4. Lead chiller telnperature pulldown rate (TEMP PULL-

DOWN 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.

5. 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.

6. 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 condi-

tions 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 EQUIP-

MENT SERVICE table on the SERVICE menu.

2. 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).

3. 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.

FAULTED CHILLER OPERATION --If file lead chiller

shuts down because of an alarm (*) condition, it stops commu-

nicating 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 communi-

cates 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:

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 condi-

tions 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. Lag chiller ACTI1/E DEMAND LIMIT value must be

gleater than 95% of full load amps.

4. Lag chiller temperature pulldown rate (TEMP PULL-

DOWN DEG/MIN) of the chilled water temperature is

less than 0.5 F (0.27 C) per minute.

5. The standby chiller is not running as a lag chiller.

6. 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 OP-

TION (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.

lee Btlih:l Control -- The selectable ice build mode per-

mits 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 opera-

tor 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:

• 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:TheIceBuildstepsdonotoccurif thechillerisconfig-

uredandoperatingasa lagor standbychillerfor lead/lag

operationandisactivelybeingcontrolledbyaleadchillerThe

leadchillercommunicatestheICE BUILD SET POINZ the

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 fol-

lowing 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.

• 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:

•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 -- Ice build opera-

tion 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.

3. Remote Contacts/Ice Level Input -- Ice build operation

terminates when the ICE BUILD TERMINATION param-

eter is set to 1 (CONTACTS) and the ICE BUILD

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.

4. 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.

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 sched-

ules 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 func-

tion stmted, when the ice build lunction ends, the plevious forces

(of less than 4 priority) me not automatic_dly restored.

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.

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 it using the

softkey and press the ]ATTACH] sollkey. The message

"UPLOADING TABLES, PLEASE WAIT' displays. The

ICVC then uploads the highlighted device or module. If

the module addi'ess cannot be found, the message "COMMU-

NICATION 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

display information on the local chillel:

ATTACHINGTOOTHERCCNMODULES-- If thechill-

erICVChasbeenconnectedtoaCCNNetworkorotherPIC

controlledchillel.sthroughCCNwiring,theICVCcanbeused

tovieworchangeptuametersontheothercontrollers.Other

PICIII chillerscanbeviewedandsetpointschanged(if the

otherunitisin CCNcontrol),if desired,fromthisparticular

ICVCmodule.

If themodulenumberisnotvalid,the"COMMUNICA-

TIONFAILURE"messagewill showanda newad&ess

numbermustbeenteredorthewiringchecked.If filemoduleis

communicatingproperly,the"UPLOADIN PROGRESS"

messagewillflashandfilenewmodulecannowbeviewed.

Wheneverthereisaquestionregardingwhichmoduleon

theICVCiscunentlybeingshown,checkthedevicename

descriptorontheupperlefthandcornerof theICVCscreen.

SeeFig.25.

WhentheCCNdevicehasbeenviewed,theATI'ACHTO

NETWORKDEVICEtableshouldbeusedtoattachtothePIC

thatisonthechillel:MovetotheATFACHTONETWORK

DEVICEtable(LOCALshouldbehighlighted)andpressthe

softkeytouploadtheLOCALdevice.TheICVC

forthe19XRVwillbeuploadedanddefaultscreenwilldisplay.

NOTE:TheICVCwillnotautomaticallyreattachtothelocal

moduleonthechillel:Pressthe_ soflkeytoattachto

theLOCALdeviceandviewthechilleroperation.

NAME DESCRIPTOR TABLE NAME

ALWAYS THE ![ /

ICVC MODULE(" l_x_ j_ ,vrrAc'H-_o_v_c_ "XI

ON THE 19XRV-_ r_l_cR1r,_ON _US A_r_R_SS | _,_H_mc-aJ

I _ tll_llllllllllll_ 0 _ _---.----,_ ............

OTH E R CCN _ DEvicesi 0_ / LOCATION

k._ _ _ OFCCN

MODULES/ o_,_a o /

|....... _/MODULE

NVICE 8 o o

I_VlCE _ 0 0

Fig. 25 -- Example of Attach to Network

Device Screen

Service Operation -- An overview of the tables and

screens available for the SERVICE function is shown in

Fig. 18.

TO ACCESS THE SERVICE SCREENS -- When the SER-

VICE screens are accessed, a password must be entered.

1. From the main MENU screen, press the [SERVICE]

soflkey. The soflkeys now correspond to the numerals 1,

2,3,4.

2. Press the four digits of the password, one at a time. An as-

terisk (*) appetus as each digit is entered

ENTER A4DIGIT PASSWORD:*

NOTE: The initial factory-set password is 1-1-1-1. If the

password is incorrect, an error message is displayed

INVALID PASSWORD

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:

NEXT PREVIOUS SELECT EXIT

F--IF--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 list of available

SERVICE screens:

• 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

the SERVICE screens listed above. Use the _ softkey to

return to the main MENU screen.

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

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

screen, press the _ and [SERVICE] softkeys. Enter the

password and, flom the SERVICE menu, highlight LOG OUT

OF NETWORK DEVICE and press the _ softkey.

The ICVC default screen will now be displayed.

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 holi-

days 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 chill-

ers) on the network.

HOLIDAYSCHEDULING(Fig.26)-- Upto 18different

holidayscanbedefinedfor specialscheduleconsideration.

Thereale two differentscreensto be configured.

Filet,in theSERVICE/EQUIPMENTCONFIGURATION/

HOLIDAYSscreen,selectthefil_t unusedholidayently

(HOLDY01S,forexmnple).AsshowninFig.26,enteranum-

berforSt_u-tMonth(1=January,2=February..... 12=Decem-

ber),anumberforStartDay(1- 31),andDurationindays(0-

99).Bydefaulttherealenoholidayssetup.Second,intheoccu-

pancyScheduletables,specifyandenable(bysetting"X"under

the"H"column)runtimeperiod(s)whichwillapplytoallholi-

days.(RefertoFig.19onpage21.)A runtimeperiodwhichis

enabledforholidaysmaybeappliedtooneormorenon-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.

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 screen, see the SERVICE menu

structure, Fig. 18.

To view or change the holiday periods for up to 18 different

holidays, perform the following operation:

1. At the Menu screen, press [SERVICE] to access the

Service menu.

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, press

_to access.

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 Config-

uration Select table now shows the holiday start month

and day. and how many days the holiday period will last.

8. Pless _ or [PREVIOUS] to highlight tfie month,

day, or duration.

9. Press _ to modify the month, day, or duration.

10. Press IINCREASEI or IDECREASEI to change the

selected value.

11. Press _ to save the changes.

12. Press _ to return to the previous menu.

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 disable the Daylight Savings Time function simply enter

0 minutes for "Start Advance" and "Stop Back".

Table 8 -- Daylight Saving Time Values

ITEM

Month

Day of Week

Week

Time

Advance/Back

DEFINITION

1 = January. 2 = February .....

12 = December.

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.

Time of day in 24-hour format

when the time advance or set

back will occur.

"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 speci-

fied amount (later in the year).

Fig. 26 -- Example of Holiday Period Screen

START-UP/SHUTDOWN/

RECYCLE SEQUENCE (Fig. 27)

Local Start-Up -- L_cal start-up (ora manual start-up) is

initiated by pressing the _ menu softkey on the default

ICVC scleen. Ix_c_d start-up can proceed when the chiller

schedule indicates that the CURRENT TIME and CURRENT

DATE have been established as a mn time and date, and after

the internal timers have expired. The timers include a

15-minute start-to-start timer and a l-minute stop-to-start tim-

el. which together serve to prevent excessive cycling and abuse

of the motol: The value of these timers is displayed as START

INHIBIT TIMER and can be viewed on the MAINSTAT and

DEFAULT 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.

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.

If the OCCUPIED ? pm'ameter on the MAINSTAT screen

is set to NO, the chiller can be forced to stm't as follows. From

the default [CVC screen, press the _ and

softkeys. Scroll to highlight MAINSTAT. Pless the

softkey. Scroll to highlight CHILLER START/STOP. Press the

softkey to override the schedule and start the chiflel:

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

released, regardless of the progrmnmed schedule. To release

the forced start, highlight CHILLER START/STOP fiom the

MAINSTAT screen and press the [RELEASE] softkey. This

action returns the chiller to the stmt and stop times established

by the schedule.

The chiller may also be stmted by overriding the time sched-

ule. From the default screen, press the _ and

[SCHEDULE] softkeys. Scroll down and select the current

schedule. Select OVERRIDE, and set the desiled override time.

Another condition for st;ut-up must be met for chillers that

have the REMOTE CONTACTS OPTION on the EQUIP-

MENT SERVICE screen set to ENABLE. For these chillers,

the REMOTE START CONTACT parameter on the MAIN-

STAT screen must be CLOSED. From the ICVC default

screen, press the _ and _ softkeys. Scroll to

highlight MAINSTAT and press the _ softkey. Scroll

down the MAINSTAT screen to highlight REMOTE START

CONTACT and press the _ softkey. Then, press the

softkey. To end the override, select REMOTE

CONTACTS INPUT and press the [RELEASE ] softkey.

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 parame-

ter 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 ener-

gizes, and the RUN STATUS line now reads STARTUR See

Table 9.

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: 19XRV units are not available with factou-installed

chilled water or condenser water flow devices (available as an

accesso Ufor use with the CCM Control board).

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:

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.

Ftfilure to verily any of the requirements up to this point will

result in the PIC III aborting the stall and displaying the appli-

cable 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.

Table 9 -- Prestart Checks

QUANTITY CHECKED

STARTS IN 12 HOURS

COMP THRUST BRG TEMP

COMP MOTOR WINDING TEMP

COMP DISCHARGE TEMP

EVAPORATOR REFRIG TEMP

OIL SUMP TEMP

CONDENSER PRESSURE

PERCENT LINE VOLTAGE

ACTUAL GUIDE VANE POS

REQUIREMENT

< 8 (not counting recycle restarts or auto restarts after power failure)

ALERT is cleared once RESET is pressed.

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

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

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

< [EVAP REFRIG TRIPPOINT] + [REFRIG OVERRIDE DELTA T]

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

< CONDENSER PRESSURE OVERRIDE -20 PSI (138 kPa) and

< 145 psi (1000 kPa)

< [UNDERVOLTAGE THRESHOLD]

> [OVERVOLTAGE THRESHOLD]

Must have been calibrated

ALERT STATE

100

101

102

103

104

105

106

107

108

109

IF FALSE

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

15-MINUTE

START*TO-START

1-MINUTE

STOP-TO-START *'TIME

ODE

3OM-

_RESSC

tUNNIN

I !

F G O/A

A -- START INITIATED: Pre-start checks are made; evaporator pump

started,

B -- Condenser water pump started (5 seconds after A),

C -- 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.

D -- Oil pressure verified (15 seconds minimum, 300 seconds maximum

after C).

E -- Compressor motor starts; compressor ontime and service ontime

start, 15-minute inhibit timer starts (10 seconds after D), total com-

pressor starts advances by one, and the number of starts over a

12-hour period advances by one.

F -- SHUTDOWN INITIATED -- Compressor motor stops; compressor

ontime and service ontime stop, and 1-minute inhibit timer starts.

G -- 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-- Restart permitted (both inhibit timers expired: minimum of 15 minutes

after E; minimum of 1 minute after F).

Fig. 27 -- Control Sequence

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

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 that occur during shutdown can change

this sequence.

• [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.

•The condenser pump shuts down when the CON-

DENSER 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 tempera-

ture, 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).

Automatic Soft Stop Amps Threshold -- The soft

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.

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:

• 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.

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, COM-

PRESSOR UNLOADING" displays on the ICVC.

The soft stop amps threshold function can be terminated and

the compressor motor deenergized immediately by depressing

the STOP button twice.

Chilled 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 shut-

down is initiated when any of the following conditions are true:

•LEA1/ING CHILLED WATER temperature (or ENTER-

ING 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 ENTER-

ING 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

ontheSETUPItable.Thecompressorwillrestartwhenthe

chilleris:

• in LCW CONTROLandthe LEAVING (7HILLED

WATER temperature is greater than the CONTROL

POINT plus the (RECYCLE CONTROL) RESTART

DELTA T.

• in ECW CONTROL and the ENTERING CHILLED

WATER temperature is greater than the CONTROL

POINT plus the (RECYCLE CONTROL) RESTART

DELTA T.

Once these conditions am met, the compressor initiates a

st_ut-up with a normal start-up sequence.

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.

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.

The chiller should not be operated below design minimum

load without a hot gas bypass installed.

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.

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

Job Data Required

• 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 Tank and Pump-

out System -- Refer to Chillers with Storage Tanks sec-

tion, page 71 for pumpout system prepmation, refngerant

transfeL and chiller evacuation.

Remove Shipping Packaging -- Remove any pack-

aging 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.

_'SAE PLUG_

_"SAE FLARENUT I_-

THERMC 8"

(203 mm)

SIGHT

DISTI

WATER OR

METHYL

ALCOHOL

Fig. 28 -- Typical Wet-Bulb Type

Vacuum Indicator

Open Oil Circuit Valves -- Check to ensure the oil fil-

ter isolation valves (Fig. 4) am open by removing the valve cap

and checking the valve stem.

Oil Charge -- The oil chmge for the 19XRV compmssor

depends on the compressor Frame 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 option --

12 gal (,45 L)

• Frame 5 compressor-- 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.

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 isola-

tion 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

Refer to Table 10 for bolt torque requimments.

Table 10- Bolt Torque Requirements, Foot Pounds

SAE 2, A307 GR A SAE 5, SA449 SAE 8, SAE354 GR BD

HEX HEAD SOCKET HEAD OR HEX HEX HEAD

BOLT SIZE NO MARKS WITH 3 RADIAL LINES WITH 6 RADIAL LINES

(in.) LOW CARBON STEEL MEDIUM CARBON STEEL MEDIUM CARBON STEEL

Minimum Maximum Minimum Maximum Minimum Maximum

1_ 4 6 6 9 9 13

_16 8 11 13 18 20 28

318 13 19 22 31 32 46

_16 21 30 35 50 53 75

l& 32 45 53 75 80 115

_16 46 65 75 110 115 168

5/8 68 95 105 150 160 225

314 105 150 175 250 260 370

718 140 200 265 380 415 590

1 210 300 410 580 625 893

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

2 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

3 6620 9460 11,040 15,770 19,900 28,440

Check Chiller Tightness-- Figure 29 outlines tile

proper sequence and procedures for leak testing.

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) nitrogen-

holding chmge in each vessel.

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 pressur-

ized. If any leaks me detected, follow the leak test procedure.

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

transferred. Adjust the springs when the refrigerant is in operat-

ing condition and the water circuits are full.

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 can also be used if the chiller is

under pressure.

Do not use air or oxygen as a means of pressurizing

the chillel: Mixtures of HFC-134a and air can undergo

combustion.

LEAK TEST OF 19XRV

1, ATTACH COMPOUND GAGE TO EACH VESSEL

2. NOTE AMBLENT TEN_IPERATURE GAGE READINGS

MACHINES WITH REFRIGERANT CHARGE

PRESSURE ON

CONDENSERVESBELtS AT REFRIGERANT

SATURATED COND!TIONS SEE REFRIGERANT

PRESSURE*TEMPERATURETABLES 1AAND 1E

COOLER PRESSURE READING

S 15 PSIG (103 kPej OR HIGHER

I REDORDRRESSURESI

POWER UP CONTROLS TO ENSURE

OIL HEATER IS ON AND OIL IS HOT,

COOLER AND CONDENSER

EQUAUZE PRESSURE BE,,_,:_4EEN

I BERPORM_.EA_TESTI

[ FIoAK[_ l

PRESSURE ON CONDENSER VESSEL IS LESS THAN

SA/URA_ED REFRIGERAN F PRESSURE

(SEE REFRIGERANT PRESSURE-

TEMPERATURE TABLES 11A AND 1113)

COOLER PRESSURE READING

IS BELOW 15 PRIG (103 kP_,t)

LEAK SUSPECTED

_,>,,'ss

POWER UP CONTROLS TO ENSURE

OIL HEATER IS ON AND OIL I9 HOT,

COOLER AND CONDENSER

EQUALIZE PRESSURE BETWEEN

:;I- ADD REFRIGERANT

UNTIL PRESSURE iS ABOVE

35 PSIG (241kP_)

{

I PBRFORMLEAK,SS,"1

I 1

FOUND

AND MARK

ALL LEAK

SOURCES

I MAGHNESW,THN,TROGENROLD,NGDHARGEI

PRESSURE READING IS LESS THAN

15 PSIG (103 kPei BUr

GREATER THAN 0 PSIG (0 kPa)

_AK SUSPEC ED

(IF USING ELECTRONIC DETECTOR, L

ADD TRACER GAS NOW) r'_

I PERFORM LEAK TEST I

USING SOAP BUBBLE SOLU]ION_

ULTRASONICS OR ELECTRONIC

DETECTOR

EVACUATB]

[ LODATEJ

AND MARK

ALL LEAK

SOURCES

ilcco,

STANDING ,1i:

RELEASE THE PRESSURE

IN THE VESSEL

REPAIR ALL LEAKS

RETEST ONLY THO_E JOtNTS

THAT WERE REPAIRED

REPAIR DEHYDRATE VESSEL IF VESSEL WAS

CONTINUE WITH MACHINE STARTUP / COMPLETE CHARGING MACHINE IIC

.I I

PRBSSURE IS AT 15 PRIG (103 kP_,)

(FACTORY CHARGE)

RELEASE NITROGEN AND I

EVACUATE HOLDING CHARGE

FROM VESSELS

ADD REFRIGERANT 1

UNTIL PRESSURE S ABOVE

30 PSIG (241kPa)

I BERFORMLEA_TESTI

[ I

Fig. 29 -- 19XRV Leak Test Procedures

Leak Test Chiller -- Due to regulations regarding refiig-

erant 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 readings are normal for the chiller

condition:

a. Evacuate the holding charge fiom the vessels, if

present.

b. Raise the chiller pressure, if necessary, by adding

refrigerant until pressure is at the equivalent satu-

rated 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.

Never charge liquid refrigerant into the chiller if the pres-

sure 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.

c. Leak test chiller as outlined in Steps 3-9.

2. If the pressure readings are abnormal for the chiller

condition:

a. Prepare to leak test chillers shipped with refriger-

ant (Step 2h).

b. 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).

c. Plainly mark any leaks that are found.

d. Release the pressure in the system.

e. Repair all leaks.

f. Retest the joints that were repaired.

g. 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.

h. 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).

3. Check the chiller carefully with an electronic leak detec-

tol: halide torch, or soap bubble solution.

4. 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

be repaired. Note the toted chiller leak rate on the start-up

_eport.

5. 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.

6. If no leak is found after a retest:

a. Transfer the refrigerant to the pumpout storage

tank and perform a standing vacuum test as

outlined in the Standing Vacuum Test section,

below.

b. If the chiller fails the standing vacuum test, check

for large leaks (Step 2b).

c. 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).

7. 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).

8. Transfer the refrigerant until the chiller pressure is at

18 in. Hg (40 kPa absolute).

9. 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, evacu-

ate it before repeating the leak test.)

Standing Vacuum Test -- When perforlning the stand-

ing 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 manometer or wet bulb

indicator to the chillel:

2. 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.

3. Valve off the pump to hold the vacuum and record the

manometer or indicator reading.

4. a. If the leakage rate is less than 0.05 in. Hg (0.17 kPa) in

24 hours, the chiller is sufficiently tight.

b. 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, pressur-

ize 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 nitro-

gen is used, limit the leak test pressure to 160 psig

(1103 kPa) maximum.

_) STORAGE TANK

VAPOR VALVE

Fig. 30 -- Typical Optional Pumpout System Piping Schematic with Storage Tank

REFRIGERANT

ISOLATION LIQUID LIVE

VALVE SERVICE

VALVE

PRESSURE

RELIEF SAFETY

VALVE_

REFRIGERANT

CHARGING

VALVE

REFRIGERANT

CHARGING

........ :: VALVE

OIL

= SERVICE VALVE ON 1_= SERVICE VALVE ON

PUMPOUT UNIT CHILLER

_SEPARATOR

....._ PUMPOUT

PUMPOUT _ _.//**./_*f CONDENSER

COMPRESSOR _] ___ i ....... "....

-_ PUMPOUT

I CONDENSER

q WATER SUPPLY

AND RETURN

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

Table 11A- HFC-134a Pressure-

Temperature (F)

TEMPERATURE, PRESSURE

F (psig)

06.60

27.52

4 8.60

6 9.66

8 10.79

10 11.96

12 13.17

14 14.42

16 15.72

18 17.06

20 18.45

22 19.88

24 21.37

26 22.90

28 24.46

30 26.11

32 27.80

34 29.53

36 31.32

38 33.17

40 35.08

42 37.04

44 39.06

46 41.14

48 43.26

50 45.46

52 47.74

54 50.07

56 52.47

58 54.93

60 57.46

62 60.06

64 62.73

66 65.47

68 68.29

70 71.18

72 74.14

74 77.18

76 80.30

78 83.49

80 66.17

82 90.13

84 93.57

86 97.09

88 100.70

90 104.40

92 108.18

94 112.06

96 116.02

98 120.08

100 124.23

102 128.47

104 132.81

106 137.25

108 141.79

110 146.43

112 151.17

114 156.01

116 160.96

118 166.01

120 171.17

122 176.45

124 181.83

126 187.32

128 192.93

130 198.66

132 204.50

134 210.47

136 216.55

138 222.76

140 229.09

Table 11B -- HFC-134a Pressure-

Temperature (C)

TEMPERATURE, PRESSURE

C (kPa)

-18.0 44.8

-16.7 51.9

-15.6 59.3

-14.4 66.6

-13.3 74.4

-12.2 82.5

-11.1 90.8

-10.0 99.4

-8.9 106.0

-7.8 118.0

-6.7 127.0

-5.6 137.0

-4.4 147.0

-3.3 158.0

-2.2 169.0

-1.1 180.0

0.0 192.0

1.1 204.0

2.2 216.0

3.3 229.0

4.4 242.0

5.0 248.0

5.6 255.0

6.1 261.0

6.7 269.0

7.2 276.0

7.8 284.0

8.3 290.0

8.9 298.0

9.4 305.0

10.0 314.0

11.1 329.0

12.2 345.0

13.3 362.0

14.4 379.0

15.6 396.0

16.7 414.0

17.8 433.0

18.9 451.0

20.0 471.0

21.1 491.0

22.2 511.0

23.3 532.0

24.4 554.0

25.6 576.0

26.7 598.0

27.8 621.0

28.9 645.0

30.0 669.0

31.1 694.0

32.2 720.0

33.3 746.0

34.4 773.0

35.6 800.0

36.7 826.0

37.8 657.0

38.9 886.0

40.0 916.0

41.1 946.0

42.2 978.0

43.3 1010.0

44.4 1042.0

45.6 1076.0

46.7 1110.0

47.8 1145.0

48.9 1180.0

50.0 1217.0

51.1 1254.0

52.2 1292.0

53.3 1330.0

54.4 1370.0

55.6 1410.0

56.7 1451.0

57.8 1493.0

58.9 1536.0

60.0 1580.0

Chiller Dehydration -- Dehy&'ation is recommended if

the chiller has been open for a considerable period of time, if

the chiller is known to contain moisture, or if there has been a

complete loss of chiller holding chmge or refrigerant pressure.

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.

Dehydiation can be done at room temperatures. Using a

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 a qualified service

representative for the dehydration techniques required.

Perform dehydiation as follows:

1. 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 as possible to

provide least resistance to gas flow.

2. Use an absolute pressure manometer or a wet bulb

vacuum indicator to measure the vacuum. Open the

shutoff valve to the vacuum indicator only when taking a

reading. Leave the valve open for 3 minutes to allow the

indicator vacuum to equalize witi1 the chiller vacuum.

3. If the entire chiller is to be dehydiated, open all isolation

v_tives (if present).

4. 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).

Operate the pump an additional 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,

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.

5. Valve off tile vacuum pump, stop the pump, and record

the instrument reading.

6. After a 2-hour wait, take another instrument reading. If

the reading has not changed, dehydi'ation is complete. If

the reading indicates vacuum loss, repeat Steps 4 and 5.

7. If tile reading continues to change after several attempts,

perform a leak test up to the maximum 160 psig

(1103 kPa) pressure. Ix)cate and lepair the leak, and

repeat dehydration.

Inspect Water Piping -- Refer to piping diagrams pro-

vided 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 specifications have been met.

_...,. TO VACUUM

FROM IIL:--;:L4 PUMP

S¥STEM-' I

_A_l_'n Im_ -.4IP- _]1 _ MIXTURE OF

_I_I_E_ENS_ES_ _ DRYICEAND

ON COLD METHYL ALCOHOL

SURFACES

Fig. 32 -- Dehydration Cold Trap

Piping systems must be properly vented with no stress on

waterbox nozzles and covel.s. Water flows through the cooler

and condenser must meet job requirements. Measure the

pressure drop across tile cooler and the condenser

Water must be within design limits, clean, and treated to

ensure proper chiller perfommnce and to reduce the poten-

tial of tube &tmage due to corrosion, scaling, or erosion.

Carrier assumes no responsibility for chiller damage result-

ing from unUeated or improperly treated watel:

Check Optional Pumpout Compressor Water

Piping- If the optkmal pumpout storage tank and/or

pmnpout system _u'e installed, check to ensure the pmnpout

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.

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.

The 19XRV relief valves are set to relieve at the 185 psig

(1275 kPa) chiller design pressure.

Identify 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 to operate in the following

environmental conditions:

CONDITION 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)

5% to 95%

Humidity (non-condensing)

This section describes how to identify tile drive using the

model number matrix and shows the major drive components.

12=ncm@[j n_

ID NO.: 18O7(X)-X)(X-XXX

Input Rating: XXXVAC X)O(A 50/60Hz 3PH

Oulput Rating: 0-48OVAC X)O(A 0-400Hz 3PH

Short Circuit Rating: XXXXXX

Interrupt Capacity Ragng: )OOOO¢,X

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. InXX)O(on XJoc)O(

Made In USA for Carder Colporagon,

Syracuse. NY 13221-4808.

Fig. 33 -- VFD Nameplate

Max. Ambient Temperature: 50°C

LF20 = LiquiFIo 2.0

Continuous Ampere Rating

and Frame Size

Coolant Method

R = refrigerant R134a

LF20 0608CC R

Fig. 34 -- Identifying the Drive Model Number

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.

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 Uor death from

electric shock.

The mtfin disconnect on the starter fiont panel may not deen-

ergize 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.

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 AC input power to the

main input circuit breaker:

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

2. 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.

3. Wire the AC input power leads by routing them through

the openings to the main input circuit breakel:

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.

4. Connect the three-phase AC input power leads (per job

specification) to the appropriate input terminals of the

circuit breaker

5. Tighten the AC input power terminals to the proper

torque as specified on the input circuit breakel:

Checking the Installation -- Use the following in-

structions to verify the condition of the instalhttion:

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

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

3. All wiring should be installed in conformance with the

applicable local, national, and international codes (e.g.,

NEC/CEC).

4. Remove any debris, such as metal shavings, from the

enclosure.

5. Check that there is adequate cle_u'ance around the

machine.

6. Verify that the wiring to the terminal strip and the power

terminals is coned.

7. Verify that all of the VFD power module circuit bo_ud

connectors are fully engaged and taped in phtce.

8. Check that the wire size is within terminal specifications

and that the wiles me tightened properly.

9. Check that specified branch circuit protection is installed

and conectly rated.

10. Check that the incoming power is within _+10% of chiller

nameplate voltage.

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.

Table 12 -- Drive Assembly and Power Module Ratings

OUTPUT

NOMINAL INPUT CURRENT

INPUT CURRENT

VOLTAGE AT 4 kHz*

(V) (AMPS) (AMPS)

380 TO 440 460

460 608 608

PARTNUMBER FRAME ENCLOSURE

SIZE RATING

19XVA2AA 2AA NEMA1

19XVA2CC 2CC

*110% outputcurrentcapabilityforl minute. 150% outputcurrentcapability _r5sec.

Inspect Wiring

Do not check the voltage supply without proper equipment

and precautions. Sedous personal injury may result. Follow

power company recommen&ttions.

Ground Fault Troubleshooting -- Follow this pro-

cedure 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

a. Open the starter main disconnect switch and follow

lockout/tagout rules.

Do not apply any kind of test voltage, even for a rotation

check, if the chiller is under a dehydration vacuum. Insula-

tion breakdown and serious &image may result.

1. Examine the wiring for conformance to the job wiring

diagrmns and all applicable electrical codes.

2. 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.

3. 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.

4. 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.

5. 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.

6. Ensure that fused disconnects or circuit breakers have

been supplied to the control center and optional pumpout

unit.

7. Ensure all electrical equipment and controls are properly

grounded in accordance with the job di'awings, certified

drawings, and all applicable electrical codes.

8. Ensure the customer's contractor has verified proper oper-

ation of the pumps, cooling tower fans, and associated

auxiliary equipment. This includes ensuring motors are

properly lubricated and have proper electric_d supply and

proper rotation.

9. 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.

Do not apply power unless a qualified Carrier technician is

present. Serious personal injuUmay 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 parame-

ters entered in VFD_CONF match the information on

the Machine Nameplate and Sales Requisition. Con-

firm that the serial numbers on the chiller, Machine

Nameplate, and Sales Requisition are consistent.

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.

b. 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 and test between

the group and ground.

c. 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.

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 tempera-

ture range of -4 F to 140 F (-9-0 C to 60 C) is required. See

table below for cables flint meet the requirements.

MANUFACTURER CABLE NO.

Alpha 2413 or 5463

American A22503

Belden 8772

Columbia 02525

When connecting tile CCN communication bus to a system

element, a color code system for the entire network is recom-

mended to simplify installation and checkout. The following

color code is recommended:

CCN BUS CCN ICVC PLUG J1

SIGNAL CONDUCTOR TERMINAL PIN NO.

