Professional Documents
Culture Documents
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Catalog No. 04-53190002-01
Printed in U.S.A.
Form 19XRV-2SS
Pg 1
11-06
Replaces: 19XRV-1SS
Book 2
Tab 5a
CONTENTS
Page
High Discharge Temperature Control . . . . . . . . . . . . 42
Oil Sump Temperature and Pump Control . . . . . . . 42
Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Remote Start/Stop Controls . . . . . . . . . . . . . . . . . . . . . 43
Spare Safety and Spare Temperature Inputs. . . . . 43
Alarm (Trip) Output Contacts . . . . . . . . . . . . . . . . . . . . 43
Kilowatt Output. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Remote Reset of Alarms. . . . . . . . . . . . . . . . . . . . . . . . . 44
Condenser Pump Control . . . . . . . . . . . . . . . . . . . . . . . 44
Condenser Freeze Prevention . . . . . . . . . . . . . . . . . . . 44
Evaporator Freeze Protection . . . . . . . . . . . . . . . . . . . 44
Tower Fan Relay Low and High . . . . . . . . . . . . . . . . . . 44
Auto. Restart After Power Failure. . . . . . . . . . . . . . . . 45
Water/Brine Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
RESET TYPE 1: 4 TO 20 mA TEMPERATURE RESET
RESET TYPE 2: REMOTE TEMPERATURE RESET
RESET TYPE 3
Surge Prevention Algorithm . . . . . . . . . . . . . . . . . . . . . 45
Surge Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Head Pressure Reference Output. . . . . . . . . . . . . . . . 47
Lead/Lag Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
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 . . . . . . . . . . . . . . . 50
ATTACHING TO OTHER CCN MODULES
Service Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
TO ACCESS THE SERVICE SCREENS
TO LOG OUT OF NETWORK DEVICE
TIME BROADCAST ENABLE
HOLIDAY SCHEDULING
DAYLIGHT SAVING TIME CONFIGURATION
START-UP/SHUTDOWN/RECYCLE
SEQUENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53-55
Local Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Shutdown Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Automatic Soft Stop Amps Threshold . . . . . . . . . . . 54
Chilled Water Recycle Mode . . . . . . . . . . . . . . . . . . . . . 54
Safety Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
BEFORE INITIAL START-UP . . . . . . . . . . . . . . . . . . 55-70
Job Data Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Equipment Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Using the Optional Storage Tank
and Pumpout System . . . . . . . . . . . . . . . . . . . . . . . . . 55
Remove Shipping Packaging . . . . . . . . . . . . . . . . . . . . 55
Open Oil Circuit Valves . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Oil Charge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Tighten All Gasketed Joints and
Guide Vane Shaft Packing . . . . . . . . . . . . . . . . . . . . . 55
Check Chiller Tightness . . . . . . . . . . . . . . . . . . . . . . . . . 56
Refrigerant Tracer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Leak Test Chiller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Standing Vacuum Test. . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Chiller Dehydration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Inspect Water Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Check Optional Pumpout Compressor
Water Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
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 . . . . . . . . . . . . . . . . . . . . . . . 9-14
Unit-Mounted VFD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
CONTROLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-52
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
ANALOG SIGNAL
DISCRETE SIGNAL
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
PIC III System Components . . . . . . . . . . . . . . . . . . . . . 14
INTERNATIONAL CHILLER VISUAL
CONTROLLER (ICVC)
CHILLER CONTROL MODULE (CCM)
OIL HEATER CONTACTOR (1C)
OIL PUMP CONTACTOR (2C)
HOT GAS BYPASS CONTACTOR RELAY (3C)
(Optional)
CONTROL TRANSFORMERS (T1, T2)
OPTIONAL TRANSFORMER (T3)
SENSORS
FLOW DETECTION
ICVC Operation and Menus. . . . . . . . . . . . . . . . . . . . . . 19
GENERAL
ALARMS AND ALERTS
ICVC MENU ITEMS
BASIC ICVC OPERATIONS (Using the Softkeys)
TO VIEW STATUS
FORCING OPERATIONS
TIME SCHEDULE OPERATION
TO VIEW AND CHANGE SET POINTS
SERVICE OPERATION
PIC III System Functions . . . . . . . . . . . . . . . . . . . . . . . . 37
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Shunt Trip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Default Screen Freeze . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Ramp Loading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Capacity Override . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
2
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CONTENTS (cont)
Page
OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . 71-73
Operator Duties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Prepare the Chiller for Start-Up . . . . . . . . . . . . . . . . . 71
To Start the Chiller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Check the Running System . . . . . . . . . . . . . . . . . . . . . 71
To Stop the Chiller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
After Limited Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . 72
Preparation for Extended Shutdown . . . . . . . . . . . . 72
After Extended Shutdown . . . . . . . . . . . . . . . . . . . . . . . 72
Cold Weather Operation. . . . . . . . . . . . . . . . . . . . . . . . . 72
Manual Guide Vane Operation. . . . . . . . . . . . . . . . . . . 72
Refrigeration Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
PUMPOUT AND REFRIGERANT TRANSFER
PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74-77
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Operating the Optional Pumpout Unit . . . . . . . . . . . 74
TO READ REFRIGERANT PRESSURES
POSITIVE PRESSURE CHILLERS WITH
STORAGE TANKS
CHILLERS WITH ISOLATION VALVES
DISTILLING THE REFRIGERANT
GENERAL MAINTENANCE . . . . . . . . . . . . . . . . . . . .77,78
Refrigerant Properties . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Adding Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Removing Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Adjusting the Refrigerant Charge . . . . . . . . . . . . . . . 77
Refrigerant Leak Testing . . . . . . . . . . . . . . . . . . . . . . . . 77
Leak Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Test After Service, Repair, or Major Leak . . . . . . . . 77
TESTING WITH REFRIGERANT TRACER
TESTING WITHOUT REFRIGERANT TRACER
TO PRESSURIZE WITH DRY NITROGEN
Repair the Leak, Retest, and Apply
Standing Vacuum Test . . . . . . . . . . . . . . . . . . . . . . . . 78
Checking Guide Vane Linkage . . . . . . . . . . . . . . . . . . 78
Trim Refrigerant Charge. . . . . . . . . . . . . . . . . . . . . . . . . 78
WEEKLY MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . 78
Check the Lubrication System . . . . . . . . . . . . . . . . . . 78
SCHEDULED MAINTENANCE . . . . . . . . . . . . . . . . 79-81
Service Ontime. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Inspect the Control Panel . . . . . . . . . . . . . . . . . . . . . . . 79
Check Safety and Operating Controls
Monthly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Changing Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Oil Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Oil Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
TO CHANGE THE OIL
Refrigerant Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Oil Reclaim Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
VFD Refrigerant Strainer . . . . . . . . . . . . . . . . . . . . . . . . 80
Inspect Refrigerant Float System . . . . . . . . . . . . . . . 80
Inspect Relief Valves and Piping . . . . . . . . . . . . . . . . 80
Compressor Bearing and Gear
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Inspect the Heat Exchanger Tubes
and Flow Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
COOLER AND OPTIONAL FLOW DEVICES
CONDENSER AND OPTIONAL FLOW DEVICES
Water Leaks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Water Treatment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Inspect the VFD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Recalibrate Pressure Transducers . . . . . . . . . . . . . . 81
Page
Check Relief Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Identify the VFD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Input Power Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Checking the Installation . . . . . . . . . . . . . . . . . . . . . . . . 62
Inspect Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Ground Fault Troubleshooting . . . . . . . . . . . . . . . . . . 63
Carrier Comfort Network Interface . . . . . . . . . . . . . 63
Power Up the Controls and
Check the Oil Heater . . . . . . . . . . . . . . . . . . . . . . . . . . 64
SOFTWARE VERSION
Software Configuration . . . . . . . . . . . . . . . . . . . . . . . . . 64
Input the Design Set Points . . . . . . . . . . . . . . . . . . . . . 64
Input the Local Occupied Schedule
(OCCPC01S) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Input Service Configurations. . . . . . . . . . . . . . . . . . . . 64
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 . . . . . . . . . . . . . . . . . . . . . . . . . . 67
PRESSURE TRANSDUCER CALIBRATION
Check Optional Pumpout System
Controls and Compressor. . . . . . . . . . . . . . . . . . . . . 68
High Altitude Locations . . . . . . . . . . . . . . . . . . . . . . . . . 68
Charge Refrigerant Into Chiller . . . . . . . . . . . . . . . . . . 68
CHILLER EQUALIZATION WITHOUT A
PUMPOUT UNIT
CHILLER EQUALIZATION WITH
PUMPOUT UNIT
TRIMMING REFRIGERANT CHARGE
INITIAL START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70,71
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Check Motor Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Check Oil Pressure and Compressor Stop . . . . . . 70
To Prevent Accidental Start-Up. . . . . . . . . . . . . . . . . . 70
Check Chiller Operating Condition . . . . . . . . . . . . . . 71
Instruct the Customer Operator . . . . . . . . . . . . . . . . . 71
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-UP, OPERATION, AND
MAINTENANCE MANUAL
3
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CONTENTS (cont)
Page
Optional Pumpout System Maintenance . . . . . . . . . 81
OPTIONAL PUMPOUT COMPRESSOR OIL
CHARGE
OPTIONAL PUMPOUT SAFETY CONTROL
SETTINGS
Ordering Replacement Chiller Parts . . . . . . . . . . . . . 81
TROUBLESHOOTING GUIDE . . . . . . . . . . . . . . . . 82-137
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Checking Display Messages. . . . . . . . . . . . . . . . . . . . . 82
Checking Temperature Sensors . . . . . . . . . . . . . . . . . 82
RESISTANCE CHECK
VOLTAGE DROP
CHECK SENSOR ACCURACY
DUAL TEMPERATURE SENSORS
Checking Pressure Transducers. . . . . . . . . . . . . . . . . 82
COOLER CONDENSER PRESSURE TRANSDUCER
AND OPTIONAL WATERSIDE FLOW DEVICE
CALIBRATION
TRANSDUCER REPLACEMENT
Control Algorithms Checkout Procedure . . . . . . . . 83
Control Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Control Modules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
RED LED (Labeled as STAT)
GREEN LED (Labeled as COM)
Notes on Module Operation . . . . . . . . . . . . . . . . . . . . 100
Chiller Control Module (CCM) . . . . . . . . . . . . . . . . . . 100
INPUTS
OUTPUTS
Replacing Defective Processor Modules . . . . . . . 101
INSTALLATION
Gateway Status LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . 102
DRIVE STATUS INDICATOR
MS STATUS INDICATOR
NET A STATUS INDICATOR
NET B STATUS INDICATOR
Physical Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
APPENDIX 19XRV LIQUIFLO 2 ICVC
PARAMETER INDEX. . . . . . . . . . . . . . . . . . . . . . 138-146
INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
INITIAL START-UP CHECKLIST FOR
19XRV HERMETIC CENTRIFUGAL
LIQUID CHILLER . . . . . . . . . . . . . . . . . . . .CL-1 to CL-12
INTRODUCTION
4
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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
Variable Frequency Drive (VFD) The VFD allows for the proper start and disconnect of electrical energy for
the compressor-motor, oil pump, oil heater, and control panel.
Motor-Compressor This component maintains system temperature and pressure differences and moves the
heat-carrying refrigerant from the cooler to the condenser.
19XRV
52
51
473
DG
64
5F (Frame 5 XRV)
5G (Frame 5 XRV)
5H (Frame 5 XRV)
60-62 (Frame 6 XRV)
65-67 (Frame 6 XRV)
70-72 (Frame 7 XRV)
75-77 (Frame 7 XRV)
80-82 (Frame 8 XRV)
85-87 (Frame 8 XRV)
Compressor Code
(First Digit Indicates Compressor Frame Size)*
*Second digit will be a letter (example 4G3) on units equipped with split ring diffuser.
MODEL NUMBER NOMENCLATURE
27 05 Q 71843
Week of Year
Unique Number
Year of Manufacture
Place of Manufacture
a19-1684
FRONT VIEW
1
13
14
15
16
17
18
19
LEGEND
Guide Vane Actuator
Split Ring Diffuser Actuator (Optional)
Suction Elbow
International Chiller Visual Control (ICVC)
Chiller Identification Nameplate
Cooler, Auto Reset Relief Valves
Cooler Pressure Transducer
Condenser In/Out Temperature Thermistors
Condenser Waterflow Device (Optional
ICVC Inputs available)
Cooler Waterflow Device (Optional
ICVC Inputs available)
Cooler In/Out Temperature Thermistors
Evaporator Saturation Temperature
Sensor (Hidden)
Liquid Line Service Valve
Typical Flange Connection
Oil Level Sight Glasses
Refrigerant Oil Cooler (Hidden)
Oil Drain/Charging Valve (Hidden)
Power Panel
Compressor Motor Housing
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
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
Tubesheet Mounting Brackets
Discharge Isolation Valve (Optional)
Refrigerant Charging Valve
Condenser Pressure Transducer (Hidden)
1
2
3
4
5
6
7
8
9
3
6
4
19
10
11
12
8
18
17
9
16
15
14
12
11
13
a19-1685
10
REAR VIEW
21
22
23
24
20
25
36
35
34
32
30
31
26
29
28
26
27
a19-1686
33
6
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REFRIGERATION CYCLE
The motor and the lubricating oil are cooled by liquid refrigerant taken from the bottom of the condenser vessel
(Fig. 3). Refrigerant flow is maintained by the pressure differential that exists due to compressor operation. After the refrigerant flows past an isolation valve, an in-line filter, and a sight
glass/moisture indicator, 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 drain line.
An orifice (in the motor shell) maintains a higher pressure in
the motor shell than in the cooler. 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 temperature 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/refrigerant plate and frame-type heat exchanger (the oil cooler in Fig. 3). The expansion valve bulbs control
oil temperature to the bearings. The refrigerant leaving the oil
cooler heat exchanger returns to the chiller cooler.
FLASC CHAMBER
CONDENSER
WATER
CONDENSER
REFRIGERANT
COOLING
ISOLATION VALVE
FLOAT VALVE
CHAMBER
FILTER
DRIER
MOTOR
TRANSMISSION
DIFFUSER
GUIDE VANE
MOTOR
STATOR
MOISTURE/
FLOW
INDICATOR
ROTOR
ORIFICE
FITTING
VFD
COOLING
ISOLATION
VALVE
GUIDE
VANES
OIL
PUMP
VFD
COOLING
ISOLATION
VALVE
OIL
COOLER
IMPELLER
COMPRESSOR
OIL
FILTER
THERMOSTATIC
EXPANSION
VALVE
(TXV)
REFRIGERANT
VAPOR
REFRIGERANT
LIQUID/VAPOR
OIL
UNIT
MOUNTED
VFD
(VARIABLE
FREQUENCY
DRIVE)
HEAT
EXCHANGER
VFD COOLING
SOLENOID
REFRIGERANT
LIQUID
CHILLED
WATER
DISTRIBUTION
PIPE
COOLER ISOLATION
VALVE (OPTION)
a19-1601
LUBRICATION CYCLE
Summary The oil pump, oil filter, and oil cooler make
oil lost from the compressor housing back to the oil reservoir
by recovering the oil from 2 areas on the chiller. The guide
vane housing is the primary area of recovery. Oil is also recovered by skimming it from the operating refrigerant level in the
cooler vessel.
PRIMARY OIL RECOVERY MODE Oil is normally recovered through the guide vane housing on the chiller. This is
possible because oil is normally entrained with refrigerant in
the chiller. As the compressor pulls the refrigerant up from the
cooler into the guide vane housing to be compressed, the oil
normally 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 eductor, the oil is drawn from the housing
and is discharged into the oil reservoir.
SECONDARY OIL RECOVERY METHOD The secondary 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 cooler. 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.
a hand valve. Two sight glasses in the oil reservoir permit oil
level observation. Normal oil level is between the middle of the
upper sight glass and the top of the lower sight glass when the
compressor is shut down. The oil level should be visible in at
least one of the 2 sight glasses during operation. Oil sump
temperature is displayed on the ICVC (International Chiller
Visual Controller) default screen. During compressor operation, the oil sump temperature ranges between 125 and 150 F
(52 and 66 C).
The oil pump suction is fed from the oil reservoir. 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 pressure on compressors equipped with rolling
element bearings is between 18 and 40 psid (124 and
276 kPad). This differential pressure can be read directly from
the ICVC default screen. The oil pump discharges oil to the oil
filter assembly. This filter can be closed to permit removal of
the filter without draining the entire oil system (see Maintenance sections, pages 77 to 81, for details). The oil is then
piped to the oil cooler heat exchanger. 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
valve on the oil cooler. The oil is then divided. Part of the oil
flows to the thrust bearing, forward pinion bearing, and gear
spray. The rest of the oil lubricates the motor shaft bearings and
the rear pinion bearing. The oil temperature is measured in the
bearing housing as it leaves the thrust and forward journal
bearings. The outer bearing race temperature is measured on
compressors with rolling element bearings. The oil then drains
into the oil reservoir at the base of the compressor. The PIC III
(Product Integrated Control III) measures the temperature of
the oil in the sump and maintains the temperature during shutdown (see Oil Sump Temperature and Pump Control section,
page 42). This temperature is read on the ICVC default screen.
During chiller start-up, the PIC III energizes the oil pump
and provides 45 seconds of pre-lubrication to the bearings after
pressure is verified before starting the compressor. During
shutdown, the oil pump will run for 60 seconds to
post-lubricate after the compressor shuts down. The oil pump
four radial bearings and four thrust bearings. The low speed
shaft assembly is supported by two journal bearings located
between the motor rotor and the bull gear. The bearing closer to
the rotor includes a babbitted thrust face which opposes the
normal axial forces which tend to pull the assembly towards
the transmission. The bearing closer to the bull gear includes a
smaller babbitted thrust face, designed to handle counterthrust
forces.
For most 19XRV compressors the high speed shaft assembly is supported by two journal bearings located at the
transmission end and mid-span, behind the labyrinth seal. The
transmission side of the midspan bearing also contains a tilting
shoe type thrust bearing which opposes the main axial 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 Frame 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 bearing temperatures than those compressors using the alternate bearing design.
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REAR MOTOR
BEARING
FWD MOTOR
BEARING
LABYRINTH
GAS LINE
MOTOR
COOLING LINE
OIL SUPPLY TO
FORWARD HIGH
SPEED BEARING
OIL
FILTER
FLOW
STRAINER
ISOLATION
VALVE
TXV BULB
PRESSURE
TRANSDUCER
OIL
PUMP
ISOLATION
VALVES
OIL
COOLER
OIL PUMP
MOTOR
FILTER
OIL
HEATER
EDUCTOR FILTER
SIGHT
GLASS
SIGHT
GLASS
ISOLATION
VALVE
OIL SKIMMER
LINE
a19-1741
STARTING EQUIPMENT
9
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OPTIONAL
METER
PACKAGE
a19-1718
a19-1725
1169A VFD
10
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1, 2
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
19
18
17
16
13
14, 15, 1
11, 1
12
7 a19-1726
9, 10
7, 8
9
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
17
15, 7
16
14
12, 13, 7
11
1169A VFD
10
a19-1727
1
2
5
6
7
8
25
9
10
11
6
7
3
8
12
10
4
11 8
1
13
14
15
Door Open
16
20
23
17
18
26
25
20
24
19
21
a23-1627stacked
22
Door Closed
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
*The inverter control assembly (item 16) and rectifier control assembly (item 18) are physically similar but are loaded with different software. These boards are NOT interchangeable.
10
UNDER
TOP
COVER
2
2X
11
8
6X
12
a19-1728
Door Open
15
14
17
16
13
2X
18
a19-1729
Door Closed
1
2
3
4
5
6
7
1169A VFD
13
14
15
16
17
18
COOLER CHARGING
VALVE (HIDDEN)
CONTROL
PANEL
GUIDE VANE
ACTUATOR
SPLIT RING
DIFFUSER
ACTUATOR
(OPTIONAL)
OIL SUMP
PRESSURE
TRANSDUCER
POWER
PANEL
OIL PUMP
DISCHARGE
PRESSURE
COOLER
PRESSURE
TRANSDUCER
WATER
SENSOR
CABLES
WATER
SENSOR
CABLES
CONDENSER
PRESSURE
TRANSDUCER
CONDENSER
3-WAY SHUTOFF
VALVE
OIL SUMP
TEMPERATURE
SENSOR
HGBP
ACTUATOR
(OPTIONAL)
CONDENSER CHARGING
VALVE (HIDDEN)
EVAPORATOR SATURATION
TEMPERATURE SENSOR
(ON BOTTOM OF COOLER)
VFD ENCLOSURE
VFD COOLING
SOLENOID
a19-1730
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 because its resistance changes in proportion to the temperature,
generating many values.)
DISCRETE SIGNAL A discrete signal is a 2-position representation of the value of a monitored source. (Example: A
switch produces a discrete signal indicating whether a value is
above or below a set point or boundary by generating an on/off,
high/low, or open/closed signal.)
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PANEL LOCATION
Control Panel
Control Panel
Control Panel
Power Panel
Power Panel
Power Panel
Power Panel
See Fig. 8.
See Fig. 8.
NOTE: Pressing any one of the four softkey buttons will activate the backlight display without implementing a softkey
function.
The ICVC 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.
ICVC
COLOR
CEPL No. SOFTWARE
OTHER
OF
(hardware)
MARKINGS
PLATE
PIC III
Marking
CEPL
CESR
on back
Metallic
130445-02 131350-0X
of green
circuit
board
MOTOR TEMPERATURE
SENSOR CABLE
OIL RECLAIM
SIGHT GLASS
BEARING TEMPERATURE
SENSOR CABLE
DIFFUSER PRESSURE
AND DIFFUSER ACTUATOR
CABLE (FRAME 4 & 5
COMPRESSOR ONLY)
CABLE FROM
CONTROL PANEL
GUIDE VALVE
ACTUATOR CABLE
COMPRESSOR DISCHARGE
TEMPERATURE SENSOR
CABLE
OIL COOLER THERMOSTATIC
EXPANSION VALVE (TXV)
HIGH PRESSURE
SWITCH LOCATION
a19-1606
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LOCATION MONITORED
Angular Position
Pressure Switch
Temperature Switch
Temperature
Pressure
REMARKS
Cooler inlet nozzle
Cooler outlet nozzle
Condenser inlet nozzle
Condenser outlet nozzle
Sensor well on bottom of evaporator
Compressor volute
Compressor oil sump
Redundant sensor provided
Redundant sensor provided
Relief valve tee
Relief valve tee
Compressor oil sump
Oil pump discharge line
Only in machines equipped with split ring diffusers
Cooler inlet nozzle
Cooler outlet nozzle
Condenser inlet nozzle
Condenser outlet nozzle
Potentiometer inside of actuator
Potentiometer inside of actuator only on machines equipped
with split ring diffusers (split ring diffuser position not displayed on ICVC)
Compressor volute, wired into the VFD control circuit
Wired into the oil pump control circuit
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CARRIER COMFORT
NETWORK (CCN)
INTERFACE
CONTROL POWER
CIRCUIT BREAKERS
OPTIONAL
DATAPORT/DATALINK
CIRCUIT BREAKERS
HUMIDITY
SENSOR
SURGE/HGBP
PARAMETER
LABEL
a19-1607
CHILLER CONTROL
MODULE (CCM)
a19-1609
CONTROL
PANEL
SIDE VIEW
REMOVABLE
BOLT
HINGE
a19-1742
T3
T2
T1
51
1 3
50
12
13
OIL HEATER
CONTACTOR
21
22
23
11
12
13
OIL PUMP
CONTACTOR
21
22
2 4
17
5 6
11
43
23
C
B
A
CONTROL PANEL
POWER CONDUIT
a19-1610
to establish flow.) On the condenser side, positive determination of flow is made if the following conditions are true: (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 differential pressure
measurement option is enabled, the waterside pressure differentials (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 PRESSURE exceeds the configured COND PRESS OVERRIDE
threshold by more than 5 psi (34.5 kPa). In addition, if the
water side differential pressure measurement option is enabled,
a differential below the configured EVAP or COND FLOW
DELTA P CUTOUT value is sufficient to establish No Flow in
either heat exchanger.
If No Flow (for either cooler or condenser) has been determined, and subsequently conditions change such that neither
conditions for Flow nor No Flow are all satisfied, the determination will remain No Flow.
In the standard ICVC 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 SETUP1 screen. Pairs of pressure transducers may be connected to the CCM at terminals
J3 13-24 in place of the standard resistors and jumpers to determine water-side pressure differentials as in the standard ICVC
configuration. (NOTE: If the FLOW DELTA P DISPLAY is
enabled, but the standard CCM connection is retained, a differential value of approximately 28.5 psi (197 kPa) will always be
displayed.)
If waterside differential pressure transducers are used, flow
is detected from differential pressure between sensors (pressure
transducers) located in water inlet and outlet nozzles, for each
heat exchanger. The thresholds for flow determination (EVAP
FLOW DELTA P CUTOUT, COND FLOW DELTA P CUTOUT) are configured in the SETUP1 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 WATER FLOW VERIFY TIME (configured in
the SETUP1 screen) after the pump is commanded to start by
the PIC, a shutdown will result, and the corresponding loss-offlow alarm (alarm state 229 or 230) will be declared. If the
measured differential exceeds the Flow Delta P cutout value,
flow is considered to be present.
Alternatively, normally open flow switches may be used for
flow indication. In this case, install an evaporator side flow
switch in parallel with a 4.3k ohm resistor between CCM
terminals J3 17-18, replacing the jumper. See page 120. For a
condenser side flow switch do the same between CCM terminals J3 23-24. If this type of flow switch circuit is used, it is
important to perform a zero point calibration (with the flow
switch open).