TYPE INSULATION CONNECTION

COLOR

+ Red RED (+) 1

Ground White WHITE (G) 2

Black BLACK (-) 3

Power Up the Controls and Check the Oil

Heater -- Ensure that an oil level is visible in the compres-

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.

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.

SOFTWARE VERSION- The 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 Configuration

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.

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.

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 SET-

POINT. 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.

Input the Local Occupied Schedule (OCCPC01S) --

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.

For more information about how to set up a time schedule,

see the Controls section, page 11.

The CCN Occupied Schedule (OCCPC03S) should be con-

figured if a CCN system is being installed or if a secon&try

time schedule is needed.

NOTE: The default CCN Occupied Schedule OCCPC03S is

configmed to be unoccupied.

Input Service Configurations -- Ti_e following con-

figurations require the ICVC scleen to be in the SERVICE por-

tion of the menu.

• password

• input time and date

• ICVC configuration

• service parameters

• equipment configuration

• automated control test

PASSWORD -- When accessing the SERVICE tables, a pass-

word must be entered. All ICVC are initially set for a password

of 1- 1- 1- 1 in the ICVC CONFIGURATION SCREEN.

INPUT TIME AND DATE -- Access the TIME AND DATE

table on the SERVICE menu. Input the present time of chy,

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.

NOTE: The date format is MM-DD-YY for English units and

DD-MM-YY format for SI metric units.

CHANGE ICVC CONFIGURATION IF NECESSARY --

From the SERVICE table, access the ICVC CONFIGU-

RATION 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 may be

changed from the ICVC CONFIGURATION screen.

1. Press the _ and [SERVICE] softkeys. Enter the

current password and highlight ICVC CONFIGURA-

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.

2. Use file _ softkey to scroll to PASSWORD. The

first digit of file password is highlighted on the screen.

3. To change the digit, press the IINCREASE] or

[DECREASE] soflkey. When the desired digit is seen,

press the _ softkey.

4. The next digit is highlighted. Change it, and the third and

fourth digits in the same way the lil.st was changed.

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

NUMBER pmametel: Press the _ softkey to leave

that screen and leturn to the SERVICE menu.

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.

TO CHANGE THE ICVC DISPLAY FROM ENGLISH TO

METRIC UNITS --By default, the ICVC displays informa-

tion in English units. To change to metric units, access the

ICVC CONFIGURATION scleen:

1. Press the _ and [SERVICE] softkeys. Enter the

password and highlight ICVC CONFIGURATION. Press

the _ softkey.

2. Use file _ softkey to scroll to US IMP/METRIC.

3. 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

the _ softkey.

2. Use the _ softkey to scroll to LID LANGUAGE.

3. PresstheINCREASEorDECREASEsoftkeyuntilthe

desiredlanguageisdisplayed.Press_ toconfirm

desiredlanguage.

MODIFYCONTROLLERIDENTIFICATIONIFNECES-

SARY-- TheICVCmoduleADDRESS can be changed from

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 PARAMETERS IF NEC-

ESSARYiThe EQUIPMENT SERVICE table has six

service tables.

VERIFY VFD CONFIGURATION AND CHANGE

PARAMETERS IF NECESSARY (Fig. 35)

IMPORTANT: The VFD controller has been factory con-

figured for use and communications to the International

Chiller Visual Controller (ICVC). Some parmneters ;ue

specific to the chiller configuration and will need to be ver-

ified prior to operation. All command functions must be

initiated from the [CVC.

VFD CHILLER FIELD SET UP AND VERIFICATION

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 the VFD_CONF

screen on the [CVC by entering the following screen

sequence when the chiller is not running:

• MENU

• SERVICE

• Password (default 1111)

• VFD CONFIG DATA

• Password (default 4444)

• VFD_CONF

Confirm that the following parameters in the

VFD_CONF screen match the values on the Internal

Machine Electrical Data Nameplate:

•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.

Mmq

MACHINE NAMEPLATE $_FI.Y DATA

M_ r_Cl_CUsT _R_A_ER_ZE I

MACHINEELECINCAL DATA

_*o_ N_M PLAXE VO AG_

Carrier

MACH_ ELEC_ICAL DATA

u_ SIDE

10AD SIDE

INTERNAL

Fig. 35 -- Machino Electrical Data Namoplato

sA,,,, COOEce_I,I_,,o,

EXTERNAL

• Motor Nameplate kW iMotor 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.

NOTE: Some of the parameters can be changed only when the

drive is stopped.

It is the operator's responsibility to distribute access to the

ICVC passwords. Carrier is not responsible for unautho-

rized access violations within the operator's organization.

Failure to observe this warning could result in bodily

injury.

See the Initial Start-Up Checklist section for VFD Job Spe-

cific 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 labelthatliststheconfigurationv_duesofthecontrolsis

locatedontheinsideoftheunit'scontrolpanel.Thesev_dues

arebasedupontheoriginalselectionofthechillel:Jobsitecon-

ditionsmayrequireaslightmodificationtotheseparameters.

If afterconfiguringavalueforthesepoints,surgepreven-

tionis operatingtoosoonor toolatefor conditions,these

parametersshouldbechangedbyfileoperatol:

Anexmnpleofsuchaconfigurationisshownbelow.

Refrigerant:HCFC-134a

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:

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 &lta. 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 tempera-

ture 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:

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

To avoid unnecessmy surge prevention, add about 10 psid

(70 kPad) to AP2 from these conditions:

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 condens-

ing temperatures will be at this point. Use the proper saturated

pressure and temperature for the particular refrigerant used.

Suction Temperature:

43 F (6.1 C) = 38 psig (262 kPa) saturated

refrigerant pressure (HFC- 134a)

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, add 20 psid

(140 kPad) at API from these conditions:

ATI = 2F(I.I C)

API = 53 psid (368 kPad)

If surge prevention occurs too soon or too late:

SURGE PREVENTION SURGE PREVENTION

LOAD OCCURS TOO SOON OCCURS TOO LATE

At low loads Increase Pl by Decrease P1 by

(<50%) 2 psid (14 kPad) 2 psid (14 kPad)

At high loads Increase P2 by Decrease P2 by

(>50%) 2 psid (14 kPad) 2 psid (14 kPad)

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.

Further adjustments can be made if response to surge preven-

tion 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 protec-

tion is active.

CONFIGURE DIFFUSER CONTROL IF NECES-

SARY- If 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.

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 NECES-

SARY -- 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)

Owner-Modified CCN Tables -- The following EQUIP-

MENT CONFIGURATION screens me described for reference

only.

OCCDEFCS- The OCCDEFCS screen contains the Ix_cal

trod CCN time schedules, which can be modified here or on the

SCHEDULE screen as described previously.

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

tables.If anyofthese3bitsissetto1,thecontroller(ICVC,

forexample)willbroadcastany;darmswhichoccm:

• first bit = 1 indicatesthatthealarmshouldberead

and processedby a "front end" device,suchas

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.

The Re-Alarm time is a time period after which, if a preex-

isting and previously broadcast ;darm has not been cleared, it

will be rebroadcast on the CCN network.

Other _ibles -- The CONSUME, NET_OPT. and RUN-

TIME screens contain parameters used with a CCN system.

See the applicable CCN manual for more information on these

screens. These tables can only be defined from a CCN

Building Supervisol:

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 0or 1. Setting a

digit to 1specifies 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 Interface Module 1

Autodail Gateway /

Local Building Supervisors(s) _ I

or ComfortWORKS I

11010

I000

I I I l

Iunused

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 0in 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 automated control test. Access the

CONTROL TEST table and select a test to be performed

function (Table 13).

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 volt-

age should be within _+10% of Nmneplate value. The comples-

sot can be put in OFF mode by pressing the STOP push button

on the [CVC. Each test asks the operator to confirm the opera-

tion is occurring and whether or not to continue. If an error oc-

curs, 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 to calibrate guide vane

actuator feedback potentiometer input on CCM (Plug J4 upper

terminals 9 and 10).

NOTE: [f during the control test the guide vanes do not open,

verify the low pressure ;dmm is not active. (An active low

plessure ;dmm causes the guide vanes to close.)

NOTE: The oil pump test will not energize the oil pump if

cooler pressure is below -5 psig (-35 kPa).

Table 13 -- Control Test Menu Functions

TESTS TO BE DEVICES TESTED

PERFORMED

1. CCM Thermistors

2. CCM Pressure

Transducers

3. Pumps

4. Discrete

Outputs

5. IGV & SRD

Actuator

6. Head Pressure

Output

7. Diffuser Actuator*

8. Pumpdown

Lockout

9. Terminate Lockout

10. Guide Vane

Calibration

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

Evaporator Pressure

Condenser Pressure

Oil Pump Delta P

Chilled Water Delta

Condenser Water Delta P

Transducer Voltage Ref

Humidity Sensor Input

Relative Humidity

Oil Pump -- Confirm Pressure

Chilled Water -- Confirm Flow and Delta P

Condenser Water -- Confirm Delta P

Oil Heater Relay

Hot Gas Bypass Relay

Tower Fan Relay Low

Tower Fan Relay High

VFD Coolant Solenoid

Alarm Relay

Shunt Trip Relay

Open/Close

If present, split ring diffuser will operate in

coordination with the guide vanes per con-

figured schedule.

Increase/Decrease 4-20 mA output

Open/Close (independent of guide vanes)

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.

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.

Automatic, displays guide vane position sig-

nal voltage. This test is required before first

startup with new Actuator or Controller.

*Diffuser tests function only on size 4 and 5 compressor with diffuser

control enabled.

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.

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.

PRESSURETRANSDUCERCALIBRATION-- Trans-

ducersmeasuringsinglepressurevalues(suchascondenser

andevaporatorpressure)arecalibratedindividually,whilea

pairof transducersmeasuringa pressuredifferential(OIL/

PUMPDELTAR CONDENSERWATERDELTAR

CHILLEDWATERDELTAP)tuecalibratedtogetherasadif-

ferential.Inunitswith[CVCcontrollers,transducel.'sforsens-

ingwatersideflowarenotprovidedasstan&ud.Thesereading

canbeviewedandcalibratedfromtheCOMPRESSand

HEAT_EXscreensontheICVCcontrollel:

Eachtransducerortransducerpaircanbec_flibratedattwo

points:zero(0psigor0kPa)and"highend"(between25and

250psig,or between173and1724kPa).It is notusually

necess_uyto calibrateat initialstart-up.Howevel,at high

altitudelocations,recalibrationmaybenecessarytoensurethe

properrefrigeranttemperature-pressurerelationship.

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.

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:

Access the HEAT EX screen under the STATUS menu,

and the CONDENSER PRESSURE or EVAPORATOR

PRESSURE to the reference pressure gage. To change the dis-

played reading, press the SELECT key to highlight the associ-

ated line in the display, then the INCREASE or DECREASE

key to set the new value, then the ENTER key. Generally, the

value can be changed to tiny value within _+15% of a nominal

value.

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 thermo-

stat, 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.

High Altitude Locations -- Because the chiller is ini-

ti;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 Trouble-

shooting Guide section.

Charge Refrigerant into Chiller

The transfel: addition, or removal of refrigerant in spring

isolated chillers may place severe stress on external piping

if springs have not been blocked in both up and down

directions. Failure to block springs in both up and down

directions could result in severe personal injury and equip-

ment damage.

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.

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.

CHILLEREQUALIZATIONWITHOUTA PUMPOUT

UNIT

Whenequ_flizingrefrigerantpressureonthe19XRVchiller

afterserviceworkorduringtheinitialchillerstall-up,do

not use the dischalig, e isolation valve to equali',.e. Eiflier the

motor cooling isolation valve or a charging hose (con-

nected between the refrigerant charging valves on top of

the cooler and condenser) should be used as the equaliza-

tion valve. Dmnage to the float valve could result.

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.

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. IMPORTANT: Turn on the chilled water and con-[

denser water pumps to prevent freezing. I

3. Slowly open the motor cooling isolation valve. The

chiller cooler and condenser pressures will gradually

equalize. This process takes approximately 15 minutes.

4. Once the pressures have equalized, the cooler isolation

v_dve, the condenser isolation valve, and the hot gas isola-

tion valve may now be opened. Refer to Fig. 30 and 31,

for the location of the valves.

Whenever turning the discharge isolation valve, be sine to

reattach the valve locking device. This prevents the valve

from opening or closing during service work or during

chiller operation, which could result in serious pel.sonal

injury.

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 and con-]

denser water pumps to prevent freezing. I

3. 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.

4. Once the pressures have equalized, the dischmge isola-

tion 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.

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 deter-

mined by adding the condenser charge to the cooler chmge as

listed in Table 14.

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 injuryor equipment &image.

Use the CONTROL TEST terminate lockout function to

monitor conditions and start the pumps.

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 refrig-

erant 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 cool-

er or condenser Do not charge liquid through the liquid line

service valve.

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.)

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.

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.

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 14- Refrigerant (HFC-134a) Charge

COOLER

CODE

REFRIGERANT

CHARGE

Ib kg

290 132

310 141

330 150

320 145

340 154

370 168

345 157

385 175

435 197

350 159

420 190

490 222

400 161

480 218

550 250

560 254

630 266

690 313

640 290

720 327

790 358

750 340

840 361

900 408

870 395

940 426

980 445

940 426

980 445

1020 463

1060 461

1090 494

1220 553

1340 608

1440 653

REFRIGERANT

CONDENSER CHARGE

CODE Ib kg

10 200 91

11 200 91

12 200 91

15 250 113

16 250 113

17 250 113

20 225 102

21 225 102

22 225 102

30 260 118

31 260 118

32 260 118

35 310 141

36 310 141

37 310 141

40 260 127

41 280 127

42 280 127

45 330 150

46 330 150

47 330 150

50 400 161

51 400 161

52 400 181

55 490 222

56 490 222

57 490 222

60 420 190

61 420 190

62 420 190

65 510 231

66 510 231

67 510 231

70 780 354

71 780 354

72 780 354

INITIAL START-UP

IMPORTANT: The Reliance VFD wmTanty will be void if

the VFD is not stmted by a technician who has completed

Reliance LiquiFlo TM Tier 1 Training and whose name is

legi stered with Reliance.

Preparation -- Before stmting file chillel; verify:

I. Power is on to the main startel: oil pump relay, tower fan

stmter, oil heater relay, and file chiller control panel.

2. Cooling tower water is at proper level and at-or-below

design entering temperature.

3. Chiller is charged with refrigerant and all refi'igerant and

oil valves are in their proper operating positions.

4. Oil is at the proper level in the reservoir sight glasses.

5. Oil reservoir temperature is above 140 F (60 C) or above

refrigerant temperature plus 50 ° F (28 ° C).

6. Vtdves in the evaporator and condenser water circuits are

open.

NOTE: If the pumps are not automatic, ensure water is

circulating properly.

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. 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.

Check Motor Rotation

1. Engage tile control power circuit breaker (CB2) located

inside the left hand side of the VFD enclosure.

Finally close the main motor disconnect (CBl) on the

front of the VFD enclosure.

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.

4. 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.

5. After the default screen status message states 'Ready to

Stmt' press the _ softkey. The PIC III control

performs start-up checks.

6. When the starter is energized and the motor begins to

turn, check for clockwise motor rotation (Fig. 37).

Do not check motor rotation during coastdown. Rotation

may have reversed during equalization of vessel pressures.

Check Oil Pressure and Compressor Stop

I. When the motor is at full speed, note the OIL PRES-

SURE 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.

2. Press the Stop button and listen for any unusual sounds

from the compressor as it coasts to a stop.

To Prevent Accidental Start-Up -- 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 [PREVIOUS] softkeys,

highlight the CHILLER START/STOP pammetel: Override the

current START value by pressing the _ softkey. Press

file _ softkey followed by the _ softkey. The

word SUPVSR! displays on the [CVC indicating the override

is in place.

To restml the chiller the STOP override setting must be

removed. Access the MAINSTAT screen and using

or ]PREVIOUS] softkeys highlight CHILLER START/STOP.

The 3 softkeys that appear represent 3 choices:

•_ -- forces tile chiller ON

• _ -- forces tile chiller OFF

• ]RELEASE ] -- puts the chiller under remote or schedule

control.

To return the chiller to normal control, press the

]RELEASE] softkey followed by the _ softkey. For

mole information, see Local Start-Up, page 50.

The default [CVC screen message line indicates which

command is in effect.

CORRECT MOTOR ROTATION

IS CLOCKWISE WHEN VIEWED

THROUGH MOTOR SIGHT GLASS

TO CHECK ROTATION, ENERGIZE COMPRESSOR MOTOR MOMENTARILY.

DO NOT LET MACHINE DEVELOP CONDENSER PRESSURE.

CHECK ROTATION IMMEDIATELY.

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 Rotation

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 Operator -- Ensure the op-

erator(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, pres-

sure transducer locations, Schmder fittings, waterboxes and

tubes, and vents find drains.

OPTIONAL PUMPOUT STORAGE TANK AND PUMP-

OUT SYSTEM -- Transfer vfdves find pumpout system,

refrigerant charging and pumpdown procedme, find relief

devices.

MOTOR COMPRESSOR ASSEMBLY -- Guide vane actu-

ator: 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.

AUXILIARY EQUIPMENT-- Disconnects, sepmate elec-

trical sources, pumps, and cooling towel:

DESCRIBE CHILLER CYCLES -- Refi'igerant, motor cool-

ing, lubrication, and oil reclaim.

REVIEW MAINTENANCE- Scheduled, routine, and ex-

tended shutdowns, importance of a log sheet, importance of

water treatment and tube cleaning, and importance of maintain-

ing a leak-free chiller

SAFETY DEVICES AND PROCEDURES -- Electrical dis-

connects, relief device inspection, and handling refrigerant.

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 MAINTE-

NANCE 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.

OPERATING INSTRUCTIONS

Operator Duties

I. Becolne falniliar with the chiller and related equiplnent

before operating the cNllel:

2. Prepare the system for start-up, start and stop the chiller.

and place the system in a shutdown condition.

3. Maintain a log of operating conditions and document any

abnormal readings.

4. Inspect the equipment, make routine adjustments, fred

perform a Control Test. Maintain the proper oil and

refrigerant levels.

5. Protect the system from &image during shutdown periods.

6. Maintain the set point, time schedules, and other PIC HI

functions.

Prepare the Chiller for Start-Up -- Follow the steps

described in the Initial Start-Up section, page 67.

To Start the Chiller

I. Start the water pumps, if they are not automatic.

2. On the ICVC default screen, press the _ or

[_ soflkey to start the system. If the chiller is in the

OCCUPIED mode find the start timel_ have expired, 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 compres-

sor starts, the operator should monitor the ICVC display find

observe the parameters for normal operating conditions:

1. The oil reselaToir temperature should be above 120 F

(49 C) during shutdown.

2. 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.

3. 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.

4. 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 compres-

sors equipped with rolling element bearings.

5. The moisture indicator sign glass on the refrigerant

motor cooling line should indicate refrigerant flow and a

dry condition.

6. 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.

7. 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).

8. Thecompressormayoperateatfullcapacityforashort

timeafterthepulldownrampinghasended,eventhough

thebuildingloadissm_dl.Theactiveelectric_ddemand

settingcanbeoveMddentolimitthecompressor[kW.or

thepulldownrotecanbedecreasedto avoida high

demandchaisefor theshortperiodof highdemand

operation.Pulldownratecanbebasedonloadrateor

temperaturerateandisaccessedontheEQUIPMENT

SERVICEscreen,RAMPDEM table (N_ble4,

Example21).

To Stop the Chiller

I. The occupancy schedule starts and stops the chiller

automatically once the time schedule is configured.

2. 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

sequence as described in the Shutdown Sequence,

Start-Up/Shutdown/Recycle Sequence section, page 50.

The chiller will not restmt until the _ or

softkey is pressed. The chiller is now in the OFF control

mode.

lIMPORTANT: Do not attempt to stop the chiller by openingan isolating knife switch. High intensity arcing may occm:

Do not restart the chiller until the problem is diagnosed

and corrected.

After Limited Shutdown-- No speci_d preparations

should be necessary. Follow the regular preliminary checks and

starting procedures.

Preparation for Extended Shutdown -- The refrig-

erant 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:

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.

After Extended Shutdown -- 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 and

compare it to the original holding charge that was left in the

chillel: [f (after adjusting for ambient temperature changes) any

loss in pressure is indicated, check for refrigerant leaks. See

Check Chiller Tightness section, page 53.

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.

C;uefully make all legular preliminary and running system

checks. Perform a Control Test before start-up. If the compres-

sor 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 Operation- When the entering con-

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).

Manual Guide Vane Operation -- It is possible to

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.

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 man-

nel, capacity control changes are directed to modulate the

guide vanes.

NOTE: Manual control mode overrides the configured pull-

down 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.

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 mainte-

nance and diagnosing chiller problems.

Keep a record of the chiller pressmes, temperatures, and liq-

uid 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.

Plant

DATE

TIME

Refrigerant

Press. Temp

REFRIGERATION LOG CARRIER 19XRV HERMETIC CENTRIFUGAL REFRIGERATION MACHINE

MODEL NO. SERIAL NO. MOTOR RLA

COOLER

Water

Pressure

In Out GPM

CONDENSER COMPRESSOR VFD

Refrigerant Water Oil

Thrust Average Average Line Average

Line Line Load

InTemPout Press. Temp In PressUreoutGPM InTemPout BearingTempPressure SumPTempLevel Current Voltage Kilowatts Current

Inverter Rectifier

Temp Temp

VFD

Coolant

Flow

OPERATOR REMARKS

INITIALS

Fig. 38 -- Refrigeration Log

PUMPOUT AND REFRIGERANT

TRANSFER PROCEDURES

Preparation -- The 19XRV chiller equippedlllay COllie

wifll an optional pumpout storage tank, pumpout system, or

pumpout compressol: The refrigerant can be pumped for ser-

vice work to either the chiller compressor vessel or chiller con-

denser vessel by using the optional pumpout system. If a

pumpout storage tank is supplied, the refrigerant can be iso-

laed in the storage tank. The following procedures describe

how to transfer refrigerant from vessel to vessel and perfonn

chiller evacuaions.

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.

TO READ REFRIGERANT PRESSURES during pumpout or

leak testing:

1. 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

file Schrader connections on each vessel (Fig. 9) by

removing the pressure transducel:

2. To determine pumpout storage tank pressure, a 30 in. Hg

vacuum -0-400 psi (-101-0-2769 kPa) gage is attached to

file storage tank.

3. Refer to Fig. 30, 31, and 40 for valve locations and

numbers.

Transfer. addition, or removal of refrigerant in spring-

isolated 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.

Do not mix lefrigerants from chillers that use different

compressor oils. Compressor &image can result.

Operating the Optional Pumpout Unit --Oil

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.

POSITIVE PRESSURE CHILLERS WITH STORAGE

TANKS -- In the Valve/Condition tables ilia accompany these

instructions, file letter "C" indicates a closed v_dve. Figures 9 and

10 show the locations of the valves.

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.

D D

CONTROL POWER H1 H4

TRANSFORMER

XFMR-1 _ x2

6oVA

HIGH PRESSURE

SAFETY

-- AUTO-N-C-OP _'_185-P _9"-SS-1OFF ON )<2

2_ "_m _ LOW PRESSURE CONTROL I

L_J'-I_| E_ NC_O-_SE-.> 2OPEN < _7 psia E15.7"6i_L H.?Lin"HG}jI

Fig. 39 -- Pumpout Unit Wiring Schematic

C 20L

C_-----_-_-2 L .... _ PUMPOUT

_-::-_ COMPRESSOR

L1 _ -- -- --HZ_'I CRANKCASE HEATER

L2 ___ 240-600v

27-40 WATT

LEGEND

C -- Contactor

FU -- Fuse

GND -- Ground

HTR -- Heater

MTR -- Motor

NC -- Normally Closed

OL -- Overload

SS -- Selector Switch

FRAME

ASSEMBLY

CONTROL

PANEL

VALVE

VALVE /

ENTERING

WATER

_COMPRESSOR

/OIL

SEPARATOR

LEAVING CONDENSER

WATER

Fig. 40 -- Pumpout Unit

Transfer Refrigerant fiOl]l Pumpout Storage Tank to Chiller

c. Turn off tile pumpout compressor.

d. Turn off the chiller water pumps.

e. Close valves 3 and 4.

f. Open valves 2 and 5.

VALVE la lb 2 34 5 6 7 10 11

CONDITION C C C C

g. Turn on pumpout condenser watec

h. Run the pumpout compressor in manual mode until

the storage tank pressure reaches 5 psig (34 kPa),

18 in. Hg vacuum (41 kPa absolute).

i. Turn off the pumpout compressor.

j. Close valves I a, I b, 2, 5, and 6.

VALVE la lb 2 34 5 6 7 10 11

CONDITION C C C C C C C C C

k. Turn off pumpout condenser watel:

Transfer the Refrigerant from Chiller to Pumpout Storage

Tank

1. Equalize refrigerant pressure.

a. Valve positions:

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.

Equ_dize refligerant 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 refrigerant 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 la lb 2 34 5 6 7 10 11

CONDITION C C C C C

d. Gradually crack open valve 5 to increase chiller

pressure to 35 psig (241 kPa). Slowly feed refriger-

ant to prevent freeze-up.

e. 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.

VALVE ]la lb 2 3 4 5 6 7 10 11

CONDITION

2. Transfer remaining refrigerant.

VALVE 11

CONDITION

a. 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.

b. Close refrigerant charging valves 7 and 10.

VALVE la lb 2 3 4 5 6 7 10 11

CONDITION C C C C C

b. Slowly open wflve 5 and refrigerant charging

valves 7 and 10 to allow liquid refrigerant to drain

by gravity into the storage tank.

VALVE 11

CONDITION

2. Transfer the remaining liquid.

a. Turn off pumpout condenser water. Place valves in

the following positions:

VALVE 11

CONDITION

b. Run the pumpout compressor in automatic mode

until vacuum switch is satisfied and compressor

stops. Close valves 7 and 10.

VALVE la lb 2 3 4 5 6 7 10 11

CONDITION C C C C

c. Turn off the pumpout compressor.

3. Remove any remaining refrigerant.

a. Turn on chiller water pumps.

b. Turn on pumpout condenser watec

c. Place valves in the following positions:

Run the pumpout compressor until the chiller pres-

sure 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.

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 abso-

lute). This can be done in On or Automatic mode.

f. Close valves I a, I b, 3, 4, and 6.

VALVE la lb 2 3 4 5 6 7 10 11

CONDITION C C C C C C C C C

g. Turn off the pumpout condenser water.

4. 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).

This operation can be done in Automatic or On mode.

In Automatic mode, the compressor will stop automati-

cally at approximately 15 in. Hg vacuum (51 kPa

absolute).

CH[LLERS WITH ISOLATION VALVES -- Tile valves re-

ferred to in the following instructions are shown in Fig. 31 and

40. Valve 7 remains closed.

Transfer All Refrigerant to Chiller Condenser Vessel

1. Push lefrigemnt into chiller condenser vessel.

a. Turn on the chiller water pumps and monitor the

chiller pressure.

b. Valve positions:

VALVE _ 11CONDITION

c. Equalize the refrigerant in the chiller cooler and

condenseE

d. Turn off chiller water pumps and pumpout con-

denser water supply.

e. Turn on pumpout compressor to push liquid out of

the chiller cooler vessel.

f. When all liquid has been pushed into the chiller

condenser vessel, close the cooler refrigerant isola-

tion valve (11 ).

g. Turn on the chiller water pumps.

h. Turn off the pumpout compressor.

2. Evacuate gas from chiller cooler vessel.

a. Close liquid line service valves 2 and 5; open

valves 3 and 4.

VALVE

CONDITION

11c

Turn on pumpout condenser water.

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).

d. Close valve la.

e. Turn off pumpout compressor.

f. Close valves lb, 3, and 4.

VALVE _ 11

CONDITION C

g. Turn off pumpout condenser watel:

h. Turn off chiller water pumps and lock out chiller

compressoc

Transfer All Refrigerant to Chiller Cooler Vessel

1. Push lefiigemnt into the chiller cooler vessel.

a. Turn on the chiller water pumps and monitor the

chiller pressure.

b. Valve positions:

VALVE _ 11

CONDITION

c. Equalize the refrigerant in the chiller cooler and

condensel:

d. Turn off chiller water pumps and pumpout con-

denser water.

e. Turn on pumpout compressor to push refrigerant

out of the chiller condenser.

f. When all liquid is out of the chiller condenser.

close valve 11 and any other liquid isolation valves

on the chiller.

g. Turn off the pumpout compressol:

Evacuate gas from chiller condenser vessel.

a. Turn on chiller water pumps.

b. Make sure that liquid line service valves 3 and 4

are closed and valves 2 and 5 are open.

VALVE _ 11CONDITION C

c. Tnrn on pumpout condenser water.

d. Run the pumpout compressor until the chiller con-

denser reaches 18 in. Hg vacuum (41 kPa absolute)

in Manual or Automatic mode. Monitor pressure at

the chiller control panel and refrigerant gages.

e. Close valve lb.

f. Turn off pumpout compressor.

g. Close valves la, 2, and 5.

VALVE _ 11CONDITION C

h. Turn off pumpout condenser water.

i. Turn off chiller water pumps and lock out chiller

compressoE

Return Refrigerant to Normal Operating Conditions

1. Be sure that the chiller vessel that was opened has been

evacuated.

2. Turn on chiller water pumps.

3. Open valves la, lb, and 3.

VALVE _ 11CONDITION C

4. Crack open valve 5, gradually increasing pressure in the

evacuated chiller vessel to 35 psig (241 kPa). Feed refiig-

erant slowly to prevent tube freeze-up.

5. Leak test to ensure chiller vessel integrity.

6. Open v_dve 5 fully.

VALVE _ 11CONDITION C

Close valves la, lb, 3, and 5.

Open chiller isolation valve 11 and any other isolation

valves, if present.

VALVE _ 11CONDITION

Turn off chiller water pumps.

DISTILLING THE 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.

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 la lb 234 5 6 7 10 11

CONDITION C C C C C

d. Gradually crack open valve 5 to increase chiller

pressure to 35 psig (241 kPa). Slowly feed refriger-

ant to prevent freeze-up.

e. Open valve 5 fully after the chiller pressure rises

above the freezing point of the refrigerant. Let the

storage tank and chiller pressure equalize.

3. Transfer remaining refrigerant.

a. Close valve 3.

b. Open valve 2.

c. Turn on pumpout condenser water.

d. Run the pumpout compressor until the storage tank

pressure reaches 5 psig (34 kPa), 18 in. Hg vacuum

(41 kPa absolute) in Manual or Automatic mode.

e. Turn off the pumpout compressor.

f. Close valves la, lb, 2, 5, and 6.

g. Turn off pumpout condenser water.

VALVE la lb 2 3 4 5 6 7 10 11

CONDITION C C C C C C C C C

4. Drain the contaminants from the bottom of the storage

tank into a containel: Dispose of contaminants safely.

GENERAL 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.

Refrigerant HFC-134a will dissolve oil and some nonme-

tallic materials, dqthe 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.

Adding Refrigerant--Follow the procedures de-

scribed in Trim Refrigerant Charge section, page 75.

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 reflig-

emnt 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 equip-

ment damage.

Removing Refrigerant -- If the optional pumpout sys-

tem 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 addi-

tion or removal of refrigerant is required to improve chiller

performance, follow the procedures given under the Trim

Refrigerant Chmge section, page 75.

Refrigerant Leak Testing -- Because HFC-134a re-

frigerantis above atmospheric pressure at room temperature,

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 read-

ings to a minimum. Before making aW necessguy repairs to a

leak, transfer all refrigerant from the leaking vessel.

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:

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.

Test After Service, Repair, or Major Leak- If

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.

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 en-

vironmentally 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 -- Anoth-

er 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.

TO PRESSURIZE WITH DRY NITROGEN

NOTE: Pressurizing with dUnitrogen for leak testing should

not be done if the full refiigerant charge is in the vessel

because purging file nitrogen is veUdill]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_,ed140 psig (965 kPa).

5. Close the charging valve on the chiller. Remove the

copper tube if it is no longer mquimdi

Repair the Leak, Retest, and Apply Standing

Vacuum Test- 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 aW 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.

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.

ACT VANE

SPROCKET ACTUATOR

CHAIN

GUARD

BRACKET

HOLDDOWN

BOLTS

VANE

SHAFT VANE

SPROCKET

Trim Refrigerant Charge -- To reraove any excess re-

frigerant, 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.

WEEKLY MAINTENANCE

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.

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.

SCHEDULED 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"

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.

GUIDE VANE SPROCKET

ADJUSTING BOLTS

Fig. 41 --Guide 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.

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.

Check Safety and Operating Controls

Monthly -- Check values of monitored parameters (see

Table 6 for safety control settings). To ensure chiller protec-

tion, the Automated Control Test should be performed at

least once per month (with machine in OFF mode). See

Table 12 for Control Test functions.

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 is off and the disconnect for the

compressor is open.

2. Disconnect the power to the oil pump.

3. Close the oil filter isolation valves located behind power

panel on top of oil pump assembly.

4. Close the isolation valves located on both ends of the oil

filtel: Have rags and a catch basin available to collect oil

spillage.

5. 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 mix-

ture which is dischm'gedi

6. Remove the oil filter assembly by loosening the hex nuts

on both ends of the filter assembly.

7. Insert the replacement tilter assembly with the rerow on

the housing pointing away from the oil pump.

8. 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)

The oil filter housing is at a high pressure. Relieve this

pressure slowly. Failure to do so could result in serious per-

sonal injury.

9. Evacuate the filter housing by placing a vacuum pump on

the charging valve. Follow the normal evacuation proce-

dures. 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 isola-

tion valves to the filter housing, and turn on the power to

the pump and the motol:

Oil Specification -- If oil is added, it must meet the fol-

lowing 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 ................................. 68

The polyolester-based oil (P/N: PP23BZI03) may be

ordered from a local Carrier representative.

Oil Changes--Cmrier 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

1. Transfer the refrigerant into the chiller condenser vessel

(for isolatable vessels) or to a pumpout storage tank.

2. Mark the existing oil level.

3. Open file control and oil heater circuit breakel:

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.

5. Change the oil filter fit this time. See Changing Oil Filter

section.

6. Change the refrigerant filter fit this time, see the next

section, Refrigerant Filtec

7. 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 condi-

tions, 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 pres-

sure. 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.

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 when-

ever 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 replace-

ment. 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 Refrigerant Float System -- Perforln this

inspection every 5 years or when the condenser is opened for

service.

1. Transfer the refrigerant into the cooler vessel or into a

pumpout storage tank.

2. Remove the float access covet:

3. Clean the chamber and valve assembly thoroughly. Be

sure the valve moves fieely. Ensure that all openings are

fiee of obstructions.

4. Examine the cover gasket and replace if necessmy.

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 danger-

ous 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.

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.

3. 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 --

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 set-

vice 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 in-

spected; 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 Exchanger Tubes and Flow

Devices

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

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

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 refiig-

erant temperature against the leaving condenser water tempera-

ture. 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 refiig-

etant, air usually does not enter the chiller

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.

Hard scale may require chemic_d treatment for its preven-

tion or removal. Consult a water treatment specialist for

proper treatment.

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.

1 2

8 7

LEGEND

1 -- Refrigerant Inlet from FLASC Chamber

2 -- Linear Float Assembly

3 -- Float Screen

4 -- Bubble Line

5 -- Float Cover

6 -- Bubble Line Connection

7 -- Refrigerant Outlet to Cooler

8 -- Gasket

Fig. 42 -- 19XRV Float Valve Design

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.

Water must be within design flow limits, clean, and treated

to ensure proper chiller performance and reduce the poten-

tial 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 the VFD

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.

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.

The disconnect on the st_uter fiont panel does not deener-

gize 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.

Periodically vacuum or blow off accumulated debris on in-

ternal VFD enclosure components with a high-velocity, low-

pressure blowec

Power connections on newly installed VFDs may relax

and loosen after a month of operation. Turn power off and

retighten. Recheck annually thereafter.

Loose power connections can cause voltage spikes, over-

heating, m¢fllimctioning, or failures.

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

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.

OPTIONAL PUMPOUT COMPRESSOR OIL CHARGE --

Use oil conforming to Carrier specifications for reciprocat-

ing compressor usage. Oil requirements are as follows:

ISO Viscosity ................................ 68 or 220

Cturier Pfut Number. ........... 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.

Relieve refrigerant pressure and add oil to the pumpout unit

follows:

1. Close service v_dves 2and4.

2. Run the pumpout compressor in Automatic mode for one

minute or until the vacuum switch is satisfied and com-

pressor shuts off.

3. Move the pumpout selector switch to OFE Pumpout

compressor shell should now be under vacuum.

4. 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

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.

TERMINAL

CONTACTOR STRIP FUSES

SWITCH

TRANSFORMER

Fig. 43 -- Pumpout Control Box (Interior)

TROUBLESHOOTING GUIDE

(Tables 15-18B)

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 condi-

tions and can be viewed while the unit is running.

• The ICVC default screen freezes when an alarm occurs.

The freeze enables the operator to view the chiller condi-

tions 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, WSM-

DEFME, 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 gen-

erated 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 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.

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.

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.

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.

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 con-

venience, 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.

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 transduc-

er. 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 VOLT-

AGE REF supply voltage. It should be 5 vdc _+.5v displayed in

CONTROL TEST under CCM PRESSURE TRANSDUC-

ERS. If the TRANSDUCER VOLTAGE REF is correct, the

transducer should be recalibrated or replaced.

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 CALI-

BRATION -- Calibration can be checked by compming the

plessme leadings from file transducer to an accurate refrigera-

tion 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 calibra-

tion 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, coolek and condenser pumps.

NOTE: There should be no flow through the heat

exchangers.

2. 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 remov-

ing the transducer from the vessel.

3. Access the HEAT_EX scleen and view the particular

transducer reading (the EVAPORATOR PRESSURE or

CONDENSER PRESSURE parameter on the HEAT EX

screen). To calibrate oil pressure or liquidside flow

device, view the particular reading (CHILLED WATER

DELTA P and CONDENSER WATER DELTA P on the

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

softkey. The value will now go to zero. No high end

calibration is necessary for OIL PRESSURE DELTA P or

flow devices.

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 trans-

ducer 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.

4. A high pressure point can fdso be calibrated between 25

and 250 psig (172.4 and 1723.7 kPa) by attaching a regu-

lated 250 psig (1724 kPa) pressure (usually from a

nitrogen cylinder). The high pressure point can be

calibrated by accessing the appropriate transducer pmam-

eter on the HEAT_EX screen, highlighting the pm'ametek

pressing the _ softkey, and then using the

[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

high altitude locations must be compensated fok so the

chiller temperature/pressure relationship is correct.

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 encoun-

tered 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 trans-

ducer 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 trans-

ducers. 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.

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.

Control Algorithms Checkout Procedure -- One

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.

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 preven-

tion, etc. The tables are:

Table 15- Control Algorithm Status Tables

TABLE EXPANDED DESCRIPTION

NAME

CAPACITY Capacity This tableshows all values used to

Control calculate the chilled water/brine

control point.

OVERRIDE Override Details of all chilled water control

Status overridevalues.

LL MAINT LEAD/LAG Indicates LEAD/LAG operation

Status status.

OCCDEFCM Time The Local and CCN occupied

Schedules schedules are displayedhere to

Status help the operator quickly deter-

mine whether the schedule is in

the "occupied" mode or not.

WSMDEFME Water The water system manager is a

System CCN module that can turn on the

Manager chiller and change the chilled water

Status control point, This screen indicates

the status of this system.

VFD HIST VFD Alarm Displays VFD values at last fault.

History

LOADSHED Loadshed DisplaysLeadshed (Demand Limit)

Status status.

CURALARM Current Displays current chiller alarms.

Alarm Status

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.

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 TO TABLES 16A-16J

CCN --

CCM --

DPI --

ICVC --

PIC III --

TXV --

VFD --

VFG --

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

A. MANUAL STOP Table 16 -- Alarm and Alert Messages

PRIMARY MESSAGE SECONDARY MESSAGE PROBABLE CAUSE/REMEDY

MANUALLY STOPPED -- PRESS CCN OR LOCAL TO START PIC III in OFF mode, press CCN or LOCAL softkey to start unit.

TERMINATE PUMPDOWN MODE TO SELECT CCN OR LOCAL 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 to stop. Water pumps are

deenergized within one minute.

ICE BUILD OPERATION COMPLETE Chiller shutdown from Ice Build operation.

SHUTDOWN IN PROGRESS RECYCLE RESTART PENDING Chilled water temperature below recycle set point. Cooling load is

less than chiller minimum capacity.

B. READY TO START

PRIMARY MESSAGE SECONDARY MESSAGE PROBABLE CAUSE/REMEDY

READY TO START IN XX MIN UNOCCUPIED MODE Time schedule for PIC III is unoccupied. Chillers will start only when

occupied. Check OCCPCnnS and Holidays screens.

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 IN EFFECT Chiller START/STOP on MAINSTAT manually forced to stop. Release

SUPERVISOR force to start.

READY TO START IN XX MIN OCCUPIED MODE Chiller timer counting down. Unit ready to start.

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 IN EFFECT 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 MODE 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 IN EFFECT Chiller START/STOP on MAINSTAT manually forced to stop. Release

SUPERVISOR force to start.

READY TO START OCCUPIED MODE Chiller timers countdown is complete. Unit will proceed to start.

READY TO START REMOTE CONTACT CLOSED Chiller timer counting down. Unit ready to start.

READY TO START START COMMAND IN EFFECT 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 EFFECT CCN Ioadshed module commanding chiller to stop.

C. IN RECYCLE SHUTDOWN

PRIMARY MESSAGE SECONDARY MESSAGE PROBABLE CAUSE/REMEDY

RECYCLE RESTART PENDING OCCUPIED MODE Unit in recycle mode, chilled water temperature is not sufficiently

above Setpoint to start.

RECYCLE RESTART PENDING REMOTE CONTACT CLOSED Unit in recycle mode, chilled water temperature is not sufficiently

above Setpoint to start.

RECYCLE RESTART PENDING START COMMAND IN EFFECT Chiller START/STOP on MAINSTAT manually forced to start, chilled

water temperature is not sufficiently above Setpoint to start.

RECYCLE RESTART PENDING ICE BUILD MODE Chiller in ICE BUILD mode. Chilled water temperature is satisfied for

ICE BUILD conditions.

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 PRIMARY SECONDARY

STATE MESSAGE MESSAGE PRIMARY CAUSE ADDITIONAL CAUSE/REMEDY

100 PRESTART STARTS LIMIT 100_Excessive compressor starts Depress the RESET softkey if additional start

ALERT EXCEEDED (8 in 12 hours), is required. Reassess start-up requirements.

101 PRESTART HIGH BEARING 101_Comp Thrust Brg Temp [VALUE] Check oil heater for proper operation.

ALERT TEMPERATURE exceeded limit of [LIMIT]*. Check for low oil level, partially closed oil sup-

ply valves, clogged oil filters.

Check the sensor wiring and accuracy.

Check Comp Thrust Brg Alert setting in

SETUP1 screen.

102 PRESTART HIGH MOTOR 102-_Comp Motor Winding Temp Check motor sensors for wiring and accuracy.

ALERT TEMPERATURE [VALUE] exceeded limit of [LIMIT]*. 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 HIGH 103_Comp Discharge Temp [VALUE] Allow discharge sensor to cool.

ALERT DISCHARGE exceeded limit of [LIMIT]*. Check sensor wiring and accuracy.

TEMP Check for excessive starts.

Check Comp Discharge Alert setting in

SETUP1 screen.

104 PRESTART LOW 104-_Evaporator Refrig Temp [VALUE] Check transducer wiring and accuracy.

ALERT REFRIGERANT exceeded limit of [LIMIT]*. Check for low chilled fluid supply

TEMP temperatures.

Check refrigerant charge.

Check Refrig Override Delta T in SETUP1

screen.

105 PRESTART LOW OIL 105_Oil Sump Temp [VALUE] Check oil heater contactor/relay and power.

ALERT TEMPERATURE exceeded limit of [LIMIT]*. Check oil level and oil pump operation.

106 PRESTART HIGH 106_Condenser Pressure [VALUE] Check transducer wiring and accuracy.

ALERT CONDENSER exceeded limit of [LIMIT]*. Check for high condenser water

PRESSURE temperatures.

Check high condenser pressure switch wiring.

107 PRESTART LOW LINE 107-_Percent Line Voltage [VALUE] Check voltage supply.

ALERT VOLTAGE exceeded limit of [LIMIT]*. Check voltage transformers and switch gear.

Consult power utility if voltage is low.

108 PRESTART HIGH LINE 108_Percent Line Voltage [VALUE] Check voltage supply.

ALERT VOLTAGE exceeded limit of [LIMIT]*. Check power transformers.

Consult power utility if voltage is high.

109 PRESTART GUIDE VANE 109_Actual Guide Vane Pos Press STOP button on ICVC and perform

ALERT CALIBRATION Calibration Required Before Startup. Guide Vane Calibration in Controls Test

screen.

Check guide vane actuator feedback

potentiometer.

110 PRESTART HIGH 110_Rectifier Temperature [VALUE] Check that VFD refrigerant isolation valves

ALERT RECTIFIER exceeded limit of [LIMIT]*. are open.

TEMP Check VFD refrigerant cooling solenoid and

refrigerant strainer.

Check for proper VFD cooling fan operation

and blockage.

111 PRESTART HIGH 111-_lnverter Temperature [VALUE] Check that VFD refrigerant isolation valves

ALERT INVERTER exceeded limit of [LIMIT]*. are open.

TEMP 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 CAUSE/REMEDY

STARTUP IN PROGRESS OCCUPIED MODE 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 IN EFFECT Chiller is starting. Chiller START/STOP in MAINSTAT manually forced to

start.

AUTORESTART IN OCCUPIED MODE Chiller is starting after power failure. Time schedule is Occupied.

PROGRESS

AUTORESTART IN REMOTE CONTACT CLOSED Chiller is starting after power failure. Remote contacts are Enabled and

PROGRESS Closed.

AUTORESTART IN START COMMAND IN EFFECT Chiller is starting after power failure. Chiller START/STOP on MAINSTAT

PROGRESS screen manually forced to start.

R NORMALRUN

Table 16 -- Alarm and Alert Messages (cont)

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 REMOTE TEMP SENSOR Auto chilled water reset active based on external input.

RUNNING -- RESET ACTIVE CHW TEMP DIFFERENCE Auto chilled water reset active based on CHW Delta T in

TEMP CTL screen.

RUNNING -- TEMP CONTROL LEAVING CHILLED WATER Default method of temperature control.

RUNNING -- TEMP CONTROL ENTERING CHILLED WATER Entering Chilled Water control enabled in TEMP CTL screen.

RUNNING -- TEMP CONTROL TEMPERATURE RAMP LOADING 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 (open). See Surge prevention

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 control.

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 RUN WITH OVERRIDES

ICVC FAULT PRIMARY SECONDARY PRIMARY CAUSE ADDITIONAL CAUSE]REMEDY

STATE MESSAGE MESSAGE

120 RUN CAPACITY HIGH CONDENSER 120-_Condenser Pressure

LIMITED PRESSURE [VALUE] exceeded limit of

[LIMIT]*.

121 RUN CAPACITY HIGH MOTOR 121_Comp Motor Winding

LIMITED TEMPERATURE Temp [VALUE] exceeded

limit of [LIMIT]*.

122 RUN CAPACITY

LIMITED

LOW EVAP REFRIG

TEMP 122_-_Evaporator Refrig

Temp [VALUE] exceeded

limit of [LIMIT]*.

123 RUN CAPACITY HIGH COMPRESSOR 123-_Surge Prevention

LIMITED LIFT Override: Lift Too High For

Compressor

124 RUN CAPACITY MANUAL GUIDE VANE 124_Run Capacity Limited:

LIMITED TARGET Manual Guide Vane Target.

125 RUN CAPACITY LOW DISCHARGE No Alert message.

LIMITED SUPERHEAT

126 RUN CAPACITY HIGH RECTIFIER TEMP 126_Rectifier Temperature

LIMITED [VALUE] exceeded limit of

[LIMIT]*.

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.

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.

Check for high condenser water temperature or

low suction temperature.

Check for high Evaporator or Condenser

approaches.

Check surge prevention parameters in

OPTIONS screen.

Target Guide Vane Position has been forced in

the COMPRESS screen. Select and RELEASE

force to return to normal (automatic) operation.

Check for oil loss or excess refrigerant charge.

Verify that the valves in the oil reclaim lines are

open.

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.

Chiller is not in automatic temperature control.127 RUN CAPACITY MANUAL SPEED No Alert message.

LIMITED CONTROL

128 RUN CAPACITY HIGH INVERTER TEMP 128-qnverter Temperature Check Inverter Temp Override in SETUP1

LIMITED [VALUE] exceeded limit of screen.

[LIMIT]*. Check that VFD refrigerant isolation valves are

open.

Check VFD refrigerant cooling solenoid.

Check for proper VFD cooling fan operation and

blockage.

*[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 PRIMARY SECONDARY

STATE MESSAGE MESSAGE PRIMARY CAUSE ADDITIONAL CAUSE/REMEDY

260 SENSOR FAULT LEAVING CHILLED WATER 260-+Sensor Fault: Check Check sensor resistance or voltage drop.

Leaving Chilled Water Sensor. Check for proper wiring.

Check for disconnected or shorted wiring.

261 SENSOR FAULT ENTERING CHILLED 261 -+Sensor Fault: Check Check sensor resistance or voltage drop.

WATER Entering Chilled Water Check for proper wiring.

Sensor. Check for disconnected or shorted wiring.

262 SENSOR FAULT CONDENSER PRESSURE 262-+Sensor Fault: Check Check sensor wiring.

Condenser Pressure Sensor. Check for disconnected or shorted wiring.

Check for condensation in transducer

connector.

263 SENSOR FAULT EVAPORATOR 263-+Sensor Fault: Check Check sensor wiring.

PRESSURE Evaporator Pressure Sensor. Check for disconnected or shorted wiring.

Check for condensation in transducer

connector.

264 SENSOR FAULT COMPRESSOR BEARING 264-+Sensor Fault: Check Check sensor resistance or voltage drop.

TEMP Comp Thrust Brg Temp Sensor. Check for proper wiring.

Check for disconnected or shorted wiring.

265 SENSOR FAULT COMPRESSOR MOTOR 265-+Sensor Fault: Check Check sensor resistance or voltage drop.

TEMP Comp Motor Winding Temp Check for proper wiring.

Sensor. Check for disconnected or shorted wiring.

266 SENSOR FAULT COMP DISCHARGE TEMP 266-+Sensor Fault: Check Check sensor resistance or voltage drop.

Comp Discharge Temp Sensor. Check for proper wiring.

Check for disconnected or shorted wiring.

267 SENSOR FAULT OIL SUMP TEMP 267-+Sensor Fault: Check Oil Check sensor resistance or voltage drop.

Sump Temp Sensor. Check for proper wiring.

Check for disconnected or shorted wiring.

268 SENSOR FAULT COMP OIL PRESS DIFF 268-+Sensor Fault: Check Oil Check sensor resistance or voltage drop.

Pump Delta P Sensor. Check for proper wiring.

Check for disconnected or shorted wiring.

269 SENSOR FAULT CHILLED WATER FLOW 269-+Sensor Fault: Check Check sensor wiring and accuracy.

Chilled Water Delta P Sensor. 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 Check sensor wiring and accuracy.

Cond Water Delta P Sensor. 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 Check sensor resistance or voltage drop.

Evap Saturation Temp Sensor. Check for proper wiring.

Check for disconnected or shorted wiring.

Table 16 -- Alarm and Alert Messages (cent)

I. CHILLER PROTECTIVE LIMIT FAULTS

ICVC FAULT PRIMARY SECONDARY PRIMARY CAUSE ADDITIONAL CAUSE/REMEDY

STATE MESSAGE MESSAGE

200 PROTECTIVE LIMIT RECTIFIER POWER 200_Rectifier Power Fault: Malfunction within VFD Power Module.

FAULT Check VFD Status. Call Carrier Service.

201 PROTECTIVE LIMIT INVERTER POWER FAULT 201_lnverter Power Fault: Malfunction within VFD Power Module.

Check VFD Status. Call Carrier Service.

202 PROTECTIVE LIMIT MOTOR AMPS NOT 202-_Motor Amps Not Check main circuit breaker for trip. Increase

SENSED Sensed -- Average Load Current % Imbalance in VFD CONF screen.

Current [VALUE].

203 FAILURE TO START MOTOR ACCELERATION 203_Motor Acceleration Fault Check that inlet guide vanes are fully closed at

FAULT -- Average Load Current start-up.

[VALUE]. Check Motor Rated Load Amps in VFD CONF

Reduce unit pressure if possible.screen.

204 FAILURE TO STOP VFD SHUTDOWN FAULT 204_VFD Shutdown Fault: VFD Circuit Board malfunction.

Check Inverter Power Unit. Call Carrier Service.

205 PROTECTIVE LIMIT HIGH DC BUS VOLTAGE 205_High DC Bus Voltage: Verify phase to phase and phase to ground line

[VALUE] exceeded limit of voltage. Monitor AC line for high transient volt-

[LIMIT]*. age conditions. VFD Circuit Board malfunction.

Call Carrier Service.

206 PROTECTIVE LIMIT VFD FAULT 206-_VFD Fault Code: See VFD Fault Code description and corrective

[VALUE]; Check VFD Fault action.

Code List.

207 PROTECTIVE LIMIT HIGH CONDENSER 207-_High Cond Pressure Check Compressor Discharge High Pressure

PRESSURE trip. [VALU E] exceeded Switch switch wiring and accuracy.

Trippoint. 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 MOTOR 208_Percent Load Current Check Motor Rated Load Amps in VFD CONF

AMPS [VALUE] exceeded limit of screen. Percent Load Current > 110%.

[LIMIT]*. Check Motor Rated Load Amps setting.

209 PROTECTIVE LIMIT LINE CURRENT 209_Line Current Imbal- Check phase to phase and phase to ground

IMBALANCE ance: Check VFD Fault His- )ower distribution bus voltage.

tory for Values. Check Line Current % Imbalance in VFD_CONF

screen. Consult power company.

210 PROTECTIVE LIMIT LINE VOLTAGE DROPOUT 210-_Single Cycle Line Volt- Temporary loss of voltage. Disable Single Cycle

age Dropout. Dropout in VFD CONF screen.

211 PROTECTIVE LIMIT HIGH LINE VOLTAGE 211_High Percent Line Volt- Check phase to phase and phase to ground dis-

age [VALUE]. tribution bus voltage. Consult power company.

212 PROTECTIVE LIMIT LOW LINE VOLTAGE 212_Low Percent Line Volt- Check phase to phase and phase to ground dis-

age [VALUE]. tribution bus voltage. Consult power company.

213 PROTECTIVE LIMIT VFD MODULE RESET 213_VFD Module Power-On Temporary loss of VFD control voltage. Check

Reset When Running. VFD control power breaker, transformer and

fuses.

214 PROTECTIVE LIMIT POWER LOSS 214_Control Power Loss Check phase to phase and phase to ground dis-

When Running. tribution 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: Verify phase-to-phase and phase-to-ground line

[VALUE] exceeded limit of voltage. VFD Circuit Board malfunction.

[LIMIT]*. Call Carrier Service.

216 PROTECTIVE LIMIT LINE VOLTAGE 216-_Line Voltage Imbal- Check phase-to-phase and phase-to-ground

IMBALANCE ance. Check VFD Fault His- distribution bus voltage. Increase Line Voltage

tory for Values. % Imbalance in VFD CONF screen.

217 PROTECTIVE LIMIT MOTOR OVERLOAD TRIP 217-+Motor Overload Trip; Any phase current > 106% RLA. Can result from

Check VFD configurations, 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 218_VFD Rectifier Temp Check that VFD refrigerant isolation valves are

OVERTEMP Exceeded: Check Cooling and open.

VFD Cenfig. Check VFD refrigerant cooling solenoid and

refrigerant strainer.

Check for proper VFD cooling fan operation and

blockage.

219 PROTECTIVE LIMIT VFD INVERTER 219-_VFD Inverter Temp Check that VFD refrigerant isolation valves are

OVERTEMP Exceeded: Check Cooling and open.

VFD Cenfig. Check VFD refrigerant cooling solenoid and

refrigerant strainer.

Check for proper VFD cooling fan operation and

blockage.

*[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.

Table 16 -- Alarm and Alert Messaged (cont)

I. CHILLER PROTECTIVE LIMIT FAULTS(cont)

ICVC FAULT PRIMARY SECONDARY PRIMARY CAUSE ADDITIONAL CAUSE/REMEDY

STATE MESSAGE MESSAGE

220 PROTECTIVE LIMIT GROUND FAULT 220-_Ground Fault Trip; Check for condensation on motor terminals.

Check Motor and Current Check motor power leads for phase to phase or

Sensors. phase to ground shorts. Disconnect motor from

VFD and megger motor.

Call Carrier Service.

221 PROTECTIVE LIMIT UNUSED 221_UNUSED

222 PROTECTIVE LIMIT LINE FREQUENCY TRIP 222-_Line Frequency -- If operating from a generator, check generator

[VALUE] exceeded limit of size and speed.

[LIMIT]; Check Power Supply.

223 LOSS OF WITH VFD GATEWAY 223_Loss of SIO Comm with Check VFD communication wiring and

COMMUNICATION MODULE VFD Gateway: Check VFG connectors on VFD Gateway and DPI board.

Module and Power. Check for compatibility between ICVC and

Gateway software.

224 PROTECTIVE LIMIT VFD COMMUNICATIONS 224_Loss of DPI Comm with Check VFD communication wiring and

FAULT VFD Gateway: Check VFG to connectors.

VFD Comm. Check status lights on DPI Communications

Interface Board.

Call Carrier Service.

225 PROTECTIVE LIMIT MOTOR CURRENT 225_Motor Current Imbal- Check Motor Current % Imbalance in

IMBALANCE ance: Check VFD Fault VFD CONF screen.

History for Values.

226 PROTECTIVE LIMIT LINE PHASE REVERSAL 226-_Line Phase Reversal:

Check Line Phases.

227 PROTECTIVE LIMIT OIL PRESS SENSOR 227_Oil Pressure Delta P

FAULT [VALUE] (Pump Off): Check

Pump/Transducers.

228 PROTECTIVE LIMIT LOW OIL PRESSURE

229

230

231

232

PROTECTIVE LIMIT

LOW CHILLED WATER

FLOW

LOW CONDENSER

WATER FLOW

HIGH DISCHARGE TEMP

LOW REFRIGERANT

TEMP

228-_Low Operating Oil

Pressure [VALUE]: Check Oil

Pump and Filter.

229_Low Chilled Water Flow;

Check Switch/Delta P Config

& Calibration.

230-_Low Condenser Water

Flow; Check Switch/Delta P

Config & Calibration.

231_Comp Discharge Temp

[VALUE] Exceeded Limit of

[LIMIT]*.

232_Evaporator Refrig Temp

[VALUE] exceeded limit of

[LIMIT]*.

Reverse connections of any two line conductors

to circuit breaker.

Check transducer wiring and accuracy.

Check power supply to pump.

Check pump operation.

Check transducer calibration.

Check transducer wiring and accuracy.

Check power supply to pump.

Check pump operation.

Check oil level.

Check for partially closed service valves.

Check oil filters.

Check for foaming oil at start-up.

Check transducer calibration.

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 isola-

tion 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.