SHRINK WRAP
STRAIN RELIEF
1/8 NPT
THERMOWELL
REMOVABLE
TEMPERATURE
SENSOR
a23-1624
a19-957
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PRIMARY STATUS
MESSAGE
GENERAL
The ICVC 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.
See 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 51.
NOTE: The date format on the default screen is MM-DD-YY
for English units and DD-MM-YY for SI metric units.
SECONDARY
STATUS
MESSAGE
DATE
ALARM LIGHT
(ILLUMINATED
WHEN POWER ON)
CONTINUOUSLY
BLINKS
ON FOR AN ALARM
BLINKS ONCE TO
CONFIRM A STOP
TIME
01-01-95 11:48
28.8 HOURS
CHW IN
CHW OUT
EVAP REF
CDW IN
CDW OUT
COND REF
OIL TEMP
% AMPS IN
55.1
85.0
OIL PRESS
21.8
CCN
44.1
95.0
132.9
LOCAL
RESET
40.7
98.1
93
MENU
STOP BUTTON
FOR ONE
HOLD
SECOND TO STOP
SOFT KEYS
a19-1613
MENU
LINE
SERVICE
19XRV_II
ALARM HISTORY
CONTROL TEST
CONTROL ALGORITHM STATUS
EQUIPMENT CONFIGURATION
VFD CONFIGURATION DATA
EQUIPMENT SERVICE
TIME AND DATE
ATTACH TO NETWORK DEVICE
LOG OUT OF DEVICE
ICVC CONFIGURATION
a19-1614
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COMPRESSOR
ON TIME
DEFAULT SCREEN
LOCAL
CCN
RESET
MENU
(SOFTKEYS)
SCHEDULE
SETPOINT
List the
Status Tables
MAINSTAT
STARTUP
COMPRESS
HEAT_EX
POWER
VFD_STAT
ICVC_PWD
Select a Status Table
PREVIOUS
NEXT
Select a Modification Point
PREVIOUS
NEXT
Modify a Discrete Point
START
STOP
ON
OFF
Modify an Analog Point
INCREASE DECREASE
Modify Control Options
DISABLE
ENABLE
SERVICE
EXIT
SELECT
EXIT
RELEASE
ENTER
RELEASE
ENTER
QUIT
ENTER
SELECT
EXIT
ENTER
QUIT
EXIT
ENTER
EXIT
(ANALOG VALUES)
Add/Eliminate a Day
ENABLE
DISABLE
ENTER
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
NEXT
PREVIOUS
SELECT
EXIT
SEE FIGURE 17
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a19-1719
SERVICE TABLE
NEXT
PREVIOUS
SELECT
EXIT
ALERT HISTORY
ALARM HISTORY
Alert History
(The table holds up to 25 alerts
with the most recent alert at
the top of the screen.)
Select a Test
NEXT
CCM Thermistors
CCM Pressure Transducers
Pumps
Discrete Outputs
IGV and SRD Actuator
Head Pressure Output
Diffuser Actuator
Pumpdown/Lockout
Terminate Lockout
Guide Vane Calibration
SELECT
PREVIOUS
EXIT
SELECT
EXIT
NET_OPT
BRODEF
OCCDEFCS
HOLIDAYS
CONSUME
RUNTIME
Select a Table
PREVIOUS
NEXT
EXIT
Select a Parameter
PREVIOUS
NEXT
SELECT
EXIT
Modify a Parameter
INCREASE DECREASE
QUIT
ENTER
(ANALOG VALUES)
QUIT
ENTER
(DISCRETE VALUES)
ENABLE
CONTINUED
ON NEXT PAGE
SELECT
DISABLE
21
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a19-1720
EQUIPMENT SERVICE
Service Tables:
OPTIONS
SETUP1
SETUP2
LEADLAG
RAMP_DEM
TEMP_CTL
Select a Service Table
PREVIOUS
NEXT
Service Tables:
VFD (STARTER) CONFIG PASSWORD
VFD_CONF
SELECT
EXIT
EXIT
DISABLE
QUIT
ENTER
(ANALOG VALUES)
ENTER
(DISCRETE VALUES)
SELECT
YES
NO
ENTER
Day of Week
Holiday Today
EXIT
(ANALOG VALUE)
EXIT
(DISCRETE VALUE)
ATTACH
RESET
MENU
ICVC CONFIGURATION
ICVC Configuration Table
INCREASE DECREASE
ENTER
EXIT
To View ICVC Software Version
To Modify ICVC CCN Address
(last 2 digits of part number
Baud Rate (Do not change this)
indicate software version)
English (U.S. IMP.) or S.I. Metric Units
Password
LID Language
a19-1618
CCN
ICVC
PIC III
VFD
LEGEND
Carrier Comfort Network
International Chiller Visual Controller
Product Integrated Control III
Variable Frequency Drive
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BASIC ICVC OPERATIONS (Using the Softkeys) To perform any of the operations described below, the PIC III must be
powered up and have successfully completed its self test.
Press QUIT to leave the selected decision or field without saving any changes.
Press SELECT to view the next screen level (highlighted with the cursor bar), or to override (if allowable)
the highlighted point value.
POINT STATUS
OFF
Ready
0.0 Min
NO
NORMAL
STOP
Open
0.0 F
44.0 F
44.6 F
100%
0.0%
a19-1615
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FORCING OPERATIONS
To Force (manually override) a Value or Status
1. From any point status screen, press NEXT
PREVIOUS to highlight the desired value.
or
For Discrete Points Press START or STOP to select the desired state.
or
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a19-1638
7. Press ENTER to register the values and to move horizontally (left to right) within a period.
SERVICE OPERATION To view the menu-driven programs available for Service Operation, see Service Operation
section, page 51. For examples of ICVC display screens, see
Table 4.
19XRV_II
SETPOINT
SETPOINT SELECT
100%
50.0 F
60.0 F
40.0 F
85.0 F
a19-1619
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STATUS
UNITS
0-500000.0
40-245
40-245
40-245
40-245
40-245
40-245
0-420
40-245
0-999
0-1
0-1
0-1
HOURS
DEG F
DEG F
DEG F
DEG F
DEG F
DEG F
PSI
DEG F
%
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 III. These values may be forced by the ICVC only.
26
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DISPLAY
CHW IN
CHW OUT
EVAP REF
CDW IN
CDW OUT
COND REF
OILPRESS
OIL TEMP
AMPS%
STATUS
NOTE 2
NOTE 3
0-15
0/1
NOTE 4
0/1
0/1
30-30
10-120
40-245
40-100
0-999
0-999
4-20
4-20
40-245
0-99999
0-8
0-500000.0
0-32767
0-1
0/1
UNITS
NOTE 2
NOTE 3
min
NO/YES
NOTE 4
STOP/START
OPEN/CLOSE
DEG F
DEG F
DEG F
%
%
%
mA
mA
DEG F
HOURS
HOURS
OPEN/CLOSE
ENABLE/EMSTOP
POINT
MODE
STATUS
T_START
OCC
SYS_ALM
CHIL_S_S
REMCON
T_RESET
LCW_STPT
CHW_TMP
DEM_LIM
LNAMPS_P
LINEKW_P
AUTODEM
AUTORES
R_RESET
c_starts
STARTS
c_hrs
S_HRS
ICE_CON
EMSTOP
NOTES:
1. Numbers in parenthesis below, indicate the equivalent CCN index for BEST programming or BACnet 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 (8), Tripout (9), Ctl Test (10),
Lockout (11), Pumpdown (12), Prestart (13)
4. Normal (0), Alert (1), Alarm (2).
5. All variables with capital letter point names are available for CCN read operation. Those shown with (*) support write operations for all CCN
devices.
STATUS
0-100
0-1
0-1
0-1
0-1
0-1
6.7-200
6.7-200
0-1
0-1
0-1
0.0-100.0
0-1
0-1
0-1
0-1
UNITS
%
OFF/ON
NO/YES
OFF/ON
NO/YES
OFF/ON
^PSI
DEG F
NO/YES
FALSE/TRUE
FALSE/TRUE
%
OFF/ON
OFF/ON
ALARM/NORMAL
OFF/ON
POINT
GV_POS
CHWP
CHW_FLOW
CDP
CDW_FLOW
OILR
OILPD
OILT
VFDSTART
START_OK
STOP_OK
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.
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STATUS
0.0-100.0
0.0-100.0
0-100
0-100
0-100
40-245
6.7-200
40-245
40-245
40-245
40-245
40-245
0/1
0-100
0-5
UNITS
%
%
%
%
%
DEG F
^PSI
DEG F
DEG F
DEG F
DEG F
DEG F
OFF/ON
%
POINT
VFD_ACT
VFD_OUT
GV_POS
GV_DELTA
GV_TRG
OILT
OILPD
CMPD
MTRB
MTRW
SPARE_T1
SPARE_T2
OILHEAT
DIFF_ACT
SPC
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.
STATUS
6.7-420
40-245
40-245
40-245
20-20
40-245
6.7-420
0-99
6.7-420
40-245
40-245
40-245
6.7-420
0-99
0.0-100.0
0/1
0/1
0-200
0-200
0-200
0-100
40-245
UNITS
PSI
DEG F
DEG F
^F
^F
DEG F
PSI
^F
PSI
DEG F
DEG F
DEG F
PSI
^F
%
OFF/ON
NO/YES
PSI
^F
^F
%
DEG F
POINT
CHWPD
ECW
LCW
CHW_DT
CHW_PULL
ERT
ERP
EVAP_APP
CDWPD
ECDW
LCDW
CRT
CRP
COND_APP
VFD_FOUT
HGBYPASS
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.
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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
0.0-99999.0
0.0-99999.0
0.0-99999.0
0.00-2.00
0-99999
0-99999
0-99999
0-99999
0-99999
0-99999
0-99999
0-99999
0-99999
0-99999
0-99999
0-99999
0-99999
0.0-999.0
0.0-99.0
0.0-100.0
0.0-100.0
0.0-100.0
0.0-100.0
0.0-100.0
0.0-100.0
0-99999
0-99999
0-99999
0-99999
0-99999
0-99999
0-99999
0-99999
0.0-300.0
0.0-300.0
0.0-300.0
0.0-300.0
0.0-5.0
0.0-100.0
0.0-100.0
0.0-100.0
UNITS
%
AMPS
%
VOLTS
kW
%
%
AMPS
kW
%
kWH
kW
AMPS
AMPS
AMPS
AMPS
AMPS
AMPS
VOLTS
VOLTS
VOLTS
AMPS
HZ
%
%
%
%
%
%
AMPS
AMPS
VOLTS
VOLTS
VOLTS
VOLTS
AMPS
AMPS
DEG F
DEG F
DEG F
DEG F
VOLTS
%
%
%
POINT
LNAMPS_P
LNAMPS_A
LNVOLT_P
LNVOLT_A
LINE_PF
LINE_KW
LINEKW_P
LDAMPS_P
LDAMPS_A
MOTOR_PF
MOTOR_KW
MOTORKWP
MOTORKWH
DEM_KW
LN_AMPS1
LN_AMPS2
LN_AMPS3
LD_AMPS1
LD_AMPS2
LD_AMPS3
LN_VOLT1
LN_VOLT2
LN_VOLT3
GF_AMPS
LINEFREQ
RECT_OV
INV_OV
MOTOR_OV
LN_IMB_I
MT_IMB_I
LN_IMB_V
AMPS_ACT
AMPS_RE
VOLT_ACT
VOLT_RE
BUS_REF
BUS_VOLT
FLUXAMPS
TORQAMPS
INV_TEMP
REC_TEMP
VFD_ENCL
CP_TEMP
HUMID_SR
HUMIDITY
VFD_FOUT
VFD_ACT
NOTE: All variables with CAPITAL LETTER point names are available for CCN read operation. Those shown with (**) shall support write
operations for ICVC only.
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STATUS
0-223
0/1
0/1
0/1
0/1
0/1
0/1
0/1
0/1
0/1
0/1
0/1
0/1
0/1
0/1
0/1
0/1
0/1
0/1
0/1
0/1
0/1
0/1
0/1
0/1
0/1
0/1
0/1
0/1
0/1
0-255
0-1000
0-1000
UNITS
NORMAL/ALARM
NORMAL/ALARM
NORMAL/ALARM
NORMAL/ALARM
NORMAL/ALARM
NORMAL/ALARM
NORMAL/ALARM
NORMAL/ALARM
NORMAL/ALARM
NORMAL/ALARM
NORMAL/ALARM
NORMAL/ALARM
NORMAL/ALARM
NORMAL/ALARM
NORMAL/ALARM
NORMAL/ALARM
NORMAL/ALARM
NORMAL/ALARM
NORMAL/ALARM
FALSE/TRUE
FALSE/TRUE
NORMAL/ALARM
NORMAL/ALARM
NORMAL/ALARM
NORMAL/ALARM
NORMAL/ALARM
NORMAL/ALARM
NORMAL/ALARM
NORMAL/ALARM
POINT
VFD_FLT
CYCLE_1
LINEIM_I
LINEIM_V
PH_REV
HI_VOLT
LOW_VOLT
HI_DCBUS
LO_DCBUS
MOTIM_I
MOTOR_OV
RECT_OI
RECT_OT
RECT_PU
INV_OI
INV_OT
INV_PU
GRND_FLT
FREQFLT
VFD_POR
START_OK
STOP_OK
PRS_TRIP
NO_AMPS
ACCELFLT
AMPSTOP
STRT_INH
CHECKSUM
VFD_COMM
VFDFAULT
VFG_VER
INV_VER
REC_VER
NOTES:
1. All variables with CAPITAL LETTER point names are available for CCN Read operation 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 ICVC default screen:
1. Press MENU .
2. Press STATUS .
3. Scroll down to highlight ICVC_PWD .
4. Press SELECT .
DESCRIPTION
Disable Service Password
**Remote Reset Option
Reset Alarm?
CCN Mode?
STATUS
0-1
0-1
0-1
0-1
UNITS
DSABLE/ENABLE
DSABLE/ENABLE
NO/YES
NO/YES
POINT
PSWD_DIS
RESETOPT
REMRESET
REM_CCN
NOTE: All variables with CAPITAL LETTER point names are available for CCN read operation. Those shown with (**) shall support write operations
for the ICVC only.
To Disable Service Password, force that item to a value of 1 using Service Tool. Once this has been done, the Service menu and the VFD Config
Data screens can be accessed without a password. This access is cancelled the time the user exits the Service menu/screen.
**If the Remote Reset Option is set to a value of 1 at the ICVC, alarms may be reset and CCN mode may be reinstated remotely using Service
Tool, Building Supervisor, or ComfortWORKS controls.
EXAMPLE 9 SETPOINT DISPLAY SCREEN
To access this display from the ICVC default screen:
1. Press MENU .
2. Press SETPOINT .
3. Press SELECT .
DESCRIPTION
Base Demand Limit
Control Point
LCW Setpoint
ECW Setpoint
Ice Build Setpoint
Tower Fan High Setpoint
STATUS
40-100
UNITS
%
POINT
DLM
DEFAULT
100
10-120
15-120
15-60
55-105
DEG F
DEG F
DEG F
DEG F
lcw_sp
ecw_sp
ice_sp
TFH_SP
50.0
60.0
40.0
75
NOTE: All variables are available for CCN read operation; forcing shall not be supported on setpoint screens.
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Press SERVICE .
Scroll down to highlight CONTROL ALGORITHM STATUS .
Press SELECT .
Scroll down to highlight CAPACITY .
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 Pos
Target VFD Speed
Actual VFD Speed
Demand Limit Inhibit
Amps/kW Ramp
STATUS
40-245
40-245
UNITS
DEG F
DEG F
POINT
ECW
LCW
10-120
99-99
99-99
99-99
99-99
99-99
2-2
0-100
0-100
0-100
0-110
0.2-2.0
40-100
DEG F
^F
^F
^F
^F
^F
%
%
%
%
%
%
%
ctrlpt
cperr
ecwdt
ecwres
lcwres
error
gvd
GV_TRG
GV_POS
VFD_OUT
VFD_ACT
DEM_INH
DMDLIM
NOTE: All variables with CAPITAL LETTER point names are available for CCN read operation; forcing shall not be supported on maintenance
screen.
EXAMPLE 11 OVERRIDE DISPLAY SCREEN
To access this display from the ICVC default screen:
1. Press MENU .
2.
3.
4.
5.
6.
Press SERVICE .
Scroll down to highlight CONTROL ALGORITHM STATUS .
Press SELECT .
Scroll down to highlight OVERRIDE .
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
165-185
0-300
125.0-200.0
0-300
125-200
20-99
6-99
40-245
UNITS
DEG F
DEG F
PSI
PSI
DEG F
DEG F
DEG F
DEG F
DEG F
DEG F
DEG F
DEG F
DEG F
DEG F
^F
^F
DEG F
POINT
MTRW
mt_over
CRP
cp_over
ERT
ert_over
CMPD
cd_alert
MTRB
tb_alert
RECT_TEMP
REC_OVER
INV_TEMP
INV_OVER
SUPRHEAT
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.
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STATUS
POINT
0.0-99999.0
AMPS
LNAMPS1H
0.0-99999.0
AMPS
LNAMPS2H
0.0-99999.0
AMPS
LNAMPS3H
0.0-99999.0
AMPS
LDAMPS1H
0.0-99999.0
AMPS
LDAMPS2H
0.0-99999.0
AMPS
LDAMPS3H
0.0-99999.0
VOLTS
LNVOLT1H
0.0-99999.0
VOLTS
LNVOLT2H
0.0-99999.0
VOLTS
LNVOLT3H
0.0-999.0
AMPS
GF_AMPSH
0.0-99.0
Hz
LINEFRQH
0.00-2.00
LINE_PFH
0.0-100.0
%
LN_IMBIH
0.0-100.0
%
LN_IMBVH
0.00-2.00
MOTORPFH
0.0-100.0
%
MT_IMBIH
0.0-100.0
%
MOTOROVH
0.0-99999.0
AMPS
AMPSACTH
0.0-99999.0
AMPS
AMPS_REH
0.0-99999.0
VOLTS
VOLTACTH
0.0-99999.0
VOLTS
VOLT_REH
0.0-99999.0
VOLTS
BUSVOLTH
0.0-99999.0
VOLTS
BUS_REFH
0.0-99999.0
AMPS
FLUXAMPH
0.0-99999.0
AMPS
TORQAMPH
0.0-300.0
DEG F
INVTEMPH
0.0-300.0
DEG F
RECTEMPH
0.0-300.0
DEG F
VFDENCLH
0.0-300.0
DEG F
CP_TEMPH
0.0-100.0
%
VFD_ACTH
200-225
VFDSTATH
200-225
VFD_FLTH
available for CCN read operation; forcing shall not be supported on maintenance
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UNITS
Press SERVICE .
Scroll down to highlight CONTROL ALGORITHM STATUS .
Press SELECT .
Scroll down to highlight WSMDEFME .
Press SELECT .
DESCRIPTION
WSM Active?
Chilled Water Temp
Equipment Status
Commanded State
CHW setpt Reset Value
Current CHW Set Point
STATUS
0/1
0.0-99.9
0/1
XXXXXXXX
0.0-25.0
0.0-99.9
UNITS
NO/YES
DEG F
OFF/ON
TEXT
^F
DEG F
POINT
WSMSTAT
CHWTEMP
CHWRST
CHWRENA
CHWRVAL
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 SERVICE .
3. Scroll down to highlight EQUIPMENT CONFIGURATION .
4. Press SELECT .
5. Scroll down to highlight NET_OPT .
6. Press SELECT
DESCRIPTION
Loadshed Function
Group Number
Demand Limit Decrease
Maximum Loadshed Time
CCN Occupancy Config:
Schedule Number
Broadcast Option
Alarm Configuration
Re-Alarm Time
Alarm Routing
STATUS
UNITS
DEFAULT
0-16
0-60
0-480
%
MIN
ldsgrp
ldsdlta
maxshed
0
20
60
3-99
0-1
DSABLE/ENABLE
occ_num
occbrcst
3
DSABLE
retime
routing
30
10000000
0-1440
xxxxxxxx
MIN
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POINT
Press SERVICE .
Scroll down to highlight VFD CONFIG DATA .
Press SELECT .
Enter password (4444 Factory Default).
STATUS
346-480
45.0-62.0
0/1
346-480
10-1500
0-7200
0-7200
10-1500
10-1500
1500-3600
0-5600
0/1
0.0-102.0
0.0-102.0
0.0-102.0
0.0-102.0
1-10
1-10
5-40
1-10
5-40
1-10
5-60
5-60
0/1
UNITS
VOLTS
Hz
NO/YES
VOLTS
AMPS
kW
kW
AMPS
AMPS
kW
Hz
Hz
Hz
Hz
%
SEC
%
SEC
%
SEC
SEC
SEC
DSABLE/ENABLE
POINT
motor_nv
comp_100
line_frq
vfd_volt
vfd_amps
vfd_rlkw
mot_rlkw
mot_rla
motorni
motorpm
motorkw
pwm_freq
skipfrq1
skipfrq2
skipfrq3
skipband
v_unbal
v_time
lineim_i
lineim_t
motim_i
motim_t
ramp_inc
ramp_dec
cycdrop
DEFAULT
460
60.0
YES
460
200
100
100
200
100
3456
100
0
102.0
102.0
102.0
0.0
10
10
40
10
40
10
30
30
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 MENU .
2.
3.
4.
5.
6.
Press SERVICE .
Scroll down to highlight EQUIPMENT SERVICE .
Press SELECT .
Scroll down to highlight OPTIONS .
Press SELECT .
DESCRIPTION
Auto Restart Option
Remote Contacts Option
Soft Stop Amps Threshold
Surge / Hot Gas Bypass
Surge Limit/HGBP Option
Select: Surge=0, HGBP=1
Min. Load Point (T1,P1)
Surge/HGBP Delta T1
Surge/HGBP Delta P1
Full Load Point (T2,P2)
Surge/HGBP Delta T2
Surge/HGBP Delta P2
Surge/HGBP Deadband
Surge Protection
Surge Delta% Amps
Surge Time Period
Ice Build Control
Ice Build Option
Ice Build Termination
0=Temp, 1=Contacts, 2=Both
Ice Build Recycle
Head Pressure Reference
Delta P at 0% (4mA)
Delta P at 100% (20mA)
Minimum Output
STATUS
0/1
0/1
40-100
UNITS
DSABLE/ENABLE
DSABLE/ENABLE
%
0/1
POINT
astart
modes
strtstop
DEFAULT
DSABLE
DSABLE
100
srg_hgbp
0.5-20
30-170
^F
PSI
hgb_dt1
hgb_dp1
1.5
50
0.5-20
50-170
0.5-3
^F
PSI
^F
hgb_dt2
hgb_dp2
hgb_db
10
85
1
5-20
7-10
%
MIN
surge_a
surge_t
10
8
0/1
0-2
DSABLE/ENABLE
ibopt
ibterm
DSABLE
0
0/1
DSABLE/ENABLE
ibrecyc
DSABLE
20-85
20-85
0-100
PSI
PSI
%
HPDPO
HPDP100
HPDPMIN%
25
50
0
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Press SERVICE .
Scroll down to highlight EQUIPMENT SERVICE .
Press SELECT .
Scroll down to highlight SETUP1 .
Press SELECT .
DESCRIPTION
Comp Motor Temp Override
Cond Press Override
Rectifier Temp Override
Inverter Temp Override
Comp Discharge Alert
Comp Thrust Brg Alert
STATUS
150-200
90-165
155-170
155-170
125-200
165-185
UNITS
DEG F
PSI
DEG F
DEG F
DEG F
DEG F
POINT
MT_OVER
CP_OVER
REC_OVER
INV _OVER
CD_ALERT
TB_ALERT
DEFAULT
200
125
160
160
200
175
Chilled Medium
Chilled Water Deadband
Evap Refrig Trippoint
Refrig Override Delta T
Evap Approach Alert
Cond Approach Alert
Condenser Freeze Point
0/1
0.5-2.0
0.0-40.0
2.0-5.0
0.5-15
0.5-15
-20 - 35
WATER/BRINE
^F
DEG F
^F
^F
^F
DEG F
MEDIUM
CWDB
ERT_TRIP
REF_OVER
EVAP_AL
COND_AL
CDFREEZE
WATER
1.0
33
3
5
6
34
0-1
0.5 - 50.0
0.5 - 50.0
0.5-5
15-300
DSABLE/ENABLE
PSI
PSI
MIN
SEC
FLOWDISP
EVAP_CUT
COND_CUT
WFLOW_T
OILPR_T
DSABLE
5.0
5.0
5
40
2.0-10.0
0.5-4.0
DEG F
DEG F
rcycr_dt
rcycs_dt
5
1
sp1_en
sp1_lim
sp2_en
sp2_lim
0
245
0
245
0-4
-40-245
0-4
-40-245
DEG F
DEG F
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.
3.
4.
5.
6.
Press SERVICE .
Scroll down to highlight EQUIPMENT SERVICE .
Press SELECT .
Scroll down to highlight SETUP2 .
Press SELECT .
DESCRIPTION
Capacity Control
Proportional Inc Band
Proportional DEC Band
Proportional ECW Band
STATUS
30-100
Diffuser Control
Diffuser Option
Guide Vane 25% Load Pt
Diffuser 25% Load Point
Guide Vane 50% Load Pt
Diffuser 50% Load Point
Guide Vane 75% Load Pt
Diffuser 75% Load Point
Diffuser Full Span mA
VFD Speed Control
VFD Gain
VFD Increase Step
VFD Minimum Speed
VFD Maximum Speed
UNITS
POINT
DEFAULT
gv_inc
gv_dec
gw_ecw
6.5
6.0
2
gv_ctrl
80
0/1
0-78
0-100
0-78
0-100
0-78
0-100
15-22
DSABLE/ENABLE
%
%
%
%
%
%
mA
diff_opt
gv_25
df_25
gv_50
df_50
gv_75
df_75
diff_ma
DSABLE
25
0
50
0
75
0
18
0.1-1.5
1-5
65-100
90-100
%
%
%
vfd_gain
vfd_step
vfd_min
vfd_max
0.75
2
70
100
2-10
2-10
1-3
NOTE: No variables are available for CCN read or write operation; forcing shall not be supported on service screens.