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 inade-

quate 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.

*[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.

Table 16 -- Alarm and Alert Messages (cent)

I. CHILLER PROTECTIVE LIMIT FAULTS(cent)

ICVC FAULT PRIMARY SECONDARY PRIMARY CAUSE ADDITIONAL CAUSE/REMEDY

STATE MESSAGE MESSAGE

233 PROTECTIVE LIMIT HIGH MOTOR 233->Comp Motor Winding

TEMPERATURE Temp [VALUE] exceeded limit

of [LIMIT]*.

234 PROTECTIVE LIMIT HIGH BEARING

TEMPERATURE

235

236

PROTECTIVE LIMIT

HIGH CONDENSER

PRESSURE

COMPRESS SURGE/LOW

SPEED

234_Comp Thrust Brg Temp

[VALUE] exceeded limit of

[LIMIT]*.

235_Condenser Pressure

[VALUE] exceeded limit of

[LIMIT]*.

236_Compressor Surge:

Check condenser water temp

and flow.

237 PROTECTIVE LIMIT SPARE SAFETY DEVICE 237_Spare Safety Device.

238 PROTECTIVE LIMIT EXCESSIVE COMPR

SURGE

239 TRANSDUCER

VOLTAGE FAULT

LOW DISCHARGE

SUPERHEAT

PROTECTIVE LIMIT

PROTECTIVE LIMIT24O

241 PROTECTIVE LIMIT RECTIFIER

OVERCURRENT

242 LOSS OF WITH CCM MODULE

COMMUNICATION

243 POTENTIAL EVAP PRESS/1-EMP TOO

FREEZE-UP LOW

244 POTENTIAL

FREEZE-UP COND PRESS/TEMP TOO

LOW

238->Compressor Surge:

Check condenser water temp

and flow.

239-->Transducer Voltage Ref

[VALUE] exceeded limit of

[LIMIT]*.

240_Check for Oil in Or

Overcharge of Refrigerant.

241 ->Rectifier Overcurrent

Fault: Check VFD Status.

242-_Loss of Communication

With CCM, Check Comm.

Connectors.

243->Evaporator Refrig Temp

[VALUE] exceeded limit of

[LIMIT]*.

244->Condenser Refrig Temp

[VALUE] exceeded limit of

[LIMIT]*.

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.

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.

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.

Spare safety input has tripped or factory

installed jumper is not present on Terminal

Block 1 (TB1).

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 perfor-

mance to design/selection temperatures across

the entire operating range of the chiller.

Check cooler approach and water flow.

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.

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.

Check for high water temperatures or changes

in water flow rates.

Check wiring and control power to CCM.

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.

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.

*[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.

Table 16 -- Alarm and Alert Messages (cont)

I. CHILLER PROTECTIVE LIMIT FAULTS(cont)

ICVC FAULT PRIMARY SECONDARY PRIMARY CAUSE

STATE MESSAGE MESSAGE

245 PROTECTIVE LIMIT HIGH VFD SPEED

246 PROTECTIVE LIMIT INVALID DIFFUSE

CONFIG.

247 PROTECTIVE LIMIT DIFFUSER POSITION

FAULT

248 PROTECTIVE LIMIT SPARE TEMPERATURE

249 PROTECTIVE LIMIT SPARE TEMPERATURE

250 UNUSED UNUSED

251 PROTECTIVE LIMIT VFD CONFIG CONFLICT

245--_Actual VFD Speed

exceeded limit of Target VFD

Speed + 10%.

246_Diffuser Control Invalid

Configuration: Check SETUP2

Entries.

247-+Diffuser Position Fault:

Check Guide Vane/Diffuser

Actuator.

248-_Spare Temperature #1

[VALUE] exceeded limit of

[LIMIT]*.

249_Spare Temperature #2

[VALUE] exceeded limit of

[LIMIT]*.

250-_Unused State.

251_VFD Config Conflict

(VFD Uploaded): Verify to

Reset Alarm.

252 PROTECTIVE LIMIT VFD CONFIG CONFLICT 252-+VFD Config Conflict

VFD Downloaded): Verify to

Reset Alarm.

253 PROTECTIVE LIMIT GUIDE VANE 253_Guide Vane Fault

CALIBRATION [VALUE]. Check Calibration.

254 PROTECTIVE LIMIT VFD CHECKSUM ERROR

255 PROTECTIVE LIMIT VFD DEW PREVENTION

INDUCTOR OVERTEMP

VFD START INHIBIT

256

257

PROTECTIVE LIMIT

254_Checksum Error:

Press Reset to Restore

Configuration.

255-_Dew Prevention - Cool-

ant Too Cold. Check Solenoid

& Cond T.

256-+Inductor Overtemp Trip -

Check Temp Switch and Cool-

ing Fans.

257_VFD Start Inhibit: Check

VFD Diagnostic Parameters

212/214.

ADDITIONAL CAUSE/REMEDY

Actual VFD Speed on COMPRESS screen must

not exceed Target VFD Speed by more than

10%.

Check 25%, 50%, and 75% Guide Vane and Dif-

fuser Load Point entries in SETUP2 screen.

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 sched-

ule 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 Pres-

sure wiring. Do not continue to operate com-

3ressor except for diagnostic purposes.

Check Spare Temperature Enable and Spare

Temperature Limit in SETUP1 Screen.

Check Spare Temperature Enable and Spare

Temperature Limit in SETUP1 Screen.

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 soft-

ware 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.

The VFD CONF table in the Gateway does not

match that which is in the ICVC.

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 feed-

back voltage is < .045 or > 3.15 VDC.

Actual VFD checksum does not match calcu-

lated 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 STATE UNUSED 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 LIMIT FAULTS (cont)

ICVC FAULT

STATE

259

282

283

284

285

286

PRIMARY

MESSAGE

PROTECTIVE LIMIT

VFD GATEWAY

PROTECTIVE LIMIT

SECONDARY

MESSAGE

CCN OVERRIDE STOP

INVALID VFD CONFIG

COMPATIBILITY

CONFLICT

COMPATIBILITY

CONFLICT

INVERTER

OVERCURRENT

PRIMARY CAUSE

259_CCN Emergency/

Override Stop.

282-+Line Frequency

[VALUE] Exceeded Configura-

tion Range.

283_Compressor 100%

Speed Config Ranges: 50=Hz

45-52; 60 Hz=55-62.

284_VFD Gateway Compati-

bility Conflict: Check VFG/

VFD Versions.

285-_VFD Gateway Compati-

bility Conflict: Check VFG/

ICVC Versions.

286_lnverter Overcurrent

Fault: Check VFD Status.

ADDITIONAL CAUSE/REMEDY

CCN has signaled the chiller to stop.This fault

must be manually reset from the default screen

of the ICVC.

LINE FREQUENCY in POWER screen must be

maintained between 45-52 Hz if LINE

FREQ=60Hz? is set to NO(50 Hz). LINE FRE-

QUENCY 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). COMPRES-

SOR 100% SPEED must be set between

55-62 Hz if LINE FREQ=60Hz? is set to YES

(60 Hz).

VFD Gateway and VFD software versions are

not compatible. Call Carrier Service.

VFD Gateway and ICVC software versions are

not compatible. Call Carrier Service.

Check for high entering water temperature or

low condenser water flow.

Check current settings in VFD CONF screen.

*[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.

J. CHILLER ALERTS

ICVC FAULT

STATE

140

141

142

143

144

145

146

147

PRIMARY

MESSAGE

SENSOR ALERT

LOW OIL

PRESSURE ALERT

AUTORESTART

PENDING

AUTORESTART

PENDING

AUTORESTART

PENDING

AUTORESTART

PENDING

AUTORESTART

PENDING

SECONDARY

MESSAGE

LEAVING COND WATER

TEMP

ENTERING COND WATER

TEMP

CHECKOILFI_ER

LINECURRENT

IMBALANCE

LINEVOLTAGE

DROPOUT

HIGH LINE VOLTAGE

LOW LINE VOLTAGE

VFD MODULE RESET

148 AUTORESTART POWER LOSS

PENDING

149 SENSOR ALERT HIGH DISCHARGE TEMP

150 SENSOR ALERT HIGH BEARING

TEMPERATURE

PRIMARY CAUSE

140-_Sensor Fault: Check

Leaving Cond Water Sensor.

141_Sensor Fault: Check

Entering Cond Water Sensor.

142_Low Oil Pressure Alert.

Check Oil Filter.

143-_Line Current Imbal-

ance: Check VFD Fault His-

tory for Values.

144-+Single Cycle Line

Voltage Dropout.

145_High Percent Line

Voltage [VALUE].

146_Low Percent Line

Voltage [VALUE].

147->VFD Module Power-On

Reset When Running.

148_Control Power-Loss

When Running.

149_Comp Discharge Temp

[VALUE] Exceeded Limit of

[LIMIT]*.

150_Comp Thrust Brg Temp

[VALUE] exceeded limit of

[LIMIT]*.

ADDITIONAL CAUSE/REMEDY

Check sensor resistance or voltage drop.

Check for proper wiring.

Check sensor resistance or voltage drop.

Check for proper wiring.

Check for partially or closed shut-off valves.

Check oil filter.

Check oil pump and power supply.

Check oil level.

Check for foaming oil at start-up.

Check transducer wiring and accuracy.

Power loss has been detected in any phase.

Chiller automatically restarting.

A drop in line voltage has been detected within

2 voltage cycles.

Chiller automatically restarting ifAuto Restart is

enabled in OPTIONS screen.

Check phase to phase and phase to ground line

)ower.

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 electro-

magnetic interference.

Check 24 vac control power supply to ICVC.

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.

Check sensor resistance or voltage drop.

Check for proper wiring.

Check for partially closed service valves.

Check oil cooler TXV.

Check oil level and oil level.

*[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.

Table 16 -- Alarm and Alert Messages (cont)

J. CHILLER ALERTS (cont)

ICVC FAULT PRIMARY SECONDARY PRIMARY CAUSE ADDITIONAL CAUSE/REMEDY

STATE MESSAGE MESSAGE

151 CONDENSER PUMP RELAY 151_High Condenser Pres- Check sensor wiring and accuracy.

PRESSURE ALERT ENERGIZED sure [VALUE]: Pump Ener- Check condenser flow and water temperature.

gized to Reduce Pressure. Check for fouled tubes.

This alarm is not caused by the High Pressure

Switch.

152 RECYCLE ALERT EXCESSIVE RECYCLE 152_Excessive recycle Chiller load is too low to keep compressor on

STARTS starts, 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: no message; ALERT only 153_Lead/Lag Disabled- Illegal chiller address configuration in Lead/Lag

ALERT Config: Duplicate Chiller screen. Both chillers require a different address.

only Address.

154 POTENTIAL COND PRESS/TEMP 154_Condenser freeze up The condenser pressure transducer is reading a

FREEZE=UP TOO LOW )revention. 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 REMOTE RESET 155-_Sensor Fault/Option Check sensor resistance or voltage drop.

FAULT SENSOR Disabled: Remote Reset Check for proper wiring to CCM connector J4.

Sensor.

156 OPTION SENSOR AUTO CHILLED WATER 156_-_Sensor Fault/Option Check sensor resistance or voltage drop.

FAULT RESET Disabled: Auto Chilled Water Check for proper wiring to CCM connector J5.

Reset.

157 OPTION SENSOR AUTO DEMAND LIMIT 157-_Sensor Fault/Option Check sensor resistance or voltage drop.

FAULT INPUT Disabled: Auto Demand Limit Check for proper wiring to CCM connector J5.

Input.

158 SENSOR ALERT SPARE TEMPERATURE 158_-_Spare Temperature 1

#1 [VALUE] exceeded limit of

[LIMIT]*.

159 SENSOR ALERT SPARE TEMPERATURE 159_Spare Temperature 2

#2 [VALUE] exceeded limit of

[LIMIT]*.

161 LOSS OF WITH WSM 161_-_WSM Cool Source --

COMMUNICATION Loss of Communication.

162 SENSOR ALERT EVAPORATOR

APPROACH 162-_ Evaporator Approach

[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.

Check sensor resistance or voltage drop.

Check for proper wiring to CCM connector J4.

Check Spare Temp #2 Limit in SETUP1 screen.

Check settings in WSMDEFME screen.

Check CCN communications link with WSM

(Water System Manager) Module.

Check Supervisory Part of WSM.

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.

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.

Actual VFD Speed on COMPRESS screen must

be at least 90% of Target VFD Speed.

163 SENSOR ALERT CONDENSER APPROACH 163-_Condenser Approach

[VALUE] Exceeded Limit of

[LIMIT]*.

164 VFD SPEED ALERT LOW VFD SPEED 164_Actual VFD Speed

exceeded limit of Target VFD

Speed -10%.

165 AUTORESTART LOW DC BUS VOLTAGE 165_Low DC Bus Voltage: Verify phase to phase and phase to ground line

PENDING [VALUE] Exceeded Limit of voltage.

[LIMIT]*.

166 AUTORESTART HIGH DC BUS VOLTAGE 166_High DC Bus Voltage: Verify phase to phase and phase to ground line

PENDING [VALUE] Exceeded Limit of voltage. Monitor AC line for high transient volt-

[LIMIT]*. age conditions.

167 SYSTEM ALERT HIGH DISCHARGE TEMP 167_Comp Discharge Temp Check sensor resistance or voltage drop.

[VALUE] exceeded limit of Check for proper wiring.

[LIMIT]*. Check for excessive starts.

Check Comp Discharge Alert setting in SETUP1

screen.

168 SENSOR ALERT HUMIDITY SENSOR 168-_Sensor Fault: Check Check humidity sensor wiring on CCM connec-

INPUT Humidity Sensor Input Sensor. tots J3 and J5.

Check Humidity Sensor Input in Controls Test.

*[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 17 -- Fault Code Descriptions and Corrective Actions

Fault Type indicates if the fault is:

1 -- Auto-resettable

2 -- Nomresettable

3- User-configurable

4 -- Normal Fault

VFD FAULT FAULT TYPE DESCRIPTION ACTION ICVC FAULT

CODE STATE

2 Auxiliary Input 1 Input is open. Check remote wiring.

3Power Loss 1, 3 DC bus voltage remained below 85% of Monitor the incoming AC line for low voltage or 215

nominal for longer than Power Loss Time line power interruption.

(185).

Enable/disable with Fault Config 1 (238).

4 UnderVoltage 1,3 DC bus voltage fell below the minimum Monitor the incoming AC line for low voltage or 215

value of 407V DC at 400/480V input )ower interruption.

Enable/disable with Fault Config 1(233).

5 OverVoltage 1 DC bus voltage exceeded maximum value. Monitor the AC line for high line voltage or 205

transient conditions. Bus overvoltage can also

be caused by motor regeneration. Extend the

decel time or install dynamic brake option.

6 Current reg saturated 206

for > timeout

7 Motor Overload 1, 3 Internal electronic overload trip. An excessive motor load exists. Reduce load 217

so drive output current does not exceed the

current set by Motor NP FLA (42).

Enable/disable with Fault Config 1 (238).

8 Invtr Base Temp 1 Base temperature exceeded limit. Check for proper temperature and flow rate of 219

coolant.

9 Invtr IGBT Temp 1 Output transistors have exceeded their Check for proper temperature and flow rate of 219

maximum operating temperature, coolant.

12 HW OverCurrent 1 The drive output current has exceeded the Check programming. Check for excess load, 286

hardware current limit, improper DC boost setting, DC brake volts set

too high or other causes of excess

cu rrent.

13 Ground Fault 1 A current path to earth ground in excess of Check the motor and external wiring to the 220

7% of drive rated amps has been detected drive output terminals for a grounded

at one or more of the drive output termF condition.

nals.

24 Decel Inhibit 3 The drive is not following a commanded 1. Verify input voltage is within drive specified 204

deceleration because it is attempting to limits.

limit bus voltage. 2. Verify system ground impedance follows

proper grounding techniques.

3. Disable bus regulation and/or add dynamic

brake resistor and/or extend deceleration

time.

25 OverSpeed Limit 1 Functions such as slip compensation or Remove excessive load or overhauling condF 206

bus regulation have attempted to add an tions or increase Overspeed Limit (83).

output frequency adjustment greater than

that programmed in Overspeed Limit (83).

29 Analog In Loss 1,3 An analog input is configured to fault on 1. Check parameters. 206

signal loss. A signal loss has occurred. 2. Check for broken/loose connections at

Configure with Anlg In 1,2 Loss (324, 327). inputs.

33 Auto Rstrt Tries 3 Drive unsuccessfully attempted to reset a Correct the cause of the fault and manually 206

fault and resume running for the pro- clear.

grammed number of Auto Rstrt Tries (174).

Enable/disable with Fault Config 1 (238).

35 Current FBK Lost 4 The magnitude of motor current feedback Verify connection of current feedback device 206

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 Imbal-

ance Time is set to the maximum value of

10.0 seconds.

36 SW OverCurrent 1 The drive output current has exceeded the Check for excess load, improper DC boost set- 286

software current, ting. DC brake volts set too high.

37 Motor I Imbalance Phase current displayed in Imbalance Dis- Clear fault. 225

play (221) > percentage set in Imbalance

Limit (49) for time set in Imbalance Time

(50).

LEGEND

DPI/I/O -- Drive Peripheral Interface Inputs/Outputs

EPROM -- Erasable, Programmable, Read-Only

FLA -- Full Load Amps

IGBT -- Insulated Gate Bipolar Transistor

NP -- 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

71- 75

81- 85

100

101

102

103

104

105

FAULT TYPE

Phase U to Grnd

Phase V to Grnd

Phase W to Grnd

Phase UV Short

Phase VW Short

Phase UW Short

Params Defaulted

Shear Pin 3

Drive OverLoad

DB Resistor Out of

Range

Port 1-5 Net Loss

Peripheral Fault at

DPI Port 6

IR Volts Range

FluxAmpsRef Rang

Excessive Load

AutoTune Aborted

Port 1-6 DPI Loss

DPI Port 6 Communi-

cation Loss

Autotune: Ixo too

large 4

Parameter Chksum 2

UserSetl Chksum 2

UserSet2 Chksum 2

UserSet3 Chksum 2

Pwr Brd Chksuml

DESCRIPTION

A phase-to-ground fault has been detected

between the drive and motor in this phase.

Excessive current has been detected

between these two output terminals•

The drive was commanded to write default

values to EPROM.

Programmed Current Lint Val (148) has

been exceeded.

Enabled/disable with Fault Config 1 (238)•

Drive rating of 110% for 1 minute or 150%

for 3 seconds has been exceeded•

The network card connected to DPI port

stopped communicating.

The fault code indicates the offending port

number (71 = port 1, 72 = port 2, etc.).

The drive autotuning default is Calculate,

and the value calculated for IR Drop Volts

is not in the range of acceptable values.

The value for flux amps determined by the

autotune procedure exceeds the pro-

grammed Motor NP FLA (42).

Motor did not come up to speed in the allot-

ted time.

The autotune procedure was canceled by

the user.

DPI port stopped communicating•

An attached peripheral with control capa-

bilities via Logic Source Sel (89) (or OIM

control) was removed.

The fault code indicates the offending port

number (81 = port 1, etc.).

Ixo voltage calculated from motor name-

)late data is too high.

The checksum read from the board does

not match the checksum calculated•

The checksum read from the user set does

not match the checksum calculated•

ACTION

• Check the wiring between the drive and

motor.

2. Check motor for grounded phase.

3. Replace drive•

• Check the motor and drive output terminal

wiring for a shorted condition•

2. Replace drive•

• Clear the fault or cycle power to the drive•

2. Program the drive parameters as needed.

Check load requirements and Current Lmt Val

(148) setting.

Reduce load or extend Accel Time (140)•

• Check communication board for proper

connection to external network.

2. Check external wiring to module on port.

Re-enter motor nameplate data.

• Reprogram Motor NP FLA (42) with the cor-

rect motor nameplate value.

2. Repeat Autotune (61).

• Uncouple load from motor.

2. Repeat Autotune (61).

Restart procedure.

• If module was not intentionally discon-

nected, check wiring to the port. Replace

wiring, port expander, modules, Main Con-

trol board or complete drive as required•

2. Check OIM connection•

Re-enter motor nameplate data.

• Restore defaults.

2. Reload user set if used.

Re-save user set.

Clear the fault or cycle power to the drive•

Pwr Brd Chksum2

The checksum read from the EPROM does

not match the checksum calculated from

the EPROM data.

The checksum read from the board does

not match the checksum calculated• • Cycle power to the drive•

2. If problem persists, replace drive•

ICVC FAULT

STATE

22O

246

206

286

206

LEGEND

DPI/I/O -- Drive Peripheral Interface Inputs/Outputs

EPROM -- Erasable, Programmable, Read-Only

FLA -- Full Load Amps

IGBT -- Insulated Gate Bipolar Transistor

NP -- Nameplate

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 FAULT TYPE DESCRIPTION ACTION ICVC FAULT

CODE STATE

106 Incompat MCB-PB 2 Drive rating information stored on the Load compatible version files into drive. 206

3ower board is incompatible with the Main

Control board.

Replaced MCB-PB k Main Control board was replaced and 1. Restore defaults, 206

3arameters were not programmed, 2. Reprogram parameters.

I/O Board Check 206

Sum Non-Resettable

I/O Board Failure 206

Non-Resettable

I/O Board Comm Loss of communication to I/O board, Cycle power. 206

Loss k

I/O Board Fail Board failure. 206

High current was detected in an IGBT. 201

107

109

110

121

122

2O0

201

202

203

204

205

206

207

208

209

210

211

212

213

214

Inverter Dsat

u,v,w

Inverter

OverCurrent

u,v,w

Invtr Gate Kill

Rectifier Dsat

u,v,w

High current was detected in an IGBT.

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.

1, Verify proper motor data is entered.

2. Reduce current limit. 286

Inverter Unused Bit 4 Inverter section of power structure hard- Check wiring harness. 206

ware reported unexpected fault.

Inverter gate kill contact is open. 207, 235

High current was detected in an IGBT. 200

Rectifier IOC

u,v,w

Close gate kill contact.

1. Check for loose connection in IGBT wire

harness,

2, Check IGBTs.

1, Verify proper motor data is entered.

2, Reduce current limit.

Rectifier overcurrent. 241

Reactor Temp Temperature switch in reactor opened, Check for proper temperature and fan 206

operation.

215 Rectifier Unused Bit Rectifier section of power structure hare- Check wiring harness. 206

4 ware reported unexpected fault.

216 Rectifier Ground Excessive ground current measured. Check for grounded input wiring. 220

Fault

217 Rectifier Base Temp Excessive rectifier temperatured Check for proper temperature and flow rate of 218

measured, coolant.

218 Rectifier IGBT Temp Excessive calculated IGBT temperature. Check for proper temperature and flow rate of 218

coolant.

219 Rectifier IT Short-term current rating of rectifier Low input voltage can result in increased cur- 212

Overload exceeded, rent load. Provide proper input voltage to the

drive.

220 Rectifier 12T Long-term current rating of rectifier Low input voltage can result in increased cur- 212

Overload exceeded, rent load. Provide proper input voltage to the

drive.

221 Ride Thru Abort Input power loss timed out. 1. Verify input power and connections. 210

2, Check Line Sync board.

3. Check AC Line I/O board.

222 High AC Line Input line voltage is too high. Reduce input voltage to meet specification of 211

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 for high line voltage or 205

transient conditions, Bus overvoltage can also

be caused by motor regeneration. Extend the

decel time or install dynamic brake option.

LEGEND

DP1/1/O -- Drive Peripheral Interface Inputs/Outputs

EPROM -- Erasable, Programmable, Read-Only

FLA -- Full Load Amps

IGBT -- Insulated Gate Bipolar Transistor

NP -- Nameplate

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 FAULT TYPE DESCRIPTION ACTION ICVC FAULT

CODE STATE

225 Input Amp Input phase current imbalance exceeded Check for loose connection in input power 209

Imbalance limits, wiring.

226 Input Volt Input voltage imbalance exceeded limits. Check for problem in input power 216

Imbalance distribution.

227 AC Line Lost Input power Lost. .Verify proper input voltage. 210

2. Check line sync board and fuse.

3. Check AC line I/O board.

4. Verify connection between boards.

228 Line Frequency Line frequency not in the range of Verify connection between AC Line Sync and 222

47-63 Hz. AC Line I/O boards.

229 Rectifier The checksum read from the board does .Restore defaults. 206

Checksum not match the checksum calculated. 2. Reload user set if used.

230 Inverter HW Inverter section of power structure hare- Check wiring harness. 206

Detected a Fault Bit ware reported unexpected fault.

Non Was Found 4

231 Recyifier HW Rectifier portion of pwoer structure hare- Check wiring harness. 206

Detected a Fault Bit ware reported unexpected fault.

Non Was Found 4

232 Rctfr Not OK A fault was detected in the rectifier other Look at rectifier parameter 243 to see fault 200

than one specifically decoded, code.

233 Precharge closed Precharge was closed when it should be .Check AUX contacts on precharge. 206

open. 2. Check input bit 0 in rectifier parameter 216

to view status of input.

3. Check wiring.

4. Check precharge resistors and fuses.

234 Precharge open Precharge was open when it should be .Check AUX contacts on precharge. 206

closed. 2. Check input bit 0 in rectifier parameter 216

to view status of input.

3. Check wiring.

4. Check precharge resistors and fuses.

235 Rctfr Pwr Board Drive rating information stored on the Load compatible version files into drive. 206

)ower board is incompatible with the Main .Cycle power to the drive.

Control board. 2. If problem persists, replace drive.

The checksum read from the board does

not match the checksum calculated.

236 Rctfr I/O Board Loss of communication to I/O board. Cycle power. 206

Board failure. .Cycle power.

2. If fault repeats, replace I/O board.

237 Rectifier Start Timed The rectifier did not regulate to the desired Replace rectifier power board and/or rectifier 206

Out 4 bus voltage within the defined time. control board.

238 Rectified Not Logged Rectifier took too long to connect to .Check the cabling between the communica- 206

In 4 inverter, tions 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.

239 Rectifier Power Input power is phased ACB rather than Switch two of the input power phases. 206

Phased ACB 4 ABC.

LEGEND

DPI/I/O -- Drive Peripheral Interface Inputs/Outputs

EPROM -- Erasable, Programmable, Read-Only

FLA -- Full Load Amps

IGBT -- Insulated Gate Bipolar Transistor

NP -- Nameplate

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

Table 18A -- Thermistor Temperature (F) vs. Resistance/Voltage Drop

PIC III

VOLTAGE

DROP (V)

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

RESISTANCE RESISTANCE

(Ohms) (Ohms)

TEMPERATURE

(F)

98,010 60

94,707 61

91,522 62

88,449 63

85,486 64

82,627 65

79,871 66

77,212 67

74,648 68

72,175 69

69,790 70

67,490 71

65,272 72

63,133 73

61,070 74

59,081 75

57,162 76

55,311 77

53,526 78

51,804 79

50,143 80

48,541 81

46,996 82

45,505 83

44,066 84

42,679 85

41,339 86

40,047 87

38,800 88

37,596 89

36,435 90

35,313 91

34,231 92

33,185 93

32,176 94

31,202 95

30,260 96

29,351 97

28,473 98

27,624 99

26,804 100

26,011 101

25,245 102

24,505 103

23,789 104

23,096 105

22,427 106

21,779 107

21,153 108

20,547 109

19,960 110

19,393 111

18,843 112

18,311 113

17,796 114

17,297 115

16,814 116

16,346 117

15,892 118

15,453 119

15,027 120

14,614 121

14,214 122

13,826 123

13,449 124

13,084 125

12,730 126

12,387 127

12,053 128

11,730 129

11,416 130

11,112 131

10,816 132

10,529 133

10,250 134

9,979 135

9,717 136

9,461 137

9,213 138

8,973 139

8,739 140

8,511 141

8,291 142

8,076 143

7,868 144

PIC III

VOLTAGE

DROP (V)

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

TEMPERATURE

(F)

7,665 145

7,468 146

7,277 147

7,091 148

6,911 149

6,735 150

6,564 151

6,399 152

6,238 153

6,081 154

5,929 155

5,781 156

5,637 157

5,497 158

5,361 159

5,229 160

5,101 161

4,976 162

4,855 163

4,737 164

4,622 165

4,511 166

4,403 167

4,298 168

4,196 169

4,096 170

4,000 171

3,906 172

3,814 173

3,726 174

3,640 175

3,556 176

3,474 177

3,395 178

3,318 179

3,243 180

3,170 181

3,099 182

3,031 183

2,964 184

2,898 185

2,835 186

2,773 187

2,713 188

2,655 189

2,597 190

2,542 191

2,488 192

2,436 193

2,385 194

2,335 195

2,286 196

2,239 197

2,192 198

2,147 199

2,103 200

2,060 201

2,018 202

1,977 203

1,937 204

1,898 205

1,860 206

1,822 207

1,786 208

1,750 209

1,715 210

1,680 211

1,647 212

1,614 213

1,582 214

1,550 215

1,519 216

1,489 217

1,459 218

1,430 219

1,401 220

1,373 221

1,345 222

1,318 223

1,291 224

1,265 225

1,240

1,214

1,190

1,165

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

9.5

Table 18B -- Thermistor Temperature (C) vs. Resistance/Voltage Drop

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

-4

--3

-2

-1

PIC III RESISTANCE

VOLTAGE DROP (V) (Ohms)

4.722 106 880

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

TEMPERATURE

(c)

100 260 39

94 165 40

88 480 41

83170 42

78125 43

73 580 44

69 250 45

65 205 46

61 420 47

57 875 48

54 555 49

51 450 50

48 536 51

45 807 52

43 247 53

40 845 54

38 592 55

38 476 56

34 489 57

32 621 58

30 866 59

29 216 60

27 633 61

26 202 62

24 827 63

23 532 64

22 313 65

21 163 66

20 079 67

19 058 68

18 094 69

17 184 70

16 325 71

15 515 72

14 749 73

14 026 74

13 342 75

12 696 76

12 085 77

11 506 78

10 959 79

10 441 80

9 949 81

9 485 82

9 044 83

8 627 84

8 231 85

7 855 86

7 499 87

7 161 88

6 840 89

6 536 90

6 246 91

5 971 92

5 710 93

5 461 94

5 225 95

5 000 96

4 786 97

4 583 98

4 389 99

4 204 100

4 028 101

3 861 102

3 701 103

3 549 104

3 404 105

3 266 106

3 134 107

3 008

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

Turn controller power off before servicing controls. This

ensures safety and prevents &image to the controllec

The ICVC and CCM modules perform continuous diagnos-

tic 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.