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Press SERVICE .
Scroll down to highlight EQUIPMENT SERVICE .
Press SELECT .
Scroll down to highlight LEADLAG .
Press SELECT .
DESCRIPTION
Lead Lag Control
LEAD/LAG: Configuration
DSABLE=0, Lead=1
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
UNITS
0-3
0/1
0/1
25-75
1-236
2-60
2-60
2-30
0/1
25-75
1-236
DSABLE/ENABLE
DSABLE/ENABLE
%
MIN
MIN
MIN
DSABLE/ENABLE
%
POINT
DEFAULT
leadlag
loadbal
commsens
lag_per
lag_add
lagstart
lagstop
preflt
stndopt
stnd_per
stnd_add
DSABLE
DSABLE
50
92
10
10
5
DSABLE
50
93
Press SERVICE .
Scroll down to highlight EQUIPMENT SERVICE .
Press SELECT .
Scroll down to highlight RAMP_DEM .
Press SELECT .
DESCRIPTION
Pulldown Ramp Type:
Select: Temp=0, Load=1
Demand Limit and kW Ramp
Demand Limit Source
Select: Amps=0, kW=1
Amps or Kw Ramp%/Min
Demand Limit Prop Band
Demand Limit At 20 mA
20 mA Demand Limit Opt
Demand Watts Interval
STATUS
0/1
UNITS
0/1
5-20
3-15
40-100
0/1
5-60
%
%
DSABLE/ENABLE
MIN
POINT
ramps1ct
DEFAULT
1
dem_src
kw_ramp
dem_app
dem_20ma
dem_sel
dw_int
10
10
40
DSABLE
15
Press SERVICE .
Scroll down to highlight EQUIPMENT SERVICE .
Press SELECT .
Scroll down to highlight TEMP_CTL .
Press SELECT .
DESCRIPTION
Control Point
ECW Control Option
Temp Pulldown Deg/Min
Temperature Reset
RESET TYPE 1
Degrees Reset At 20 mA
RESET TYPE 2
Remote Temp > No Reset
Remote Temp > Full Reset
Degrees Reset
RESET TYPE 3
CHW Delta T > No Reset
CHW Delta T > Full Reset
Degrees Reset
Enable Reset Type
STATUS
UNITS
POINT
DEFAULT
0/1
2-10
DSABLE/ENABLE
^F
ecw_opt
tmp_ramp
DSABLE
3
30- 30
^F
deg_20ma
10
40-245
40-245
30-30
DEG F
DEG F
^F
res_rt1
res_rt2
deg_rt
85
65
10
0-15
0-15
30-30
^F
^F
^F
restd_1
restd_2
deg_chw
10
0
5
res_sel
0-3
36
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GUIDE VANE
DELTA
From +0.2 to
+2.0
Increase
1st
Increase
when IGV
= max
From 0.2 to
2.0
Decrease
when VFD
speed =
min
Decrease
1st
SURGE
PREVENTION
MODE
IGV
VFD
Increase
only if VFD
speed =
max and if
Increase
hot gas
1st
bypass is
present
and open
Decrease
CAPACITY CONTROL Generally the chiller adjusts capacity in response to deviation of leaving or entering chilled
water temperature from CONTROL POINT. CONTROL
POINT is based on the configured SETPOINT (in the
SETPOINT screen: LCW SET POINT or ECW SET POINT or
ICE BUILD SET POINT), and CONTROL POINT is equal to
this SETPOINT plus any active chilled water reset value. A reset value may originate from any of the three chilled water/brine
reset options configured in the ICVC Service/Equipment
Service/TEMP_CTL screen (see page 45) or from a CCN device. The default reset value is 0 F. 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 PROPORTIONAL ECW (Entering Chilled Water) GAIN in the Service/
Equipment Service/SETUP2 screen. Increasing the PROPORTIONAL INC 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 38.
Factors and variables used in the capacity control determination are displayed in the Service/Control Algorithm Status/
Capacity screen and in the Status/COMPR screen. Viewing this
data will aid in troubleshooting and understanding current
operation.
Variable Speed (VFD) Application The PIC III controls
the machine capacity by modulating both motor speed and
inlet guide vanes in response to chilled water temperature deviation from the CONTROL POINT (see above). During operation, when the CONTROL POINT is not met within 1/3 of the
width of the CHILLED WATER DEADBAND, the controller
will calculate a GUIDE VANE DELTA which will effect a percentage change to either the guide vane position or TARGET
VFD SPEED. Factors considered in the capacity control algorithm include: (1) the sign and magnitude of GUIDE VANE
DELTA (based on deviation from CONTROL POINT adjusted
for the error trends and CHILLED WATER DEADBAND), (2)
ACTUAL GUIDE VANE POSITION, (3) ACTUAL VFD
SPEED, and (4) surge prevention mode. Generally the controller will maintain the highest inlet guide vane setting at the lowest speed to maximize efficiency while avoiding surge.
First, the calculation 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 an IGV or VFD position decrease (within limits). Next, the surge prevention mode is
determined based on location of the present operating point on
the CHILLED WATER DELTA T/ACTIVE DELTA P map relative the configured surge prevention line. This mode will either
be Normal or Surge Prevention. The following table indicates
which output is modulated first. When the first output reaches its
limit (ACTUAL GUIDE VANE position reaches maximum),
the second output is modulated. See Table 5.
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NORMAL
CONTROL
MODE
IGV
VFD
Control Output
(Actuator Position)
DIFFUSER POSITION
2 mA
(0%)
Full 4 mA
Open (0.2%)
75 % Load Point
surge less likely
50 % Load Point
rotating stall
less likely
Full
Closed
approx.
4 mA*
(100%)
25 % Load Point
0%
50 %
78 %
a19-1620
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ALARM/
ALERT
260-271,
140,141
260-271
231
167
103
233
102
101
234
243
232
104
239
235
Switch
207
Prestart
106
244
154
228
Low Pressure
Low Pressure
142
227
Low Temperature
105
211/145
High
108
Low
212/146
Low
107
Imbalance
216
210/144
209/143
222
214/148
LIMIT
.06 > Voltage Ratio > .98 or 40 F >
Temperature>245 F for 3 seconds
.06 > Voltage Ratio > .98 for 3 seconds
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COMMENTS
ALARM/ALERT
LIMIT
238
> 5 surge events within SURGE TIME PERIOD
and VFD SPEED > 90%
236
> 5 surge events within SURGE TIME PERIOD
and VFD SPEED < 90%
225
MOTOR CURRENT IMBALANCE > MOTOR
CURRENT % IMBALANCE
Overload Trip
217
Excessive Amps
Acceleration Fault
208
203
202
100
229
230
162
Condenser
163
245
Failure to Stop
204
218
110
Overcurrent
Power Fault
241
200
219
111
286
201
256
Power Fault
Inductor Overtemperature Switch
DC Bus Voltage High
Low
205/166
215
Ground Fault
Optional Limits Spare Temperature
220
158,159,
248,249
253
240
255
Sensor Fault
168
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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
Oil Sump Temperature and Pump Control The oil sump temperature 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 difference between these 2 temperatures is 50 F (27.8 C) or
less, the start-up will be delayed until either of these conditions
is no longer true. Once this temperature criteria is satisfied, the
start-up continues.
The oil heater relay is energized whenever the chiller compressor is off and the oil sump temperature is less than 140 F
(60.0 C) or the OIL SUMP TEMP is less than the EVAP
REFRIG TEMP plus 53 F (29.4 C). The oil heater is turned
off when the OIL SUMP TEMP is either:
more than 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 during the time the oil is being heated (for 30 seconds at the end of every 30 minutes).
The oil pump will not operate if the EVAPORATOR PRESSURE is less than 5 psig (34.5 kPa).
Oil Cooler The oil must be cooled when the compressor is running. This is accomplished through a small, plate-type
heat exchanger (also called the oil cooler) located behind the
oil pump. The heat exchanger uses liquid condenser refrigerant
as the cooling liquid. Refrigerant thermostatic expansion
valves (TXVs) regulate refrigerant flow to control the oil temperature entering the bearings. The bulbs for the expansion
valves are strapped to the oil supply line leaving the heat
exchanger, and the valves are set to maintain 110 F (43 C).
NOTE: The TXVs are not adjustable. The oil sump temperature
may be at a lower temperature during compressor operation.
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View/Modify on
ICVC Screen
SETUP1
SETUP1
SETUP1
OPTIONS
2 to 5 F
(1.1 to 2.8 C)
None
0 to 100%
COMPRESS
Automatic
VFD MINIMUM
SPEED to 100%
Motor Load
(ACTIVE DEMAND LIMIT)
MAINSTAT
Automatic
40 to 100%
OVERRIDE
None
155 to 170 F
(68 to 77 C)
155 to 170 F
(68 to 77 C)
ACTUAL SUPERHEAT
< SUPERHEAT REQUIRED
1.25 F (0.7 C)
ACTUAL SUPERHEAT
> SUPERHEAT REQUIRED
+ 1 F (0.56 C)
RECTIFIER TEMP
> RECTIFIER TEMP OVERRIDE
+ 10 F (5.6 C)
INVERTER TEMP
> INVERTER TEMP OVERRIDE
+ 10 F (5.6 C)
RECTIFIER TEMP
< RECTIFIER TEMP OVERRIDE
5 F (2.8 C)
INVERTER TEMP
< INVERTER TEMP OVERRIDE
5 F (2.8 C)
Normally closed (NC) discrete inputs for additional fieldsupplied safeties may be wired to the spare protective limits
input channel in place of the factory-installed jumper on
terminals 19 and 20 of the low voltage terminal strip. The
opening of any contact will result in a safety shutdown and a
display on the ICVC. Refer to the certified drawings for safety
contact ratings.
Extra analog temperature sensors may also be added to the
CCM module (SPARE TEMPERATURE #1 and SPARE
TEMPERATURE #2) at terminals J4 25-26 and J4 27-28,
respectively. The analog temperature sensors may be configured in the EQUIPMENT SERVICE/SETUP1 table to cause
an alert (Enable value 1 or 2) or alarm (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 1 or 3), configurable between 40 F to
245 F (40 C to 118 C). The spare temperature sensors are
readable on the CCN network. They also have specific uses
as common temperature sensors in a Lead/Lag system. See
page 47.
The contacts for remote start are wired into terminals 23 and
24 of the low voltage terminal strip in the VFD enclosure. See
43
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Automatic
SETUP1
Value
CONDENSER PRESSURE
< CONDENSER PRESS
OVERRIDE 1 PSI (6.9 kPa)
COMPR MOTOR WINDING
TEMP < COMP MOTOR TEMP
OVERRIDE 2 F (1.1 C)
None
COMPRESS
SETUP1
Value
CONDENSER PRESSURE
> COND PRESS OVERRIDE
+ 2.4 psig (16.5 kPA)
COMP MOTOR WINDING TEMP
> COMP MOTOR TEMP OVERRIDE + 10 F (5.6 C)
EVAPORATOR REFRIG TEMP
< EVAP REF OVERRIDE TEMP
- 1 F (.6 C)
NOTE: EVAP REF OVERRIDE
TEMP = EVAP REFRIG TRIPPOINT + REFRIG OVERRIDE
DELTA T
OVERRIDE TERMINATION
0.5 - 2.0 F
(0.3 - 1.1 C)
30 - 170 psid
(207 - 1172 kPad)
0.5 - 20 F
(0.3 - 11.1 C)
50 - 170 psid
(345 - 1172 kPad)
module [Terminal J8-1 (+) and J8-2 ()] to represent the power
consumption of the chiller. The 4 to 20 mA signal generated by
the CCM module can be wired to the building automation or
energy management system to monitor the chillers energy
consumption. Output is 2 mA with the chiller off, and it
varies linearly from 4 mA (representing 0% rated kilowatt
consumption) to 20 mA (representing 100% RATED LINE
KILOWATTS). The rated peak kilowatt consumption is
configured by the user in the VFD_CONF display screen by
setting the RATED LINE KILOWATTS from the machine electrical data nameplate.
Evaporator Freeze Protection When the EVAPORATOR REFRIG TEMP is less than the EVAP REFRIG
TRIPPOINT plus the REFRIG OVERRIDE DELTA T (configurable from 2 to 5 F or 1.1 to 2.8 C), Alert State 122 will be
displayed, and a capacity override will occur. (See Table 7.)
When the unit is running or in recycle, if the EVAPORATOR
REFRIG TEMP is equal to or less than the EVAP REFRIG
TRIPPOINT (33 F or 0.6 C for water, configurable for brine),
Protective Limit Alarm State 232 will be displayed, the unit
will shut down, and the CHILLED WATER PUMP will remain
on. The alarm will be clearable when the leaving chilled water
temperature rises 5F (2.8C) above the CONTROL POINT.
When the unit is off, if the EVAPORATOR REFRIG TEMP
is less than the EVAP REFRIG TRIPPOINT plus 1 F (0.6 C),
Alarm State 243 will be generated and the CHILLED WATER
PUMP will be turned on. The alarm 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-
tor the CONDENSER PRESSURE and may turn on the condenser pump if the condenser pressure becomes too high while
the compressor is shut down. The COND PRESS OVERRIDE
parameter is used to determine this pressure point. COND
PRESS OVERRIDE is found in the SETUP1 display screen,
which is accessed from the EQUIPMENT SERVICE table.
The default value is 125 psig (862 kPa).
If the CONDENSER PRESSURE is greater than or equal to
the COND PRESS OVERRIDE, and the ENTERING CONDENSER WATER temperature is less than 115 F (46 C), the
condenser pump will energize to try to decrease the pressure
and Alert 151 will be generated. The pump will turn off when
the condenser pressure is 3.5 psi (24.1 kPa) less than the
pressure override and the CONDENSER REFRIG TEMP is
within 3 F (1.7 C) of the ENTERING CONDENSER WATER
temperature.
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The tower fan relay control is not a substitute for a condenser water temperature control. When used with a water
temperature control system, the tower fan relay control can
be used to help prevent low condenser water temperatures.
The portion of the surge count threshold attributable to current 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.
a19-1621
LEGEND
Entering Chilled Water
Hot Gas Bypass
Leaving Chilled Water
ECW
HGBP
LCW
a19-1622
ECW
HGBP
LCW
LEGEND
Entering Chilled Water
Hot Gas Bypass
Leaving Chilled Water
DELTA P
NON-ZERO
EXAMPLE OF
MINIMUM
REFERENCE
OUTPUT
DELTA P
AT 0%
0 mA 2 mA 4 mA
(0%)
4 T0 20 mA OUTPUT
a19-1658
20 mA
(100%)
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Ice Build Control The selectable ice build mode permits use of the chiller to refreeze or control the temperature of
an ice reservoir which may, for example, be used for thermal
storage. This mode differs from water or brine chilling in that
termination (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 III
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 OPTIONS 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 from 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 24, for more
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 SETPOINT. In this case, the operator sets the ICE BUILD TERMINATION parameter to 0
(the default setting) on the OPTIONS screen.
the ICE BUILD CONTACTS input from an ice level
indicator are opened. In this case, the operator sets the
ICE BUILD TERMINATION parameter to 1 on the
OPTIONS screen.
the chilled water temperature is less than the ICE BUILD
SETPOINT and the ICE BUILD CONTACTS input
from an ice level indicator are open. In this case, the
operator sets the ICE BUILD TERMINATION parameter
to 2 on the OPTIONS screen.
the end of the ice build time schedule (OCCPC02S) has
been reached.
ICE BUILD INITIATION The ice build time schedule
(OCCPC02S) is the means for activating the ice build option.
Ice Build is enabled if:
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),
and 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 parameters value can be forced, that is, the value
can be manually changed at the ICVC by an operator, changed
from another CCN device, or changed by other algorithms in
the PIC III control system.
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
perform a RECOVERY START REQUEST (LL_MAINT
screen). The lead chiller will start up when the following conditions are met.
1. Lag chiller ramp loading must be complete.
2. Lag CHILLED WATER TEMP (MAINSTAT screen) is
greater than CONTROL POINT plus 1/2 the CHILLED
WATER DEADBAND temperature.
3. Lag chiller ACTIVE DEMAND LIMIT value must be
greater than 95% of full load amps.
4. Lag chiller temperature pulldown rate (TEMP PULLDOWN DEG/MIN) of the chilled water temperature is
less than 0.5 F (0.27 C) per minute.
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 started when the lag (acting lead) chillers ramp loading
is completed.
LOAD BALANCING When the LOAD BALANCE OPTION (see LEADLAG screen) is enabled, the lead chiller sets
the ACTIVE DEMAND LIMIT in the lag chiller to the lead
chillers 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 chillers
CONTROL POINT value. If the LOAD BALANCE OPTION is
disabled, the ACTIVE DEMAND LIMIT and the CONTROL
POINT are both forced to the same value as the lead chiller.
AUTO. RESTART AFTER POWER FAILURE When an
auto. restart condition occurs, each chiller may have a delay
added to the start-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 are closed.
After the guide vane position is confirmed, the delay for lag
and standby chillers occurs prior to energizing the oil pump.
The normal start-up sequence then continues. The auto. restart
delay sequence occurs whether the chiller is in CCN or
LOCAL mode and is intended to stagger the compressor motor
starts. Preventing the motors from starting simultaneously
helps reduce the inrush demands on the building power system.
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NOTE: The Ice Build steps do not occur if the chiller is configured and operating as a lag or standby chiller for lead/lag
operation and is actively being controlled by a lead chiller. The
lead chiller communicates the ICE BUILD SET POINT, 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 PIC III checks the following conditions, based on the ICE BUILD TERMINATION
value, to avoid starting the compressor unnecessarily:
if ICE BUILD TERMINATION is set to the TEMP option
and the ENTERING CHILLED WATER temperature is
less than or equal to the ICE BUILD SETPOINT;
if ICE BUILD TERMINATION is set to the CONTACTS
option and the ICE BUILD CONTACT is open;
if the ICE BUILD TERMINATION is set to the BOTH
(temperature and contacts) option and the ENTERING
CHILLED WATER temperature is less than or equal
to the ICE BUILD SETPOINT and the ICE BUILD
CONTACT is open.
The ICE BUILD RECYCLE on the OPTIONS screen
determines whether or not the chiller will go into an ice build
RECYCLE mode.
If the ICE BUILD RECYCLE is set to DSABLE (disable),
the PIC 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 LEAVING 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 (configured on TEMP_CTL screen).
20 mA DEMAND LIMIT OPT (configured on
RAMP_DEM screen).
TERMINATION OF ICE BUILD The ice build function
terminates under the following conditions:
1. Time Schedule When the current time on the ice build
time schedule (OCCPC02S) is not set as an ice build time
period.
2. Entering Chilled Water Temperature Ice build operation terminates, based on temperature, if the ICE BUILD
TERMINATION parameter 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. If the ICE BUILD
RECYCLE OPTION is set to ENABLE, a recycle
shutdown occurs and recycle start-up depends on
the LEAVING CHILLED WATER temperature being
greater than the water/brine CONTROL POINT plus the
RESTART DELTA T temperature.
3. Remote Contacts/Ice Level Input Ice build operation
terminates when the ICE BUILD TERMINATION parameter is set to 1 (CONTACTS) and the ICE BUILD
ATTACHING TO OTHER CCN MODULES If the chiller ICVC has been connected by CCN wiring to the CCN network or other PIC controlled chillers, the ICVC can be used to
view or change parameters on the other controllers. Other PIC
III chillers can be viewed and set points changed (if the other
unit is in CCN control), if desired, from this particular ICVC
module.
If the module number is not valid, the COMMUNICATION FAILURE message will show and a new address
number must be entered or the wiring checked. If the module is
communicating properly, the UPLOAD IN PROGRESS
message will flash and the new module can now be viewed.
Whenever there is a question regarding which module on
the ICVC is currently being shown, check the device name
descriptor on the upper left hand corner of the ICVC screen.
See Fig. 25.
When the CCN device has been viewed, the ATTACH TO
NETWORK DEVICE table should be used to attach to the PIC
that is on the chiller. Move to the ATTACH TO NETWORK
DEVICE table (LOCAL should be highlighted) and press the
ATTACH softkey to upload the LOCAL device. The ICVC
for the 19XRV will be uploaded and default screen will display.
a19-1743
2. Press the four digits of the password, one at a time. An asterisk (*) appears as each digit is entered.
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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 specified amount (later in the year).
a19-1624
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START-UP/SHUTDOWN/
RECYCLE SEQUENCE (Fig. 27)
Local Start-Up Local start-up (or a manual start-up) is
initiated by pressing the LOCAL menu softkey on the default
ICVC screen. Local start-up can proceed when the chiller
schedule indicates that the CURRENT TIME and CURRENT
DATE have been established as a run time and date, and after
the internal timers have expired. The timers include a
15-minute start-to-start timer and a 1-minute stop-to-start timer, which together serve to prevent excessive cycling and abuse
of the motor. The value of these timers is displayed as START
INHIBIT TIMER and can be viewed on the MAINSTAT and
DEFAULT screens. Both timers must expire before the chiller
will start. If the timers have not expired, the RUN STATUS
parameter on the MAINSTAT screen will read TIMEOUT.
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 <[EVAPORATOR REFRIG TEMP] + 50 F (27.8 C)
< [COND PRESS OVERRIDE] 20 PSI (138 kPa) and
< 145 psi (1000 kPa)
< [Undervoltage Threshold]
> [Overvoltage Threshold]
Controls test guide vane calibration must be performed
< RECTIFIER TEMP OVERRIDE 20 F (11.1 C)
< INVERTER TEMP OVERRIDE 20 F (11.1 C)
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The condenser pump shuts down when the CONDENSER PRESSURE is less than the COND PRESS
OVERRIDE threshold minus 3.5 psi (24.1 kPa) and the
CONDENSER REFRIG TEMP is less than or equal to the
ENTERING CONDENSER WATER temperature plus
3 F (1.6 C).
If the chiller shuts down due to low refrigerant temperature, the chilled water pump continues to run until the
LEAVING CHILLED WATER temperature is greater than
the CONTROL POINT temperature, plus 5 F (2.8 C).
a19-765
A
a19-658
Open Oil Circuit Valves Check to ensure the oil filter isolation valves (Fig. 4) are open by removing the valve cap
and checking the valve stem.
Equipment Required
mechanics 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 700 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
the time the chiller arrives at the jobsite. Tighten all gasketed
joints and the guide vane shaft packing to ensure a leak-tight
chiller. Gasketed joints (excluding O-rings) may include joints
at some or all of the following:
Waterbox covers
Compressor suction elbow flanges (at compressor and at
the cooler)
Compressor discharge flange
Compressor discharge line spacer (both sides) if no isolation valve
Cooler inlet line spacer (both sides) if no isolation valve
Hot gas bypass valve (both sides of valve)
Hot gas bypass flange at compressor
Refer to Table 10 for bolt torque requirements.
Using the Optional Storage Tank and Pumpout System Refer to Chillers with Storage Tanks sec-
Remove Shipping Packaging Remove any packaging material from the control panel, power panel, guide vane
actuator, motor cooling and oil reclaim solenoids, motor and
bearing temperature sensor covers, and the VFD.
55
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16
3/
7/16
1/
9/
16
5 /8
3/
7/
1
1 1 /8
1 1 /4
1 3 /8
1 1 /2
1 5 /8
1 3 /4
1 7 /8
2
2 1 /4
2 1 /2
2 3 /4
3
SAE 2, A307 GR A
HEX HEAD
NO MARKS
LOW CARBON STEEL
Minimum
Maximum
4
6
8
11
13
19
21
30
32
45
46
65
65
95
105
150
140
200
210
300
330
475
460
660
620
885
740
1060
1010
1450
1320
1890
1630
2340
1900
2720
2180
3120
3070
4380
5120
7320
6620
9460
SAE 5, SA449
SOCKET HEAD OR HEX
WITH 3 RADIAL LINES
MEDIUM CARBON STEEL
Minimum
Maximum
6
9
13
18
22
31
35
50
53
75
75
110
105
150
175
250
265
380
410
580
545
780
770
1,100
1,020
1,460
1,220
1,750
1,670
2,390
2,180
3,110
2,930
4,190
3,150
4,500
4,550
6,500
5,000
7,140
8,460
12,090
11,040
15,770
transferred. Adjust the springs when the refrigerant is in operating condition and the water circuits are full.
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SAE 8, SA354 GR BD
HEX HEAD
WITH 6 RADIAL LINES
MEDIUM CARBON STEEL
Minimum
Maximum
9
13
20
28
32
46
53
75
80
115
115
165
160
225
260
370
415
590
625
893
985
1,410
1,380
1,960
1,840
2,630
2,200
3,150
3,020
4,310
3,930
5,610
5,280
7,550
5,670
8,100
8,200
11,710
11,350
16,210
15,710
22,440
19,900
28,440
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Leak Test Chiller Due to regulations regarding refrigerant 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 refrigerant pressure/
temperature values.
1. If the pressure readings are normal for the chiller
condition:
a. Evacuate the holding charge from the vessels, if
present.
b. Raise the chiller pressure, if necessary, by adding
refrigerant until pressure is at the equivalent saturated pressure for the surrounding temperature.
Follow the pumpout procedures in the Transfer
Refrigerant from Pumpout Storage Tank to Chiller
section, Steps 1a - e, page 75.
5.
6.
Never charge liquid refrigerant into the chiller if the pressure in the chiller is less than 35 psig (241 kPa) for
HFC-134a. Charge as a gas only, with the cooler and
condenser pumps running, until this pressure is reached,
using PUMPDOWN LOCKOUT and TERMINATE
LOCKOUT mode on the PIC III. Flashing of liquid
refrigerant at low pressures can cause tube freeze-up and
considerable damage.
7.
8.
9.
Standing Vacuum Test When performing the standing vacuum test or chiller dehydration, use a manometer or a
wet bulb indicator. 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 chiller.
2. Evacuate the vessel (see Pumpout and Refrigerant
Transfer Procedures section, page 74) to at least 18 in. Hg
vac, ref 30-in. bar (41 kPa), using a vacuum pump or the
pumpout 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. If the leakage rate exceeds 0.05 in. Hg (0.17 kPa) in
24 hours, repressurize the vessel and test for leaks.
If refrigerant is available in the other vessel, pressurize by following Steps 2-10 of Return Chiller To
Normal Operating Conditions section, page 76. If
not, use nitrogen and a refrigerant tracer. Raise the
vessel pressure in increments until the leak is
detected. If refrigerant is used, the maximum gas
pressure is approximately 70 psig (483 kPa) for
HFC-134a at normal ambient temperature. If nitrogen is used, limit the leak test pressure to 160 psig
(1103 kPa) maximum.
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1b REFRIGERANT
CHARGING VALVE
CHILLER
CONDENSER
VESSEL
1a REFRIGERANT
CHARGING VALVE
CHILLER
COOLER
VESSEL
COOLER 11
REFRIGERANT
ISOLATION
VALVE
TEE FOR
CHARGING
PRESSURE
RELIEF SAFETY
VALVE
STORAGE
10 TANK LIQUID
VALVE
OIL
SEPARATOR
LIQUID LINE
SERVICE
VALVE
PUMPOUT
COMPRESSOR
= SERVICE VALVE ON
CHILLER (FIELD
SUPPLIED)
= SERVICE VALVE ON
PUMPOUT UNIT
PUMPOUT
CONDENSER
2
PUMPOUT
CONDENSER
WATER SUPPLY
AND RETURN
6 STORAGE TANK
VAPOR VALVE
a19-1721
Fig. 30 Typical Optional Pumpout System Piping Schematic with Storage Tank
1b
REFRIGERANT
CHARGING
VALVE
CHILLER
CONDENSER
VESSEL
CHILLER
COOLER
VESSEL
COOLER 11
REFRIGERANT
ISOLATION
VALVE
LIQUID LINE
SERVICE
VALVE
PRESSURE
RELIEF SAFETY
VALVE
1a
REFRIGERANT
CHARGING
VALVE
OIL
SEPARATOR
= SERVICE VALVE ON
PUMPOUT UNIT
= SERVICE VALVE ON
CHILLER
PUMPOUT
CONDENSER
PUMPOUT
COMPRESSOR
2
PUMPOUT
CONDENSER
WATER SUPPLY
AND RETURN
a19-1722
Fig. 31 Typical Optional Pumpout System Piping Schematic without Storage Tank
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PRESSURE
(psig)
6.50
7.52
8.60
9.66
10.79
11.96
13.17
14.42
15.72
17.06
18.45
19.88
21.37
22.90
24.48
26.11
27.80
29.53
31.32
33.17
35.08
37.04
39.06
41.14
43.28
45.48
47.74
50.07
52.47
54.93
57.46
60.06
62.73
65.47
68.29
71.18
74.14
77.18
80.30
83.49
86.17
90.13
93.57
97.09
100.70
104.40
108.18
112.06
116.02
120.08
124.23
128.47
132.81
137.25
141.79
146.43
151.17
156.01
160.96
166.01
171.17
176.45
181.83
187.32
192.93
198.66
204.50
210.47
216.55
222.76
229.09
TEMPERATURE,
C
18.0
16.7
15.6
14.4
13.3
12.2
11.1
10.0
8.9
7.8
6.7
5.6
4.4
3.3
2.2
1.1
0.0
1.1
2.2
3.3
4.4
5.0
5.6
6.1
6.7
7.2
7.8
8.3
8.9
9.4
10.0
11.1
12.2
13.3
14.4
15.6
16.7
17.8
18.9
20.0
21.1
22.2
23.3
24.4
25.6
26.7
27.8
28.9
30.0
31.1
32.2
33.3
34.4
35.6
36.7
37.8
38.9
40.0
41.1
42.2
43.3
44.4
45.6
46.7
47.8
48.9
50.0
51.1
52.2
53.3
54.4
55.6
56.7
57.8
58.9
60.0
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PRESSURE
(kPa)
44.8
51.9
59.3
66.6
74.4
82.5
90.8
99.4
108.0
118.0
127.0
137.0
147.0
158.0
169.0
180.0
192.0
204.0
216.0
229.0
242.0
248.0
255.0
261.0
269.0
276.0
284.0
290.0
298.0
305.0
314.0
329.0
345.0
362.0
379.0
396.0
414.0
433.0
451.0
471.0
491.0
511.0
532.0
554.0
576.0
598.0
621.0
645.0
669.0
694.0
720.0
746.0
773.0
800.0
828.0
857.0
886.0
916.0
946.0
978.0
1010.0
1042.0
1076.0
1110.0
1145.0
1180.0
1217.0
1254.0
1292.0
1330.0
1370.0
1410.0
1451.0
1493.0
1536.0
1580.0
a19-661
Inspect Water Piping Refer to piping diagrams provided in the certified drawings. Inspect the piping to the cooler
and condenser. Be sure that the flow directions are correct and
that all piping specifications have been met.
Humidity
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SPECIFICATION
32 to 122 F (0 to 50 C)
-40 to 149 F (-40 to 65 C)
5% to 95%
(non-condensing)
a19-1723
LF20
0608CC
a19-1629
The main disconnect on the VFD front panel may not deenergize all internal circuits. Open all internal and remote
disconnects before servicing the VFD. Failure to do so could
result in serious personal injury or death from electric shock.
PART NUMBER
FRAME
SIZE
ENCLOSURE
RATING
NAMEPLATE
INPUT
VOLTAGE
(V)
MAX
INPUT
CURRENT
(AMPS)
19XVA2AA__________
19XVA2CC__________
19XVA4CC__________
2AA
2CC
4CC
NEMA 1
380 TO
460
442
608
1169
*110% output current capability for 1 minute. 150% output current capability for 5 sec.
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MAX
OUTPUT
CURRENT
AT 4 kHz*
(AMPS)
442
608
1169
Inspect Wiring
SIGNAL
TYPE
+
Ground
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CABLE NO.
2413 or 5463
A22503
8772
02525
CCN BUS
CONDUCTOR
INSULATION
COLOR
Red
White
Black
CCN
TERMINAL
CONNECTION
ICVC PLUG J1
PIN NO.
RED (+)
WHITE (G)
BLACK ()
1
2
3
Software Configuration
4. The next digit is highlighted. Change it, and the third and
fourth digits in the same way the first was changed.
5. After the last digit is changed, the ICVC goes to the BUS
NUMBER parameter. Press the EXIT softkey to leave
that screen and return to the SERVICE menu.
Input Service Configurations The following configurations require the ICVC screen to be in the SERVICE portion of the menu.
password
input time and date
ICVC configuration
service parameters
equipment configuration
automated control test
PASSWORD When accessing the SERVICE tables, a password must be entered. All ICVC are initially set for a password
of 1-1-1-1 in the ICVC CONFIGURATION SCREEN.
INPUT TIME AND DATE Access the TIME AND DATE
table on the SERVICE menu. Input the present time of day,
IMPORTANT: The VFD controller has been factory configured for use and communications to the International
Chiller Visual Controller (ICVC). Some parameters are
specific to the chiller configuration and will need to be verified prior to operation. All command functions must be
initiated from the ICVC.
VFD CHILLER FIELD SET UP AND VERIFICATION
Label Locations Verify that the following labels have been
installed properly and match the chiller requisition:
Surge Parameters Located inside the control panel.
See Fig. 10.
Refrigeration Machine Nameplate Located on the
right side of the control panel. See Fig. 10.
External Machine Electrical Data Nameplate Located
on the right side of the VFD as viewed from its front. See
Fig. 35.
Internal Machine Electrical Data Nameplate Located
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 ICVC 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:
Motor Nameplate Voltage Voltage required to run at
motor rating.
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.
a19-1626
INTERNAL
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EXTERNAL
Decrease P2 by
2 psid (14 kPad)
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left, first) are used. The others do not matter. The bits can be
set by any device which can access and change configuration
tables. If any of these 3 bits is set to 1, the controller (ICVC,
for example) will broadcast any alarms which occur.
first bit = 1 indicates that the alarm should be read
and processed by a front end device, such as a
ComfortWORKS device.
second bit = 1 indicates that the alarm should be read and
processed by a TeLINK 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, or DataLINK modules.
The Re-Alarm time is a time period after which, if a preexisting and previously broadcast alarm has not been cleared, it
will be rebroadcast on the CCN network. See Fig. 36.
Other Tables The CONSUME, NET_OPT, and RUNTIME 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 Supervisor.
ALARM CONTROL
ALARM ROUTING
This decision determines which CCN system elements will receive
and process alarms sent by the CSM. Input for the decision consists
of eight digits, each of which can be set to either 0 or 1. Setting a
digit to 1 specifies that alarms will be sent to the system element
that corresponds to that digit. Setting all digits to 0 disables alarm
processing. Digits in this decision correspond to CCN system
elements in the following manner:
Alarm Printer Interface Module
Autodail Gateway
Local Building Supervisors(s)
or ComfortWORKS
a19-1627
0
unused
00000000 to 11111111
0 = Disabled, 1 = Enabled
Default Value
10000000
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key to set the new value, then the ENTER key. Generally, the
value can be changed to any value within 15% of a nominal
value.
PRESSURE TRANSDUCER CALIBRATION Transducers measuring single pressure values (such as condenser
and evaporator pressure) are calibrated individually, while a
pair of transducers measuring a pressure differential (OIL/
PUMP DELTA P, CONDENSER WATER DELTA P,
CHILLED WATER DELTA P) are calibrated together as a differential. In units with ICVC controllers, transducers for sensing water side flow are not provided as standard. These
readings can be viewed and calibrated from the COMPRESS
and HEAT_EX screens on the ICVC controller.
Each transducer or transducer pair can be calibrated at two
points: zero (0 psig or 0 kPa) and high end (between 25 and
250 psig, or between 173 and 1724 kPa). It is not usually
necessary to calibrate at initial start-up. However, at high
altitude locations, recalibration may be necessary to ensure the
proper refrigerant temperature-pressure relationship.
ZERO POINT CALIBRATION Shut down the compressor,
and cooler and condenser pumps. There must be no water flow
through the heat exchangers, but these systems must be filled.
For differential pairs, leave the transducers installed. For single
value transducers, disconnect the transducers electrical cable,
remove the sensor from its Schrader fitting, then reconnect the
cable.
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 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 calibration, the
INCREASE and DECREASE keys have no effect.) The value should change to 0.0.
a 0.5-amp fuse, the compressor overloads, an internal thermostat, a compressor contactor, refrigerant low pressure cut-out,
and a refrigerant high pressure cutout. The high pressure cutout
is factory set to open at 185 psig (1276 kPa) and reset at
140 psig (965 kPa). The low pressure cutout is factory set to
open at 7 psia (15.7 in. HG) and close at 9 psia (11.6 in. HG).
Ensure the water-cooled condenser has been connected. Ensure
oil is visible in the compressor sight glass. Add oil if necessary.
See the Pumpout and Refrigerant Transfer Procedures and
Optional Pumpout System Maintenance sections, pages 74 and
81, for details on the transfer of refrigerant, oil specifications,
etc.
High Altitude Locations Because the chiller is initially calibrated at sea level, it is necessary to recalibrate the
pressure transducers if the chiller has been moved to a high
altitude location. See the calibration procedure in the Troubleshooting Guide section.
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69
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REFRIGERANT
CHARGE
lb
kg
345
156
385
175
435
197
350
159
420
191
490
222
400
181
480
218
550
249
560
254
630
286
690
313
640
290
720
327
790
358
750
340
840
381
900
408
870
395
940
426
980
445
940
426
980
445
1020
463
1020
463
1060
481
1090
494
1220
553
1340
608
1440
653
1365
619
1505
683
1625
737
1500
680
1620
735
1730
785
1690
767
1820
826
1940
880
CONDENSER
CODE
20
21
22
30
31
32
35
36
37
40
41
42
45
46
47
50
51
52
55
56
57
60
61
62
65
66
67
70
71
72
75
76
77
80
81
82
85
86
87
REFRIGERANT
CHARGE
lb
kg
225
102
225
102
225
102
260
118
260
118
260
118
310
141
310
141
310
141
280
127
280
127
280
127
330
150
330
150
330
150
400
181
400
181
400
181
490
222
490
222
490
222
420
190
420
190
420
190
510
231
510
231
510
231
780
354
780
354
780
354
925
420
925
420
925
420
720
327
720
327
720
327
860
390
860
390
860
390
INITIAL START-UP
IMPORTANT: The Reliance VFD warranty will be void if
the VFD is not started by a technician who has completed
Reliance LiquiFlo Tier 1 Training and whose name is
registered with Reliance.
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OPERATING INSTRUCTIONS
a19-1326
Operator Duties
1. Become familiar with the chiller and related equipment
before operating the chiller.
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, and
perform a Control Test. Maintain the proper oil and
refrigerant levels.
5. Protect the system from damage during shutdown periods.
6. Maintain the set point, time schedules, and other PIC III
functions.
sure that chiller temperatures, pressures, water flows, and oil and
refrigerant levels indicate the system is functioning properly.
Instruct the Customer Operator Ensure the operator(s) understand all operating and maintenance procedures.
Point out the various chiller parts and explain their function as
part of the complete system.
COOLER-CONDENSER Float chamber, relief valves,
refrigerant charging valve, temperature sensor locations, pressure transducer locations, Schrader fittings, waterboxes and
tubes, and vents and drains.
OPTIONAL PUMPOUT STORAGE TANK AND PUMPOUT SYSTEM Transfer valves and pumpout system,
refrigerant charging and pumpdown procedure, and relief
devices.
MOTOR COMPRESSOR ASSEMBLY Guide vane actuator, transmission, motor cooling system, oil cooling system,
temperature and pressure sensors, oil sight glasses, integral oil
pump, isolatable oil filter, extra oil and motor temperature
sensors, synthetic oil, and compressor serviceability.
MOTOR COMPRESSOR LUBRICATION SYSTEM
Oil pump, cooler filter, oil heater, 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, and auxiliary and optional controls.
AUXILIARY EQUIPMENT Disconnects, separate electrical sources, pumps, and cooling tower.
DESCRIBE CHILLER CYCLES Refrigerant, motor cooling, lubrication, and oil reclaim.
REVIEW MAINTENANCE Scheduled, routine, and extended shutdowns, importance of a log sheet, importance of
water treatment and tube cleaning, and importance of maintaining a leak-free chiller.
SAFETY DEVICES AND PROCEDURES Electrical disconnects, relief device inspection, and handling refrigerant.
CHECK OPERATOR KNOWLEDGE Start, stop, and
shutdown procedures, safety and operating controls, refrigerant
and oil charging, and job safety.
REVIEW THE START-UP OPERATION, AND MAINTENANCE MANUAL.
NOTE: Manuals and 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.
sor starts, the operator should monitor the ICVC display and
observe the parameters for normal operating conditions:
1. The oil reservoir 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 bearings, and up to 175 F (79 C) for Frame
3 compressors equipped with rolling element bearings. If
the bearing temperature reads more than 180 F (83 C)
with 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 compressors equipped with rolling element bearings.
5. The moisture indicator sight 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 and 45 F (1 and 8 C).
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Preparation for Extended Shutdown The refrigerant should be transferred into the pumpout storage tank (if
supplied; see Pumpout and Refrigerant Transfer Procedures) to
reduce chiller pressure and the possibility of leaks. Maintain a
holding charge of 5 to 10 lb (2.27 to 4.5 kg) of refrigerant or
nitrogen to prevent air from leaking into the chiller.
If freezing temperatures are likely to occur in the chiller
area, drain the chilled water, condenser water, and the pumpout
condenser water circuits to avoid freeze-up. Keep the waterbox
drains open.
Leave the oil charge in the chiller with the oil heater and
controls energized to maintain the minimum oil reservoir
temperature.
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73
TIME
DATE
Plant
Press. Temp
Refrigerant
In
Water
Out
GPM
Pressure
COOLER
In
Out
Temp
MODEL NO.
Press. Temp
Refrigerant
In
Out
GPM
Pressure
Water
CONDENSER
In
Pressure
Sump
Temp
Oil
COMPRESSOR
Level
Out
Temp
Thrust
Bearing
Temp
SERIAL NO.
Average Average
Average Inverter Rectifier
VFD
Line
Line
Line
Load
Temp Coolant
Current Voltage Kilowatts Current Temp
Flow
VFD
MOTOR RLA
OPERATOR
INITIALS
REMARKS
Transfer, addition, or removal of refrigerant in springisolated chillers may place severe stress on external piping
if springs have not been blocked in both up and down
directions.
POSITIVE PRESSURE CHILLERS WITH STORAGE
TANKS In the Valve/Condition tables that accompany these
instructions, the letter C indicates a closed valve. Figures 8 and
9 show the locations of the valves.
2 OL
2 OL
2 OL
L1
FIELD
POWER
SUPPLY
L2
MTR-1
L3
GND
L1
H1
X2
X2
55-1
OFF
AUTO ON
2
C
FU
GND
HTR
MTR
NC
OL
SS
0.5A
FU3
HIGH PRESSURE
SAFETY
NC OPEN > 185psig
LEGEND
Contactor
Fuse
Ground
Heater
Motor
Normally Closed
Overload
Selector Switch
X2
a23-1615
CRANKCASE HEATER
240-600v
27-40 WATT
H4
CONTROL POWER
TRANSFORMER X1
XFMR-1
69 VA
HTR-1
0.25A
FU1
0.25A
FU2
L2
PUMP OUT
COMPRESSOR
CONTROL
PANEL
FRAME
ASSEMBLY
VALVE
CONDITION
VALVE
2
COMPRESSOR
OIL
HEATER
VALVE
5
VALVE
CONDITION
ENTERING
WATER
LEAVING
WATER
CONDENSER
OIL FILL
FITTING
OIL
SEPARATOR
a23-1546
VALVE
CONDITION
VALVE
CONDITION
2
C
4
C
5
C
7
C
10
C
VALVE
CONDITION
1a
1b
2
C
4
C
10
VALVE
CONDITION
11
7
C
10
C
11
1a
C
1b
C
2
C
3
C
4
C
5
C
6
C
7
C
10
C
11
1a
1b
2
C
4
C
5
C
7
C
10
C
11
1a
1b
2
C
4
C
10
11
1a
1b
3
C
4
C
10
11
1a
1b
3
C
4
C
7
C
10
C
11
10
C
11
1a
1b
2
C
5
C
7
C
d. Run the pumpout compressor until the chiller pressure reaches 35 psig (241 kPa); then, shut off the
pumpout compressor. Warm chiller condenser
water will boil off any entrapped liquid refrigerant
and chiller pressure will rise.
e. When chiller pressure rises to 40 psig (276 kPa),
turn on the pumpout compressor until the pressure
again reaches 35 psig (241 kPa), then, turn off the
pumpout compressor. Repeat this process until the
chiller pressure no longer rises; then, turn on the
pumpout compressor and pump out until the chiller
pressure reaches 18 in. Hg vacuum (41 kPa absolute). This can be done in On or Automatic mode.
11
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4
C
3
C
1a
VALVE
CONDITION
1b
VALVE
3
VALVE
4
1a
1a
C
1b
C
2
C
3
C
4
C
5
C
6
C
7
C
10
C
11
VALVE
CONDITION
1a
1b
3
C
4
C
VALVE
CONDITION
11
1a
1b
2
C
5
C
VALVE
CONDITION
11
C
VALVE
CONDITION
1b
C
2
C
3
C
VALVE
CONDITION
4
C
5
C
11
1a
1b
3
C
4
C
11
C
1a
C
1b
C
2
C
3
C
4
C
5
C
11
C
1a
1b
2
C
4
C
5
C
11
C
1a
1b
2
C
4
C
11
C
11
C
VALVE
CONDITION
1a
C
1b
C
2
C
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4
C
3
C
VALVE
CONDITION
1b
1a
3
C
4
C
5
C
11
1a
1b
2
C
4
C
5
C
7
C
10
C
Adding Refrigerant Follow the procedures described in Trim Refrigerant Charge section, page 78.
11
1a
1b
3
C
4
C
7
C
10
C
Adjusting the Refrigerant Charge If the addition or removal of refrigerant is required to improve chiller
performance, follow the procedures given under the Trim
Refrigerant Charge section, page 78.
Refrigerant Leak Testing Because HFC-134a refrigerant is above atmospheric pressure at room temperature,
leak testing can be performed with refrigerant in the chiller.
Use an electronic halide leak detector, soap bubble solution, or
ultrasonic leak detector. Ensure that the room is well ventilated
and free from concentration of refrigerant to keep false readings to a minimum. Before making any necessary repairs to a
leak, transfer all refrigerant from the leaking vessel.
11
1a
C
1b
C
2
C
3
C
4
C
5
C
6
C
7
C
10
C
11
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 containers 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 nonmetallic materials, dry the skin, and, in heavy concentrations,
may displace enough oxygen to cause asphyxiation. When
handling this refrigerant, protect the hands and eyes and
avoid breathing fumes.
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Trim Refrigerant Charge To remove any excess refrigerant, follow the procedure in Transfer Refrigerant from
Chiller to Pumpout Storage Tank section, Steps 1a and b,
page 75.
Refer to the Trimming Refrigerant Charge section on
page 69.
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 drain charging valve (Fig. 2). A
pump is required when adding oil against refrigerant pressure.
The oil charge for the 19XRV compressor 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 12 gal
(45 L)
Frame 5 compressor 18 gal (67.8 L)
The added oil must meet Carrier specifications for the
19XRV. Refer to Changing Oil Filter and Oil Changes section
on page 79. 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 parameter reads ON. If 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 III 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.
SUCTION
HOUSING
GUIDE VANE
ACTUATOR
SET
SCREWS
GUIDE VANE
ACTUATOR
SPROCKET
DRIVE
CHAIN
ACTUATOR
BRACKET
CL OS
E
CHAIN
GUARD
O
P
HOLDDOWN
BOLTS (3)
EN
GUIDE VANE
SHAFT
GUIDE VANE
SPROCKET
a19-1731
the valve so that new oil can be pumped into the filter
housing. Fill with the same amount that was removed;
then close the charging valve.
10. Remove the hose from the charging valve, open the isolation valves to the filter housing, and turn on the power to
the pump and the motor.
SCHEDULED MAINTENANCE
Establish a regular maintenance schedule based on actual
chiller requirements such as chiller load, run hours, and water
quality. The time intervals listed in this section are offered as
guides to service only.
Oil Specification If oil is added, it must meet the following Carrier specifications:
Oil Type for units using R-134a . . . . . . . . . . . . . . . . . . Inhibited
polyolester-based synthetic
compressor oil formatted for
use with HFC, gear-driven,
hermetic compressors.
ISO Viscosity Grade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
The polyolester-based oil (P/N: PP23BZ103) may be
ordered from a local Carrier representative.
after the first year of operation and every three to five years
thereafter as a minimum in addition to a yearly oil analysis.
However, if a continuous oil monitoring system is functioning
and a yearly oil analysis is performed, the 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 the control and oil heater circuit breaker.
4. When the chiller pressure is 5 psig (34 kPa) or less, drain
the oil reservoir by opening the oil charging valve
(Fig. 2). Slowly open the valve against refrigerant
pressure.
5. Change the oil filter at this time. See Changing Oil Filter
section.
6. Change the refrigerant filter at this time, see the next
section, Refrigerant Filter.
7. Charge the chiller with oil. Charge until the oil level is
equal to the oil level marked in Step 2. Turn on the power
to the oil heater and let the PIC III warm it up to at least
140 F (60 C). Operate the oil pump manually, using the
Control Test function, for 2 minutes. For shutdown conditions, the oil level should be full in the lower sight glass.
If the oil level is above 1/2 full in the upper sight glass,
remove the excess oil. The oil level should now be equal
to the previous oil levels mark (Step 2).
Table 6 for safety control settings). To ensure chiller protection, the Automated Control Test should be performed at
least once per month (with machine in OFF mode). See
Table 13 for Control Test functions.
on this chiller protect the system against the potentially dangerous effects of overpressure. To ensure against damage 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 year, disconnect the vent piping at the
valve outlet and carefully inspect the valve body and
mechanism for any evidence of internal corrosion or rust,
dirt, scale, 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 valves are vented into a corrosive atmosphere,
inspect the relief valves at more frequent intervals.
Hard scale may require chemical treatment for its prevention or removal. Consult a water treatment specialist for
proper treatment.
7
8
1
2
3
4
5
6
7
8
a23-1632
LEGEND
Refrigerant Inlet from FLASC Chamber
Linear Float Assembly
Float Screen
Bubbler Line
Float Cover
Bubbler Line Connection
Refrigerant Outlet to Cooler
Gasket
Before working on any VFD, shut off the chiller, open and
tag all disconnects supplying power to the VFD. After disconnecting input power to a VFD and before touching any
internal components, wait five minutes for the DC bus
capacitors to discharge, then check the voltage with a voltmeter. Failure to observe this precaution could result in
sever bodily injury or death.