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

If there is no input powel, check the luses and circuit breaker

If the fuse is good, check for a shorted secondary of the trans-

former 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 con-

troller and the network modules and should blink continuously.

Notes on Module Operation

1. The chiller operator monitors and modifies configura-

tions in the microprocessor by using the 4 softkeys and

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.

2. If a green LED is on continuously, check the communica-

tion 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.

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.

3. Power is supplied to the modules within the control panel

via the 24-vac TI and T2 transformers. The transformers

_u'elocated 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 DataPort TM or

DataLINK TM modules.

Power is connected to Plug Jl on each module.

Chiller Control 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.

OUTPUTS- Output is 24 vac. There are 2 termimds per

output. Refer to the chiller wiring diagram for a specific

application for the correct terminal numbel_.

CONTRAST

ADJUSTMENT

MODULE PART NUMBER

SOFTWARE PART NUMBER

BACK OFICVC

o o @ o \

ICVC [

/ / \

J7 SIO J1 POWER/ J8 SERVICE

CCN

CCN INTERFACE

CONNECTION /

We •/•

DATALINK OR

DATAPORT MODULE (OPTION)

[]

CB1

SWl

Fig 44 -- Rear of ICVC (International Chiller Visual Controller)

ANA' OUT

SIO

J6 "------.-

SW2

V/I INPUTS

24 VAC

° ©

Fig. 45 -- Chiller Control Module (CCM)

Replacing Defective Processor Modules i

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 all

electrical power before servicing.

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. 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, config-

urations 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.

If a CCN Building Supervisor or Service Tool is avail-

able, 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.

Power off the controls.

Remove the old ICVC.

Install the new ICVC module. Turn the control power

back on.

The [CVC now automatically attaches to the local

network device.

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. Performtheguidevanecalibrationprocedure(inControl

Test).Checkandrecalibratepressuretransducerleadings

(refertopage64).CheckthattheCURRENT TIME and

DATE in the TIMEAND 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 Status LEDs- The RS485 VFD Gateway

provides a communication link between the CCM and ICVC

SIO bus to the VFD Drive Peripheral Interface (DPI) board.

The SIO bus communicates with the Gateway through VFD

connector A32. See Fig. 47.

The Gateway has four status indicators on the top side of the

module.

DRIVE STATUS INDICATOR -- The DRIVE status indica-

tor is on the right side of the Gateway. See Table 19.

DPI RIBBON

CABLE CONNECTOR

A32

TERMINAL BLOCK

STATUS DESCRIPTION

NUMBER INDICATOR

1DRIVE DPI Connection Status

2 MS Module Status

3NET A Serial Communication Status

4 NET B Serial Communication Traffic Status

NOTE: If all status indicators are off, the Gateway is not receiving

power.

Fig. 47 -- Gateway Status LEDs

IJ uO

0 = T=0 Ill =

,7.11 ° °-°

RECTIFIER LED INTVERTER LED

COLOR

Gteen

Yellow

Red

Red Inverter

Green Rectifier

STATE

Flashing

Steady

Flashing

Steady

Flashing

Steady

DESCRIPTION

Drive ready, but not running and no faults are present

Drive running, no faults are present.

The drive is not ready. A VFD start inhibit is in effect.

An alarm condition exits. Check VFD Fault Code in ICVC VFD STAT screen.

A fault has occurred. Check VFD Fault Code in ICVC VFD STAT screen.

A non-resettable fault has occurred. Check VFD Fault Code in ICVC VFD STAT screen.

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- DPI Communications Interface Board Status LEDs

Table 19 -- DRIVE Status Indicator

STATE

Off

Flashing

Red

Solid

Red

Orange

Flashing

Green

CAUSE

The Gateway is not

powered or is not con-

nected properly to the

drive.

The Gateway is not

receiving a ping mes-

sage from the drive.

The drive has refused

an I/O connection from

the Gateway.

The Gateway is con-

nected to a product that

does not support Rock-

well Automation DPI

communications.

The Gateway is estab-

lishing an I/O connec-

tion to the drive or the

I/O has been disabled.

The Gateway is prop-

erly connected and is

communicating with the

drive.

CORRECTIVE ACTION

• Securely connect the

Gateway to the drive using

the DPI ribbon cable.

• Apply power to the drive.

• 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 dam-

aged. Replace cables if

necessary.

• Check wires leading to the

A32 terminal block.

• Check that A32 terminal

block is fully engaged.

Normal behavior.

Solid No action required.

Green

MS STATUS INDICATOR -- The MS status indicator is the

second LED from the fight of the Gateway. See Table 20.

Table 20 -- MS Status Indicator: State Definitions

STATE CAUSE

Off The Gateway is not

)owered.

Flashing

Green

Solid

Red

The Gateway is opera-

tional. No I/O data is

being transferred.

The Gateway is opera-

tional and transferring

I/O data.

CORRECTIVE ACTION

• Securely connect the

Gateway to the drive using

the ribbon cable.

• Apply power to the drive.

Normal behavior during SIC

configuration initialization

3rocess.

No action required.

NET A STATUS INDICATOR -- The NET A status indica-

tor is tile third LED from the right of the Gateway. See

Table 21.

Table 21 -- NET A Status Indicator:

State Definitions

STATE CAUSE CORRECTIVE ACTION

Off The module is not pow- • Securely connect the

ered or is not properly Gateway ribbon cable to

connected to the the drive DPI board.

network. • Attach the RS485 cable in

First incoming network Gateway to the connector.

command not yet rec- • Apply power to the drive.

ognized.

Flashing Online to network, but No action required. The LED

Green not producing or con- will turn solid green when

suming I/O information, communication resumes.

Solid The module is properly No action required.

Green connected and commu-

nicating on the network.

NET BSTATUS INDICATOR -- Tile NETB status indicator

is the left LED on file Gateway. See Table 22.

Table 22 -- NET B Status Indicator:

State Definitions

STATE CAUSE CORRECTIVE ACTION

Off Gateway not receiving • Check wires leading to

data over the network. A32 terminal block.

• Check that A32 terminal

block is fully engaged.

Solid Gateway is transmit- No action required.

Green ting data.

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 sche-

matics for the operator's convenience during troubleshooting.

Do not attempt to disconnect flanges while the machine is

under pressure. Failure to relieve pressure can result in per-

somd injury or damage to the unit.

Before rigging the compressor, disconnect all wires enter-

ing the power panel.

100

Table 23A -- Heat Exchanger Data (English)

SIZE

NUMBER OF TUBES Dry (Rigging) Weight (Ib)

Cooler Condenser Cooler Only Condenser Only Cooler Condenser Cooler

10 142 180 2,707 2,704 290 200 34 42

11 161 200 2,777 2,772 310 200 37 45

12 180 225 2,848 2,857 330 200 40 49

15 142 180 2,968 2,984 320 250 39 48

16 161 200 3,054 3,068 340 250 43 52

17 180 225 3,141 3,173 370 250 47 57

20 200 218 3,407 3,373 345 225 48 48

21 240 266 3,555 3,540 385 225 55 55

22 282 315 3,711 3,704 435 225 62 63

30 200 218 4,071 3,694 350 260 56 56

31 240 267 4,253 3,899 420 260 64 65

32 280 315 4,445 4,100 490 260 72 74

35 200 218 4,343 4,606 400 310 61 62

36 240 267 4,551 4,840 480 310 70 72

37 280 315 4,769 5,069 550 310 80 83

40 324 370 4,908 8,039 560 280 104 110

41 364 417 5,078 5,232 630 280 112 119

42 400 463 5,226 5,424 690 280 119 129

45 324 370 5,363 5,602 640 330 112 120

46 364 417 5,559 5,824 720 330 122 130

47 400 463 5,730 6,044 790 330 130 141

50 431 509 8,713 6,090 750 400 132 147

51 485 556 5,940 6,283 840 400 143 156

52 519 602 6,083 6,464 900 400 150 165

5A 225 -- 5,124 -- 500 -- 123 --

5B 241 -- 5,177 -- 520 -- 126 --

50 258 -- 5,243 -- 550 -- 129 --

55 431 509 6,257 6,785 870 490 144 161

56 485 556 6,517 7,007 940 490 156 171

57 519 602 6,682 7,215 980 490 164 182

5F 225 -- 5,577 -- 550 -- 133 --

5G 241 -- 5,640 -- 570 -- 137 --

5H 258 -- 5,716 -- 600 -- 141 --

60 557 648 6,719 6,764 940 420 168 182

61 599 695 6,895 6,949 980 420 176 191

62 633 741 7,038 7,130 1020 420 183 200

65 557 648 7,392 7,682 1020 510 183 200

66 599 695 7,594 7,894 1060 510 193 210

67 633 741 7,759 8,102 1090 510 201 220

70 644 781 9,942 10,782 1220 780 241 267

71 726 870 10,330 11,211 1340 780 259 286

72 790 956 10,632 11,612 1440 780 274 305

ENGLISH

Chiller Charge

Refrigerant Weight (Ib) Water Volume (gal)

Condenser

NOTES: 2. Condenser data: based on a condenser with standard wall tub-

1. Cooler data: based on a coolerwith standard wall tubing, 2-pass, ing, 2-pass, 150 psig, nozzle-in-head waterbox with victaulic

150 psig, nozzle-in-head waterbox with victaulic grooves. Weight grooves. Weight includes the float valve, discharge elbow, and

includes suction elbow, control panel, and distribution piping, distribution piping. Weight does not include unit-mounted starter,

Weight does not include compressor, isolation valves, and pumpout unit.

101

Table 23B -- Heat Exchanger Data (Sl)

SIZE

NUMBER OF TUBES Sl

Dry (Rigging) Weight (kg)

Cooler Condenser Cooler Only Condenser Only

10 142 180 1228 1227

11 161 200 1260 1257

12 180 225 1292 1296

15 142 180 1346 1354

16 161 200 1385 1392

17 180 225 1425 1439

20 200 218 1545 1530

21 240 266 1613 1606

22 282 315 1683 1680

30 200 218 1847 1676

31 240 266 1929 1769

32 282 315 2016 1860

35 200 218 1970 2089

36 240 266 2064 2195

37 282 315 2163 2299

40 324 366 2226 2286

41 364 415 2303 2373

42 400 464 2370 2460

45 324 366 2433 2541

46 364 415 2522 2642

47 400 464 2599 2742

50 431 507 2591 2762

51 485 556 2694 2850

52 519 602 2759 2932

5A 225 -- 2324 --

5B 241 -- 2348 --

50 258 -- 2378 --

55 431 507 2838 3078

56 485 556 2956 3178

57 519 602 3031 3273

5F 225 -- 2530 --

5G 241 -- 2558 --

5H 258 -- 2593 --

60 557 648 3048 3068

61 599 695 3128 3152

62 633 741 3192 3234

65 557 648 3353 3485

66 599 895 3445 3581

67 633 741 3519 3675

70 644 781 4510 4891

71 726 870 4686 5085

72 790 956 4823 5267

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 pip-

ing. Weight does not include compressor.

Refrigerant Weight(kg)

Cooler Condenser

132 91

141 91

150 91

145 113

154 113

168 113

156 102

175 102

197 102

159 118

191 118

222 118

181 141

218 141

249 141

254 127

286 127

313 127

290 150

327 150

358 150

340 181

381 181

408 181

227

236

249

395 222

426 222

445 222

249

259

272

426 191

445 191

463 191

463 231

481 231

494 231

553 354

608 354

653 354

Chiller Charge

Water Volume (L)

Cooler Condenser

129 159

140 170

151 185

148 182

163 197

178 216

182 182

208 208

235 238

212 212

242 246

273 280

231 235

265 273

303 314

394 416

424 450

450 488

424 454

462 492

492 534

500 556

541 591

568 625

466

477

488

545 609

591 647

621 689

503

519

534

636 689

666 723

693 757

731 795

761 833

912 1011

980 1083

1037 1155

2. Condenser data: based on a condenser with standard wall tub-

ing, 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*

COOLER FRAME, PASS

FRAME 2, 1 AND 3 PASS

FRAME 2, 2 PASS

FRAME 3_ 1AND 3 PASS

FRAME 3, 2 PASS

FRAME 4, 1 AND 3 PASS

FRAME 4, 2 PASS

FRAME 5, 1 AND 3 PASS

FRAME 5, 2 PASS

FRAME 6, 1 AND 3 PASS

FRAME 6, 2 PASS

FRAME 7, 1 AND 3 PASS

FRAME 7, 2 PASS

FRAME 8, 1 AND 3 PASS

FRAME 8, 2 PASS

FRAME 2, 1 AND 3 PASS

FRAME 2, 2 PASS

FRAME 3, 1 AND 3 PASS

FRAME 3, 2 PASS

FRAME 4, 1 AND 3 PASS

FRAME 4, 2 PASS

FRAME 5, 1 AND 3 PASS

FRAME 5, 2 PASS

FRAME 6, 1 AND 3 PASS

FRAME 6, 2 PASS

FRAME 7, 1 AND 3 PASS

FRAME 7, 2 PASS

FRAME 8, 1 AND 3 PASS

FRAME 8, 2 PASS

peig (Ib)

150 730

150 365

150 730

150 365

150 1888

150 944

150 2448

150 1223

150 2860

150 1430

150 3970

150 1720

150 5048

150 2182

300 860

300 430

300 860

300 430

300 2162

300 1552

300 2655

300 1965

300 3330

300 2425

300 5294

300 4140

300 6222

300 4952

*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.

ENGLISH SI

Rigging Weight Water Volume Rigging Weight Water Volume

(L)

318

159

318

159

412

2O5

462

231

(gal) kPa (kg)

84 1034 331

42 1034 166

84 1034 331

42 1034 166

109 1034 856

54 1034 428

122 1034 1109

61 1034 555

139 1034 1297

69 1034 649

309 1034 1801

155 1034 780

364 1034 2290

182 1034 990

84 2068 390

42 2068 195

84 2068 390

42 2068 195

109 2068 981

47 2068 704

122 2068 1204

53 2068 891

139 2068 1510

58 2068 1100

309 2068 2401

146 2068 1878

364 2068 2822

161 2068 2246

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*

CONDENSER FRAME, PASS

FRAME 2, 1 AND 3 PASS

FRAME 2, 2 PASS

FRAME 3, 1AND 3 PASS

FRAME 3, 2 PASS

FRAME 4, 1 AND 3 PASS

FRAME 4, 2 PASS

FRAME 5, 1 AND 3 PASS

FRAME 5, 2 PASS

FRAME 6, 1 AND 3 PASS

FRAME 6, 2 PASS

FRAME 7, 1 AND 3 PASS

FRAME 7, 2 PASS

FRAME 8, 1 AND 3 PASS

FRAME 8, 2 PASS

FRAME 2, 1 AND 3 PASS

FRAME 2, 2 PASS

FRAME 3, 1 AND 3 PASS

FRAME 3, 2 PASS

FRAME 4, 1 AND 3 PASS

FRAME 4, 2 PASS

FRAME 5, 1 AND 3 PASS

FRAME 5, 2 PASS

FRAME 6, 1 AND 3 PASS

FRAME 6, 2 PASS

FRAME 7, 1 AND 3 PASS

FRAME 7, 2 PASS

FRAME 8, 1 AND 3 PASS

FRAME 8, 2 PASS

ENGLISH

Rigging Weight

psig !lb)

150 N/A

150 365

150 N/A

150 365

150 N/A

150 989

150 N/A

150 1195

150 N/A

150 1443

150 N/A

150 1561

150 N/A

150 1751

300 N/A

300 430

300 N/A

300 430

300 N/A

300 1641

300 N/A

300 1909

300 N/A

300 2451

300 N/A

300 4652

300 N/A

300 4559

*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.

Water Volume kPa Rigging Weight

N/A 1034 N/A

42 1034 166

N/A 1034 N/A

42 1034 166

N/A 1034 N/A

54 1034 449

N/A 1034 N/A

60 1034 542

N/A 1034 N/A

69 1034 655

N/A 1034 N/A

123 1034 708

N/A 1034 N/A

141 1034 794

N/A 1034 N/A

42 2068 195

N/A 2068 N/A

42 2068 195

N/A 2068 N/A

47 2068 744

N/A 2068 N/A

50 2068 866

N/A 2068 N/A

58 2068 1112

N/A 2068 N/A

94 2068 2110

N/A 2068 N/A

94 2068 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

MOTOR

CODE

BD 900

BE 915

BF 975

BG 1000

BH 1030

BJ 1105

CB 1154

CC 1182

CD 1220

CE 1253

CL 1261

CM 1294

CN 1321

CP 1343

CO 1419

CR 1567

DB 1570

DC 1580

DD 1919

DE 1939

DF 1989

DG 2054

DH 2099

DJ 2159

DK 2380

ER 2700

EJ 2760

EK 2760

EL 2800

EM 2800

EN 2960

EP 2960

EO 3110

*Stator weight includes stator and shell.

tRotor weight includes rotor and shaft.

Table 25A -- 19XRV Motor Weights -- Standard Motors

StatorWeight*(Ib)

60 Hz 50 Hz

915

965

1000

1060

1175

1188

1196

1258

1272

1328

1353

1386

1413

1522

1725

1737

2069

2089

2139

1998

2056

2101

2770

2890

2960

3110

ENGLISH

Rotor Weightt (Ib)

60 Hz 50 Hz

190 205

200 220

215 230

230 250

240 265

265

236 255

243 260

252 270

261 281

265 284

273 293

280 303

282 308

300 336

335

324 347

326 354

423 458

428 463

448 478

473 422

488 443

508 464

522

651 701

670 701

670 718

685 751

751 801

780 801

801

End Bell Stator Weight* (kg)

60 Hz 50 Hz

408 415

415 438

442 454

454 481

467 501

501

523 539

536 542

553 571

568 577

572 602

587 614

599 629

609 641

644 690

711

712 782

717 788

870 938

880 948

902 970

932 906

952 933

979 953

1080

1388 1415

1408 1474

1442 1474

1442 1529

1483 1529

1483 1597

1515 1597

1411

NOTE: When different voltage

largest weightis given.

End Bell

60 Hz Cover(kg)

86 93 84

91 100 84

98 104 84

104 113 84

109 120 84

120 -- 84

107 116 125

110 118 125

114 122 125

118 127 125

120 129 125

124 133 125

127 137 125

128 140 125

136 152 125

152 -- 125

147 157 107

148 161 107

192 208 144

194 210 144

203 217 144

215 191 144

221 201 144

230 210 144

237 -- 145

295 341 188

325 341 188

325 348 188

334 363 188

363 386 188

376 386 188

363 -- 188

motors have different weights the

Cover(Ib)

185

274

236

318

414

Rotor Weightt (kg)

50 Hz

104

MOTOR

CODE

Table 25B -- 19XRV Motor Weights -- High-Efficiency Motors

Stator

60 Hz

BD 1030

BE 1070

BF 1120

BG 1175

BH 1175

BJ 1175

CB 1235

CC 1260

CD 1286

CE 1305

CL 1324

CM 1347

CN 1358

CP 1401

CQ 1455

CR 1567

DB 1950

DC 1950

DD 2150

DE 2150

DF 2250

DG 2250

DH 2380

DJ 2380

DK 2380

LB 1873

LC 1939

LD 2023

LE 2043

LF 2096

LG 2133

LH 2199

ER 3060

EJ 3105

EK 3180

EL 3180

EM 3270

EN 3270

EP 3340

EQ 3520

*Stator weightincludes stator and shell.

tRotor weightincludesrotor and shaft.

Weight*(Ib)

50 Hz

1030

1070

1120

1175

1290

1295

1358

1377

1435

1455

1467

1479

1950

2025

2250

2380

1939

2023

2043

2096

2133

2199

3120

3250

3370

3520

ENGLISH

Rotor Weightt (Ib)

60 Hz 50 Hz

240 240

250 250

265 265

290 290

290

242 255

249 259

258 273

265 279

280 296

303 298

316 316

329 316

329 329

335

406 406

406 429

536 546

550 550

575 567

599 599

604 604

614 614

614

364 389

389 406

406 417

417 434

434 444

444 458

458

701 751

716 751

716 768

737 801

801 851

830 851

851

End Bell

Cover (Ib)

185

274

318

414

StatorWeight*(kg)

60 Hz 50 Hz

467 467

485 485

508 508

533 533

533

560 585

572 587

583 616

592 625

601 651

611 660

616 665

635 671

660 671

711

885 885

885 919

975 1021

1021 1080

1080 1080

1080

850 880

850 918

880 927

918 951

927 968

951 997

968

1388 1415

1408 1474

1442 1474

1442 1529

1483 1529

1483 1597

1515 1597

1597

60 Hz

109

113

120

132

110

113

117

120

127

137

143

149

152

184

243

249

261

272

274

279

165

176

184

189

197

201

2O8

318

325

334

363

376

386

Rotor Weightt (kg)

50 Hz

109

113

120

132

116

117

124

127

134

135

143

149

184

195

248

249

257

272

274

279

176

184

189

197

201

2O8

341

348

363

386

NOTE: When different voltage motors have

largest weight is given.

End Bell

Cover (kg)

125

144

188

different weights the

105

HEAT

EXCHANGER

Table 26A -- 19XRV Waterbox Cover Weights -- English (Ib)

WATERBOX DESCRIPTION

NIH, 1 Pass Cover, 150 psig

NIH, 2 Pass Cover, 150 psig

NIH, 3 Pass Cover, 150 psig

NIH Plain End Cover, 150 psig

COOLER/ MWB End Cover, 150 psig

CONDENSER NIH, 1 Pass Cover, 300 psig

NIH, 2 Pass Cover, 300 psig

NIH, 3 Pass Cover, 300 psig

NIH Plain End Cover, 300 psig

MWB End Cover, 300 psig

FRAME 1

Standard

Nozzles Flanged

177 204

185 218

180 196

136 136

248 301

255 324

253 288

175 175

FRAME 2

Standard

Nozzles

32O

310

3OO

411

433

4OO

Standard

Nozzles Flanged

320 350

310 340

300 300

411 486

411 518

433 468

400 400

FRAME 3

Flanged

35O

34O

3OO

486

518

468

4OO

HEAT

EXCHANGER WATERBOX DESCRIPTION

NIH, 1 Pass Cover, 150 psig

NIH, 2 Pass Cover, 150 psig

NIH, 3 Pass Cover, 150 psig

NIH Plain End Cover, 150 psig

COOLER/ MWB End Cover, 150 psig

CONDENSER NIH, 1 Pass Cover, 300 psig

NIH, 2 Pass Cover, 300 psig

NIH, 3 Pass Cover, 300 psig

NIH/MWB End Cover, 300 psig

FRAME 4

Standard

Nozzles Flanged

148 185

202 256

473 489

138 138

317 317

593 668

594 700

621 656

569 569

FRAME 5

Standard

Nozzles

187

257

817

172

503

959

923

980

913

Standard

Nozzles Flanged

168 229

224 298

629 655

154 154

393 393

764 839

761 878

795 838

713 713

FRAME 6

Flanged

223

330

843

172

503

1035

1074

1031

913

HEAT

EXCHANGER WATERBOX DESCRIPTION

NIH, 1 Pass Cover, 150 psig

NIH, 2 Pass Cover, 150 psig

NIH, 3 Pass Cover, 150 psig

NIH Plain End Cover, 150 psig

COOLER/ MWB End Cover, 150 psig

CONDENSER

NIH, 1 Pass Cover, 300 psig

NIH, 2 Pass Cover, 300 psig

NIH, 3 Pass Cover, 300 psig

NIH/MWB End Cover, 300 psig

FRAME 7 COOLER

Standard

Nozzles Flanged

329 441

426 541

1202 1239

315 315

789 789

1636 1801

1585 1825

1660 1741

1451 1451

Standard

Nozzles

329

426

1113

315

7O3

1472

1410

1496

1440

FRAME 7 CONDENSER

Flanged

441

541

1171

315

7O3

1633

1644

1613

1440

HEAT

EXCHANGER WATERBOX DESCRIPTION

NIH, 1 Pass Cover, 150 psig

NIH, 2 Pass Cover, 150 psig

NIH, 3 Pass Cover, 150 psig

NIH Plain End Cover, 150 psig

COOLER/ MWB End Cover, 150 psig

CONDENSER

NIH, 1 Pass Cover, 300 psig

NIH, 2 Pass Cover, 300 psig

NIH, 3 Pass Cover, 300 psig

NIH/MWB End Cover, 300 psig

LEGEND

NIH -- Nozzle-lmHead

MWB -- Marine Waterbox

FRAME 8 COOLER

Standard

Nozzles Flanged

417 494

531 685

1568 1626

404 404

1339 1339

2265 2429

2170 2499

2273 2436

1923 1923

FRAME 8 CONDENSER

Standard

Nozzles Flanged

417 494

531 685

1438 1497

404 404

898 898

1860 2015

1735 2044

1883 1995

1635 1635

NOTE:Weightfor NIH 2-Pass Cover, 150 psigisincludedinthe heat

exchanger weights showninTable 23A.

106

HEAT

EXCHANGER

Table 26B -- 19XRV Waterbox Cover Weights -- Sl (kg)

WATERBOX DESCRIPTION

NIH, 1 Pass Cover, 1034 kPa

NIH, 2 Pass Cover, 1034 kPa

NIH, 3 Pass Cover, 1034 kPa

NIH Plain End Cover, 1034 kPa

COOLER/ MWB End Cover, 1034 kPa

CONDENSER NIH, 1 Pass Cover, 2068 kPa

NIH, 2 Pass Cover, 2068 kPa

NIH, 3 Pass Cover, 2068 kPa

NIH Plain End Cover, 2068 kPa

MWB End Cover, 2068 kPa

FRAME1

Standard

Nozzles Flanged

80 93

84 99

82 89

62 62

112 137

116 147

115 131

79 79

FRAME 2

Standard

Nozzles

145

141

136

186

196

181

Standard

Nozzles Flanged

145 159

141 154

136 136

186 220

186 235

196 212

181 181

FRAME 3

Flanged

159

154

136

22O

235

212

181

HEAT

EXCHANGER WATERBOX DESCRIPTION

NIH, 1 Pass Cover, 1034 kPa

NIH, 2 Pass Cover, 1034 kPa

NIH, 3 Pass Cover, 1034 kPa

NIH Plain End Cover, 1034 kPa

COOLER/

CONDENSER MWB End Cover, 1034 kPa

NIH, 1 Pass Cover, 2068 kPa

NIH, 2 Pass Cover, 2068 kPa

NIH, 3 Pass Cover, 2068 kPa

NIH/MWB End Cover, 2068 kPa

FRAME4

Standard

Nozzles Flanged

67 84

92 116

215 222

63 63

144 144

269 303

269 318

282 298

258 258

FRAME 5

Standard

Nozzles

117

371

228

435

419

445

414

Standard

Nozzles Flanged

76 104

102 135

285 297

70 70

178 178

347 381

345 398

361 380

323 323

FRAME 6

Flanged

101

150

382

228

469

487

468

414

HEAT

EXCHANGER WATERBOX DESCRIPTION

NIH, 1 Pass Cover, 1034 kPa

NIH, 2 Pass Cover, 1034 kPa

NIH, 3 Pass Cover, 1034 kPa

NIH Plain End Cover, 1034 kPa

COOLER/

CONDENSER MWB End Cover, 1034 kPa

NIH, 1 Pass Cover, 2068 kPa

NIH, 2 Pass Cover, 2068 kPa

NIH, 3 Pass Cover, 2068 kPa

NIH/MWB End Cover, 2068 kPa

FRAME 7 COOLER

Standard

Nozzles Flanged

149 200

193 245

545 562

143 143

358 358

742 817

719 828

753 790

658 658

Standard

Nozzles

149

193

5O5

143

319

668

640

679

653

FRAME 7 CONDENSER

Flanged

2OO

245

531

143

319

741

746

732

653

HEAT

EXCHANGER WATERBOX DESCRIPTION

NIH, 1 Pass Cover, 1034 kPa

NIH, 2 Pass Cover, 1034 kPa

NIH, 3 Pass Cover, 1034 kPa

NIH Plain End Cover, 1034 kPa

COOLER/

CONDENSER MWB End Cover, 1034 kPa

NIH, 1 Pass Cover, 2068 kPa

NIH, 2 Pass Cover, 2068 kPa

NIH, 3 Pass Cover, 2068 kPa

NIH/MWB End Cover, 2068 kPa

LEGEND

NIH -- Nozzle-In-Head

MWB -- Marine Waterbox

FRAME 8 COOLER

Standard

Nozzles Flanged

189 224

241 311

711 738

183 183

607 607

1027 1102

984 1134

1031 1105

872 872

FRAME 8 CONDENSER

Standard

Nozzles Flanged

189 224

241 311

652 679

183 183

407 407

844 914

787 927

854 905

742 742

NOTE:Weightfor NIH 2-Pass Cover, 1034 kPa is included in the

heatexchanger weights showninTable 23B.