CONTACTOR
TERMINAL
STRIP
FUSES
SWITCH
Loose power connections can cause voltage spikes, overheating, malfunctioning, or failures.
a19-1569
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TRANSFORMER
TROUBLESHOOTING GUIDE
(Tables 15-18B)
Overview The PIC III has many features to help the
operator and technician troubleshoot a 19XRV chiller.
The ICVC shows the chillers actual operating conditions 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 conditions at the time of alarm. The STATUS screens continue
to show current information. Once all alarms have been
cleared (by correcting the problems and pressing the
RESET softkey), the ICVC default screen returns to
normal operation.
The CONTROL ALGORITHM STATUS screens (which
include the CAPACITY, OVERRIDE, LL_MAINT,
VFD_HIST, LOADSHED, CUR_ALARM, WSMDEFME, and OCCDEFCM screens) display information
that helps to diagnose problems with chilled water
temperature control, chilled water temperature control
overrides, hot gas bypass, surge algorithm status, and
time schedule operation. See Table 15.
The control test feature facilitates the proper operation
and test of temperature sensors, pressure transducers, the
guide vane actuator, oil pump, water pumps, tower
control, and other on/off outputs while the compressor is
stopped. It also has the ability to lock off the compressor
and turn on water pumps for pumpout operation. The
ICVC shows the temperatures and pressures required
during these operations.
From other SERVICE tables, the operator/technician can
access configured items, such as chilled water resets,
override set points, etc.
If an operating fault is detected, an alarm message is generated and displayed on the ICVC default screen. A more
detailed message along with a diagnostic message
is also stored into the ALARM HISTORY and ALERT
HISTORY 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.
TABLE
CAPACITY
OVERRIDE
LL_MAINT
OCCDEFCM
WSMDEFME
VFD_HIST
Override
Status
LEAD/LAG
Status
Time
Schedules
Status
Water
System
Manager
Status
VFD Alarm
History
LOADSHED
Loadshed
Status
CUR_ALARM Current
Alarm Status
HEAT_EX*
Surge and
HGBP Status
DESCRIPTION
This table shows all values used to
calculate the chilled water/brine
control point.
Details of all chilled water control
override values.
Indicates LEAD/LAG operation
status.
The Local and CCN occupied
schedules are displayed here to
help the operator quickly determine whether the schedule is in
the occupied mode or not.
The water system manager is a
CCN module that can turn on the
chiller and change the chilled water
control point. This screen indicates
the status of this system.
Displays VFD values at last fault.
Displays Loadshed (Demand Limit)
status.
Displays current chiller alarms.
The surge and hot gas bypass
control algorithm status is viewed
from this screen. All values related
to this control are displayed.
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EXPANDED
NAME
Capacity
Control
Control Test The Control Test feature can check all the
thermistor temperature sensors, pressure transducers, pumps
and their associated flow devices, the guide vane actuator, 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 troubleshooting issues. During pumpdown operations,
the pumps are energized to prevent freeze-up and the vessel
pressures and temperatures are displayed. The Pumpdown/
Lockout feature prevents compressor start-up when there is no
refrigerant in the chiller or if the vessels are isolated. The
SECONDARY MESSAGE
PROBABLE CAUSE/REMEDY
SHUTDOWN IN PROGRESS
SHUTDOWN IN PROGRESS
COMPRESSOR UNLOADING
COMPRESSOR DEENERGIZED
ICE BUILD
SHUTDOWN IN PROGRESS
OPERATION COMPLETE
RECYCLE RESTART PENDING
PIC III in OFF mode, press CCN or LOCAL softkey to start unit.
Enter the CONTROL TEST table and select TERMINATE LOCKOUT
to unlock compressor.
Chiller unloading before shutdown due to soft/stop feature.
Chiller compressor is being commanded to stop. Water pumps are
deenergized within one minute.
Chiller shutdown from Ice Build operation.
Chilled water temperature below recycle set point. Cooling load is
less than chiller minimum capacity.
B. READY TO START
PRIMARY MESSAGE
READY TO START IN XX MIN
SECONDARY MESSAGE
UNOCCUPIED MODE
OCCUPIED MODE
REMOTE CONTACT CLOSED
READY TO START
READY TO START
READY TO START
READY TO START
READY TO START
OCCUPIED MODE
REMOTE CONTACT CLOSED
START COMMAND IN EFFECT
STARTUP INHIBITED
LOADSHED IN EFFECT
PROBABLE CAUSE/REMEDY
Time schedule for PIC III is unoccupied. Chillers will start only when
occupied. Check OCCPCnnS and Holidays screens.
Remote contacts are open. Close contacts to start.
Chiller START/STOP on MAINSTAT manually forced to stop. Release
SUPERVISOR force to start.
Chiller timer counting down. Unit ready to start.
Chiller timer countdown complete. Unit will proceed to start. Remote
contact Enabled and Closed.
Chiller START/STOP on MAINSTAT manually forced to start. Release
SUPERVISOR force to start under normal control.
Chiller is recycle 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.
Remote contacts have stopped the chiller. Close contacts to start.
Chiller START/STOP on MAINSTAT manually forced to stop. Release
SUPERVISOR force to start.
Chiller timers countdown is complete. Unit will proceed to start.
Chiller timer counting down. Unit ready to start.
Chiller START/STOP on MAINSTAT has been manually forced to
start. Chiller will start regardless of time schedule or remote contact
status.
CCN loadshed module commanding chiller to stop.
C. IN RECYCLE SHUTDOWN
PRIMARY MESSAGE
RECYCLE RESTART PENDING
SECONDARY MESSAGE
OCCUPIED MODE
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PROBABLE CAUSE/REMEDY
Unit in recycle mode, chilled water temperature is not sufficiently
above Setpoint to start.
Unit in recycle mode, chilled water temperature is not sufficiently
above Setpoint to start.
Chiller START/STOP on MAINSTAT manually forced to start, chilled
water temperature is not sufficiently above Setpoint to start.
Chiller in ICE BUILD mode. Chilled water temperature is satisfied for
ICE BUILD conditions.
PRIMARY
MESSAGE
PRESTART
ALERT
PRESTART
ALERT
SECONDARY
MESSAGE
STARTS LIMIT
EXCEEDED
HIGH BEARING
TEMPERATURE
102
PRESTART
ALERT
HIGH MOTOR
TEMPERATURE
103
PRESTART
ALERT
HIGH
DISCHARGE
TEMP
104
PRESTART
ALERT
LOW
REFRIGERANT
TEMP
105
PRESTART
ALERT
PRESTART
ALERT
LOW OIL
TEMPERATURE
HIGH
CONDENSER
PRESSURE
107
PRESTART
ALERT
LOW LINE
VOLTAGE
108
PRESTART
ALERT
HIGH LINE
VOLTAGE
109
PRESTART
ALERT
GUIDE VANE
CALIBRATION
110
PRESTART
ALERT
HIGH
RECTIFIER
TEMP
111
PRESTART
ALERT
HIGH
INVERTER
TEMP
101
106
PRIMARY CAUSE
ADDITIONAL CAUSE/REMEDY
*[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
STARTUP IN PROGRESS
STARTUP IN PROGRESS
STARTUP IN PROGRESS
AUTORESTART IN
PROGRESS
AUTORESTART IN
PROGRESS
AUTORESTART IN
PROGRESS
SECONDARY MESSAGE
CAUSE/REMEDY
OCCUPIED MODE
Chiller is starting. Time schedule is Occupied.
REMOTE CONTACT CLOSED
Chiller is starting. Remote contacts are Enabled and Closed.
START COMMAND IN EFFECT Chiller is starting. Chiller START/STOP in MAINSTAT manually forced to
start.
OCCUPIED MODE
Chiller is starting after power failure. Time schedule is Occupied.
REMOTE CONTACT CLOSED
Chiller is starting after power failure. Remote contacts are Enabled and
Closed.
START COMMAND IN EFFECT Chiller is starting after power failure. Chiller START/STOP on MAINSTAT
screen manually forced to start.
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SECONDARY MESSAGE
BY 4-20 mA SIGNAL
REMOTE TEMP SENSOR
CHW TEMP DIFFERENCE
BY LOCAL SIGNAL
ICE BUILD MODE
MOTOR LOAD CURRENT
CAUSE/REMEDY
Auto chilled water reset active based on external input.
Auto chilled water reset active based on external input.
Auto chilled water reset active based on CHW Delta T in
TEMP_CTL screen.
Default method of temperature control.
Entering Chilled Water control enabled in TEMP_CTL screen.
Ramp Loading in effect. Use RAMP_DEM screen to modify.
Ramp Loading in effect. Use RAMP_DEM screen to modify.
Demand limit set point is less than actual demand.
Demand limit is active based on external auto demand limit option.
Demand limit is active based on control limit signal from CCN.
Demand limit is active based on LOADSHED screen set-up.
Hot gas bypass valve is energized (open). See Surge prevention
description.
Active demand limit manually overridden on MAINSTAT table.
Chiller is running under Ice Build temperature control.
Chiller has reached 100% of Load Current Rating during normal
operation.
Chiller has reached 100% of Line Current Rating during normal
operation.
SECONDARY
MESSAGE
HIGH CONDENSER
PRESSURE
PRIMARY CAUSE
120Condenser Pressure
[VALUE] exceeded limit of
[LIMIT]*.
121
RUN CAPACITY
LIMITED
HIGH MOTOR
TEMPERATURE
122
RUN CAPACITY
LIMITED
122Evaporator Refrig
Temp [VALUE] exceeded
limit of [LIMIT]*.
123
RUN CAPACITY
LIMITED
HIGH COMPRESSOR
LIFT
123Surge Prevention
Override: Lift Too High For
Compressor
124
RUN CAPACITY
LIMITED
125
RUN CAPACITY
LIMITED
LOW DISCHARGE
SUPERHEAT
No Alert message.
126
RUN CAPACITY
LIMITED
127
RUN CAPACITY
LIMITED
RUN CAPACITY
LIMITED
MANUAL SPEED
CONTROL
HIGH INVERTER TEMP
128
No Alert message.
128Inverter Temperature
[VALUE] exceeded limit of
[LIMIT]*.
ADDITIONAL CAUSE/REMEDY
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.
Check Inverter Temp Override in SETUP1
screen.
Check that VFD refrigerant isolation valves are
open.
Check VFD refrigerant cooling solenoid.
Check for proper VFD cooling fan operation and
blockage.
*[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.
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PRIMARY
MESSAGE
SENSOR FAULT
261
SENSOR FAULT
262
SENSOR FAULT
263
SENSOR FAULT
264
SENSOR FAULT
265
SENSOR FAULT
266
SENSOR FAULT
267
SENSOR FAULT
268
SENSOR FAULT
269
SENSOR FAULT
270
SENSOR FAULT
271
SENSOR FAULT
SECONDARY
PRIMARY CAUSE
MESSAGE
LEAVING CHILLED WATER 260Sensor Fault: Check
Leaving Chilled Water Sensor.
ADDITIONAL CAUSE/REMEDY
87
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FAILURE TO STOP
205
206
207
208
209
210
211
212
213
214
215
216
217
218
219
ADDITIONAL CAUSE/REMEDY
Malfunction within VFD Power Module.
Call Carrier Service.
Malfunction within VFD Power Module.
Call Carrier Service.
Check main circuit breaker for trip. Increase
Current % Imbalance in VFD_CONF screen.
Check that inlet guide vanes are fully closed at
start-up.
Check Motor Rated Load Amps in VFD_CONF
screen. Reduce unit pressure if possible.
VFD Circuit Board malfunction.
Call Carrier Service.
Verify phase to phase and phase to ground line
voltage. Monitor AC line for high transient voltage conditions. VFD Circuit Board malfunction.
Call Carrier Service.
See VFD Fault Code description and corrective
action.
*[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.
88
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221
222
223
LOSS OF
COMMUNICATION
224
PROTECTIVE LIMIT
225
PROTECTIVE LIMIT
226
PROTECTIVE LIMIT
227
PROTECTIVE LIMIT
228
PROTECTIVE LIMIT
229
PROTECTIVE LIMIT
230
PROTECTIVE LIMIT
231
PROTECTIVE LIMIT
232
PROTECTIVE LIMIT
PRIMARY CAUSE
220Ground Fault Trip;
Check Motor and Current
Sensors.
ADDITIONAL CAUSE/REMEDY
Check for condensation on motor terminals.
Check motor power leads for phase to phase or
phase to ground shorts. Disconnect motor from
VFD and megger motor.
Call Carrier Service.
221UNUSED
222Line Frequency
[VALUE] exceeded limit of
[LIMIT]; Check Power Supply.
223Loss of SIO Comm with
VFD Gateway: Check VFG
Module and Power.
*[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.
89
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PRIMARY CAUSE
233Comp Motor Winding
Temp [VALUE] exceeded
limit of [LIMIT]*.
234
235
235Condenser Pressure
[VALUE] exceeded limit of
[LIMIT]*.
236
236Compressor Surge:
Check condenser water temp
and flow.
237
238
238Compressor Surge:
Check condenser water temp
and flow.
239
240
241
241Rectifier Overcurrent
Fault: Check VFD Status.
242Loss of Communication With CCM, Check
Comm. Connectors.
243Evaporator Refrig
Temp [VALUE] exceeded
limit of [LIMIT]*.
242
243
POTENTIAL
FREEZE-UP
EVAP PRESS/TEMP
TOO LOW
244
POTENTIAL
FREEZE-UP
COND PRESS/TEMP
TOO LOW
244Condenser Refrig
Temp [VALUE] exceeded
limit of [LIMIT]*.
ADDITIONAL CAUSE/REMEDY
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.
Confirm that TXV bulb is secured in place and
insulated.
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 performance 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 temperature sensor.
Check for high water temperatures or changes in
water flow rates.
Check wiring and control power to CCM.
Confirm that all CCM SW1 switches are in the
OFF position.
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 F.
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.
90
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PRIMARY CAUSE
ADDITIONAL CAUSE/REMEDY
246
247
248
249
250
251
UNUSED
UNUSED
PROTECTIVE LIMIT VFD CONFIG CONFLICT
252
253
254
255
256
257
258
248Spare Temperature #1
[VALUE] exceeded limit of
[LIMIT]*.
249Spare Temperature #2
[VALUE] exceeded limit of
[LIMIT]*.
250Unused State.
251VFD Config Conflict
(VFD Uploaded): Verify to
Reset Alarm.
*[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.
91
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PRIMARY CAUSE
259CCN Emergency/
Override Stop.
282
282Line Frequency
[VALUE] Exceeded Configuration Range.
283
283Compressor 100%
Speed Config Ranges: 50=Hz
45-52; 60 Hz=55-62.
284
VFD GATEWAY
COMPATIBILITY
CONFLICT
285
VFD GATEWAY
COMPATIBILITY
CONFLICT
286
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 FREQUENCY must be maintained between
55-62 Hz if LINE FREQ=60Hz? is set to YES
(60 Hz).
Check 2C AUX/HPR Gate Kill circuit.
COMPRESSOR 100% SPEED in VFD_CONF
screen must be set between 45-52 Hz if LINE
FREQ=60Hz? is set to NO(50 Hz). COMPRESSOR 100% SPEED must be set between
55-62 Hz if LINE FREQ=60Hz? is set to YES
(60 Hz).
VFD Gateway 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
PRIMARY
STATE
MESSAGE
140
SENSOR ALERT
SECONDARY
MESSAGE
LEAVING COND WATER
TEMP
ENTERING COND WATER
TEMP
CHECK OIL FILTER
141
SENSOR ALERT
142
LOW OIL
PRESSURE ALERT
143
AUTORESTART
PENDING
LINE CURRENT
IMBALANCE
144
AUTORESTART
PENDING
LINE VOLTAGE
DROP OUT
145
AUTORESTART
PENDING
AUTORESTART
PENDING
AUTORESTART
PENDING
146
147
148
PRIMARY CAUSE
140Sensor Fault: Check
Leaving Cond Water Sensor.
141Sensor Fault: Check
Entering Cond Water Sensor.
142Low Oil Pressure Alert.
Check Oil Filter.
149
AUTORESTART
PENDING
SENSOR ALERT
POWER LOSS
148Control Power-Loss
When Running.
HIGH DISCHARGE TEMP 149Comp Discharge Temp
[VALUE] Exceeded Limit of
[LIMIT]*.
150
SENSOR ALERT
HIGH BEARING
TEMPERATURE
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 if Auto Restart is
enabled in OPTIONS screen.
Check phase to phase and phase to ground line
power.
Check phase to phase and phase to ground line
power.
VFD Module has detected a hardware fault due
to electrical noise, power loss or software and
has reset. Chiller automatically restarting.
Check for power loss and sources of electromagnetic interference.
Check 24 vac control power supply to ICVC.
*[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.
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PRIMARY CAUSE
151High Condenser Pressure [VALUE]: Pump Energized to Reduce Pressure.
152
RECYCLE ALERT
EXCESSIVE RECYCLE
STARTS
152Excessive recycle
starts.
153
no message:
ALERT
only
POTENTIAL
FREEZE-UP
155
OPTION SENSOR
FAULT
REMOTE RESET
SENSOR
156
OPTION SENSOR
FAULT
157
OPTION SENSOR
FAULT
158
SENSOR ALERT
SPARE TEMPERATURE
#1
159
SENSOR ALERT
SPARE TEMPERATURE
#2
161
LOSS OF
COMMUNICATION
WITH WSM
162
SENSOR ALERT
EVAPORATOR
APPROACH
163
SENSOR ALERT
164
165
AUTORESTART
PENDING
166
AUTORESTART
PENDING
167
SYSTEM ALERT
168
SENSOR ALERT
154
COND PRESS/TEMP
TOO LOW
155Sensor Fault/Option
Disabled: Remote Reset
Sensor.
156Sensor Fault/Option
Disabled: Auto Chilled Water
Reset.
157Sensor Fault/Option
Disabled: Auto Demand Limit
Input.
158Spare Temperature 1
[VALUE] exceeded limit of
[LIMIT]*.
159Spare Temperature 2
[VALUE] exceeded limit of
[LIMIT]*.
161WSM Cool Source
Loss of Communication.
162Evaporator Approach
[VALUE] Exceeded Limit of
[LIMIT]*.
ADDITIONAL CAUSE/REMEDY
Check sensor wiring and accuracy.
Check condenser flow and water temperature.
Check for fouled tubes.
This alarm is not caused by the High Pressure
Switch.
Chiller load is too low to keep compressor on
line and there has been more than 5 starts in
4 hours.
Increase chiller load, adjust hot gas bypass,
increase RECYCLE RESTART DELTA T from
SETUP1 Screen.
Illegal chiller address configuration in Lead/Lag
screen. Both chillers require a different address.
The condenser pressure transducer is reading a
pressure 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.
Check sensor resistance or voltage drop.
Check for proper wiring to CCM connector J4.
Check sensor resistance or voltage drop.
Check for proper wiring to CCM connector J5.
Check sensor resistance or voltage drop.
Check for proper wiring to CCM connector J5.
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.
Verify phase to phase and phase to ground line
voltage.
*[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.
93
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DESCRIPTION
ACTION
Check remote wiring.
Monitor the incoming AC line for low voltage or
line power interruption.
UnderVoltage 1, 3
OverVoltage 1
Input is open.
DC bus voltage remained below 85% of
nominal for longer than Power Loss Time
(185).
Enable/disable with Fault Config 1 (238).
DC bus voltage fell below the minimum
value of 407V DC at 400/480V input
Enable/disable with Fault Config 1(233).
DC bus voltage exceeded maximum value.
Motor Overload 1, 3
12
HW OverCurrent 1
13
Ground Fault 1
24
Decel Inhibit 3
25
OverSpeed Limit 1
29
Analog In Loss 1, 3
33
35
36
SW OverCurrent 1
37
Motor I Imbalance
DPI
EPROM
FLA
IGBT
I/O
NP
215
205
LEGEND
Drive Peripheral Interface
Erasable, Programmable, Read-Only
Full Load Amps
Insulated Gate Bipolar Transistor
Inputs/Outputs
Nameplate
94
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ICVC FAULT
STATE
206
215
217
219
219
286
220
204
206
206
206
206
286
225
Phase UV Short
Phase VW Short
Phase UW Short
Params Defaulted
63
Shear Pin 3
64
Drive OverLoad
70
HW Fault 4
71- 75
76
77
Peripheral Fault at
DPI Port 6
IR Volts Range
78
FluxAmpsRef Rang
79
Excessive Load
80
AutoTune Aborted
81- 85
ACTION
A phase-to-ground fault has been detected a. Check the wiring between the drive and
between the drive and motor in this phase.
motor.
b. Check motor for grounded phase.
c. Replace drive.
Excessive current has been detected
a. Check the motor and drive output terminal
between these two output terminals.
wiring for a shorted condition.
b. Replace drive.
The drive was commanded to write default
values to EPROM.
Programmed Current Lmt 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.
Inverter section of power structure
hardware detected an unexpected fault
during power stage diagnostics.
The network card connected to DPI port
stopped communicating.
The fault code indicates the offending port
number (71 = port 1, 72 = port 2, etc.).
100
101
102
103
104
105
ICVC FAULT
STATE
220
246
206
286
a. Cycle power.
b. Call Carrier service.
206
206
206
206
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 programmed Motor NP FLA (42).
Motor did not come up to speed in the allotted time.
The autotune procedure was canceled by
the user.
DPI port stopped communicating.
An attached peripheral with control capabilities via Logic Source Sel (89) (or OIM
control) was removed.
The fault code indicates the offending port
number (81 = port 1, etc.).
Ixo Voltage Range
Ixo voltage calculated from motor nameplate data is too high.
Parameter Chksum 2 The checksum read from the board does
not match the checksum calculated.
UserSet1 Chksum 2 The checksum read from the user set does
UserSet2 Chksum 2 not match the checksum calculated.
UserSet3 Chksum 2
Pwr Brd Chksum1
The checksum read from the EPROM does
not match the checksum calculated from
the EPROM data.
Pwr Brd Chksum2
The checksum read from the board does
not match the checksum calculated.
87
DPI
EPROM
FLA
IGBT
I/O
NP
DESCRIPTION
LEGEND
Drive Peripheral Interface
Erasable, Programmable, Read-Only
Full Load Amps
Insulated Gate Bipolar Transistor
Inputs/Outputs
Nameplate
95
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206
a. Reprogram Motor NP FLA (42) with the correct motor nameplate value.
b. Repeat Autotune (61).
a. Uncouple load from motor.
b. Repeat Autotune (61).
Restart procedure.
206
206
206
a. If module was not intentionally disconnected, check wiring to the port. Replace
wiring, port expander, modules, Main Control board or complete drive as required.
b. Check OIM connection.
206
206
a. Press reset.
b. Reload user set if used.
Press reset.
206
206
206
206
Inverter Dsat
U, V, W
203
204
205
206
Inverter
OverCurrent
U, V, W
Inverter Unused Bit 4 Inverter section of power structure hardware reported unexpected fault.
Invtr Gate Kill
Inverter gate kill contact is open.
Rectifier Dsat
High current was detected in an IGBT.
R, S, T
207
208
209
210
211
212
213
214
ACTION
Load compatible version files into drive.
a. Press reset.
b. Reprogram parameters.
Restore I/O board to original configuration, or,
if new configuration is desired, reset fault.
Cycle power.
a. Cycle power.
b. If fault repeats, replace I/O board.
a. Check for loose connection in IGBT wire
harness.
b. Check IGBTs.
c. Check precharge resistors and fuses.
d. Check precharge contactor.
a. Verify proper motor data is entered.
b. Reduce current limit.
Check wiring harness.
Close gate kill contact.
a. Check for loose connection in IGBT wire
harness.
b. Check IGBTs.
ICVC FAULT
STATE
206
206
206
206
206
201
286
206
207, 235
200
Rectifier IOC
R, S, T
Rectifier overcurrent.