107

Table 27 -- Optional Pumpout Electrical Data

PUMPOUT UNIT

19XR04026501

19XR04026502

19XR04026503

LEGEND

LRA

RLA

VOLTS-PH-Hz MAX RLA LRA

208/230-3-60 15.8 105

208/230-3-50 15.8 105

460-3-60 7.8 52

400-3-50 7.8 52

-- Locked Rotor Amps

-- Rated Load Amps

ITEM

Table 28 -- Additional Miscellaneous Weights

FRAME 2 FRAME 3 FRAME 4

COMPRESSOR COMPRESSOR COMPRESSOR

Ib kg

34 15

26 12

1600 726

Ib kg

34 15

46 21

13 6

1600 726

Ib kg

34 15

74 34

13 6

1600 726

CONTROL CABINET

OPTIONAL DISCHARGE ISOLATION VALVE

OPTIONAL COOLER INLET ISOLATION VALVE

UNIT-MOUNTED VFD

LEGEND

VFD -- Variable Frequency Drive

FRAME 5

COMPRESSOR

Ib kg

34 15

108 49

24 11

1600 726

Table 29 -- Motor Voltage Code

MOTOR CODE VOLTS FREQUENCY

62 380 60

63 416 60

64 460 60

52 400 50

108

19XRV COMPRESSOR FITS AND CLEARANCES (in.)

COMPRESSOR FRAME 2 FRAME 3 FRAME 4 FRAME 4 FRAME 5

Code 201-299 321-390, 3ZZ 421-490 4B1-4W8 501-600

ITEM With Rolling Split Ring Split Ring

DESCRIPTION Fixed Diffuser Element Fixed Diffuser Diffuser Diffuser

Bearings

A Low Speed Journal-Gear End .0050/.0040 .0050/.0040 .0055/.0043 .0055/.0043 .0069/.0059

B Low Speed Journal-Motor End .0050/.0040 .0050/.0040 .0053/.0043 .0053/.0043 .0065/.0055

Cl Low Speed Labyrinth to Thrust Disk .0115/.0055 N/A .010/-.005 .010/-.005 N/A

C2 Labyrinth to Low Speed Shaft N/A .010/.005 .0095/.0055 .0095/.0055 .013/.009

D Low Speed Shaft Thrust Float .020/.008 .020/.008 .023/.008 .023/.008 .020/.008

E Impeller Eye to Shroud

Ff Impeller Bore to Shaft-Rear -.0020/-.0005 -.0025/-.0010 -.0021/-.0006 -.0021/-.0006 -.0019/-.0005

F2 Impeller Bore to Shaft-Front N/A N/A -.0014/.0000 -.0014/.0000 -.0014/.0000

G Impeller Discharge to Shroud

H Impeller Spacer to Shaft .0025/.0010 .0025/.0010 .0025/.0010 .0025/.0010 .0024/.0010

I Slinger to Shaft .0013/.0005 .0012/.0004 .0012/.0004 .0012/.0004 .0012/.0004

J Labyrinth to Slinger .013/.009 .010/.006 .010/.006 .010/.006 .010/.006

K Labyrinth to Impeller .012/.008 .012/.008 .012/.008 .012/.008 .012/.008

L High Speed Journal-Impeller End .0047/.0037 N/A .0040/.0028 .0040/.0028 .0048/.0038

M Thrust Assembly Seal Ring Axial Clearance .006/.002 N/A .006/.002 .006/.002 .006/.002

N Thrust Assembly Seal Ring to Shaft .0045/.0015 N/A .0045/.0015 .0045/.0015 .0045/.0015

O High Speed Shaft Thrust Float .014/.008 0 Float .014/.008 .014/.008 .014/.008

P High Speed Journal-Gear End .0050/.0040 N/A .0048/.0038 .0048/.0038 .0062/.0052

*Depends on impeller size, contact your Carrier Service Re 3resen-

tative for more information.

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

must be removed from the high speed shaft and bearing assem-

bly before the high speed shaft and bearing assembly can be

separated from the transmission.

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.

Impeller spacing should be performed in accordance with the

most recent Carrier Impeller Spacing Service Bulletin.

Fig. 48 -- Compressor Fits and Clearances

109

SEE VIEW A10RA2 A 2 3 SEE VIEW B

COMPRESSOR, TRANSMISSION AREA (FRAME 5 COMPRESSOR SHOWN)

1) OIL HEATER RETAINING NUT (NOT SHOWN)

2) BULLGEAR RETAINING BOLT

3) DEMISTER BOLTS (NOT SHOWN)

4) IMPELLER BOLT

COMPRESSOR, TRANSMISSION AREA

THRUST

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 SHAFT (FRAME 3)

Fig. 48 -- Compressor Fits and Clearances (cont)

III

VIEW C -- HIGH SPEED SHAFT RING SEAL

ACAUTION

USE COPPER CONDtJC'I'0RS0NY

UTII,]SEZ DES CONDUCTEURS EN CUIVRE SEU,MENT

ALWAYS USE 2 WRENCHES T0 TIGHTEN,

• TERM INSULATOR TO M0'10R 15+35 it+ lb

• BRASS NUT T0 TERM INSULATOR ....3ft. lb. max

• ADAPTOR TO TERM STUD - 3035 ft [b,

• LUG BOLTS (1/2") 32 45 ft. [b.

Insulate +,ntir'r+ cnnnection with eler_Ir]eai iz_slllation

including 1 inch of cable insulation and 1 inch of @Je

term insulator.

3©

TERMINAL STUD- _ _-INSULATION

r....... -'\4---I

A DAD'p]_N? _ ,1 L'-TERMINAL

........ _A_NSS NU]" ] INSIJLATOR

CAUTION

USE COPPER CONDUCTORS ONLY

UTII,ISEZDES CONDUCTEUBS EN CUIVRE SEUI,MENT

ALWAYS USE 2 WRENCHES TO T]GHTEN,

o TERM INSULATOR TO MOTOR 15 35 ft Ib

o CABLE LUG NUTS ..... ft.lb.

Insulate entire connection with electrical insulation

including 1 inch of (¸:able insula±,io_ and I i_ch of the

term insulator.

1© @6

8@ @,5

TAPETO EXTENDTO AND OVER

LEAD }_TRE |NS[H,A lCN

<-_-'A?+[ER ATTACHrNE LEAD, 'tHiS AREA

TO BE WRAPPED?_THONELAYFROF

TIIERNALINSULATIONPUTTY AND AT

I[,EAS'] FOUR LAYERS OF APPROPRIATE

ELECTRICAL INSULATING TAPE

MOTOR LEAD INSTALLATION LABELS

19XRV COMPRESSOR ASSEMBLY TORQUES

COMPRESSOR FRAME 2 FRAME 3 FRAME 4 FRAME 4 FRAME 5

Code 201-299 321=390, 3ZZ 421-490 4B1-4W8 501-600

ITEM With Rolling Split Ring Split Ring

DESCRIPTION Fixed Diffuser Element Fixed Diffuser

Bearings Diffuser Diffuser

1 Oil Heater Retaining Nut- ft-lb (N'm) N/A 18-22 (25-30) 18-22 (25-30) 18-22 (25-30) 18-22 (25-30)

2 Bull Gear Retaining Bolt-- ft-lb (N'm) 80-90 (108-122) 80-90 (108-122) 80-90 (108-122) 80-90 (108-122) 80-90 (108-122)

3 Demister Bolts -- ft Ib (N'm) 15-19 (20-26) 15-19 (20-26) 15-19 (20-26) 15-19 (20-26) 15-19 (20-26)

4 Impeller bolt Torque -- ft-lb (N'm) 32-48 (43-65) 55-60 (75-81) 55-60 (75-81) 55-60 (75-81) 160-225 (217-305)

Fig. 48 -- Compressor Fits and Clearances (cont)

ll2

LEGEND FOR FIG. 49-54

AUX --

CB --

CCM --

CCN --

COM --

COMM --

DUDP --

GRD --

GVA --

HGBP --

HPS --

ICVC --

IGV --

RHS --

VFD --

Auxiliary 1C

Circuit Breaker 2C

Chiller Control Module 3C

Carrier Comfort Network

Common

Communications

Data Link/Data Port

Chassis Ground

Guide Vane Actuator

Hot Gas Bypass _ >---

High Pressure Switch

International Chiller Visual Controller I I

Inlet Guide Vane

Junction •

Relative Humidity Sensor <_

Transformer

Terminal Block @

Variable Frequency Drive

Compressor Oil Heater Contactor

Oil Pump Contactor

Hot Gas Bypass Relay

Field Control Wiring

Field Power Wiring

Factory Wiring

Shielded Cable

Male/Female Connector

Terminal Block Connection

Wire Splice or Junction

Component Terminal

Thermistor

Transducer

o-Aro

Potentiometer

Pressure Switch

Compr Oil Pump Terminal

Cartridge Fuse

Resistor

Chassis Ground

Temperature Switch

Common Potential

VFD Terminal

Transformer

IGBT

113

_ 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 PUMP TERMINA

DENOTES POWER PANEL TERMINAL

0 D_NOTES COMPONLNT TERMINAL

W_RE SP_CE

O_T_ON W_R_NG

_ DENOTES MALE/F_MALE _,C,

DENOTES MACH, CONTROL PANEL CONN,

• _ DENOTES VFD PANE_ CONN,

COMPR OiL HEALER

lYEL

VBLi_ABE _ 22 2B 12 BL_

PER JOB -- O_ _ 0 (BLK) --

REGMT '

10 GVA L2 _ (WHT)

tO GVA L (BLK)

TO CCM J12 2_ (WHI}

COMPR OiL

PUMP MOTOR

(1 i/2 HP)

(RED)

TO VFD/AB2/2_

iO VFD/A32/4m_

TO VFD/A32/3_

TO STARTER ORD

TO CCM J?_3_

TO CCH J7_2_

TO CCH J?_i_

(RED)

(BLK)

{CLR)

COMPR DISCH (BLK)

HIGH PRES5

TO CB/_

(WHT) I

J12-5_

POWER PANEL

(BLK)

I (BLU)

[............................. (RED) ..................

(W_T) (W_T)

ABBREV At ON LISTING

CB C RCUIT BREAKER HGBP HOT GAS BYPASS

DDM (:HILLER CONTROL MODULE TB TERMINAL BOARD

_v_ GD,OEVINE ACP_',TGU__t__. --

i i i i i i i - _ COMPONENTi

LAYOUT i

/C (BLK) + (B K) _N _ OPTIONAL i

c ii

/_ _ K) _A/\

/C 230 WIRING ODIFC_FION

i i i--i'i i i i

KBLK> I

r IIIIII I

(GRN) I

I ( U) /, • )

i _:0 (LU) t I I

p _ { D) HD_P II_ I II I

I _ (YL) _ SOLENOIDI I III/// I I

i(Y) " -_eK)--III I o I III

IIII(LK) _) 3C 2 (BIi I K) I 1 _2 co,,i I I

II os II

I2sc)VWIBNGrII IiI° BGBPII I

(_R_,) 1 I

I LIA#_A_DRII '

I _ (BLU) !I iiiii -

II,<ED) ._LL)_ _R) II

II _ (RE_)I HGBP lI, '_,_I '

I I _ (YE) _ SOL NOID I I_L) CB_K)I

•IlBV CONIRO ONY

I_V_'ABB I

TO CB2_ iIHGBP

(CLR) (OPTIONAL) (BLU) (Oi

VFD COOLANT TO CCM

SOLENOID Ji2 4m

TO CCM

W1RING 5CHENATIC ,'_,

O tt o

Fig. 50 -- Power Panel Wiring Schematic

VFD ENCLOSURE

I _ BLK)

VF-D ENCLOSURE

I _I I (WHT)

PDWER PANEL

OIL PUMP CDNTACTOR

(_-12_[J_- --( Y EL.)

(RZD)

T[ _(B

=tXTE

J<)

(BLK)

I-<D

-0 Ic

OIL HEATER

CONTACTOR

COHPRESSI]R OIL PUNP

3BDI4161480V-3-60

(1 t12 H, P.) 400-3-._0

BLK)

(l15v ONLY} >___J

L(WHT)_( Bt._

COMPRESSOR [:_30wArTs-D2XR£

OILHEA_ tmO varr_-mxR_.0Z_R4

-(WHT)

-(RED)

FiGDP FR_IE 7HX

115V ONLY

HO_P FR,_HE 1 [HRU 6HX

115V ONLY

<WHT)

(BLK)

[_HINAL

,c<>

(RED)

I'_'---HSBP FR,_IE 1 THRU 7HX tl_V

F _LI<)

-(BLK) -<_ _ (I).-K)----e-----(BLK )--

g71a _'_ (YZL)----e-----< YEL)--

FRAME ITHRU 6 HX 115V ONLY (I]PTIONAL)

(B_K>------l

T _ T

(RED) "_ (WHT)

(SEE _4 VKD

(RED IIHT)-

II.K)---- 1

I _-----------(RE O_>--_ W HI">.-

(BLK)

l*IGgP SE]L£NO]D ] (/_L_)I

SEE _4V

FOR C_rTROL$

(RED) $

(BLU)

L(WHT>-_

(WHT)

HGBP ACTUATOR

< _FRAME 7 HX ONLY

HGBP SOLENOI D

>lc

Fig. 51 -- 19XRV Chiller Control Schematic

_JI2

CBe

--(DL C_I

IEVC-Jt i( _yi--J '

CB]

CB1 q

_UIO _E_ND L[MIIZZZSZZZZ Z

....

.... r-'V---

i $

l t

(_HIELIO/._---J

EvaPm_r_ rm, V---_'_ RED)--

E_CA_RATCIR LV& _)---( RED)+---+

uaTm T_:Np, _)----< _I.I<)-_

CORI_ZN_ Bl, _REII_

wATERIZNP. _>----< _LFO_

VATER TEMP, _>---( SL.KZ_-_

G,V+ _S[TION

FEE]JI_C_K

EVAP,,SATUma_TION_>_( R{I))_

+a,e. _ ELK>---

REm+E+E++ F_.--->_ v#_>--

COMPRESSB_ _>---< RZ_>-----

DI$CHN_GE I[MI:+_>----( BLK)----

CIIMP_SOR _CLR_.....--

tHRUST ]_F_AR[NO BLK)---

r_P_r_g SPARE)

++ "fZN_RAI'UR[ L_>--.-( +LK)-----

MI]'fl]RTEMP+ _LK _--'--"

'_-'_:_( SPARD

SPARE "TEMP.#] F --i>>--'(VHT)--

_>--< BLK)---

FEE-->>--<v_--

CONTINLEI) ON SHEEI 6

CHILLER CONTROL

((_RY)

CcM

SEE CHART _EU]W

+°i+

PANEL _+_c.i

24 V_£ I_RN)

+d_ZS)

(_I_Y) J1 _/_L_RM --

ICVC

I I F<Ra>-_T_ -k s'_op -- |

I II"I IseI-I_I÷Ir_ _mN>_ 1 (_K_ I

'_ISLO) (S_4"I)+C_4

I I F '_" _-r I I I _---_oml ---I

¢_: I_ _ ' _ iLI ]_li._=ii,

(C_)-- _J6 _DLIDP

I (R_> _ (OPTION)

..@

Jll

CONTINUE_ ZI_ SHEET 6

_VER P_

_----1_------(REl))_ (REIi)--VF_ IA3 _/3

_'(SHIELII b

'IC

FEED BACK

P_i TZNTI_TERC(<ONH

INFERNAL VARIABLE

GUIDE V#C_E CONTROL /

SEE I15/230V FOR R3WER "x

CONTINUED ON SI_EE'T6

Fig. 51 -- lgXRV Chiller Control Schematic (cont)

_INUED FROM _EET 5

c_ (BLK)

C_E (gLK)

_-.-._>---< _LK_

OIL SUMP [_>---< CLR)----

PRESSURE _>---< RED>----

OIL PUMP _>--"( I_LK)-----

DISCH. PRESSURE [_'_>-'--<CLR}------

F----<_LK)--

LOAD RESISTOR I

_:.L_HVc IRHSF--'_$ ....

HLAMI]]]IY l.e_u>----

LOAD RESIS]OR

LOAD RESISTOR

JUMPER

LOAD RESISTOR

JUMPER

EVAP_ATOR _ BLK)-----

REFI_IOER_NT CLF_

PESSURE _>---( R_

CONDENSER t-_>__< CLR).._

REFR ]6ERANT

PRESSURE _>---( REI)>----

CONTINUED FROM SHET 5

CONTINUED FROM SHEET 5

J12

-i1

(3RN)

OIL PUMP MOll]R

YF11OODLANT SOLENOID

(BLK)------_,

SWI

"-PT-[4-_o_.,

_c aux HPS

ET_D r--_ _ 8_-

CLOSE:110_7 PSIG. I--

VFD ENCLOSURE

AI VFO PDWER MODULE

SIAND_RD]/0 ]

B531

D_19-

(BB',_ >IC

B31_

-----<_----- T1

>ic

Fig. 51 -- 19XRV Chiller Control Schematic (cont)

CARRIER 19XRV LF2 VFD WIRING DIAGRAM

_z_e

CR_D_

_SLK_

_Z_C

iAe_ec--

_e_ _osz__, c. oll _M_

Fig. 52 -- 19XRV Chiller VFD Schematic

--:,4] I1_:;;:,:::::::)'_......J

]

_N_OL pANEL

¢CM MCOLAJ_

OATAUNK 13_

DATAPOR'[ MOOULE

ITI_ 1 OR2)

_E oPnON

]S_NO BELOW)

.... ,7,

----r"r-p-----"IAUIO DEMAND RESE1

-_-_-_--- _CONIROLLER INPUT (SEE NOTE #I)

__----IT--IAUmC_fLLEO_ATERRESE_

---,_--JCON_OLLERINPUT(SEENOTE_)

____ t___ 4--20r.A(O-IOOXkw)

_--(_) ....

SPARETEMP12 SENSOR

(COMMONREIURN)(SEENOTE#2)

SPARE _EMP #1 SmSOR

(COMMON SUPPLY] CSEE NOTE #2)

REMOIE 1EMP RESEI SENSOR

(_ N01Z /2)

4s_

C l(/h(//l

D-SHELLI _ I

CONTROL PANEL OPTIONAL W1RING

PROIECTIVE G_ID 1TRANSMW DATA

RECEIVE DATA I

RS-2Z2 PORT

fO BAS

CONIRQ__'_CE

(SEENOTE _)

÷ 0

03NTRCL pANEL j

TD_MINAL BLOCK

SP 1 2

OPTION USTING

CHECK TO

ITE_ DESCRIPTION ORDER

I DAIAPORT MOOULE

2DAIAUNK MOOULE

3SENSOR PA_KA(_£ °°°i

Icvc

o oo@

NOTE_

1. THIS FEATURE IS STANDARD IN THE PIC II OONTROLS,

BUT REQUIRE5 A CONIROLIJZR Y_TH ANON--GROUNDED 4-2OmA

OR 1-5Vdc OUTI_UT SIONAL NOT BY CARRIE_

2. _IS FEA_RE IS SIANDARD IN THE PIC II_ONTROLS,

BUT REOUIRES A SENSOR PACKAGE OPTION, BY CARRIER.

(ITEM #3, SEE OPTION LISTINO)

3. PINS SHOWN FOR REFERENCE ONLY.

ACTUAL PIN LAYOUT NOT SHOWN,

DATAUNK OR

TRANSFORMER

(OPIION) RELAY

(oRno.}

POWER PANEL COMPONENT LAYOUT

(_OWN _ COVERREMOVED)

INSIDE PANEL COVER CONTROL PANEL COMPONENT LAYOUT

Fig. 53 -- 19XRV Chiller Control Panel Component Layout

NOTES:

I GENERAL

1,0 VFD SHALL BE DESIGNED AND MANUFACTURED IN ACCORDANCE WITH

CARRIER ENGINEERING REQUIREMENT Z-420o

1,1 ALL FIELD-SUPPUED CONDUCTORS, DEVICES AND 'THE FIELD-INSTALLATION

WIRING, TI'3:_MINAIlON GF CONDUCTORS AND DEVICES, MUS'f 8E IN COMPUANCE

WITH ALL APPUCABLE CODES AND JOB SPECIFICATION&

1.2 THE ROUTING OF FIELD-INS'[ALLEDCONDUIT AND CONDUCTORS AND THE LOCA]ION

OF FIELD-INSTALLED DEVICES, MUST NOT INTERFERE WITH EQUIPMENT ACCESS

OR THE READING. AOdUSIlNG OR SERVICING OF ANY COMPONENT,

1,3 EQUIPMENT INSIALLATION AND ALL STARIINO AND CONTROL DEVICES. MUST

COMPLY _lll DEIAILS IN EQUIPMENT SUBMITTAL DRA_NOS AND UTERATURE.

1,4 CONrACIS AND S_TCHES ARE SHOWN IN THE POSITION IHEY WOULD ASSUME

WITH THE CIRCUIT DE-ENERGIZED AND THE CHILLER SHUII]OYvN.

1,5 NARNING - DO NOT USE ALUMINUM CONDUCTORS,

POWER _RING TO VFD

2,0 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'_:TIONSHALL BE FUSED TYPE

OR EQUiVALEN'f CIRCUIT BREAKDR PER SHEEI 3OF 4 OF THIS DOCUMEN'f.

Z,1 METAL CONDUII MUST BE USED FGR IHE POI_ER WIRES, FROVI VFD TO BRANCH

FEEDER.

2,2 UNE S@E POWER CONDUCTOR RATING MUST MEET VFD NAMEPLATE VOLTAGE

AND CHILLER FULL LOAD AMPS (MINIMUM CIRCUIT AMPACITY),

2,3 UNE LUG ADAPTORS ARE REQUIRED AT INSTALLATION. MINIMUM QUANTITY

(# CONDUCTORS) AND SIZE (CONDUCTOR RANGE) CABLES PER PHASE AS FI_I_I.OWS:

CONTROL _RI N(3

&O FIELD SUPPLIED CONTROL CONDUCTORS TO BE AT LEAST 18 A_ OR LAROEP,.

3.1 ICE BUILD START/ERMINATE DEVICE CONTACTS, REMOTE START/STOP DEVICE CONTACTS

AND SPARE SAFELY DEVICE CONTAC:TS_ (DEVICES NOI SUPPUED BY CARRIER],

MUST HAVE 24VAC RATING. MAX CURRENT IS BOrnA. NOMINAL CURRENT IS 10mA.

SWI'[CHES WITH C43LI)PLATED BIFURCATED C:ONIAC'ISARE RECX3MMENDED.

3.2 REMOVE ,.LIMPERWIRE BETWEEN TBI-Ig AND "fBI-20 BEFORE CDNNECI]N_ AUXILLIARY

SAFETIES BETV_ THESE TERMINALS.

3,_ TME VF'D CONTACT OUTPUTS CAN CONTROL LOADS (VA) FOR COOLER AND

FOR CONDENSER PUMP, TOWER FAN MOTOR CONTACTOR COIL AND ALARM

ANNUNCIATOR DEVICES IS RATED 5 AMPS AT 115VAC UP TO 3 AMPS AT

277VAC. CONTROL WIRING REOUIRED FOR CARRIER TO START PUMPS AND TOWER

FAN MOTORS MUST BE PROVIDED TO ASSURE MACHINE PROTECTION, IF PRIMARY

PUMP AND TOWER FAN MOTOR CONTROL IS BY OTHER MEANS. ALSO PROVIDE A

PARALLEL MEANS FOR DDNTROL BY CARRIER. DD NOT USE STARTER CONTROL

TRANSFORMER AS THE POWER SOURCE FOR CONTACTOR COIL, ACTUATOR MOTOR

DR ANT OTHER LOADS.

3.4 DO NOT ROUTE CONTROL WIRINI_CARRYING 3DV OR LESS WIIHIN A CONDUIT "NHICH

HAS WIRES 'CARRYING 50V OR HIGHER OR ALONG SIDE WIRES CARR'fING 50V OR HIGHER,

3.5 SPARE $-20mA OUTPUT SIGNAL IS DESIGNED FOR CONTROLLERS WITH A

NON--GROUNDEO 4-20mA INPUT SIGNAL AND A MAXIMUM INPUT IMPEDANCE

OF 500 OHMS.

3.6 REMOVE JUMPER WIRE TB1/19 TO TB1/20 IF INSTALLING SPARE SAFETY" CONTACT.

VFD STANDARD 65KAIC LUG CAPACITY (PER PHASE) OP_ONAL IOOKAIC LUG CAPACITY (PER PHASE)

MAX INPUT

AMPS. # CONDUCTORS CONDUCTOR RANGE # CONDUCTORS CONDUCTOR RANGE

405A 33/0 -500MCM 2 40D -500MCM

608A 3 3/0- 500MCM 3 3/0 - 400MCM

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

INCOMING

POWER WATER-PUMPS

AND FANS

[

VARIABLE

FREQUENCY

DRIVE

AMp, CLASS J, TIME DELAY, 6DD VOLT

AMP. _LA$S L'lIME DELAY. 600 VOL1

J V-1PH-50/60HZ ]

I REQUIRED POWER WIRING

-- REQUIRED CONTROL WIRING

...... OPTIONAL WIRINC

....... FIELD WIRING

CUSTOMER SUPPLIED RE_IOTE ALARM (OPTIONAL)

SEE NO_ ;5,3

Fig. 54 -- 19XRV Field Wiring (cont)

L_J

:1=

122

F,- T"

-VOLTS -VOLTS

EVAPORATOR UCdJID

PUMP MOTOR

{NOT BY CARRIER)

CONDENSE]R LIQUID

PUMP MOTOR

(NOT BY CARRIER)

............ --7

L 4-20mA OUIPU1 REFERENCE TO DDACE CHOICE(NOT BY CAI:_IER)

....... [ _ aPeS: I TOWER BY_°ASS VAL_

-TDVVERSPEED CON]ROL

- ,CONDENSER PUMP SPEED CONTROL

(SEE NOTE 3.5)

PRIMARY

COOLING TOWER FAN

<HIOH FAN/#2)

(NOT BY CARRIER)

-VDL'fS

3-PHASE

OPTIONAL

'H AND- OFF- AUTC,--SW.

SEE NQTE 3.3

OP_ONAL

COOLING TOWER FAN

(LOW FANI_)

<NOT BY CARRIER)

Fig. 54 -- 19XRV Field Wiring (cont)

123

PANEL

....

1. OROUNO _41ELD AT ONE 1_4D ONLY.

D. COMMON POINT S_NSX_t_; ARE REQUIRED I= *g'fZ OODLES ON

PARA[tZL FLOW MAI:HINL_ ARE SUPPUE0 BY A SINGLE (C0XMON)

OAIJ*ED WA1ER PUMP_

3, FO3MMON CHILLED WATER T_P_ATURZ SEN_R'3 ARE INSTALLED,

_lr CC_MON _N_(LWR 0PI1ON _ ENABLE,

NST&[I COMMON P_AN'[ 5ENSOR5 A MINIMU_ OF 10 PIPE 01_METER5

DOWN STREAM OF TEE.

CHILLER //I

PLAN VIEW

Fig. 55- 19XRV Lead Lag Schematic

F---.<

(sN,a.o)

<_E NO__) (',,t,4r)

CHILLER _/LEAD LAG CONTROL

LEAO LAG CCNRGURA_ON

(LEAD- 0 - O-AC-;_) PER JOB

LOAD BALANCE OPTION PER JOB

COMMON SENSOR OP_ON _WSABL_/ENABLE

{_IZ NOTE _)

LAG _ CAPACITY PER JOB

LAG ADDRESS '_ PER JOB

LAG STAR_ _MER PER JOB

LAD STOP riMER PER JOB

PRESI'ART FAUL_ TIMER PER JOB

ACORESS OF CH_LL_:R #I

-- :::I) Te_M_N,',LBLOC<

(R_D)

CN_LL_ l(l

ICVC

0000

CONTROL PANE].

CHILLER #1 CONTROL¢,

CHILLER #l/LEAD LA_ _ON1RO.

LEAD LAG CONR_URATION

(L_AO=I) -- (LAG=2) PER JOB

LOAD BALANCE OPTION PER JOB

COMMON SENSOR OP_ON {S_E N[_

[_SABLZ ABLE

LAG _ CAPACITY PER JOB

LAG ADDRESS * PER JOB

LAG _TART TIMER PE_R JOB

LAG STOP _M_ PER JOB

PRESIART FAULI _MER PER JOB

ADORE55 (3F" CH;LLER #2

(}.fILLER #T21LEAD LA¢ CONTROL

LEAD LAG CONFIGURATION

(LEAD=l) -- (LAG=2] PER JOB

LOAD S_LANCE OPTION PER JOB

C(_AMON SE]qSOR OPTION DISABLE

[SEE NOTE _,)

LAG _. C_PAOTY pER JOB

LAG ADDRESS * PER dOS

LAG START TIMER P_ ,JOB

LAG STOP "nMER PER JOB

PRESTART FAULT "IJ3M_ P{_:_ JOB

• ADDRESS OF" CHILLER #t

PANEL

CHILLER #2

(sE_NO_ #2)

BECM

_2e

CHILLER #I

LJ_

PLAN VIEW

I00 {'/.}11

I(_) (=)1 I

I0=0 (_.}11

Fig. 55 -- 19XRV Lead Lag Schematic (cont)

PLAN VIEW

_._ GROUND DRAIN WIRE

DRAIN WIRE

BLACK --

-- WHITE ----'Y/

--RED-- -- --V-I-I---

IIi

II_

III

DRAIN WIRE

-- - BLACK

WHITE -- -- --

- RED ._ BLACK

WHITE

"_- RED-

ill

Ill

LJ.J

i i

' 1

II i

DRAIN WIRE

---- BLACK

__ i -WHI_ -- -- --

.... RED

II I

Ill

.LLI

i i

,©

i i

i¢

i i

,©

19XRV CHILLERS

LEGEND

1 -- Carrier Comfort Network (CCN) Interface

2 -- Circuit Breakers

3 -- Control Panel Internal View

4-- Chiller Control Module (CCM)

Factory Wiring

Field Wiring

NOTE: Field supplied terminal strip must be located in control panel.

Fig. 56 -- CCN Communication Wiring For Multiple Chillers (Typical)

APPENDIX-- 19XRV LIQUIFLO TM 2 ICVC PARAMETER INDEX

MENU TABLE SCREEN NAME CONFIGURABLE

PARAMETER SOFTKEY

0% Actual Guide Vane Position SERVICE CONTROL TEST GUIDE VANE CALIBRATION X

100% Actual Guide Vane Position SERVICE CONTROL TEST GUIDE VANE CALIBRATION X

1stcurrent Alarm State SERVICE CONTROL ALGORITHM STATUS CUR ALARM

20mA Demand Limit Opt SERVICE EQUIPMENT SERVICE RAMP DEM X

2 nd Current Alarm State SERVICE CONTROL ALGORITHM STATUS CUR ALARM

3 rd Current Alarm State SERVICE CONTROL ALGORITHM STATUS CUR ALARM

4 th Current Alarm State SERVICE CONTROL ALGORITHM STATUS CURALARM

5thCurrent Alarm State SERVICE CONTROL ALGORITHM STATUS CURALARM

Active Delta P STATUS HEAT EX

Active Delta T STATUS HEAT EX

Active Demand Limit STATUS MAINSTAT X

Actual Guide Vane Pos STATUS STARTUP

Actual Guide Vane Pos STATUS COMPRESS

Actual Guide Vane Pos SERVICE CONTROL ALGORITHM STATUS CAPACITY

Actual Guide Vane Position SERVICE CONTROL TEST GUIDE VANE CALIBRATION

Actual Guide Vane Position SERVICE CONTROL TEST IGV & SRD ACTUATOR

Actual Superheat SERVICE CONTROL ALGORITHM STATUS OVERRIDE

Actual VFD Speed STATUS COMPRESS

Actual VFD Speed STATUS POWER

Actual VFD Speed SERVICE CONTROL ALGORITHM STATUS CAPACITY

Actual VFD Speed SERVICE CONTROL ALGORITHM STATUS VFD HIST

Address SERVICE ICVC CONFIGURATION X

Alarm Configuration SERVICE EQUIPMENT CONFIGURATION NET OPT

ALARM HISTORY SERVICE

Alarm Relay Test SERVICE CONTROL TEST DISCRETE OUTPUTS X

Alarm Routing SERVICE EQUIPMENT CONFIGURATION NET OPT X

ALERT HISTORY SERVICE

Amps or kW Ramp %/Min. SERVICE EQUIPMENT SERVICE RAMP DEM X

Amps/kW Ramp SERVICE CONTROL ALGORITHM STATUS CAPACITY

ATTACH TO NETWORK DEVICE SERVICE

Auto Chilled Water Reset STATUS MAINSTAT

Auto Demand Limit Input STATUS MAINSTAT

Auto Restart Option SERVICE EQUIPMENT SERVICE OPTIONS X

Average Line Current STATUS POWER

Average Line Voltage STATUS POWER

Average Load Current STATUS POWER

Base Demand Limit SETPOINT SETPOINT X

Baud Rate SERVICE ICVC CONFIGURATION X

Broadcast Option SERVICE EQUIPMENT CONFIGURATION NET OPT X

Bus Number SERVICE ICVC CONFIGURATION X

Capacity Control SERVICE CONTROL ALGORITHM STATUS CAPACITY

Capacity Control SERVICE EQUIPMENT SERVICE SETUP2

CCM Pressure Transducers SERVICE CONTROL TEST

CCM Temperature Thermistors SERVICE CONTROL TEST

CCN DEFAULT SCREEN X

CCN Mode? STATUS ICVC PWD X

CCN Occupancy Config: SERVICE EQUIPMENT CONFIGURATION NET OPT

CCN Time Schedule SCHEDULE OCCP03S X

CCN Time Schedule (OCCPC03S) SERVICE EQUIPMENT CONFIGURATION OCCDEFCS X

Chill Water Pulldown/Min STATUS HEAT EX

Chilled Medium SERVICE EQUIPMENT SERVICE SETUP1 X

Chilled Water Deadband SERVICE EQUIPMENT SERVICE SETUP1 X

Chilled Water Delta P STATUS HEAT EX

Chilled Water Delta P SERVICE CONTROL TEST PRESSURE TRANSDUCERS

Chilled Water Delta P SERVICE CONTROL TEST PUMPS

Chilled Water Delta T STATUS HEAT EX

Chilled Water Flow STATUS STARTUP

Chilled Water Flow SERVICE CONTROL TEST PUMPS

Chilled Water Pump STATUS STARTUP

Chilled Water Pump SERVICE CONTROL TEST PUMPS

127

APPENDIX -- 19XRV LIQUlFLO TM 2 ICVC PARAMETER INDEX (cont)

MENU TABLE SCREEN NAME CONFIGURABLE

PARAMETER SOFTKEY

Chilled Water Temp STATUS MAINSTAT

Chilled Water Temp SERVICE CONTROL ALGORITHM STATUS WSMDEFME

Chiller Fault State SERVICE CONTROL ALGORITHM STATUS VFD HIST

Chiller Start/Stop STATUS MAINSTAT X

CHW Delta T->Full Reset SERVICE EQUIPMENT SERVICE TEMP CTL X

CHW Delta T->No Reset SERVICE EQUIPMENT SERVICE TEMP CTL X

CHW Setpt Reset Value SERVICE CONTROL ALGORITHM STATUS WSMDEFME

Commanded State SERVICE CONTROL ALGORITHM STATUS WSMDEFME

Common Sensor Option SERVICE EQUIPMENT SERVICE LEADLAG X

Comp Discharge Alert SERVICE CONTROL ALGORITHM STATUS OVERRIDE

Comp Discharge Alert SERVICE EQUIPMENT SERVICE SETUP1 X

Comp Discharge Temp STATUS COMPRESS

Comp Discharge Temp SERVICE CONTROL ALGORITHM STATUS OVERRIDE

Comp Discharge Temp SERVICE CONTROL TEST THERMITORS

Comp Motor Temp Override SERVICE CONTROL ALGORITHM STATUS OVERRIDE

Comp Motor Temp Override SERVICE EQUIPMENT SERVICE SETUP1 X

Comp Motor Winding Temp STATUS COMPRESS

Comp Motor Winding Temp SERVICE CONTROL ALGORITHM STATUS OVERRIDE

Comp Motor Winding Temp SERVICE CONTROL TEST THERMITORS

Comp Thrust Brg Alert SERVICE CONTROL ALGORITHM STATUS OVERRIDE

Comp Thrust Brg Alert SERVICE EQUIPMENT SERVICE SETUP1 X

Comp Thrust Brg Temp STATUS COMPRESS

Comp Thrust Brg Temp SERVICE CONTROL ALGORITHM STATUS OVERRIDE

Comp Thrust Brg Temp SERVICE CONTROL TEST THERMITORS

Compressor 100% Speed SERVICE VFD CONFIG DATA VFD CONF X

Compressor Ontime STATUS MAINSTAT

Compressor Ontime DEFAULT SCREEN

Cond Approach Alert SERVICE EQUIPMENT SERVICE SETUP1 X

Cond Flow Delta P Cutout SERVICE EQUIPMENT SERVICE SETUP1 X

Cond Press Override SERVICE CONTROL ALGORITHM STATUS OVERRIDE

Cond Press Override SERVICE EQUIPMENT SERVICE SETUP1 X

Condenser Approach STATUS HEAT EX

Condenser Freeze Point SERVICE EQUIPMENT SERVICE SETUP1 X

Condenser High Pressure STATUS VFD STAT

Condenser Pressure STATUS HEAT EX

Condenser Pressure SERVICE CONTROL ALGORITHM STATUS OVERRIDE

Condenser Pressure SERVICE CONTROL TEST PRESSURE TRANSDUCERS

Condenser Refrig Temp STATUS HEAT EX

Condenser Refrig Temp SERVICE CONTROL ALGORITHM STATUS OVERRIDE

Condenser Refrigerant Temperature DEFAULT SCREEN

Condenser Water Delta P STATUS HEAT EX

Condenser Water Delta P SERVICE CONTROL TEST PRESSURE TRANSDUCERS

Condenser Water Delta P SERVICE CONTROL TEST PUMPS

Condenser Water Flow STATUS STARTUP

Condenser Water Flow SERVICE CONTROL TEST PUMPS

Condenser Water Pump STATUS STARTUP

Condenser Water Pump SERVICE CONTROL TEST PUMPS

CONSUME SERVICE EQUIPMENT CONFIGURATION CONSUME X

Control Mode STATUS MAINSTAT

Control Point SERVICE CONTROL ALGORITHM STATUS CAPACITY

Control Point STATUS MAINSTAT X

Control Point SERVICE EQUIPMENT SERVICE TEMP CTL

Control Point SETPOINT SETPOINT X

Control Point Error SERVICE CONTROL ALGORITHM STATUS CAPACITY

CONTROL TEST SERVICE

Current CHW Setpoint SERVICE CONTROL ALGORITHM STATUS WSMDEFME

Current Date SERVICE TIME AND DATE X

Current Mode SERVICE CONTROL ALGORITHM STATUS LL MAINT

Current Time SERVICE TIME AND DATE X

128

APPENDIX -- 19XRV LIQUlFLO TM 2 ICVC PARAMETER INDEX (cont)

MENU TABLE SCREEN NAME CONFIGURABLE

PARAMETER SOFTKEY

Date SERVICE TIME AND DATE X

Day of Week SERVICE TIME AND DATE X

Daylight Savings SERVICE EQUIPMENT CONFIGURATION BRODEF X

DC Bus Voltage STATUS POWER

DC Bus Voltage SERVICE CONTROL ALGORITHM STATUS VFD HIST

DC Bus Voltage Reference STATUS POWER

DC Bus Voltage Reference SERVICE CONTROL ALGORITHM STATUS VFD HIST

Decrease Ramp Time SERVICE VFD CONFIG DATA VFD CONF X

Degrees Reset SERVICE EQUIPMENT SERVICE TEMP CTL X

Degrees Reset At 20 mA SERVICE EQUIPMENT SERVICE TEMP CTL X

Delta P at 0% (4 mA) SERVICE EQUIPMENT SERVICE OPTIONS X

Delta P at 100% (20 mA) SERVICE EQUIPMENT SERVICE OPTIONS X

Demand Kilowatts STATUS POWER

Demand Limit and kW Ramp SERVICE EQUIPMENT SERVICE RAMP DEM

Demand Limit At 20 mA SERVICE EQUIPMENT SERVICE RAMP DEM X

Demand Limit Decrease SERVICE EQUIPMENT CONFIGURATION NET OPT X

Demand Limit Inhibit SERVICE CONTROL ALGORITHM STATUS CAPACITY

Demand Limit Prop Band SERVICE EQUIPMENT SERVICE RAMP DEM X

Demand Limit Source SERVICE EQUIPMENT SERVICE RAMP DEM X

Demand Watts Interval SERVICE EQUIPMENT SERVICE RAMP DEM X

Description SERVICE ICVC CONFIGURATION

Device Name SERVICE ICVC CONFIGURATION

Diffuser 25% Load Point SERVICE EQUIPMENT SERVICE SETUP2 X

Diffuser 50% Load Point SERVICE EQUIPMENT SERVICE SETUP2 X

Diffuser 75% Load Point SERVICE EQUIPMENT SERVICE SETUP2 X

Diffuser Actuator STATUS COMPRESS

Diffuser Actuator SERVICE CONTROL TEST

Diffuser Actuator SERVICE CONTROL TEST IGV & SRD ACTUATOR

Diffuser Actuator SERVICE CONTROL TEST DIFFUSER ACTUATOR X

Diffuser Control SERVICE EQUIPMENT SERVICE SETUP2

Diffuser Full Span mA SERVICE EQUIPMENT SERVICE SETUP2 X

Diffuser Option SERVICE EQUIPMENT SERVICE SETUP2 X

Disable Service Password STATUS ICVC PWD X

Discharge Pressure SERVICE CONTROL TEST PRESSURE TRANSDUCERS

Discrete Outputs Control Test SERVICE CONTROL TEST

ECW Control Option SERVICE EQUIPMENT SERVICE TEMP CTL X

ECW Delta T SERVICE CONTROL ALGORITHM STATUS CAPACITY

ECW Reset SERVICE CONTROL ALGORITHM STATUS CAPACITY

ECW Setpoint SETPOINT SETPOINT X

Emergency Stop STATUS MAINSTAT X

Enable Reset Type SERVICE EQUIPMENT SERVICE TEMP CTL X

Entering Chilled Water STATUS HEAT EX

Entering Chilled Water STATUS CONTROL ALGORITHM STATUS CAPACITY

Entering Chilled Water DEFAULT SCREEN

Entering Chilled Water SERVICE CONTROL TEST THERMITORS

Entering Cond Water SERVICE CONTROL TEST THERMITORS

Entering Condenser Water STATUS HEAT EX

Entering Condenser Water DEFAULT SCREEN

Equipment Status SERVICE CONTROL ALGORITHM STATUS WSMDEFME

Evap Approach Alert SERVICE EQUIPMENT SERVICE SETUP1 X

Evap Flow Delta P Cutout SERVICE EQUIPMENT SERVICE SETUP1 X

Evap Ref Override Temp SERVICE CONTROL ALGORITHM STATUS OVERRIDE

Evap Refrig Trippoint SERVICE EQUIPMENT SERVICE SETUP1 X

Evap Saturation Temp STATUS HEAT EX

Evap Saturation Temp SERVICE CONTROL TEST THERMITORS

Evaporator Approach STATUS HEAT EX

Evaporator Pressure STATUS HEAT EX

Evaporator Pressure SERVICE CONTROL TEST PRESSURE TRANSDUCERS

129

APPENDIX -- 19XRV LIQUlFLO TM 2 ICVC PARAMETER INDEX (cont)

MENU TABLE SCREEN NAME CONFIGURABLE

PARAMETER SOFTKEY

Evaporator Refrig Temp STATUS HEAT EX

Evaporator Refrig Temp SERVICE CONTROL ALGORITHM STATUS OVERRIDE

Evaporator Refrigerant Temperature DEFAULT SCREEN

Flow Delta P Display SERVICE EQUIPMENT SERVICE SETUP1 X

Flux Current STATUS POWER

Flux Current SERVICE CONTROL ALGORITHM STATUS VFD HIST

Frequency Fault STATUS VFD STAT

Full Load Point (T2, P2) SERVICE EQUIPMENT SERVICE OPTIONS

Ground Fault STATUS VFD STAT

Ground Fault Current STATUS POWER

Ground Fault Current SERVICE CONTROL ALGORITHM STATUS VFD HIST

Group Number SERVICE EQUIPMENT CONFIGURATION NET OPT X

Guide Vane 25% Load Pt SERVICE EQUIPMENT SERVICE SETUP2 X

Guide Vane 50% Load Pt SERVICE EQUIPMENT SERVICE SETUP2 X

Guide Vane 75% Load Pt SERVICE EQUIPMENT SERVICE SETUP2 X

Guide Vane Calibration SERVICE CONTROL TEST

Guide Vane Control SERVICE CONTROL TEST IGV & SRD ACTUATOR X

Guide Vane Delta SERVICE CONTROL ALGORITHM STATUS CAPACITY

Guide Vane Delta STATUS COMPRESS

Guide Vane Travel Limit SERVICE EQUIPMENT SERVICE SETUP2 X

Head Pressure Output Control Test SERVICE CONTROL TEST X

Head Pressure Reference STATUS HEAT EX

Head Pressure Reference SERVICE EQUIPMENT SERVICE OPTIONS

Head Pressure Reference SERVICE CONTROL TEST HEAD PRESSURE OUTPUT

High DC Bus Voltage STATUS VFD STAT

High Line Voltage STATUS VFD STAT

Holiday SERVICE TIME AND DATE X

HOLIDAYS SERVICE EQUIPMENT CONFIGURATION HOLIDAYS X

Hot Gas Bypass Relay STATUS HEAT EX

Hot Gas Bypass Relay Test SERVICE CONTROL TEST DISCRETE OUTPUTS X

Humidity Sensor Input STATUS POWER

Humidity Sensor Input SERVICE CONTROL TEST PRESSURE TRANSDUCERS

Ice Build Contact STATUS MAINSTAT

Ice Build Control SERVICE EQUIPMENT SERVICE OPTIONS

Ice Build Option SERVICE EQUIPMENT SERVICE OPTIONS X

Ice Build Recycle SERVICE EQUIPMENT SERVICE OPTIONS X

Ice Build Setpoint SETPOINT SETPOINT X

Ice Build Termination SERVICE EQUIPMENT SERVICE OPTIONS X

Ice Build Time Schedule SCHEDULE OCCP02S X

Ice Build Time Schedule (OCCPC02S) SERVICE EQUIPMENT CONFIGURATION OCCDEFCS X

ICVC CONFIGURATION SERVICE

IGV & SRD Actuator SERVICE CONTROL TEST

Incompatibility Fault STATUS VFD STAT

Increase Ramp Time SERVICE VFD CONFIG DATA VFD CONF X

Inverter Overcurrent STATUS VFD STAT

Inverter Overload STATUS POWER

Inverter Overtemp STATUS VFD STAT

Inverter Power Fault STATUS VFD STAT

Inverter PWM Frequency SERVICE VFD CONFIG DATA VFD CONF X

Inverter Temp Override SERVICE CONTROL ALGORITHM STATUS OVERRIDE

Inverter Temp Override SERVICE EQUIPMENT SERVICE SETUP1 X

Inverter Temperature STATUS POWER

Inverter Temperature SERVICE CONTROL ALGORITHM STATUS OVERRIDE

Inverter Temperature SERVICE CONTROL ALGORITHM STATUS VFD HIST

LAG % Capacity SERVICE EQUIPMENT SERVICE LEADLAG X

LAG Address SERVICE EQUIPMENT SERVICE LEADLAG X

LAG CHILLER: Mode SERVICE CONTROL ALGORITHM STATUS LL MAINT

LAG Start Time SERVICE CONTROL ALGORITHM STATUS LL MAINT

LAG START Timer SERVICE EQUIPMENT SERVICE LEADLAG X

LAG Stop Time SERVICE CONTROL ALGORITHM STATUS LL MAINT

LAG STOP Timer SERVICE EQUIPMENT SERVICE LEADLAG X

130

APPENDIX -- 19XRV LIQUlFLO TM 2 ICVC PARAMETER INDEX (cont)

MENU TABLE SCREEN NAME CONFIGURABLE

PARAMETER SOFTKEY

LCW Reset SERVICE CONTROL ALGORITHM STATUS CAPACITY

LCW Setpoint SETPOINT SETPOINT X

LEAD CHILLER in Control SERVICE CONTROL ALGORITHM STATUS LLMAINT

Lead Lag Control SERVICE CONTROL ALGORITHM STATUS LLMAINT

Lead Lag Control SERVICE EQUIPMENT SERVICE LEADLAG

LEAD/LAG: Configuration SERVICE CONTROL ALGORITHM STATUS LLMAINT

LEAD/LAG: Configuration SERVICE EQUIPMENT SERVICE LEADLAG X

Leaving Chilled Water STATUS HEAT EX

Leaving Chilled Water SERVICE CONTROL ALGORITHM STATUS CAPACITY

Leaving Chilled Water DEFAULT SCREEN

Leaving Chilled Water SERVICE CONTROL TEST THERMITORS

Leaving Cond Water SERVICE CONTROL TEST THERMITORS

Leaving Condenser Water STATUS HEAT EX

Leaving Condenser Water DEFAULT SCREEN

LID Language SERVICE ICVC CONFIGURATION X

Line Active Current STATUS POWER

Line Active Current SERVICE CONTROL ALGORITHM STATUS VFD HIST

Line Active Voltage STATUS POWER

Line Active Voltage SERVICE CONTROL ALGORITHM STATUS VFD HIST

Line Current % Imbalance SERVICE VFD CONFIG DATA VFD CONF X

Line Current Imbal Time SERVICE VFD CONFIG DATA VFD CONF X

Line Current Imbalance STATUS POWER

Line Current Imbalance STATUS VFD STAT

Line Current Imbalance SERVICE CONTROL ALGORITHM STATUS VFD HIST

Line Current Phl (R) STATUS POWER

Line Current Phl (R) SERVICE CONTROL ALGORITHM STATUS VFD HIST

Line Current Ph2 (S) STATUS POWER

Line Current Ph2 (S) SERVICE CONTROL ALGORITHM STATUS VFD HIST

Line Current Ph3 (T) STATUS POWER

Line Current Ph3 (T) SERVICE CONTROL ALGORITHM STATUS VFD HIST

Line Freq=60 Hz? (No=50) SERVICE VFD CONFIG DATA VFD CONF X

Line Frequency STATUS POWER

Line Frequency SERVICE CONTROL ALGORITHM STATUS VFD HIST

Line Kilowatts STATUS POWER

Line Phase Reversal STATUS VFD STAT

Line Power Factor STATUS POWER

Line Power Factor SERVICE CONTROL ALGORITHM STATUS VFD HIST

Line Reactive Current STATUS POWER

Line Reactive Current SERVICE CONTROL ALGORITHM STATUS VFD HIST

Line Reactive Voltage STATUS POWER

Line Reactive Voltage SERVICE CONTROL ALGORITHM STATUS VFD HIST

Line Volt Imbalance Time SERVICE VFD CONFIG DATA VFD CONF X

Line Voltage % Imbalance SERVICE VFD CONFIG DATA VFD CONF X

Line Voltage Imbalance STATUS POWER

Line Voltage Imbalance STATUS VFD STAT

Line Voltage Imbalance SERVICE CONTROL ALGORITHM STATUS VFD HIST

Line Voltage Phl (RS) STATUS POWER

Line Voltage Phl (RS) SERVICE CONTROL ALGORITHM STATUS VFD HIST

Line Voltage Ph2 (ST) STATUS POWER

Line Voltage Ph2 (ST) SERVICE CONTROL ALGORITHM STATUS VFD HIST

Line Voltage Ph3 (TR) STATUS POWER

Line Voltage Ph3 (TR) SERVICE CONTROL ALGORITHM STATUS VFD HIST

Load Balance Option SERVICE CONTROL ALGORITHM STATUS LL MAINT

Load Balance Option SERVICE EQUIPMENT SERVICE LEADLAG X

Load Current Phl (U) STATUS POWER

Load Current Phl (U) SERVICE CONTROL ALGORITHM STATUS VFD HIST

Load Current Ph2 (V) STATUS POWER

Load Current Ph2 (V) SERVICE CONTROL ALGORITHM STATUS VFD HIST

Load Current Ph3 (W) STATUS POWER

Load Current Ph3 (W) SERVICE CONTROL ALGORITHM STATUS VFD HIST

131

APPENDIX -- 19XRV LIQUlFLO TM 2 ICVC PARAMETER INDEX (cont)

MENU TABLE SCREEN NAME CONFIGURABLE

PARAMETER SOFTKEY

Loadshed SERVICE CONTROL ALGORITHM STATUS LOADSHED

Loadshed Function SERVICE EQUIPMENT CONFIGURATION NET OPT

Loadshed Function SERVICE CONTROL ALGORITHM STATUS LOADSHED

Loadshed Timer SERVICE CONTROL ALGORITHM STATUS LOADSHED

LOCAL DEFAULT SCREEN X

Local Network Device SERVICE ATTACH TO NETWORK DEVICE X

Local Time Schedule SCHEDULE OCCP01S X

Local Time Schedule (OCCPC01 S) SERVICE EQUIPMENT CONFIGURATION OCCDEFCS X

LOG OUT OF DEVICE SERVICE

Low DC Bus Voltage STATUS VFD STAT

Low Line Voltage STATUS VFD STAT

Maximum Loadshed Time SERVICE EQUIPMENT CONFIGURATION NET OPT X

Min. Load Point (T1, P1) SERVICE EQUIPMENT SERVICE OPTIONS

Minimum Output SERVICE EQUIPMENT SERVICE OPTIONS X

Model Number SERVICE ICVC CONFIGURATION

Motor Amps Not Sensed STATUS VFD STAT

Motor Current % Imbalance SERVICE VFD CONFIG DATA VFD CONF X

Motor Current Imbal Time SERVICE VFD CONFIG DATA VFD CONF X

Motor Current Imbalance STATUS POWER

Motor Current Imbalance STATUS VFD STAT

Motor Current Imbalance SERVICE CONTROL ALGORITHM STATUS VFD HIST

Motor Kilowatt Hours STATUS POWER

Motor Kilowatts STATUS POWER

Motor Nameplate Amps SERVICE VFD CONFIG DATA VFD CONF X

Motor Nameplate kW SERVICE VFD CONFIG DATA VFD CONF X

Motor Nameplate RPM SERVICE VFD CONFIG DATA VFD CONF X

Motor Nameplate Voltage SERVICE VFD CONFIG DATA VFD CONF X

Motor Overload STATUS POWER

Motor Overload STATUS VFD STAT

Motor Overload SERVICE CONTROL ALGORITHM STATUS VFD HIST

Motor Power Factor STATUS POWER

Motor Power Factor SERVICE CONTROL ALGORITHM STATUS VFD HIST

Motor Rated Load Amps SERVICE VFD CONFIG DATA VFD CONF X

Motor Rated Load kW SERVICE VFD CONFIG DATA VFD CONF X

OCCPC01S (Local Time Schedule) SCHEDULE OCCP01S X

OCCPC02S (Ice Build Time Schedule) SCHEDULE OCCP02S X

OCCPC03S (CCN Time Schedule) SCHEDULE OCCP03S X

OCCPC01S (Local Time Schedule) SERVICE EQUIPMENT CONFIGURATION OCCDEFCS X

OCCPC02S (Ice Build Time Schedule) SERVICE EQUIPMENT CONFIGURATION OCCDEFCS X

OCCPC03S (CCN Time Schedule) SERVICE EQUIPMENT CONFIGURATION OCCDEFCS X

Occupied? STATUS MAINSTAT

Oil Heater Relay STATUS COMPRESS

Oil Heater Relay Test SERVICE CONTROL TEST DISCRETE OUTPUTS X

Oil Press Verify Time SERVICE EQUIPMENT SERVICE SETUP1 X

Oil Pressure DEFAULT SCREEN

Oil Pressure Acceptable? SERVICE CONTROL TEST PUMPS

Oil Pump Delta P STATUS STARTUP X

Oil Pump Delta P STATUS COMPRESS X

Oil Pump Delta P SERVICE CONTROL TEST PRESSURE TRANSDUCERS

Oil Pump Delta P SERVICE CONTROL TEST PUMPS

Oil Pump Relay STATUS STARTUP

Oil Pump Relay SERVICE CONTROL TEST PUMPS

Oil Sump Temp STATUS STARTUP

Oil Sump Temp STATUS COMPRESS

Oil Sump Temp DEFAULT SCREEN

Oil Sump Temp SERVICE CONTROL TEST THERMITORS

Password (VFD CONFIG DATA) SERVICE VFD CONFIG DATA X

Password (SERVICE) SERVICE ICVC CONFIGURATION X

132

APPENDIX -- 19XRV LIQUlFLO TM 2 ICVC PARAMETER INDEX (cont)

MENU TABLE SCREEN NAME CONFIGURABLE

PARAMETER SOFTKEY

Percent Line Current STATUS MAINSTAT

Percent Line Current STATUS POWER

Percent Line Current DEFAULT SCREEN

Percent Line Kilowatts STATUS MAINSTAT

Percent Line Kilowatts STATUS POWER

Percent Line Voltage STATUS POWER

Percent Load Current STATUS POWER

Percent Motor Kilowatts STATUS POWER

Pressure Transducers Control Test SERVICE CONTROL TEST

PRESTART FAULT Time SERVICE CONTROL ALGORITHM STATUS LL MAINT

PRESTART FAULT Timer SERVICE EQUIPMENT SERVICE LEADLAG X

PRIMARY MESSAGE DEFAULT SCREEN

Proportional Dec Band SERVICE EQUIPMENT SERVICE SETUP2 X

Proportional ECW Gain SERVICE EQUIPMENT SERVICE SETUP2 X

Proportional Inc Band SERVICE EQUIPMENT SERVICE SETUP2 X

Pulldown Ramp Type: SERVICE EQUIPMENT SERVICE RAMP DEM X

Pulldown: Delta T/Min SERVICE CONTROL ALGORITHM STATUS LL MAINT

Pumpdown/Lockout Control Test SERVICE CONTROL TEST X

Pumpdown/Lockout Control Test SERVICE CONTROL TEST CONTROL TEST

Pumps Control Test SERVICE CONTROL TEST

Rated Line Amps SERVICE VFD CONFIG DATA VFD CONF X

Rated Line Kilowatts SERVICE VFD CONFIG DATA VFD CONF X

Rated Line Voltage SERVICE VFD CONFIG DATA VFD CONF X

Re-alarm Time SERVICE EQUIPMENT CONFIGURATION NET OPT X

Recovery Start Request SERVICE CONTROL ALGORITHM STATUS LLMAINT

Rectifier Overcurrent STATUS VFD STAT

Rectifier Overload STATUS POWER

Rectifier Overtemp STATUS VFD STAT

Rectifier Power Fault STATUS VFD STAT

Rectifier Temp Override SERVICE CONTROL ALGORITHM STATUS OVERRIDE

Rectifier Temp Override SERVICE EQUIPMENT SERVICE SETUP1 X

Rectifier Temperature STATUS POWER

Rectifier Temperature SERVICE CONTROL ALGORITHM STATUS OVERRIDE

Rectifier Temperature SERVICE CONTROL ALGORITHM STATUS VFD HIST

Recycle Control SERVICE EQUIPMENT SERVICE SETUP1 X

Redline SERVICE CONTROL ALGORITHM STATUS LOADSHED

Reference Number SERVICE ICVC CONFIGURATION

Refrig Override Delta T SERVICE EQUIPMENT SERVICE SETUP1 X

Relative Humidity SERVICE CONTROL TEST PRESSURE TRANSDUCERS

Relative Humidity STATUS POWER

Remote Contacts Option SERVICE EQUIPMENT SERVICE OPTIONS X

Remote Reset Option STATUS ICVC PWD X

Remote Reset Sensor STATUS MAINSTAT

Remote Reset Sensor SERVICE CONTROL TEST THERMITORS

Remote Start Contact STATUS MAINSTAT X

Remote Temp->Full Reset SERVICE EQUIPMENT SERVICE TEMP CTL X

Remote Temp->No Reset SERVICE EQUIPMENT SERVICE TEMP CTL X

RESET DEFAULT SCREEN X

Reset Alarm? STATUS ICVC PWD X

RESET TYPE 1 SERVICE EQUIPMENT SERVICE TEMP CTL

RESET TYPE 2 SERVICE EQUIPMENT SERVICE TEMP CTL

RESET TYPE 3 SERVICE EQUIPMENT SERVICE TEMP CTL

Restart Delta T SERVICE EQUIPMENT SERVICE SETUP1 X

Run Status SERVICE CONTROL ALGORITHM STATUS LL MAINT

Run Status STATUS MAIN STAT

133

APPENDIX -- 19XRV LIQUlFLO TM 2 ICVC PARAMETER INDEX (cont)