241
Reactor Temp
206
220
217
Rectifier HW Unused
4
Rectifier Ground
Fault
Rectifier Base Temp
219
Rectifier IT
Overload
220
Rectifier I2T
Overload
221
222
High AC Line
223
224
Low DC Bus
Rctfr Over Volt
218
218
215
216
DPI
EPROM
FLA
IGBT
I/O
NP
LEGEND
Drive Peripheral Interface
Erasable, Programmable, Read-Only
Full Load Amps
Insulated Gate Bipolar Transistor
Inputs/Outputs
Nameplate
96
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206
218
212
212
210
211
215
205
228
Line Frequency
229
Rectifier
Checksum
Inverter HW
Unknown 4
Rectifier HW
Unknown 4
Rctfr Not OK
230
231
232
ACTION
233
234
235
236
237
238
239
DPI
EPROM
FLA
IGBT
I/O
NP
DESCRIPTION
LEGEND
Drive Peripheral Interface
Erasable, Programmable, Read-Only
Full Load Amps
Insulated Gate Bipolar Transistor
Inputs/Outputs
Nameplate
97
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ICVC FAULT
STATE
209
216
210
222
206
206
206
200
206
206
206
206
206
206
206
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
4.056
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
2.946
2.914
2.882
2.850
2.819
2.788
2.756
2.724
2.692
2.660
2.628
2.596
RESISTANCE
(Ohms)
TEMPERATURE
(F)
97,706
94,549
91,474
88,480
85,568
82,737
79,988
77,320
74,734
72,229
69,806
67,465
65,205
63,027
60,930
58,915
56,981
55,129
53,358
51,669
50,062
48,536
47,007
45,528
44,098
42,715
41,380
40,089
38,843
37,639
36,476
35,354
34,270
33,224
32,214
31,239
30,298
29,389
28,511
27,663
26,844
26,052
25,285
24,544
23,826
23,130
22,455
21,800
21,163
20,556
19,967
19,396
18,843
18,307
17,787
17,284
16,797
16,325
15,868
15,426
14,997
14,582
14,181
13,791
13,415
13,050
12,696
12,353
12,021
11,699
11,386
11,082
10,787
10,500
10,221
9,949
9,689
9,436
9,190
8,951
8,719
8,494
8,275
8,062
7,855
7,655
7,460
7,271
7,088
6,909
6,736
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
119
120
121
122
123
124
125
126
127
128
129
130
131
132
133
134
135
136
137
138
139
140
141
142
143
144
145
146
147
148
149
150
151
152
153
154
155
156
PIC III
VOLTAGE
DROP (V)
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
1.909
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
0.769
0.756
0.744
0.731
0.719
0.707
0.696
0.684
0.673
0.662
0.651
0.640
98
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RESISTANCE
(Ohms)
TEMPERATURE
(F)
6,568
6,405
6,246
6,092
5,942
5,796
5,655
5,517
5,382
5,252
5,124
5,000
4,880
4,764
4,650
4,539
4,432
4,327
4,225
4,125
4,028
3,934
3,843
3,753
3,667
3,582
3,500
3,420
3,342
3,266
3,192
3,120
3,049
2,981
2,914
2,849
2,786
2,724
2,663
2,605
2,547
2,492
2,437
2,384
2,332
2,282
2,232
2,184
2,137
2,092
2,047
2,003
1,961
1,920
1,879
1,840
1,801
1,764
1,727
1,691
1,656
1,622
1,589
1,556
1,524
1,493
1,463
1,433
1,404
1,376
1,348
1,321
1,295
1,269
1,244
1,219
1,195
1,172
1,149
1,126
1,104
1,083
1,062
1,041
1,021
1,002
983
964
945
928
910
157
158
159
160
161
162
163
164
165
166
167
168
169
170
171
172
173
174
175
176
177
178
179
180
181
182
183
184
185
186
187
188
189
190
191
192
193
194
195
196
197
198
199
200
201
202
203
204
205
206
207
208
209
210
211
212
213
214
215
216
217
218
219
220
221
222
223
224
225
226
227
228
229
230
231
232
233
234
235
236
237
238
239
240
241
242
243
244
245
246
247
248
PIC III
VOLTAGE
DROP (V)
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
0.211
0.208
0.205
0.203
0.198
0.195
0.192
0.190
0.187
0.184
0.182
0.179
0.176
0.174
0.172
0.169
0.167
0.164
0.162
0.160
0.158
0.155
0.153
RESISTANCE
(Ohms)
893
876
859
843
827
812
797
782
768
753
740
726
713
700
687
675
663
651
639
628
616
605
595
584
574
564
554
544
535
526
516
508
499
490
482
474
466
458
450
442
435
428
421
414
407
400
393
387
381
374
368
362
356
351
345
339
334
329
323
318
313
308
303
299
294
289
285
280
276
272
267
263
259
255
251
248
244
240
236
233
229
226
223
219
216
213
210
207
204
201
198
195
PIC III
VOLTAGE
DROP (V)
4.722
4.706
4.688
4.670
4.650
4.630
4.608
4.586
4.562
4.538
4.512
4.486
4.458
4.429
4.399
4.368
4.336
4.303
4.269
4.233
4.196
4.158
4.119
4.079
4.037
3.994
3.951
3.906
3.861
3.814
3.765
3.716
3.667
3.617
3.565
3.512
3.459
3.406
3.353
3.298
3.242
3.185
3.129
3.074
3.016
2.959
2.901
2.844
2.788
2.730
2.672
2.615
2.559
2.503
2.447
2.391
2.335
2.280
2.227
2.173
2.120
2.067
2.015
1.965
1.914
1.865
1.816
1.768
1.721
1.675
1.629
1.585
1.542
1.499
1.457
1.417
1.377
RESISTANCE
(Ohms)
TEMPERATURE
(C)
105 616
99 640
93 928
88 480
83 297
78 377
73 722
69 332
65 205
61 343
57 745
54 411
51 341
48 536
45 819
43 263
40 858
38 598
36 476
34 484
32 613
30 858
29 211
27 663
26 208
24 838
23 545
22 323
21 163
20 083
19 062
18 097
17 185
16 325
15 513
14 747
14 023
13 341
12 696
12 087
11 510
10 963
10 444
9 949
9 486
9 046
8 628
8 232
7 855
7 499
7 160
6 839
6 535
6 246
5 972
5 711
5 463
5 226
5 000
4 787
4 583
4 389
4 204
4 028
3 861
3 701
3 549
3 404
3 266
3 134
3 008
2 888
2 773
2 663
2 559
2 459
2 363
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
119
120
99
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PIC III
VOLTAGE
DROP (V)
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
0.210
0.205
0.198
0.193
0.188
0.183
0.178
0.174
0.170
0.165
0.161
0.157
0.153
RESISTANCE
(Ohms)
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
1 117
1 079
1 041
1 006
971
938
906
876
846
818
791
765
740
715
692
670
648
628
608
588
570
552
535
518
502
487
472
458
444
431
418
405
393
382
371
360
349
339
330
320
311
302
294
286
278
270
262
255
248
242
235
229
223
217
211
205
200
195
Control Modules
CCN INTERFACE
CONNECTION
DATALINK OR
DATAPORT MODULE (OPTION)
ICVC
CONTRAST
ADJUSTMENT
BACK OF ICVC
J7 SIO
J1 POWER/
CCN
J8 SERVICE
100
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SW1
a19-1633
J11
DISCRETE
OUTPUTS
J12
DISCRETE
OUTPUTS
J1
24 VAC
ANALOG OUT
J8
SIO
J7
SIO
J6
SW2 V/I INPUT
CONFIGURATION
DIP SWITCH 1
MUST BE OFF
V/I INPUTS
J5
STAT
COMM
THERMISTORS
J4
DIFF PRESSURE
J3
PRESSURE
a19-1724
J2
3.
4.
5.
6.
7.
8.
101
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If a CCN Building Supervisor or Service Tool is available, the module configuration should have already been
uploaded into memory. When the new module is
installed, the configuration can be downloaded from the
computer.
Any communication wires from other chillers or CCN
modules should be disconnected to prevent the new
ICVC module from uploading incorrect run hours into
memory.
Record values 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 ICVC now automatically attaches to the local
network device.
Set the current time and date 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-11.) 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. If forced using Service Tool,
DPI RIBBON
CABLE CONNECTOR
NODE ADDRESS
TENS DIGIT = 0
(DO NOT
CHANGE)
DATA
RATE = PGM
(DO NOT
CHANGE)
A32
TERMINAL BLOCK
NODE ADDRESS
ONES DIGIT = 1
(DO NOT CHANGE)
NUMBER
1
2
3
4
STATUS
INDICATOR
DRIVE
MS
NET A
NET B
a23-1618
DESCRIPTION
DPI Connection Status
Module Status
Serial Communication Status
Serial Communication Traffic Status
NOTE: If all status indicators are off, the Gateway is not receiving power.
INVERTER LED
RECTIFIER LED
a19-1634
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. Normal condition when chiller not running because the ICVC has issued a stop command.
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.
Steady
VFD Gate Kill circuit has opened because the compressor high pressure switch has opened.
STATE
Flashing
Steady
Flashing
Steady
Flashing
Steady
DESCRIPTION
Rectifier ready, but not running and no faults are present.
Rectifier running, no faults are present.
Rectifier is not ready. A VFD start inhibit is in effect. This is a normal state if the inverter is not running and/or the precharge contacts are open.
Rectifier alarm condition exits. Check VFD FAULT CODE in ICVC VFD_STAT screen.
Rectifier 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.
Steady
VFD Gate Kill circuit has opened because the compressor high pressure switch has opened.
DESCRIPTION
Control board application firmware may be corrupt. Call Carrier Service.
Control board RAM failure or control board firmware may be corrupt. Call Carrier Service.
DRIVE STATUS INDICATOR The DRIVE status indicator is on the right side of the Gateway. See Table 19.
NET A STATUS INDICATOR The NET A status indicator is the third LED from the right of the Gateway. See
Table 21.
STATE
Off
CAUSE
The Gateway is not
powered or is not connected properly to the
drive.
Flashing The Gateway is not
Red
receiving a ping message from the drive.
Solid
The drive has refused
Red
an I/O connection from
the Gateway.
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 damaged. Replace cables if
necessary.
Orange The Gateway is con Check wires leading to the
nected to a product that
A32 terminal block.
does not support Rock- Check that A32 terminal
well Automation DPI
block is fully engaged.
communications.
Flashing The Gateway is estab- Normal behavior.
Green
lishing an I/O connection to the drive or the
I/O has been disabled.
Solid
The Gateway is propNo action required.
Green
erly connected and is
communicating with the
drive.
STATE
Off
CAUSE
The module is not powered or is not properly
connected to the
network.
First incoming network
command not yet
recognized.
Flashing Network has timed out.
Red
Solid
The Gateway has
Red
detected an error that
has made it incapable
of communication on
the network.
Flashing Online to network, but
Green
not producing or consuming I/O information.
Solid
The module is properly
Green
connected and communicating on the network.
Solid
Red
Flashing
Green
Solid
Green
STATE
Off
CORRECTIVE ACTION
Securely connect the
Gateway ribbon cable to
the drive DPI board.
Attach the RS485 cable in
Gateway to the connector.
Apply power to the drive.
CORRECTIVE ACTION
Securely connect the
Gateway to the drive using
the ribbon cable.
Apply power to the drive.
Cycle power to the drive. If
cycling power does not correct the problem, the firmware may need to be flashed
into the module.
Cycle power to the drive
Replace the Gateway
Normal behavior during SIO
configuration initialization
process.
No action required.
Solid or
Blinking
Green
CAUSE
Gateway not receiving
data over the network.
Gateway is transmitting data.
CORRECTIVE ACTION
Check wires leading to
A32 terminal block.
Check that A32 terminal
block is fully engaged.
No action required.
Before rigging the compressor, disconnect all wires entering the power panel.
103
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20
21
22
30
31
32
35
36
37
40
41
42
45
46
47
50
51
52
5A
5B
5C
55
56
57
5F
5G
5H
60
61
62
65
66
67
70
71
72
75
76
77
80
81
82
85
86
87
ENGLISH
Dry (Rigging) Weight (lb)
Cooler
Condenser
Cooler Only
Condenser Only
200
240
282
200
240
280
200
240
280
324
364
400
324
364
400
431
485
519
225
241
258
431
485
519
225
241
258
557
599
633
557
599
633
644
726
790
644
726
790
829
901
976
829
901
976
218
266
315
218
267
315
218
267
315
370
417
463
370
417
463
509
556
602
509
556
602
648
695
741
648
695
741
781
870
956
781
870
956
990
1080
1170
990
1080
1170
3,407
3,555
3,711
4,071
4,253
4,445
4,343
4,551
4,769
4,908
5,078
5,226
5,363
5,559
5,730
5,713
5,940
6,083
5,124
5,177
5,243
6,257
6,517
6,682
5,577
5,640
5,716
6,719
6,895
7,038
7,392
7,594
7,759
9,942
10,330
10,632
10,840
11,289
11,638
12,664
12,998
13,347
13,804
14,191
14,597
3,373
3,540
3,704
3,694
3,899
4,100
4,606
4,840
5,069
5,039
5,232
5,424
5,602
5,824
6,044
6,090
6,283
6,464
6,785
7,007
7,215
6,764
6,949
7,130
7,682
7,894
8,102
10,782
11,211
11,612
11,854
12,345
12,803
12,753
13,149
13,545
14,008
14,465
14,923
NOTES:
1. Cooler data: based on a cooler with standard wall tubing, 2-pass,
150 psig, nozzle-in-head waterbox with victaulic grooves. Weight
includes suction elbow, control panel, and distribution piping.
Weight does not include compressor.
2. Condenser data: based on a condenser with standard wall tubing, 2-pass, 150 psig, nozzle-in-head waterbox with victaulic
grooves. Weight includes the float valve, discharge elbow, and
distribution piping. Weight does not include unit-mounted VFD,
isolation valves, and pumpout unit.
104
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Chiller Charge
Refrigerant Weight (lb)
Water Volume (gal)
Cooler
Condenser
Cooler
Condenser
345
225
48
48
385
225
55
55
435
225
62
63
350
260
56
56
420
260
64
65
490
260
72
74
400
310
61
62
480
310
70
72
550
310
80
83
560
280
104
110
630
280
112
119
690
280
119
129
640
330
112
120
720
330
122
130
790
330
130
141
750
400
132
147
840
400
143
156
900
400
150
165
500
123
520
126
550
129
870
490
144
161
940
490
156
171
980
490
164
182
550
133
570
137
600
141
940
420
168
182
980
420
176
191
1020
420
183
200
1020
510
183
200
1060
510
193
210
1090
510
201
220
1220
780
241
267
1340
780
259
286
1440
780
274
305
1365
925
262
291
1505
925
283
314
1625
925
300
335
1500
720
327
357
1620
720
343
377
1730
720
360
397
1690
860
354
388
1820
860
373
411
1940
860
392
434
20
21
22
30
31
32
35
36
37
40
41
42
45
46
47
50
51
52
5A
5B
5C
55
56
57
5F
5G
5H
60
61
62
65
66
67
70
71
72
75
76
77
80
81
82
85
86
87
SI
Dry (Rigging) Weight (kg)
Cooler
Condenser
Cooler Only
Condenser Only
200
240
282
200
240
282
200
240
282
324
364
400
324
364
400
431
485
519
225
241
258
431
485
519
225
241
258
557
599
633
557
599
633
644
726
790
644
726
790
829
901
976
829
901
976
218
266
315
218
266
315
218
266
315
366
415
464
366
415
464
507
556
602
507
556
602
648
695
741
648
695
741
781
870
956
781
870
956
990
1080
1170
990
1080
1170
1545
1613
1683
1847
1929
2016
1970
2064
2163
2226
2303
2370
2433
2522
2599
2591
2694
2759
2324
2348
2378
2838
2956
3031
2530
2558
2593
3048
3128
3192
3353
3445
3519
4510
4686
4823
4917
5121
5279
5744
5896
6054
6261
6437
6621
1530
1606
1680
1676
1769
1860
2089
2195
2299
2286
2373
2460
2541
2642
2742
2762
2850
2932
3078
3178
3273
3068
3152
3234
3485
3581
3675
4891
5085
5267
5377
5600
5807
5785
5964
6144
6354
6561
6769
NOTES:
1. Cooler data: based on a cooler with standard wall tubing, 2-pass,
1034 kPa, nozzle-in-head waterbox with victaulic grooves.
Weight includes suction elbow, control panel, and distribution piping. Weight does not include compressor.
2. Condenser data: based on a condenser with standard wall tubing, 2-pass, 1034 kPa, nozzle-in-head waterbox with victaulic
grooves. Weight includes the float valve, discharge elbow, and
distribution piping. Weight does not include unit-mounted VFD,
isolation valves, and pumpout unit.
105
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Chiller Charge
Refrigerant Weight (kg)
Water Volume (L)
Cooler
Condenser
Cooler
Condenser
156
102
182
182
175
102
208
208
197
102
235
238
159
118
212
212
191
118
242
246
222
118
273
280
181
141
231
235
218
141
265
273
249
141
303
314
254
127
394
416
286
127
424
450
313
127
450
488
290
150
424
454
327
150
462
492
358
150
492
534
340
181
500
556
381
181
541
591
408
181
568
625
227
466
236
477
249
488
395
222
545
609
426
222
591
647
445
222
621
689
249
503
259
519
272
534
426
191
636
689
445
191
666
723
463
191
693
757
463
231
693
757
481
231
731
795
494
231
761
833
553
354
912
1011
608
354
980
1083
653
354
1037
1155
619
420
992
1102
683
420
1071
1189
737
420
1136
1268
680
327
1238
1351
735
327
1298
1427
785
327
1363
1503
767
390
1340
1469
826
390
1412
1556
880
390
1484
1643
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, 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
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
psig
150
300
ENGLISH
Rigging Weight
(lb)
730
365
730
365
1888
944
2445
1223
2860
1430
3970
1720
5048
2182
860
430
860
430
2162
1552
2655
1965
3330
2425
5294
4140
6222
4952
Water Volume
(gal)
84
42
84
42
109
54
122
61
139
69
309
155
364
182
84
42
84
42
109
47
122
53
139
58
309
146
364
161
kPa
1034
2068
SI
Rigging Weight
(kg)
331
166
331
166
856
428
1109
555
1297
649
1801
780
2290
990
390
195
390
195
981
704
1204
891
1510
1100
2401
1878
2822
2246
Water Volume
(L)
318
159
318
159
412
205
462
231
524
262
1170
585
1376
688
318
159
318
159
412
178
462
199
524
218
1170
553
1376
609
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, 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
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
psig
150
300
ENGLISH
Rigging Weight
(lb)
N/A
365
N/A
365
N/A
989
N/A
1195
N/A
1443
N/A
1561
N/A
1751
N/A
430
N/A
430
N/A
1641
N/A
1909
N/A
2451
N/A
4652
N/A
4559
106
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Water Volume
(gal)
N/A
42
N/A
42
N/A
54
N/A
60
N/A
69
N/A
123
N/A
141
N/A
42
N/A
42
N/A
47
N/A
50
N/A
58
N/A
94
N/A
94
kPa
1034
2068
SI
Rigging Weight
(kg)
N/A
166
N/A
166
N/A
449
N/A
542
N/A
655
N/A
708
N/A
794
N/A
195
N/A
195
N/A
744
N/A
866
N/A
1112
N/A
2110
N/A
2068
Water Volume
(L)
N/A
159
N/A
159
N/A
205
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
356
N/A
355
COMPONENT
SUCTION ELBOW
DISCHARGE ELBOW
TRANSMISSION*
SUCTION HOUSING
IMPELLER SHROUD
COMPRESSOR BASE
DIFFUSER
OIL PUMP
HIGH SPEED SHAFT ASSEMBLY
IMPELLER
MISCELLANEOUS
(Incl. Low Speed Gear)
TOTAL COMPRESSOR WEIGHT
(Less Motor and Elbows)
FRAME 4
COMPRESSOR
WEIGHT
(With Split
Ring Diffuser)
lb
kg
239
108
157
71
656
298
810
367
200
91
2020
916
130
59
150
68
30
14
15
7
FRAME 3
COMPRESSOR
WEIGHT
lb
116
100
320
370
35
1260
35
125
15
5
kg
53
45
145
168
16
572
16
57
7
2
lb
185
125
400
400
79
1565
67
150
12
8
kg
84
57
181
181
36
710
30
68
5
4
135
61
135
61
144
65
200
2300
1043
2816
1277
3425
1553
4211
FRAME 5
COMPRESSOR
WEIGHT
lb
407
325
1000
1200
500
3700
350
185
65
50
kg
185
147
454
544
227
1678
159
84
29
23
91
235
107
1910
7285
3304
NOTE: The weights indicated do not include motor, stator, rotor, low
speed shaft, motor case, motor end cover, or any other related components. See Tables 26A and 26B.
107
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FRAME 4
COMPRESSOR
WEIGHT
(Without Split
Ring Diffuser)
lb
kg
239
108
157
71
656
298
585
265
126
57
1589
721
130
59
150
68
30
14
15
7
FRAME 2
COMPRESSOR
WEIGHT
1220
1212
1253
1259
1261
1271
1294
1318
1341
1357
1343
1413
1419
1522
1522
1522
1900
1850
1950
1850
2150
2050
2150
2150
2250
2150
2250
2250
2380
2250
2380
2200
2843
2943
2855
2943
2943
2997
2932
3058
2932
3096
3023
3281
3068
3288
3203
ENGLISH
Rotor Weight (lb)
60 Hz
50 Hz
206
224
217
238
231
255
245
273
259
294
294
256
280
261
281
272
293
273
305
293
305
293
321
305
336
346
389
389
389
405
497
536
497
536
497
536
536
555
536
555
536
555
555
741
775
769
775
803
810
803
871
854
871
854
974
871
974
914
End Bell
Cover (lb)
182
182
182
182
182
182
274
274
274
274
274
274
274
274
318
318
318
318
318
318
318
318
318
414
414
414
414
414
414
414
414
SI
Rotor Weight (kg)
60 Hz
50 Hz
93
102
98
108
105
116
111
124
117
133
133
116
127
118
127
123
133
124
138
133
138
133
146
138
152
157
176
176
176
184
225
243
225
243
225
243
243
252
243
252
243
252
252
336
352
349
352
364
367
364
395
387
395
387
442
395
442
415
End Bell
Cover (kg)
83
83
83
83
83
83
124
124
124
124
124
124
124
124
144
144
144
144
144
144
144
144
144
188
188
188
188
188
188
188
188
108
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553
550
568
571
572
577
587
598
608
616
609
641
644
690
711
690
862
839
885
839
975
930
975
975
1021
975
1021
1021
1080
1021
1080
998
1290
1335
1295
1335
1335
1359
1330
1387
1330
1404
1371
1488
1392
1491
1453
1171
1238
1216
1285
1242
1328
1321
1380
1369
1423
1411
1444
1411
1444
1428
965
995
995
1015
1015
1045
1045
1065
1065
1090
1090
1110
1110
1950
1950
1950
2025
2150
2250
2150
2250
2250
2380
2250
2380
2203
2380
2228
2380
2305
1873
1939
1939
2023
2023
2043
2043
2096
2096
2133
2133
2199
2199
3000
3125
3105
3250
3105
3250
3195
3340
3195
3340
3195
3415
3195
3415
3195
ENGLISH
Rotor Weight (lb)
60 Hz
50 Hz
240
255
252
273
266
294
289
311
289
328
328
288
313
305
330
305
346
313
363
330
379
346
387
363
387
335
221
229
229
236
236
244
244
251
251
259
259
267
267
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
810
862
855
862
855
872
872
872
872
914
872
974
872
974
872
End Bell
Cover (lb)
182
182
182
182
182
182
274
274
274
274
274
274
274
274
274
274
274
274
274
274
274
318
318
318
318
318
318
318
318
318
318
318
318
318
318
318
318
414
414
414
414
414
414
414
414
SI
Rotor Weight (kg)
60 Hz
50 Hz
109
116
114
124
121
133
131
141
131
149
149
131
142
138
150
138
157
142
165
150
172
157
176
165
176
152
100
104
104
107
107
111
111
114
114
117
117
121
121
184
184
184
195
243
248
249
249
261
257
272
272
274
274
279
279
279
165
176
176
184
184
189
189
197
197
201
201
208
208
367
391
388
391
388
396
396
396
396
415
396
442
396
442
396
End Bell
Cover (kg)
83
83
83
83
83
83
124
124
124
124
124
124
124
124
124
124
124
124
124
124
124
144
144
144
144
144
144
144
144
144
144
144
144
144
144
144
144
188
188
188
188
188
188
188
188
109
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531
562
552
583
563
602
599
626
621
645
640
655
640
655
648
438
451
451
460
460
474
474
483
483
494
494
503
503
885
885
885
919
975
1021
975
1021
1021
1080
1021
1080
999
1080
1011
1080
1046
850
880
880
918
918
927
927
951
951
968
968
997
997
1361
1417
1408
1474
1408
1474
1449
1515
1449
1515
1449
1549
1449
1549
1449
WATERBOX DESCRIPTION
COOLER
HEAT
EXCHANGER
WATERBOX DESCRIPTION
COOLER
HEAT
EXCHANGER
COOLER
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
MWB End Cover, 150 psig
MWB Return Cover, 150 psig
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 2
Standard
Flanged
Nozzles
282
318
287
340
294
310
243
243
315
315
243
243
411
486
411
518
433
468
291
291
619
619
445
445
FRAME 3
Standard
Flanged
Nozzles
282
318
287
340
294
310
243
243
315
315
243
243
411
486
411
518
433
468
291
291
619
619
445
445
FRAME 4
Standard
Flanged
Nozzles
148
185
202
256
472
488
138
138
314
314
138
138
633
709
626
733
660
694
522
522
FRAME 5
Standard
Flanged
Nozzles
168
229
222
276
617
634
154
154
390
390
154
154
764
840
760
867
795
830
658
658
FRAME 7
Standard
Flanged
Nozzles
329
441
426
541
1250
1291
315
315
844
844
315
315
1712
1883
1662
1908
1724
1807
1378
1378
FRAME 8
Standard
Flanged
Nozzles
417
494
531
685
1629
1687
404
404
1339
1339
404
404
2359
2523
2369
2599
2353
2516
1951
1951
LEGEND
MWB Marine Waterbox
NIH Nozzle-In-Head
NOTE: Weight for NIH 2-Pass Cover, 150 psig is included in the heat
exchanger weights shown in Tables 23A and 23B.
110
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FRAME 6
Standard
Flanged
Nozzles
187
223
258
331
765
791
172
172
487
487
172
172
978
1053
927
1078
997
1050
834
834
WATERBOX DESCRIPTION
COOLER
HEAT
EXCHANGER
WATERBOX DESCRIPTION
COOLER
HEAT
EXCHANGER
COOLER
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
MWB End Cover, 150 psig
MWB Return Cover, 150 psig
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 2
Standard
Flanged
Nozzles
128
144
130
154
133
141
110
110
143
143
110
110
186
220
186
235
196
212
132
132
281
281
202
202
FRAME 3
Standard
Flanged
Nozzles
128
144
130
154
133
141
110
110
143
143
110
110
186
220
186
235
196
212
132
132
281
281
202
202
FRAME 4
Standard
Flanged
Nozzles
67
84
92
116
214
221
63
63
142
142
63
63
287
322
284
332
299
315
237
237
FRAME 5
Standard
Flanged
Nozzles
76
104
101
125
280
288
70
70
177
177
70
70
347
381
345
393
361
376
299
298
FRAME 7
Standard
Flanged
Nozzles
149
200
193
245
567
586
143
143
383
383
143
143
777
854
754
865
782
820
625
625
FRAME 8
Standard
Flanged
Nozzles
189
224
241
311
739
765
183
183
607
607
183
183
1070
1144
1075
1179
1067
1141
885
885
LEGEND
MWB Marine Waterbox
NIH Nozzle-In-Head
NOTE: Weight for NIH 2-Pass Cover, 1034 kPa is included in the
heat exchanger weights shown in Tables 23A and 23B.
111
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FRAME 6
Standard
Flanged
Nozzles
85
101
117
150
347
359
78
78
221
221
78
78
444
478
420
489
452
476
378
378
WATERBOX DESCRIPTION
CONDENSER
HEAT
EXCHANGER
WATERBOX DESCRIPTION
CONDENSER
HEAT
EXCHANGER
WATERBOX DESCRIPTION
CONDENSER
FRAME 2
Standard
Flanged
Nozzles
282
318
287
340
294
310
225
225
234
234
225
225
411
486
411
518
433
468
270
270
474
474
359
359
FRAME 3
Standard
Flanged
Nozzles
282
318
287
340
294
310
225
225
234
234
225
225
411
486
411
518
433
468
270
270
474
474
359
359
FRAME 4
Standard
Flanged
Nozzles
148
185
191
245
503
519
138
138
314
314
138
138
633
709
622
729
655
689
522
522
FRAME 5
Standard
Flanged
Nozzles
168
229
224
298
628
655
154
154
390
390
154
154
764
840
727
878
785
838
658
658
FRAME 7
Standard
Flanged
Nozzles
329
441
404
520
1222
1218
315
315
781
781
700
700
315
315
1690
1851
1628
1862
1714
1831
1276
1276
FRAME 8
Standard
Flanged
Nozzles
417
494
508
662
1469
1527
404
404
1007
1007
1307
1307
404
404
1986
2151
1893
2222
1993
2112
1675
1675
LEGEND
MWB Marine Waterbox
NIH Nozzle-In-Head
NOTE: Weight for NIH 2-Pass Cover, 150 psig is included in the heat
exchanger weights shown in Tables 23A and 23B.
112
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FRAME 6
Standard
Flanged
Nozzles
187
223
245
318
772
799
172
172
487
487
172
172
978
1053
926
1077
995
1049
834
834
WATERBOX DESCRIPTION
CONDENSER
HEAT
EXCHANGER
WATERBOX DESCRIPTION
CONDENSER
HEAT
EXCHANGER
WATERBOX DESCRIPTION
CONDENSER
FRAME 2
Standard
Flanged
Nozzles
128
144
130
154
133
141
102
102
106
106
102
102
186
220
186
235
196
212
122
122
215
215
163
163
FRAME 3
Standard
Flanged
Nozzles
128
144
130
154
133
141
102
102
106
106
102
102
186
220
186
235
196
212
122
122
215
215
163
163
FRAME 4
Standard
Flanged
Nozzles
67
84
87
111
228
235
63
63
142
142
63
63
287
322
282
331
297
313
237
237
FRAME 5
Standard
Flanged
Nozzles
76
104
102
135
285
297
70
70
177
177
70
70
347
381
330
398
356
380
298
298
FRAME 7
Standard
Flanged
Nozzles
149
200
183
236
554
552
143
143
354
354
318
318
143
143
767
840
738
845
777
831
579
579
FRAME 8
Standard
Flanged
Nozzles
189
224
230
300
666
693
183
183
457
457
593
593
183
183
901
976
859
1008
904
958
760
760
LEGEND
MWB Marine Waterbox
NIH Nozzle-In-Head
NOTE: Weight for NIH 2-Pass Cover, 1034 kPa is included in the
heat exchanger weights shown in Tables 23A and 23B.
113
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FRAME 6
Standard
Flanged
Nozzles
85
101
111
144
350
362
78
78
221
221
78
78
444
478
420
489
451
476
378
378
VOLTS-PH-Hz
208/230-3-60
208/230-3-50
460-3-60
400-3-50
MAX RLA
15.8
15.8
7.8
7.8
LRA
105
105
52
52
LEGEND
LRA Locked Rotor Amps
RLA Rated Load Amps
VFD
FRAME 2
COMPRESSOR
lb
kg
FRAME 3
COMPRESSOR
lb
kg
FRAME 4
COMPRESSOR
lb
kg
FRAME 5
COMPRESSOR
lb
kg
116
100
34
8
26
1600
185
125
34
13
46
1600
239
157
34
20
74
1600
2800
1049
407
325
34
24
108
2800
1049
53
45
15
4
12
726
84
57
15
6
21
726
LEGEND
Variable Frequency Drive
VOLTS
380
416
460
400
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FREQUENCY
60
60
60
50
108
71
15
9
34
726
1270
476
185
147
15
11
49
1270
476
FRAME 2
201-299, 2ZZ
FRAME 3
FRAME 4
FRAME 4
321-389, 3ZZ
421-487
4B1-4W7
With Rolling
Split Ring
Fixed Diffuser
Element
Fixed Diffuser
Diffuser
Bearings
.0050/.0040
.0050/.0040
.0055/.0043
.0055/.0043
.0050/.0040
.0050/.0040
.0053/.0043
.0053/.0043
.0115/.0055
N/A
.010/.005
.010/.005
N/A
.010/.005
.0095/.0055
.0095/.0055
.020/.008
.020/.008
.023/.008
.023/.008
*
*
*
*
.0020/.0005 .0025/.0010 .0021/.0006 .0021/.0006
N/A
N/A
.0014/.0000
.0014/.0000
*
*
*
*
.0025/.0010
.0025/.0010
.0025/.0010
.0025/.0010
.0013/.0005
.0012/.0004
.0012/.0004
.0012/.0004
.013/.009
.010/.006
.010/.006
.010/.006
.012/.008
.012/.008
.012/.008
.012/.008
.0047/.0037
N/A
.0040/.0028
.0040/.0028
.006/.002
N/A
.006/.002
.006/.002
.0045/.0015
N/A
.0045/.0015
.0045/.0015
.014/.008
0 Float
.014/.008
.014/.008
.0050/.0040
N/A
.0048/.0038
.0048/.0038
Split Ring
Diffuser
.0069/.0059
.0065/.0055
N/A
.013/.009
.020/.008
*
.0019/.0005
.0014/.0000
*
.0024/.0010
.0012/.0004
.010/.006
.012/.008
.0048/.0038
.006/.002
.0045/.0015
.014/.008
.0062/.0052
must be removed from the high speed shaft and bearing assembly before the high speed shaft and bearing assembly can be
separated from the transmission.
4. If any components within the Frame 3 rolling element high speed
shaft and bearing assembly are damaged it is recommended that
the entire high speed shaft and bearing assembly be replaced.
5. Impeller spacing should be performed in accordance with the
most recent Carrier Impeller Spacing Service Bulletin.
*Depends on impeller size, contact your Carrier Service Representative 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
115
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FRAME 5
501-599
SEE VIEW A1 OR A2
SEE VIEW B
a19-1635
C1
C2
THRUST
THRUST
B
C1
B
a19-1637
a19-1636
VIEW A2
LOW SPEED SHAFT THRUST DISK
VIEW A1
LOW SPEED SHAFT THRUST DISK
116
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SEE
NOTE 5
E
H
F1
F2
THRUST
I
J
IMPELLER SHIMMING
TO BE DETERMINED
AT ASSEMBLY
L
K
SEE VIEW C
a19-1639
0.025
0.005
+0.0007
-0.0007
0.0050
0.0020
+0.0007
-0.0007
THRUST
0.0011
0.0013
INTERFERENCE
0.0011
0.0013
INTERFERENCE
0.0012
0.0004
117
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a19-1640
a19-1641
a19-1642
a19-1643
FRAME 2
201-299, 2ZZ
DESCRIPTION
Fixed Diffuser
ITEM
1
2
3
4
N/A
80-90 (108-122)
15-19 (20-26)
32-48 (43-65)
FRAME 3
321-389, 3ZZ
With Rolling
Element
Bearings
18-22 (25-30)
80-90 (108-122)
15-19 (20-26)
55-60 (75-81)
FRAME 4
421-487
FRAME 4
4B1-4W7
FRAME 5
501-599
Fixed Diffuser
Split Ring
Diffuser
Split Ring
Diffuser
18-22 (25-30)
80-90 (108-122)
15-19 (20-26)
55-60 (75-81)
18-22 (25-30)
18-22 (25-30)
80-90 (108-122) 80-90 (108-122)
15-19 (20-26)
15-19 (20-26)
55-60 (75-81) 160-225 (217-305)
Auxiliary
Circuit Breaker
Chiller Control Module
Carrier Comfort Network
Common
Communications
Data Link/Data Port
Chassis Ground
Inlet Guide Vane
Guide Vane Actuator
Hot Gas Bypass
High Pressure Switch
International Chiller Visual Controller
Junction
Negative Temperature Coefficient
Relative Humidity Sensor
Transformer
Terminal Block
Variable Frequency Drive
1C
2C
3C
Male/Female Connector
Chassis Ground
Temperature Switch
Thermistor
Transducer
119
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Component Terminal
Pressure Switch
Shielded Cable
Potentiometer
Common Potential
VFD Terminal
Transformer
Capacitor
a19-1716
120
Fig. 49 Electronic PIC III Control Panel Wiring Schematic (Frame 2, 3, 4 Compressor, Standard Diffuser)
121
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122
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123
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124
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125
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126
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127
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128
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129
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130
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LEGEND
ITEM
ANCILLIARY
METERING
PROTECTION
2
A
B
C
D
E
F
G
H
J
K
L
M
N
P
DESCRIPTION
Unit-Mounted VFD Model 0442
Unit-Mounted VFD Model 0608
Unit-Mounted VFD Model 1169
VFD with 65 KAIC Circuit Breaker (Std)
VFD with 100 KAIC Circuit Breaker (Optional)
Includes:
(1) N.O. Chilled Water Pump Contact Output
(1) N.O. Condenser Water Pump Contact Output
(1) N.O. Tower Fan Low/#1 Contact Output
(1) N.O. Tower Fan High/#2 Contact Output
(1) N.O. Alarm Contact Output
(1) 4-20mA Head Pressure Reference Output
(1) N.C. Spare Safety (Dry) Contact Input
(1) N.O. Remote Start (Dry) Contact Input
(1) N.O. Ice Build (Dry) Contact Input
3 Phase Under/Over Voltage Protection (Line Side)
Phase Loss/Imbalance/Reversal Protection (Line Side)
Frequency Shift Protection (Line Side)
Over Current Protection (Line and Load Side)
Phase to Ground Fault Protection (Line and Load Side)
3 Phase Amps (Chiller Display Line and Load Side)
3 Phase Volts (Chiller Display Line Side)
4-20mA kW Transducer Output (Line Side) From Chiller Control Module (CCM)
kW Hours/Demand kW (Chiller Display Line Side)
kW Metering (Chiller Display Line and Load Side)
Control Power Transformer (3 KVA)
Controls and Oil Heater Disconnect
3 Phase Analog Volts/Amps Meter Package (Option)
System Feeder (Short Circuit, Ground Fault and Protection)
Evaporator Liquid Pump Starter Disconnect
Evaporator Liquid Pump Motor Starter
Condenser Liquid Pump Starter Disconnect
Condenser Liquid Pump Motor Starter
Cooling Tower Fan Starter Disconnect (Low Fan/#1)
Cooling Tower Fan Starter (Low Fan/#1)
Cooling Tower Fan Starter Disconnect (High Fan/#2)
Cooling Tower Fan Starter (High Fan/#2)
Spare Safety Devices [N.C.] See Note 3.1
Remote Start/Stop Device [N.O.] See Note 3.1
Remote Alarm See Note 3.3
Remote Annunciator See Note 3.3
Line Side Lug Adapters See Note 2.3
Ice Build Start/Terminate Device See Note 3.1
131
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a19-1713
132
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a19-1714
133
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NOTES
If larger lugs are required, they can be purchased from the
manufacturer of the circuit breaker (Cutler-Hammer or
Square D).
2.4 Compressor motor and controls must be grounded by using
equipment grounding lug provided inside unit-mounted VFD
enclosure.
I General
1.0 Variable Frequency Drive (VFD) shall be designed and manufactured in accordance with Carrier engineering requirement
Z-420.
1.1 All field-supplied conductors and devices must be compliant,
and be installed in compliance with all applicable codes and
job specifications.
1.2 The routing of field-installed conduit and conductors and the
location of field-installed devices must not interfere with
equipment access or the reading, adjusting or servicing of
any component.
1.3 Equipment installation and all starting and control devices
must comply with details in equipment submittal drawings
and literature.
1.4 Contacts and switches are shown in the position they would
assume with the circuit deenergized and the chiller shutdown.
1.5 Warning Do not use aluminum conductors.
1.6 Warning Remove panel above VFD main circuit breaker
before drilling. Do not drill into any other VFD cabinet panels.
Control wiring required for Carrier to start pumps and tower fan
motors, and established flows must be provided to assure
machine protection. If primary pump, tower fan and flow control
is by other means, also provide a parallel means for control by
Carrier. Failure to do so could result in machine freeze-up or
overpressure.
Do not use control transformers in the VFD enclosure or
power panel as the power source for external or field-supplied
contactor coils, actuator motors or any other loads.
3.4 Do not route control wiring carrying 30 v or less within a conduit which has wires carrying 50 v or higher or along side
wires carrying 50 v or higher.
3.5 Spare 4 to 20 mA output signal is designed for controllers
with a non-grounded 4 to 20 mA input signal and a maximum
input impedance of 500 ohms.
STANDARD 65KAIC
OPTIONAL 100KAIC
LUG CAPACITY
LUG CAPACITY
VFD
(PER PHASE)
(PER PHASE)
MAX INPUT
AMPS
No. of
Conductor
No. of
Conductor
Conductors
Range
Conductors
Range
442A
3
3/0 500MCM
2
400 500MCM
608A
3
3/0 500MCM
3
3/0 400MCM
1169A
4
500 1000MCM
4
500 1000MCM
134
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135
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136
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137
LEGEND
3
1
WHT
BLK
RED
2
RED
WHT
BLK
19XRV CHILLERS
1
2
3
4
5
a19-1744
RED
WHT
BLK
MENU
SOFTKEY
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
STATUS
STATUS
STATUS
STATUS
STATUS
SERVICE
SERVICE
SERVICE
SERVICE
STATUS
STATUS
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
STATUS
STATUS
SERVICE
STATUS
STATUS
STATUS
SETPOINT
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
STATUS
SERVICE
SCHEDULE
SERVICE
STATUS
SERVICE
SERVICE
STATUS
SERVICE
SERVICE
STATUS
STATUS
SERVICE
STATUS
SERVICE
TABLE
SCREEN NAME
CONFIGURABLE
CONTROL TEST
CONTROL TEST
CONTROL ALGORITHM STATUS
EQUIPMENT SERVICE
CONTROL ALGORITHM STATUS
CONTROL ALGORITHM STATUS
CONTROL ALGORITHM STATUS
CONTROL ALGORITHM STATUS
X
X
EQUIPMENT CONFIGURATION
CONTROL TEST
EQUIPMENT CONFIGURATION
DISCRETE OUTPUTS
NET_OPT
X
X
EQUIPMENT SERVICE
CONTROL ALGORITHM STATUS
RAMP_DEM
CAPACITY
EQUIPMENT SERVICE
EQUIPMENT CONFIGURATION
CONTROL ALGORITHM STATUS
EQUIPMENT SERVICE
EQUIPMENT CONFIGURATION
EQUIPMENT CONFIGURATION
EQUIPMENT SERVICE
EQUIPMENT SERVICE
CONTROL TEST
CONTROL TEST
CONTROL TEST
CONTROL TEST
138
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MAINSTAT
MAINSTAT
OPTIONS
POWER
POWER
POWER
SETPOINT
ICVC CONFIGURATION
NET_OPT
ICVC CONFIGURATION
CAPACITY
SETUP2
CONTROL TEST
CONTROL TEST
DEFAULT SCREEN
ICVC_PWD
NET_OPT
OCCP03S
OCCDEFCS
HEAT_EX
SETUP1
SETUP1
HEAT_EX
PRESSURE TRANSDUCERS
PUMPS
HEAT_EX
STARTUP
PUMPS
STARTUP
PUMPS
X
X
X
X
X
X
X
X
X
X
MENU
SOFTKEY
STATUS
SERVICE
SERVICE
STATUS
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
STATUS
SERVICE
SERVICE
SERVICE
SERVICE
STATUS
SERVICE
SERVICE
SERVICE
SERVICE
STATUS
SERVICE
SERVICE
SERVICE
STATUS
SERVICE
SERVICE
SERVICE
SERVICE
STATUS
SERVICE
STATUS
STATUS
SERVICE
SERVICE
STATUS
SERVICE
STATUS
SERVICE
SERVICE
STATUS
SERVICE
STATUS
SERVICE
SERVICE
STATUS
SERVICE
STATUS
SERVICE
SETPOINT
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
TABLE
CONTROL ALGORITHM STATUS
CONTROL ALGORITHM STATUS
EQUIPMENT SERVICE
EQUIPMENT SERVICE
CONTROL ALGORITHM STATUS
CONTROL ALGORITHM STATUS
EQUIPMENT SERVICE
CONTROL ALGORITHM STATUS
EQUIPMENT SERVICE
CONTROL ALGORITHM STATUS
CONTROL TEST
CONTROL ALGORITHM STATUS
EQUIPMENT SERVICE
CONTROL ALGORITHM STATUS
CONTROL TEST
CONTROL ALGORITHM STATUS
EQUIPMENT SERVICE
CONTROL ALGORITHM STATUS
CONTROL TEST
VFD CONFIG DATA
EQUIPMENT SERVICE
EQUIPMENT SERVICE
CONTROL ALGORITHM STATUS
EQUIPMENT SERVICE
EQUIPMENT SERVICE
CONTROL TEST
CONTROL TEST
CONTROL TEST
CONTROL TEST
EQUIPMENT CONFIGURATION
CONTROL ALGORITHM STATUS
EQUIPMENT SERVICE
CONTROL ALGORITHM STATUS
CONTROL ALGORITHM STATUS
CONTROL ALGORITHM STATUS
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SCREEN NAME
MAINSTAT
WSMDEFME
VFD_HIST
MAINSTAT
TEMP_CTL
TEMP_CTL
WSMDEFME
WSMDEFME
LEADLAG
OVERRIDE
SETUP1
COMPRESS
OVERRIDE
THERMITORS
OVERRIDE
SETUP1
COMPRESS
OVERRIDE
THERMITORS
OVERRIDE
SETUP1
COMPRESS
OVERRIDE
THERMITORS
VFD_CONF
MAINSTAT
DEFAULT SCREEN
SETUP1
SETUP1
OVERRIDE
SETUP1
HEAT_EX
SETUP1
VFD_STAT
HEAT_EX
OVERRIDE
PRESSURE TRANSDUCERS
HEAT_EX
OVERRIDE
DEFAULT SCREEN
HEAT_EX
PRESSURE TRANSDUCERS
PUMPS
STARTUP
PUMPS
STARTUP
PUMPS
CONSUME
MAINSTAT
CAPACITY
MAINSTAT
TEMP_CTL
SETPOINT
CAPACITY
WSMDEFME
TIME AND DATE
LL_MAINT
TIME AND DATE
CONFIGURABLE
X
X
X
X
X
X
X
X
X
X
X
X
X
MENU
SOFTKEY
SERVICE
SERVICE
SERVICE
STATUS
SERVICE
STATUS
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
STATUS
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
STATUS
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
SETPOINT
STATUS
SERVICE
STATUS
SERVICE
TABLE
EQUIPMENT CONFIGURATION
CONTROL ALGORITHM STATUS
CONTROL ALGORITHM STATUS
VFD CONFIG DATA
EQUIPMENT SERVICE
EQUIPMENT SERVICE
EQUIPMENT SERVICE
EQUIPMENT SERVICE
EQUIPMENT SERVICE
EQUIPMENT SERVICE
EQUIPMENT SERVICE
EQUIPMENT CONFIGURATION
CONTROL ALGORITHM STATUS
EQUIPMENT SERVICE
EQUIPMENT SERVICE
EQUIPMENT SERVICE
EQUIPMENT SERVICE
EQUIPMENT SERVICE
EQUIPMENT SERVICE
CONTROL TEST
CONTROL TEST
EQUIPMENT SERVICE
EQUIPMENT SERVICE
EQUIPMENT SERVICE
CONTROL TEST
EQUIPMENT SERVICE
CONTROL ALGORITHM STATUS
CONTROL ALGORITHM STATUS
EQUIPMENT SERVICE
CONTROL ALGORITHM STATUS
SERVICE
SERVICE
STATUS
CONTROL TEST
CONTROL TEST
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
STATUS
SERVICE
STATUS
STATUS
SERVICE
CONTROL TEST
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SCREEN NAME
CONFIGURABLE
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
MENU
SOFTKEY
STATUS
SERVICE
TABLE
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SCREEN NAME
HEAT_EX
OVERRIDE
DEFAULT SCREEN
SETUP1
POWER
VFD_HIST
VFD_STAT
OPTIONS
VFD_STAT
POWER
VFD_HIST
NET_OPT
SETUP2
SETUP2
SETUP2
CONTROL TEST
IGV & SRD ACTUATOR
CAPACITY
COMPRESS
SETUP2
CONTROL TEST
HEAT_EX
OPTIONS
HEAD PRESSURE OUTPUT
VFD_STAT
VFD_STAT
TIME AND DATE
HOLIDAYS
HEAT_EX
DISCRETE OUTPUTS
POWER
PRESSURE TRANSDUCERS
MAINSTAT
OPTIONS
OPTIONS
OPTIONS
SETPOINT
OPTIONS
OCCP02S
OCCDEFCS
CONTROL TEST
VFD_STAT
VFD_CONF
VFD_STAT
POWER
VFD_STAT
VFD_STAT
VFD_CONF
OVERRIDE
SETUP1
POWER
OVERRIDE
VFD_HIST
LEADLAG
LEADLAG
LL_MAINT
LL_MAINT
LEADLAG
LL_MAINT
LEADLAG
CONFIGURABLE
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
MENU
SOFTKEY
SERVICE
SETPOINT
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
STATUS
SERVICE
SERVICE
SERVICE
STATUS
SERVICE
STATUS
SERVICE
STATUS
SERVICE
SERVICE
SERVICE
STATUS
STATUS
SERVICE
STATUS
SERVICE
STATUS
SERVICE
STATUS
SERVICE
SERVICE
STATUS
SERVICE
STATUS
STATUS
STATUS
SERVICE
STATUS
SERVICE
STATUS
SERVICE
SERVICE
SERVICE
STATUS
STATUS
SERVICE
STATUS
SERVICE
STATUS
SERVICE
STATUS
SERVICE
SERVICE
SERVICE
STATUS
SERVICE
STATUS
SERVICE
STATUS
SERVICE
TABLE
SCREEN NAME
CAPACITY
SETPOINT
LL_MAINT
LL_MAINT
LEADLAG
LL_MAINT
LEADLAG
HEAT_EX
CAPACITY
DEFAULT SCREEN
THERMITORS
THERMITORS
HEAT_EX
DEFAULT SCREEN
ICVC CONFIGURATION
POWER
VFD_HIST
POWER
VFD_HIST
VFD_CONF
VFD_CONF
POWER
VFD_STAT
VFD_HIST
POWER
VFD_HIST
POWER
VFD_HIST
POWER
VFD_HIST
VFD_CONF
POWER
VFD_HIST
POWER
VFD_STAT
POWER
VFD_HIST
POWER
VFD_HIST
POWER
VFD_HIST
VFD_CONF
VFD_CONF
POWER
VFD_STAT
VFD_HIST
POWER
VFD_HIST
POWER
VFD_HIST
POWER
VFD_HIST
LL_MAINT
LEADLAG
POWER
VFD_HIST
POWER
VFD_HIST
POWER
VFD_HIST
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CONFIGURABLE
X
X
X
X
X
PARAMETER
Loadshed
Loadshed Function
Loadshed Function
Loadshed Timer
LOCAL
Local Network Device
Local Time Schedule
Local Time Schedule (OCCPC01S)
LOG OUT OF DEVICE
Low DC Bus Voltage
Low Line Voltage
Maximum Loadshed Time
Min. Load Point (T1, P1)
Minimum Output
Model Number
Motor Amps Not Sensed
Motor Current % Imbalance
Motor Current Imbal Time
Motor Current Imbalance
Motor Current Imbalance
Motor Current Imbalance
Motor Kilowatt Hours
Motor Kilowatts
Motor Nameplate Amps
Motor Nameplate kW
Motor Nameplate RPM
Motor Nameplate Voltage
Motor Overload
Motor Overload
Motor Overload
Motor Power Factor
Motor Power Factor
Motor Rated Load Amps
Motor Rated Load kW
OCCPC01S (Local Time Schedule)
OCCPC02S (Ice Build Time Schedule)
OCCPC03S (CCN Time Schedule)
OCCPC01S (Local Time Schedule)
OCCPC02S (Ice Build Time Schedule)
OCCPC03S (CCN Time Schedule)
Occupied?
Oil Heater Relay
Oil Heater Relay Test
Oil Press Verify Time
Oil Pressure
Oil Pressure Acceptable?