MENU TABLE SCREEN NAME CONFIGURABLE

PARAMETER SOFTKEY

RUNTIME SERVICE EQUIPMENT CONFIGURATION RUNTIME X

Schedule Number SERVICE EQUIPMENT CONFIGURATION NET OPT X

SECONDARY MESSAGE DEFAULT SCREEN

Serial Number SERVICE ICVC CONFIGURATION

Service Ontime STATUS MAINSTAT

Shunt Trip Relay STATUS STARTUP

Shunt Trip Relay Test SERVICE CONTROL TEST DISCRETE OUTPUTS X

Shutdown Delta T SERVICE EQUIPMENT SERVICE SETUP1 X

Single Cycle Dropout STATUS VFD STAT

Single Cycle Dropout SERVICE VFD CONFIG DATA VFD_CONF X

Skip Frequency 1 SERVICE VFD CONFIG DATA VFD CONF X

Skip Frequency 2 SERVICE VFD CONFIG DATA VFD_CONF X

Skip Frequency 3 SERVICE VFD CONFIG DATA VFD CONF X

Skip Frequency Band SERVICE VFD CONFIG DATA VFD CONF X

Soft Stop Amps Threshold SERVICE EQUIPMENT SERVICE OPTIONS X

Software Part Number SERVICE ICVC CONFIGURATION

Spare Alert/Alarm Enable SERVICE EQUIPMENT SERVICE SETUP1

Spare Safety Input STATUS STARTUP

Spare Temp #1 Enable SERVICE EQUIPMENT SERVICE SETUP1 X

Spare Temp #1 Limit SERVICE EQUIPMENT SERVICE SETUP1 X

Spare Temp #2 Enable SERVICE EQUIPMENT SERVICE SETUP1 X

Spare Temp #2 Limit SERVICE EQUIPMENT SERVICE SETUP1 X

Spare Temperature 1 STATUS COMPRESS

Spare Temperature 1 SERVICE CONTROL ALGORITHM STATUS LL MAINT

Spare Temperature 1 SERVICE CONTROL TEST THERMITORS

Spare Temperature 2 STATUS COMPRESS

Spare Temperature 2 SERVICE CONTROL ALGORITHM STATUS LL MAINT

Spare Temperature 2 SERVICE CONTROL TEST THERMITORS

STANDBY % Capacity SERVICE EQUIPMENT SERVICE LEADLAG X

STANDBY Address SERVICE EQUIPMENT SERVICE LEADLAG X

STANDBY Chiller Option SERVICE EQUIPMENT SERVICE LEADLAG X

STANDBY CHILLER: Mode SERVICE CONTROL ALGORITHM STATUS LL_MAINT

Start Acceleration Fault STATUS VFD_STAT

Start Advance SERVICE EQUIPMENT CONFIGURATION BRODEF X

Start Complete STATUS STARTU P

Start Complete STATUS VFD_STAT

Start Day of Week SERVICE EQUIPMENT CONFIGURATION BRODEF X

Start Inhibit Timer STATUS MAINSTAT

Start Month SERVICE EQUIPMENT CONFIGURATION BRODEF X

Start Time SERVICE EQUIPMENT CONFIGURATION BRODEF X

Start Week SERVICE EQUIPMENT CONFIGURATION BRODEF X

Start/Stop SERVICE CONTROL ALGORITHM STATUS LL MAINT

Starts In 12 Hours STATUS MAINSTAT

Stop Back SERVICE EQUIPMENT CONFIGURATION BRODEF X

Stop Complete STATUS STARTU P

Stop Complete STATUS VFD_STAT

Stop Day of Week SERVICE EQUIPMENT CONFIGURATION BRODEF X

Stop Fault STATUS VFD_STAT

Stop Month SERVICE EQUIPMENT CONFIGURATION BRODEF X

Stop Time SERVICE EQUIPMENT CONFIGURATION BRODEF X

Stop Week SERVICE EQUIPMENT CONFIGURATION BRODEF X

Superheat Required SERVICE CONTROL ALGORITHM STATUS OVERRIDE

Surge/HGBP Active? STATUS HEAT_EX

Surge/Hot Gas Bypass SERVICE EQUIPMENT SERVICE OPTIONS

Surge Delta % Amps SERVICE EQUIPMENT SERVICE OPTIONS X

Surge Limit/HGBP Option SERVICE EQUIPMENT SERVICE OPTIONS X

Surge Protection SERVICE EQUIPMENT SERVICE OPTIONS

Surge Protection Counts STATUS COMPRESS

Surge Time Period SERVICE EQUIPMENT SERVICE OPTIONS X

134

APPENDIX -- 19XRV LIQUlFLO TM 2 ICVC PARAMETER INDEX (cont)

MENU TABLE SCREEN NAME CONFIGURABLE

PARAMETER SOFTKEY

Surge/HGBP Deadband SERVICE EQUIPMENT SERVICE OPTIONS X

Surge/RGBP Delta P1 SERVICE EQUIPMENT SERVICE OPTIONS X

Surge/RGBP Delta P2 SERVICE EQUIPMENT SERVICE OPTIONS X

Surge/RGBP Delta T STATUS HEAT EX

Surge/RGBP Delta T1 SERVICE EQUIPMENT SERVICE OPTIONS X

Surge/RGBP Delta T2 SERVICE EQUIPMENT SERVICE OPTIONS X

System Alert/Alarm STATUS MAINSTAT

Target Guide Vane Pos STATUS COMPRESS X

Target Guide Vane Pos SERVICE CONTROL ALGORITHM STATUS CAPACITY

Target VFD Speed STATUS COMPRESS X

Target VFD Speed STATUS STARTUP

Target VFD Speed SERVICE CONTROL ALGORITHM STATUS CAPACITY

Temp Pulldown Deg/Min. SERVICE EQUIPMENT SERVICE TEMP CTL X

Temperature Reset STATUS MAINSTAT

Temperature Reset SERVICE EQUIPMENT SERVICE TEMP CTL

Terminate Lockout SERVICE EQUIPMENT SERVICE CONTROL TEST X

Thermistors Control Test SERVICE CONTROL TEST

TIME AND DATE SERVICE TIME AND DATE

Time Broadcast Enable SERVICE EQUIPMENT CONFIGURATION BRODEF

Torque Current STATUS POWER

Torque Current SERVICE CONTROL ALGORITHM STATUS VFD HIST

Total Compressor Starts STATUS MAINSTAT

Total Error + Resets SERVICE CONTROL ALGORITHM STATUS CAPACITY

Tower Fan High Setpoint SETPOINT SETPOINT X

Tower Fan Relay High STATUS STARTUP

Tower Fan Relay High Test SERVICE CONTROL TEST DISCRETE OUTPUTS X

Tower Fan Relay Low STATUS STARTUP

Tower Fan Relay Low Test SERVICE CONTROL TEST DISCRETE OUTPUTS X

Transducer Voltage Ref SERVICE CONTROL TEST PRESSURE TRANSDUCERS

US Imp /Metric SERVICE ICVC CONFIGURATION X

Values at Last Fault: SERVICE CONTROL ALGORITHM STATUS VFD HIST

VFD Checksum Error STATUS VFD STAT

VFD Cold Plate Temp STATUS POWER

VFD Cold Plate Temp SERVICE CONTROL ALGORITHM STATUS VFD HIST

VFD Comm Fault STATUS VFD STAT

VFD CONFIG PASSWORD SERVICE VFD CONFIG DATA X

VFD Coolant Flow STATUS HEAT EX

VFD Coolant Flow STATUS POWER

VFD Coolant Solenoid Test SERVICE CONTROL TEST DISCRETE OUTPUTS X

VFD Enclosure Temp STATUS POWER

VFD Enclosure temp SERVICE CONTROL ALGORITHM STATUS VFD HIST

VFD Fault STATUS VFD STAT

VFD Fault Code STATUS VFD STAT

VFD Fault Code SERVICE CONTROL ALGORITHM STATUS VFD HIST

VFD FAULT HISTORY SERVICE CONTROL ALGORITHM STATUS VFD HIST

VFD Gain SERVICE EQUIPMENT SERVICE SETUP2 X

VFD Gateway Version # STATUS VFD STAT

VFD Increase Step SERVICE EQUIPMENT SERVICE SETUP2 X

VFD Inverter Version # STATUS VFD STAT

VFD Maximum Speed SERVICE EQUIPMENT SERVICE SETUP2 X

VFD Minimum Speed SERVICE EQUIPMENT SERVICE SETUP2 X

VFD Power On Reset STATUS VFD STAT

VFD Rectifier Version # STATUS VFD STAT

VFD Speed Control SERVICE EQUIPMENT SERVICE SETUP2

VFD Start STATUS STARTUP

VFD Start Inhibit STATUS VFD STAT

Water Flow Verify Time SERVICE EQUIPMENT SERVICE SETUP1 X

WSM Active? SERVICE CONTROL ALGORITHM STATUS WSMDEFME

135

INDEX

Abbreviations and explanations 4, 5 Notes on module operation 97

Adding refrigerant 74 Oil changes 76

Adjusting the refrigerant charge 74 Oil charge .52

After extended shutdown 69 Oil cooler 39

Alter limited shutdown 69 Oil pressure _mdcompressor stop (check) 67

Alarm (trip) output contacts 40 Oil reclaim filter 76

Attach to network device control 47 Oil reclaim system 8

Automatic soft stop amps threshold 51 Oil specification 76

Auto. restart alter power failure 42 Oil sump temperature and pump control 39

Bearings 8Open oil circuit valves .52

Before initial start-up .52-67 Operating instructions 68-70

Capacity override .;9 Operating the optional pumpout unit 71

Carrier Comfort Network interface 60 Operator duties 68

Changing oil filter 76 Optional pumpout compressor

Charge refrigerant into chiller 65 water piping (check) 5_5'

Chilled water recycle mode 51 Optional pumpout system controls and

Chiller control module (CCM) 97 compressor(check) 65

Chiller dehydration 58 Optional pumpout system maintenance 78

Chiller familiarization 5, 6 Ordering replacement chiller parts 78

Chiller information nameplate 5Overview (troubleshooting guide) 79

Chiller operating condition (check) 68 Perform a control test 64

Chiller tightness (check) 53 Physical data 99

Chillers with isolation valves 73 PIC III system components 11

Chillers with storage tanks 71 PIC III system functions .;4

Cold weather operation 69 Power up the controls and check

Compressor bearing and gear maintenance 77 the oil heater 61

Condenser 5Preparation (initialstart-up) 67

Condenser freeze prevention 41 Preparation (pumpout and refrigerant

Condenser pump control 41 transfer procedures) 71

Control algorithms checkout procedure 80 Prepare the chiller for start-up 68

Controlpanel 5Pressure transducers (check) 79

Control modules 97 Prevent accidental start-up 67

Control test 64,81 Pumpont and refrigerant transfer

Controls 11-49 procedures 71-74

Cooler 5Ramp loading 39

Defimlt screen freeze .;6 Recalibmte pressure transducers 7,5'

Definitions (controls) 11 Refrigerant filter 76

Design set points, (input) 61 Refrigerant float system (inspect) 77

Details (lubrication cycle) 8Refrigerant leak testing 74

Display messages (check) 79 Refrigerant properties 74

Equipment required .52 Refrigerant (removing) 74

Evaporator freeze protection 41 Refrigerant tracer 53

Extended shutdown (preparation for) 69 Refrigeration cycle 7

General (controls) 11 Refrigeration log 69

General maintenance 74, 75 Relief valves (check) 58

Ground fault troubleshooting 60 Relief valves and piping (inspect) 77

Guide vane linkage (check) 7.5 Remote reset of alarms 41

Head pressure reference output 44 Remote start/stop controls 40

Heat exchanger tubes and Repair the leak, retest, and

flow devices (inspect) 77 apply standing vacuum test 7.5

High altitude locations 65 Replacing defective processor modules 98'

High discharge temperature control .;9 Running system (check) 68

Ice build control 46 Safety and operating controls

ICVC operation and menus 16 (check monthly) 76

Initial start-up 6Z 6_5' Safety considerations 1

Initial start-up checklist for 19XRV hermetic Safety controls .;6

centrifugal liquid chiller CL-lro CL-12 Safety shutdown 52

Input power wiring 59 Scheduled maintenance 75-78

Inspect the control panel 76 Service configurations (input) 61

Instruct the customer operator 68 Ser_.ice ontime 7.5

Introduction 4Seta.'ice operation 48'

Job data required .52 Shipping packaging (remove) .52

Kilowatt output 41 Shunt trip (option) 36

Lead/lag control 44 Shutdown sequence 51

Leak rate 74 Software configuration 61

Leak test chiller .5.5 Spare safety and space temperature inputs 40

Local occupied schedule (input) 61 Standing vacuum test 55

Local start-up 50 Starting equipment 9-11

Lubrication cycle 8, 9 Start-up/shutdown/recycle sequence 50-.52

Lubrication system (check) 7.5 Start the chiller 68

Manual guide vane operation 69 Stop the chiller 69

Motor and lubricating oil cooling cycle 7Storage vessel 5

Motor-compressor 5Sunnnary (lubrication cycle) 8

Motor rotation (check) 67 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

Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.

PC 211 Catalog No. 531-986 Printed in U.S.A. Form 19XRV-1SS Pg 136 4-05 Replaces: New

INITIAL START-UP CHECKLIST

FOR 19XRV HERMETIC CENTRIFUGAL LIQUID CHILLER

(Remove and use for job file.)

MACHINE INFORMATION:

NAME

ADDRESS

CITY STATE

JOB NO.

MODEL

ZIP S/N

DESIGN CONDITIONS:

TONS BRINE

(kW)

COOLER

CONDENSER

FLOW TEMPERATURE

RATE IN TEMPERATURE PRESSURE PASS SUCTION

OUT DROP TEMPERATURE CONDENSER

TEMPERATURE

COMPRESSOR: Volts

STARTER: Mfg

OIL PUMP: Volts

RLA OLTA

Type S/N

RLA OLTA

REFRIGERANT: Type: __

CARRIER OBLIGATIONS:

Charge __

Assemble ................... Yes [] No []

Leak Test ................... Yes [] No []

Dehydrate .................. Yes [] No []

Charging ................... Yes [] No []

Operating Instructions Hrs.

START-UP TO BE PERFORMED IN ACCORDANCE WITH APPROPRIATE MACHINE START-UP INSTRUCTIONS

JOB DATA REQUIRED:

1. Machine Installation Instructions .................. Yes [] No []

2. Machine Assembly, Wiring and Piping Diagrams ...... Yes [] No []

3. Starting Equipment Details and Wiring Diagrams ...... Yes [] No []

4. Applicable Design Data (see above) ................ Yes [] No []

5. Diagrams and Instructions for Special Controls ....... Yes [] No []

INITIAL MACHINE PRESSURE:

YES NO

Was Machine Tight?

If Not, Were Leaks Corrected?

Was Machine Dehydrated After Repairs?

CHECK OIL LEVEL AND RECORD:

RECORD PRESSURE DROPS: Cooler

CHARGE REFRIGERANT: Initial Charge

3/4

1/2 Top sight glass

1/4

3/4

1/2 Bottom sight glass

1/4

ADD OIL: Yes []

Amount:

No []

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.

Book 2h PC 211 Catalog No, 531-986 Printed in U.S,A. Form 19XRV-1SS CL-1 4-05 Replaces: New

Tab

INSPECT WIRING AND RECORD ELECTRICAL DATA:

RATINGS:

Motor Voltage Motor(s) Amps Oil Pump Voltage Starter LRA Rating

Line Voltages: Motor Oil Pump Controls/Oil Heater

FIELD-INSTALLED 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.

MEGGER MOTOR "PHASE TO PHASE .... PHASE TO GROUND"

T1 -T2 T1 -T3 T2-T3 T1-G T2-G T3-G

10-Second Readings:

60-Second Readings:

Polarization Ratio:

VFD Manufacturer

VFD Serial Number

VFD Date Code

CONTROLS: SAFETY, OPERATING, ETC.

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: Do these safeties shut down machine?

Condenser Water Flow Yes [] No []

Chilled Water Flow Yes [] No []

Pump Interlocks Yes [] No []

Yes

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

Check Compressor Motor Rotation (Motor End Sight Glass) and Record: Clockwise

Restart Compressor, Bring Up To Speed. Shut Down. Any Abnormal Coastdown Noise?

*If yes, determine cause.

Yes* [] No []

START MACHINE AND OPERATE. COMPLETE THE FOLLOWING:

A: Trim charge and record under Charge Refrigerant Into Chiller section on page 65.

B: Complete any remaining control calibration and record under Controls section (pages 11-49).

C: Take at least two sets of operational log readings and record.

D: After machine has been successfully run and set up, shut down and mark shutdown oil and refrigerant levels.

E: Give operating instructions to owner's operating personnel. Hours Given: Hours

F: Call your Carrier factory representative to report chiller start-up.

SIGNATURES:

CARRIER

TECHNICIAN CUSTOMER

REPRESENTATIVE

DATE DATE

CL-2

I-

CO/WO

19XRV PIC III SETPOINT 3ABLE CONFIGURATION StIEET

DESCRIlrrlON RANGE UNITS DEFAULT VALUE

Base Demand Limit 40 to 100 %100

10to 120

LCW Setpoint (- 12.2 to 48.9) DEG F (C) 50.0 (10)

15to 120

ECW Setpoint (-9.4 to 48.9) DEG F (C) 60.0 (15.6)

15 to 60

Ice Build Setpoint (-9.4 to 15.6) DEG F (C) 40.0 (4.4)

55 to 105

Tower Fan Itigh Setpoint (13 to 41 ) DEG F (C) 75 (24)

Upload all control configuration tables via service tool'? Yes [] No []

ICVC Softwme Version Number:

ICVC Controller Identification: BUS: ADDRESS:

CL-3

Period 1:

Period 2:

Period 3:

Period 4:

Period 5:

Period 6:

Period 7:

19XRV PIC III TIME SCHEDULE CONFIGURATION SHEET OCCPC01S

Day Flag Occupied

M T W T F S S II Time

Period 8:

NOTE: Default setting isOCCUPIED 24 hours/day.

IICE BUILD 19XRV PIC III TIME SCHEDULE CONFIGURATION SHEET OCCPC02S

Period 1:

Period 2:

Period 3:

Period 4:

Period 5:

Period 6:

Period 7:

Period 8:

Unoccupied

Time

NOTE: Default setting is UNOCCUPIED 24 hours/day.

Day Flag Occupied Unoccupied

M T W T F S S It Time Time

19XRV PIC III TIME SCHEDULE CONFIGURATION SHEET OCCPC03S

Day Flag Occupied Unoccupied

M T W T F S S It Time Time

CL-4

Period 1:

Period 2:

Period 3:

Period 4:

Period 5:

Period 6:

Period 7:

Period 8:

NOTE: Default setting isOCCUPIED 24 hours/day.

I-

19XRV PIC III VFD_CONF TABLE CONFIGURATION SIIEET

DESCRIIrFION RANGE UNITS DEFAULT VALUE

Motor Nameplate Voltage 380-460 VOLTS 460

Compressor 100% Speed 45.0-62.0 Hz 60.0

Line Freq=60 Hz? (No=50) 0/l NO/YES YES

* Rated Line Voltage 346-480 VOLTS 460

* Rated Line Amps l 0-1500 AMPS 200

* Rated Line Kilowatts 0-7200 kW 100

* Motor Rated Load KW 0-7200 kW 100

* Motor Rated Load Amps 10-1500 AMPS 200

Motor Nameplate Amps l 0-1500 AMPS 100

Motor Nameplate RPM 1500-3600 3456

Motor Nameplate KW 0-5600 kW 100

Inverter PWM Frequency 0/l 0

(0=4 k Hz, 1=2 k Hz)

Skip Frequency I 0.0-102.0 Hz 102.0

Skip Frequency 2 0.0-102.0 Hz 102.0

Skip Frequency 3 0.0-102.0 Hz 102.0

Skip Frequency Band 0.0-102.0 Hz 0.0

Line Voltage % Imbalance l -l0 % l0

Line Volt Imbalance Time l -l0 SEC l0

Line Current % Imbalance 5-40 % 40

Line Current Imbal Time l-l0 SEC l0

Motor Current % Imbalance 5-40 % 40

Motor Current Imbal Time l - l0 SEC l0

Increase Ramp Time 5-60 SEC 30

Decrease Ramp Time 5-60 SEC 30

Single Cycle Dropout 0/l DSABLE/ENABLE DSABLE

NOTE: Those parameters marked with a * shall not be downloaded to the VFD, but shall be used in other calculations and algorithms in the ICVC.

CL-5

19XRV PIC HI OIq'IONS TABLE CONFIGURATION SIIEET

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 (T2, P2)

Surge/ltGBP Delta T2

Surge/IR_BP Delta P2

Surge/liGBP Deadband

Surge Protection

Surge Delta% Amps

Surge Time Period

Ice Build Control

Ice Build Option

Ice Build Termination

0=Temp, l=Contacts, 2=Both

Ice Build Recycle

Iiead Pressure Reference

Delta Pat 0% (4 mA)

Delta P at 100% (20 mA)

Minimum Output

RANGE

0/1

40 to 100

0/1

0.5 to 20

(.3to 11.1)

30 to 170

(206.9 to 1172.2)

0.5 to 20

(.3to 11.1)

50 to 170

(344.8 to 1172.2)

0.5 to 3

(.3 to 1.7)

5to 20

7to 10

0/1

Oto 2

0/1

20 to 85

(138 to 586)

20 to 85

(138 to 586)

0 to 100

UNITS

DSABLE/ENABLE

^F fie)

PSI (kPa)

^F fie)

PSI (kPa)

^F (^C)

MIN

DSABLE/ENABLE

psi (kPa)

DEFAULT

DSABLE

100

1.5(0.8)

50 (344.8)

10 (5.6)

85 (586.1)

1 (0.6)

DSABLE

25 (172)

50 (344.8)

VALUE

LI3

CL-6

CO/WO

19XRV PIC IIl SETUP1 TABLE CONFIGURATION SttEET

DESCRHrl'ION RANGE UNITS DEFAULT VALUE

Comp Motor Temp Override 150 to 200

(66 to 93) °F (°C) 200 (93)

Cond Press Override 90 to 165

(621 to 1138) PSI (kPa) 125 (862)

155 to 170

Rectifier Temp Override (68 to 77) °F (°C) 160 (71)

155 to 170

Inverter Temp Override (68 to 77) °F (°C) 160 (71)

125 to 200

Comp Discharge Alert (52 to 93) °F (°C) 200 (93)

165 to 185

Comp Thrust Brg Alert (74 to 85) °F (°C) 175 (79)

WATER/

Chilled Medium 0/1 WATER

BRINE

.5 to 2.0

Chilled Water Deadband (0.3 to 1.1) T (_C) 1.0 (0.6)

0.0 to 40.0

Evap Refrig Trippoint (-17.8 to 4.4) °F (°C) 33 (0.6)

2.0 to 5.0

Refrig Override Delta T (1.1 to 2.8) T (_C) 3 (1.7)

0.5 to 15

Evap Approach Alert (0.3 to 8.3) T CC) 5 (2.8)

0.5 to 15

Cond Approach Alert (0.3 to 8.3) T (_C) 6 (3.3)

Condenser Freeze Point -20 to 35

(-28.9 to 1.7) °F (°C) 34(1.1)

DSABLE/

Flow Delta P Display 0 to 1 ENABLE DSABLE

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 0.5 to 5 MIN 5

Oil Press Verify Time 15 to 300 SEC 40

Recycle Control

2.0 to 10.0

Restart Delta T (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 0

Spare Temp #1 Limit _40 to 245

(_40 to 118) °F (°C) 245 (118)

Spare Temp #2 Enable 0 to 4 0

Spare Temp #2 Limit _40 to 245

(_40 to 118) °F (°C) 245 (118)

NOTE:Novariablesareavailablefor CCNreadoperation. Forcing shallnotbesupported on servicescreens.

CL-7

19XRV PIC IH SETUP2 TABLE CONFIGURATION SIIEET

DESCRIPFION STATUS UNITS DEFAULT VALUE

Capacity Control

Proportional Inc Band 2 to 10 6.5

Proportional DEC Band 2 to 10 6.0

Proportional ECW Gain I to 3 2.0

Guide Vane Travel Limit 30 to 100 % 80

Diffuser Control

Diffuser Option 0/1 DSABLE/ENABLE DSABLE

Guide Vane 25% Load Pt 0to 78 %25

Diffuser 25% Load Point 0to 100 % 0

Guide Vane 50% Load Pt 0to 78 % 50

Diffuser 50% Load Point 0to 100 % 0

Guide Vane 75% Load Pt 0to 78 % 75

Diffuser 75% Load Point 0to 100 %0

Diffuser Full Span mA 15 to 22 mA 18

VFD Speed Control

VFD Gain 0.1 to 1.5 0.75

VFD Increase Step 1 to 5 % 2

VFD Minimum Speed 65 to 100 % 70

VFD Maximum Speed 90 to 100 % 100

CL-8

CO/WO

19XRV PIC HI LEADLAG TABLE CONFIGURATION StlEET

DESCRIF1TON RANGE UNITS DEFAULT VALUE

Lead Lag Control

LEAD/LAG: Configuration

DSABLE=0, LEAD=l, 0 to 3 0

LAG=2, STANDBY=3

Load Balance Option 0/1 DSABLE/ENABLE DSABLE

Common Sensor Option 0/1 DSABLE/ENABLE DSABLE

LAG% Capacity 25 to 75 % 50

LAG Address 1 to 236 92

LAG START Timer 2 to 60 MIN 10

LAG STOP Timer 2 to 60 MIN 10

PRESTART FAULT Timer 2 to 30 MIN 5

STANDBY Chiller Option 0/1 DSABLE/ENABLE DSABLE

STANDBY% Capacity 25 to 75 % 50

STANDBY Address I to 236 93

CL-9

19XRV PIC III RAMP_DEM TABLE CONFIGURATION SIIEET

DESCRIFI'ION RANGE UNITS DEFAULT VALUE

Pulldown Ramp Type: 0/1 1

Select: Temp=0, Load=l

Demand Limit and kW Ramp

Demand Limit Source 0/1 0

Select: Amps=0, kW= 1

Amps or kW Load Ramp% Min 5 to 20 10

Demand Limit Prop Band 3 to 15 % 10

Demand Limit At 20 mA 40 to 100 % 40

20 mA Demand Limit Opt 0/1 DSABLE/ENABLE DSABLE

Demand Watts Interval 5 to 60 MIN 15

19XRV PIC Ill TEMP_CTL TABLE CONFIGURATION SIIEET

DESCRIlrl'ION RANGE UNITS DEFAULT VALUE

Control Point

ECW Control Option 0/1 DSABLE/ENABLE DSABLE

2to 10

Temp Pulldown Deg/Min (1.1 to 5.6) ^F (^C) 3 (1.7)

Temperature Reset

RESET TYPE 1

-30 to 30

Degrees Reset At 20 mA (-17 to 17) ^F (_C) 10 (6)

RESET TYPE 2

-40 to 245

Remote Temp -> No Reset (-40 to 118) DEG F (C) 85 (29)

-40 to 245

Remote Temp -> Full Reset (-40 to 118) DEG F (C) 65 (18)

-30 to 30

Degrees Reset (-17 to 17) ^F (^C) 10 (6)

RESET TYPE 3

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) _F (_C) 0 (0)

-30 to 30

Degrees Reset (-17 to 17) ^F (_C) 5 (3)

Enable Reset Type 0 to 3 0

CL-10

lad

CO/WO

BROADCAST (BRODEF) CONFIGURATION StlEET

DESCRIF1TON RANGE UNITS DEFAULT VALUE

Time Broadcast Enable DSABLE/ENABLE DSABLE

Daylight Savings

Start Month I to 12 4

Start Day of Week 1 to 7 7

Start \¥eek 1 to 5 1

Start Time 00:00 to 24:00 HH:MM 02:00

Start Advance 0 to 360 MIN 0

Stop Month 1 to 12 10

Stop Day of Week 1 to 7 7

Stop Week 1 to 5 5

Stop Time 00:00 to 24:00 02:00

Stop Back 0 to 360 MIN 0

CL-II

CO/_O_

ICVC DISPLAY AND ALARM SItUTDOWN STATE RECORD SIIEET

fPRIMARY MESSAGE:

SECONDARY MESSAGE:

CHW IN CHW OUT

DATE: TIME:

COMPRESSOR ONTIME:

EVAP REF

CDW IN CDW OUT COND REF

OILPRESS OILTEMP AMPS %IN

COMMUNICATION MESSAGE

CCN LOCAL RESET MENU J

Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.

Book 2J2 PC 211 Catalog No. 531-988 Printed in U.SA. Form 19XRV-1SS CL-12 4-05 Replaces: New

Tab

I-

CARRIER Package Units(both Units Combined) Manual L0522671

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