Oil Pump Delta P
Oil Pump Delta P
Oil Pump Delta P
Oil Pump Delta P
Oil Pump Relay
Oil Pump Relay
Oil Sump Temp
Oil Sump Temp
Oil Sump Temp
Oil Sump Temp
Password (VFD CONFIG DATA)
Password (SERVICE)
TABLE
SCREEN NAME
CONFIGURABLE
LOADSHED
NET_OPT
LOADSHED
LOADSHED
DEFAULT SCREEN
ATTACH TO NETWORK DEVICE
OCCP01S
OCCDEFCS
X
X
X
X
SERVICE
SCHEDULE
SERVICE
EQUIPMENT CONFIGURATION
SERVICE
STATUS
STATUS
SERVICE
EQUIPMENT CONFIGURATION
SERVICE
EQUIPMENT SERVICE
SERVICE
EQUIPMENT SERVICE
SERVICE
STATUS
SERVICE
VFD CONFIG DATA
SERVICE
VFD CONFIG DATA
STATUS
STATUS
SERVICE CONTROL ALGORITHM STATUS
STATUS
STATUS
SERVICE
VFD CONFIG DATA
SERVICE
VFD CONFIG DATA
SERVICE
VFD CONFIG DATA
SERVICE
VFD CONFIG DATA
STATUS
STATUS
SERVICE CONTROL ALGORITHM STATUS
STATUS
SERVICE CONTROL ALGORITHM STATUS
SERVICE
VFD CONFIG DATA
SERVICE
VFD CONFIG DATA
SCHEDULE
SCHEDULE
SCHEDULE
SERVICE
EQUIPMENT CONFIGURATION
SERVICE
EQUIPMENT CONFIGURATION
SERVICE
EQUIPMENT CONFIGURATION
STATUS
STATUS
SERVICE
CONTROL TEST
SERVICE
EQUIPMENT SERVICE
SERVICE
STATUS
STATUS
SERVICE
SERVICE
STATUS
SERVICE
STATUS
STATUS
SERVICE
SERVICE
SERVICE
CONTROL TEST
CONTROL TEST
CONTROL TEST
CONTROL TEST
CONTROL TEST
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VFD_STAT
VFD_STAT
NET_OPT
OPTIONS
OPTIONS
ICVC CONFIGURATION
VFD_STAT
VFD_CONF
VFD_CONF
POWER
VFD_STAT
VFD_HIST
POWER
POWER
VFD_CONF
VFD_CONF
VFD_CONF
VFD_CONF
POWER
VFD_STAT
VFD_HIST
POWER
VFD_HIST
VFD_CONF
VFD_CONF
OCCP01S
OCCP02S
OCCP03S
OCCDEFCS
OCCDEFCS
OCCDEFCS
MAINSTAT
COMPRESS
DISCRETE OUTPUTS
SETUP1
DEFAULT SCREEN
PUMPS
STARTUP
COMPRESS
PRESSURE TRANSDUCERS
PUMPS
STARTUP
PUMPS
STARTUP
COMPRESS
DEFAULT SCREEN
THERMITORS
VFD CONFIG DATA
ICVC CONFIGURATION
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
MENU
SOFTKEY
STATUS
STATUS
STATUS
STATUS
STATUS
STATUS
STATUS
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
STATUS
STATUS
STATUS
STATUS
SERVICE
SERVICE
STATUS
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
STATUS
SERVICE
STATUS
STATUS
SERVICE
STATUS
SERVICE
SERVICE
STATUS
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
STATUS
TABLE
CONTROL TEST
EQUIPMENT SERVICE
EQUIPMENT SERVICE
EQUIPMENT SERVICE
EQUIPMENT SERVICE
EQUIPMENT SERVICE
EQUIPMENT SERVICE
CONTROL ALGORITHM STATUS
144
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SCREEN NAME
MAINSTAT
POWER
DEFAULT SCREEN
MAINSTAT
POWER
POWER
POWER
POWER
CONTROL TEST
LL_MAINT
LEADLAG
DEFAULT SCREEN
SETUP2
SETUP2
SETUP2
RAMP_DEM
LL_MAINT
CONTROL TEST
CONTROL TEST
CONTROL TEST
VFD_CONF
VFD_CONF
VFD_CONF
NET_OPT
LL_MAINT
VFD_STAT
POWER
VFD_STAT
VFD_STAT
OVERRIDE
SETUP1
POWER
OVERRIDE
VFD_HIST
SETUP1
LOADSHED
ICVC CONFIGURATION
SETUP1
PRESSURE TRANSDUCERS
POWER
OPTIONS
ICVC_PWD
MAINSTAT
THERMITORS
MAINSTAT
TEMP_CTL
TEMP_CTL
DEFAULT SCREEN
ICVC_PWD
TEMP_CTL
TEMP_CTL
TEMP_CTL
SETUP1
LL_MAINT
MAINSTAT
CONFIGURABLE
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
MENU
SOFTKEY
SERVICE
SERVICE
SERVICE
STATUS
STATUS
SERVICE
SERVICE
STATUS
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
STATUS
SERVICE
SERVICE
SERVICE
SERVICE
STATUS
SERVICE
SERVICE
STATUS
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
STATUS
SERVICE
STATUS
STATUS
SERVICE
STATUS
SERVICE
SERVICE
SERVICE
SERVICE
STATUS
SERVICE
STATUS
STATUS
SERVICE
STATUS
SERVICE
SERVICE
SERVICE
SERVICE
STATUS
SERVICE
SERVICE
SERVICE
SERVICE
STATUS
SERVICE
TABLE
SCREEN NAME
CONFIGURABLE
EQUIPMENT CONFIGURATION
EQUIPMENT CONFIGURATION
RUNTIME
NET_OPT
DEFAULT SCREEN
ICVC CONFIGURATION
MAINSTAT
STARTUP
DISCRETE OUTPUTS
SETUP1
VFD_STAT
VFD_CONF
VFD_CONF
VFD_CONF
VFD_CONF
VFD_CONF
OPTIONS
ICVC CONFIGURATION
SETUP1
STARTUP
SETUP1
SETUP1
SETUP1
SETUP1
COMPRESS
LL_MAINT
THERMITORS
COMPRESS
LL_MAINT
THERMITORS
LEADLAG
LEADLAG
LEADLAG
LL_MAINT
VFD_STAT
BRODEF
STARTUP
VFD_STAT
BRODEF
MAINSTAT
BRODEF
BRODEF
BRODEF
LL_MAINT
MAINSTAT
BRODEF
STARTUP
VFD_STAT
BRODEF
VFD_STAT
BRODEF
BRODEF
BRODEF
OVERRIDE
HEAT_EX
OPTIONS
OPTIONS
OPTIONS
OPTIONS
COMPRESS
OPTIONS
X
X
CONTROL TEST
EQUIPMENT SERVICE
VFD CONFIG DATA
VFD CONFIG DATA
VFD CONFIG DATA
VFD CONFIG DATA
VFD CONFIG DATA
EQUIPMENT SERVICE
EQUIPMENT SERVICE
EQUIPMENT SERVICE
EQUIPMENT SERVICE
EQUIPMENT SERVICE
EQUIPMENT SERVICE
CONTROL ALGORITHM STATUS
CONTROL TEST
CONTROL ALGORITHM STATUS
CONTROL TEST
EQUIPMENT SERVICE
EQUIPMENT SERVICE
EQUIPMENT SERVICE
CONTROL ALGORITHM STATUS
EQUIPMENT CONFIGURATION
EQUIPMENT CONFIGURATION
EQUIPMENT CONFIGURATION
EQUIPMENT CONFIGURATION
EQUIPMENT CONFIGURATION
CONTROL ALGORITHM STATUS
EQUIPMENT CONFIGURATION
EQUIPMENT CONFIGURATION
EQUIPMENT CONFIGURATION
EQUIPMENT CONFIGURATION
EQUIPMENT CONFIGURATION
CONTROL ALGORITHM STATUS
EQUIPMENT SERVICE
EQUIPMENT SERVICE
EQUIPMENT SERVICE
EQUIPMENT SERVICE
EQUIPMENT SERVICE
145
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X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
MENU
SOFTKEY
SERVICE
SERVICE
SERVICE
STATUS
SERVICE
SERVICE
STATUS
STATUS
SERVICE
STATUS
STATUS
SERVICE
SERVICE
STATUS
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
STATUS
SERVICE
STATUS
SERVICE
SETPOINT
STATUS
SERVICE
STATUS
SERVICE
SERVICE
SERVICE
SERVICE
STATUS
STATUS
SERVICE
STATUS
SERVICE
STATUS
STATUS
SERVICE
STATUS
SERVICE
STATUS
STATUS
SERVICE
SERVICE
SERVICE
STATUS
SERVICE
STATUS
SERVICE
SERVICE
STATUS
STATUS
SERVICE
STATUS
STATUS
SERVICE
SERVICE
TABLE
SCREEN NAME
CONFIGURABLE
EQUIPMENT SERVICE
EQUIPMENT SERVICE
EQUIPMENT SERVICE
OPTIONS
OPTIONS
OPTIONS
HEAT_EX
OPTIONS
OPTIONS
MAINSTAT
COMPRESS
CAPACITY
COMPRESS
STARTUP
CAPACITY
TEMP_CTL
MAINSTAT
TEMP_CTL
CONTROL TEST
CONTROL TEST
TIME AND DATE
BRODEF
POWER
VFD_HIST
MAINSTAT
CAPACITY
SETPOINT
STARTUP
DISCRETE OUTPUTS
STARTUP
DISCRETE OUTPUTS
PRESSURE TRANSDUCERS
ICVC CONFIGURATION
VFD_HIST
VFD_STAT
POWER
VFD_HIST
VFD_STAT
VFD CONFIG DATA
HEAT_EX
POWER
DISCRETE OUTPUTS
POWER
VFD_HIST
VFD_STAT
VFD_STAT
VFD_HIST
VFD_HIST
SETUP2
VFD_STAT
SETUP2
VFD_STAT
SETUP2
SETUP2
VFD_STAT
VFD_STAT
SETUP2
STARTUP
VFD_STAT
SETUP1
WSMDEFME
X
X
X
EQUIPMENT SERVICE
EQUIPMENT SERVICE
EQUIPMENT CONFIGURATION
CONTROL ALGORITHM STATUS
CONTROL ALGORITHM STATUS
CONTROL TEST
CONTROL TEST
CONTROL TEST
CONTROL ALGORITHM STATUS
CONTROL TEST
CONTROL ALGORITHM STATUS
EQUIPMENT SERVICE
EQUIPMENT SERVICE
CONTROL ALGORITHM STATUS
146
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X
X
X
X
X
X
X
X
X
X
X
X
INDEX
Abbreviations and explanations 4, 5
Adding refrigerant 77
Adjusting the refrigerant charge 77
After extended shutdown 72
After limited shutdown 72
Alarm (trip) output contacts 43
Attach to network device control 50
Automatic soft stop amps threshold 54
Auto. restart after power failure 45
Bearings 8
Before initial start-up 55-70
Capacity override 42
Carrier Comfort Network interface 63
Changing oil filter 79
Charge refrigerant into chiller 68
Chilled water recycle mode 54
Chiller control module (CCM) 100
Chiller dehydration 61
Chiller familiarization 5, 6
Chiller information nameplate 5
Chiller operating condition (check) 71
Chiller tightness (check) 56
Chillers with isolation valves 76
Chillers with storage tanks 74
Cold weather operation 72
Compressor bearing and gear maintenance 80
Condenser 5
Condenser freeze prevention 44
Condenser pump control 44
Control algorithms checkout procedure 83
Control panel 5
Control modules 100
Control test 67, 84
Controls 14-52
Cooler 5
Default screen freeze 39
Definitions (controls) 14
Design set points, (input) 64
Details (lubrication cycle) 8
Display messages (check) 82
Equipment required 55
Evaporator freeze protection 44
Extended shutdown (preparation for) 72
Gateway status LEDs 102
General (controls) 14
General maintenance 77, 78
Ground fault troubleshooting 63
Guide vane linkage (check) 78
Head pressure reference output 47
Heat exchanger tubes and
flow devices (inspect) 80
High altitude locations 68
High discharge temperature control 42
Ice build control 49
ICVC operation and menus 19
Initial start-up 70, 71
Initial start-up checklist for 19XRV hermetic
centrifugal liquid chiller CL-1 to CL-12
Input power wiring 62
Inspect the control panel 79
Instruct the customer operator 71
Introduction 4
Job data required 55
Kilowatt output 44
Lead/lag control 47
Leak rate 77
Leak test chiller 58
Local occupied schedule (input) 64
Local start-up 53
Lubrication cycle 8, 9
Lubrication system (check) 78
Manual guide vane operation 72
Motor and lubricating oil cooling cycle 7
Motor-compressor 5
Motor rotation (check) 70
Notes on module operation 100
Oil changes 79
Oil charge 55
Oil cooler 42
Oil pressure and compressor stop (check) 70
Oil reclaim filter 79
Oil reclaim system 8
Oil specification 79
Oil sump temperature and pump control 42
Open oil circuit valves 55
Operating instructions 71-73
Operating the optional pumpout unit 74
Operator duties 71
Optional pumpout compressor
water piping (check) 61
Optional pumpout system controls and
compressor (check) 68
Optional pumpout system maintenance 81
Ordering replacement chiller parts 81
Overview (troubleshooting guide) 82
Perform a control test 67
Physical data 103
PIC III system components 14
PIC III system functions 37
Power up the controls and check
the oil heater 64
Preparation (initial start-up) 70
Preparation (pumpout and refrigerant
transfer procedures) 74
Prepare the chiller for start-up 71
Pressure transducers (check) 82
Prevent accidental start-up 70
Pumpout and refrigerant transfer
procedures 74-77
Ramp loading 42
Recalibrate pressure transducers 81
Refrigerant filter 79
Refrigerant float system (inspect) 80
Refrigerant leak testing 77
Refrigerant properties 77
Refrigerant (removing) 77
Refrigerant tracer 56
Refrigeration cycle 7
Refrigeration log 72
Relief valves (check) 61
Relief valves and piping (inspect) 80
Remote reset of alarms 44
Remote start/stop controls 43
Repair the leak, retest, and
apply standing vacuum test 78
Replacing defective processor modules 101
Running system (check) 71
Safety and operating controls
(check monthly) 79
Safety considerations 1
Safety controls 39
Safety shutdown 55
Scheduled maintenance 79-81
Service configurations (input) 64
Service ontime 79
Service operation 51
Shipping packaging (remove) 55
Shunt trip 39
Shutdown sequence 54
Software configuration 64
Spare safety and space temperature inputs 43
Standing vacuum test 58
Starting equipment 9-14
Start-up/shutdown/recycle sequence 53-55
Start the chiller 71
Stop the chiller 72
Storage vessel 5
Summary (lubrication cycle) 8
Surge prevention algorithm 45
Surge protection 46
System components 5
Temperature sensors (check) 82
Test after service, repair, or major leak 77
Tighten all gasketed joints and
guide vane packing 55
Tower fan relay low and high 44
147
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JOB NO.
ADDRESS
MODEL
CITY
STATE
ZIP
S/N
DESIGN CONDITIONS:
TONS
(kW)
BRINE
FLOW
RATE
TEMPERATURE
IN
TEMPERATURE PRESSURE
OUT
DROP
PASS
SUCTION
TEMPERATURE
COOLER
CONDENSER
******
CONDENSER
TEMPERATURE
******
Volts
Volts
FLA
RLA
Type:
CARRIER OBLIGATIONS:
OLTA
OLTA
Charge
Assemble... . . . . . . . . . . . . . . . .
Leak Test . . . . . . . . . . . . . . . . . . .
Dehydrate . . . . . . . . . . . . . . . . . .
Charging . . . . . . . . . . . . . . . . . . .
Operating Instructions
Yes
Yes
Yes
Yes
No
No
No
No
Hrs.
NO
3/4
1/2 Top sight glass
1/4
ADD OIL:
Yes
No
Amount:
3/4
1/2 Bottom sight glass
1/4
a23-190
Book
Tab
Cooler
Initial Charge
Condenser
Final Charge After Trim
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
2
Catalog No. 04-53190002-01
Printed in U.S.A.
Form 19XRV-2SS
Pg CL-1
11-06
Replaces: 19XRV-1SS
5a
VFD
Oil Pump
Controls/Oil Heater
Yes
No
Yes
No
Mfd in _____________________________________
on ________________________________________
10-Second Readings:
PHASE TO PHASE
T1-T2
T1-T3
T2-T3
____
____
____
PHASE TO GROUND
T1-G
T2-G
T3-G
____
____
____
60-Second Readings:
____
____
____
____
____
____
Polarization Ratio:
____
____
____
____
____
____
MEGGER MOTOR
WATER/BRINE PUMP CONTROL: Can the Carrier controls independently start the pumps?
Condenser Water Pump
Yes
No
Chilled Water Pump
Yes
No
RUN MACHINE: Do these safeties shut down machine?
Condenser Water Flow
Yes
No
Chilled Water Flow
Yes
No
Pump Interlocks
Yes
No
INITIAL START:
Line Up All Valves in Accordance With Instruction Manual:
Start Water Pumps and Establish Water Flow
Oil Level OK and Oil Temperature OK
Check Oil Pump Rotation-Pressure
Check Compressor Motor Rotation (Motor End Sight Glass) and Record:
Clockwise
Restart Compressor, Bring Up To Speed. Shut Down. Any Abnormal Coastdown Noise?
Yes*
No
CUSTOMER
REPRESENTATIVE
DATE
DATE
CL-2
RANGE
40 to 100
10 to 120
(-12.2 to 48.9)
15 to 120
(-9.4 to 48.9)
15 to 60
(-9.4 to 15.6)
55 to 105
(13 to 41)
UNITS
%
DEFAULT
100
DEG F (C)
50.0 (10)
DEG F (C)
60.0 (15.6)
DEG F (C)
40.0 (4.4)
DEG F (C)
75 (24)
Yes
No
CL-3
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ADDRESS:
VALUE
Day Flag
M T W T F S
S H
Occupied
Time
Unoccupied
Time
Period 1:
Period 2:
Period 3:
Period 4:
Period 5:
Period 6:
Period 7:
Period 8:
NOTE: Default setting is OCCUPIED 24 hours/day.
ICE BUILD 19XRV PIC III TIME SCHEDULE CONFIGURATION SHEET OCCPC02S
Day Flag
M T W T F S
S H
Occupied
Time
Unoccupied
Time
Period 1:
Period 2:
Period 3:
Period 4:
Period 5:
Period 6:
Period 7:
Period 8:
NOTE: Default setting is UNOCCUPIED 24 hours/day.
CL-4
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S H
Occupied
Time
Unoccupied
Time
RANGE
380-460
45.0-62.0
0/1
346-480
10-1500
0-7200
0-7200
10-1500
10-1500
1500-3600
0-5600
UNITS
VOLTS
Hz
NO/YES
VOLTS
AMPS
kW
kW
AMPS
AMPS
kW
0/1
0.0-102.0
0.0-102.0
0.0-102.0
0.0-102.0
1-10
1-10
5-40
1-10
5-40
1-10
5-60
5-60
0/1
DEFAULT
460
60.0
YES
460
200
100
100
200
100
3456
100
VALUE
0
Hz
Hz
Hz
Hz
%
SEC
%
SEC
%
SEC
SEC
SEC
DSABLE/ENABLE
102.0
102.0
102.0
0.0
10
10
40
10
40
10
30
30
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
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DESCRIPTION
Auto Restart Option
Remote Contacts Option
Soft Stop Amps Threshold
RANGE
0/1
0/1
40 to 100
0/1
Surge/HGBP Delta T1
Surge/HGBP Delta P1
UNITS
DSABLE/ENABLE
DSABLE/ENABLE
%
DEFAULT
DSABLE
DSABLE
100
0.5 to 20
F (C)
(.3 to 11.1)
30 to 170
PSI (kPa)
(206.9 to 1172.2)
1.5 (0.8)
50 (344.8)
0.5 to 20
F (C)
(.3 to 11.1)
50 to 170
(344.8 to 1172.2) PSI (kPa)
0.5 to 3
F (C)
(.3 to 1.7)
10 (5.6)
85 (586.1)
1 (0.6)
5 to 20
7 to 10
%
MIN
10
8
0/1
DSABLE/ENABLE
DSABLE
0 to 2
0/1
DSABLE/ENABLE
DSABLE
psi (kPa)
25 (172)
psi (kPa)
50 (344.8)
20 to 85
(138 to 586)
20 to 85
(138 to 586)
0 to 100
CL-6
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VALUE
Chilled Medium
Chilled Water Deadband
Evap Refrig Trippoint
Refrig Override Delta T
Evap Approach Alert
Cond Approach Alert
Condenser Freeze Point
RANGE
150 to 200
(66 to 93)
90 to 165
(621 to 1138)
155 to 170
(68 to 77)
155 to 170
(68 to 77)
125 to 200
(52 to 93)
165 to 185
(74 to 85)
0/1
.5 to 2.0
(0.3 to 1.1)
0.0 to 40.0
(17.8 to 4.4)
2.0 to 5.0
(1.1 to 2.8)
0.5 to 15
(0.3 to 8.3)
0.5 to 15
(0.3 to 8.3)
20 to 35
(28.9 to 1.7)
0 to 1
0.5 to 50.0
(3.4 to 344.8)
0.5 to 50.0
(3.4 to 344.8)
0.5 to 5
15 to 300
2.0 to 10.0
(1.1 to 5.6)
0.5 to 4.0
(0.3 to 2.2)
UNITS
DEFAULT
F (C)
200 (93)
PSI (kPa)
125 (862)
F (C)
160 (71)
F (C)
160 (71)
F (C)
200 (93)
F (C)
175 (79)
WATER/
BRINE
WATER
F (C)
1.0 (0.6)
F (C)
33 (0.6)
F (C)
3 (1.7)
F (C)
5 (2.8)
F (C)
6 (3.3)
F (C)
34 (1.1)
DSABLE/
ENABLE
DSABLE
PSI (kPa)
5.0 (34.5)
PSI (kPa)
5.0 (34.5)
MIN
SEC
5
40
F (C)
5 (2.8)
F (C)
1 (.0.6)
0 to 4
40 to 245
(40 to 118)
0 to 4
40 to 245
(40 to 118)
0
F (C)
245 (118)
0
F (C)
245 (118)
NOTE: No variables are available for CCN read operation. Forcing shall not be supported on service screens.
CL-7
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VALUE
DESCRIPTION
Capacity Control
Proportional Inc Band
Proportional DEC Band
Proportional ECW Gain
STATUS
UNITS
2 to 10
2 to 10
1 to 3
30 to 100
80
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
0/1
0 to 78
0 to 100
0 to 78
0 to 100
0 to 78
0 to 100
15 to 22
DSABLE/ENABLE
%
%
%
%
%
%
mA
DSABLE
25
0
50
0
75
0
18
0.1 to 1.5
1 to 5
65 to 100
90 to 100
%
%
%
0.75
2
70
100
6.5
6.0
2.0
CL-8
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DEFAULT
VALUE
RANGE
UNITS
0 to 3
0/1
0/1
25 to 75
1 to 236
2 to 60
2 to 60
2 to 30
0/1
25 to 75
1 to 236
0
DSABLE/ENABLE
DSABLE/ENABLE
%
MIN
MIN
MIN
DSABLE/ENABLE
%
CL-9
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DEFAULT
DSABLE
DSABLE
50
92
10
10
5
DSABLE
50
93
VALUE
DESCRIPTION
Pulldown Ramp Type:
Select: Temp=0, Load=1
Demand Limit and kW Ramp
Demand Limit Source
Select: Amps=0, kW=1
Amps or kW Load Ramp% Min
Demand Limit Prop Band
Demand Limit At 20 mA
20 mA Demand Limit Opt
Demand Watts Interval
RANGE
UNITS
DEFAULT
0/1
0/1
5 to 20
3 to 15
40 to 100
0/1
5 to 60
%
%
DSABLE/ENABLE
MIN
VALUE
10
10
40
DSABLE
15
RANGE
0/1
2 to 10
(1.1 to 5.6)
UNITS
DEFAULT
DSABLE/ENABLE
DSABLE
F (C)
3 (1.7)
F (C)
10 (6)
DEG F (C)
85 (29)
DEG F (C)
65 (18)
F (C)
10 (6)
F (C)
F (C)
10 (6)
0 (0)
F (C)
5 (3)
Temperature Reset
RESET TYPE 1
Degrees Reset At 20 mA
30 to 30
(17 to 17)
RESET TYPE 2
Remote Temp -> No Reset
Remote Temp -> Full Reset
Degrees Reset
RESET TYPE 3
CHW Delta T -> No Reset
CHW Delta T -> Full Reset
Degrees Reset
Enable Reset Type
40 to 245
(40 to 118)
40 to 245
(40 to 118)
30 to 30
(17 to 17)
0 to 15 (0 to 8)
0 to 15 (0 to 8)
30 to 30
(17 to 17)
0 to 3
CL-10
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VALUE
RANGE
DSABLE/ENABLE
1 to 12
1 to 7
1 to 5
00:00 to 24:00
0 to 360
1 to 12
1 to 7
1 to 5
00:00 to 24:00
0 to 360
HH:MM
MIN
MIN
CL-11
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UNITS
DEFAULT
DSABLE
4
7
1
02:00
0
10
7
5
02:00
0
VALUE
PRIMARY MESSAGE:
DATE:
SECONDARY MESSAGE:
COMPRESSOR ONTIME:
TIME:
CHW IN
CHW OUT
EVAP REF
CDW IN
CDW OUT
COND REF
OILPRESS
OIL TEMP
AMPS %IN
COMMUNICATION MESSAGE
CCN
LOCAL
RESET
MENU
a19-1657
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
2
Catalog No. 04-53190002-01
Printed in U.S.A.
Form 19XRV-2SS
Pg CL-12
11-06
Replaces: 19XRV-1SS
5a