EVERGREEN®
19XRV
Hermetic Centrifugal Liquid Chillers
with PIC III Controls and HFC-134a
50/60 Hz
Start-Up, Operation, and Maintenance Instructions
SAFETY CONSIDERATIONS
Centrifugal liquid chillers are designed to provide safe
and reliable service when operated within design specifications. When operating this equipment, use good
judgment and safety precautions to avoid damage to
equipment and property or injury to personnel.
Be sure you understand and follow the procedures
and safety precautions contained in the chiller instructions as well as those listed in this guide.
DANGER
DO NOT VENT refrigerant relief valves within a building. Outlet
from rupture disc or relief valve must be vented outdoors in accordance with the latest edition of ANSI/ASHRAE 15 (American
National Standards Institute/American Society of Heating, Refrigerating, and Air Conditioning Engineers). The accumulation of refrigerant
in an enclosed space can displace oxygen and cause asphyxiation.
PROVIDE adequate ventilation in accordance with ANSI/ASHRAE
15, especially for enclosed and low overhead spaces. Inhalation of
high concentrations of vapor is harmful and may cause heart irregularities, unconsciousness, or death. Misuse can be fatal. Vapor is heavier
than air and reduces the amount of oxygen available for breathing.
Product causes eye and skin irritation. Decomposition products are
hazardous.
DO NOT USE OXYGEN to purge lines or to pressurize a chiller for
any purpose. Oxygen gas reacts violently with oil, grease, and other
common substances.
NEVER EXCEED specified test pressures, VERIFY the allowable
test pressure by checking the instruction literature and the design pressures on the equipment nameplate.
DO NOT USE air for leak testing. Use only refrigerant or dry
nitrogen.
DO NOT VALVE OFF any safety device.
BE SURE that all pressure relief devices are properly installed and
functioning before operating any chiller.
THERE IS A RISK OF INJURY OR DEATH by electrocution. High
voltage may be present on the motor leads even though the motor is
not running. Open the power supply disconnect before touching
motor leads or terminals.
WARNING
DO NOT WELD OR FLAMECUT any refrigerant line or vessel until
all refrigerant (liquid and vapor) has been removed from chiller.
Traces of vapor should be displaced with dry air or nitrogen and the
work area should be well ventilated. Refrigerant in contact with an
open flame produces toxic gases.
DO NOT USE eyebolts or eyebolt holes to rig chiller sections or the
entire assembly.
DO NOT work on high-voltage equipment unless you are a qualified
electrician.
DO NOT WORK ON electrical components, including control
panels, switches, VFD, or oil heater until you are sure ALL POWER
IS OFF and no residual voltage can leak from capacitors or solid-state
components.
LOCK OPEN AND TAG electrical circuits during servicing. IF
WORK IS INTERRUPTED, confirm that all circuits are deenergized
before resuming work.
AVOID SPILLING liquid refrigerant on skin or getting it into the
eyes. USE SAFETY GOGGLES. Wash any spills from the skin with
soap and water. If liquid refrigerant enters the eyes, IMMEDIATELY
FLUSH EYES with water and consult a physician.
NEVER APPLY an open flame or live steam to a refrigerant cylinder.
Dangerous over pressure can result. When it is necessary to heat
refrigerant, use only warm (110 F [43 C]) water.
DO NOT REUSE disposable (nonreturnable) cylinders or attempt to
refill them. It is DANGEROUS AND ILLEGAL. When cylinder is
emptied, evacuate remaining gas pressure, loosen the collar and
unscrew and discard the valve stem. DO NOT INCINERATE.
CHECK THE REFRIGERANT TYPE before adding refrigerant to
the chiller. The introduction of the wrong refrigerant can cause
damage or malfunction to this chiller.
Operation of this equipment with refrigerants other than those
cited herein should comply with ANSI/ASHRAE 15 (latest edition).
Contact Carrier for further information on use of this chiller with other
refrigerants.
DO NOT ATTEMPT TO REMOVE fittings, covers, etc., while
chiller is under pressure or while chiller is running. Be sure pressure is
at 0 psig (0 kPa) before breaking any refrigerant connection.
CAREFULLY INSPECT all relief devices, rupture discs, and other
relief devices AT LEAST ONCE A YEAR. If chiller operates in a
corrosive atmosphere, inspect the devices at more frequent intervals.
DO NOT ATTEMPT TO REPAIR OR RECONDITION any relief
device when corrosion or build-up of foreign material (rust, dirt, scale,
etc.) is found within the valve body or mechanism. Replace the
device.
DO NOT install relief devices in series or backwards.
USE CARE when working near or in line with a compressed spring.
Sudden release of the spring can cause it and objects in its path to act
as projectiles.
CAUTION
DO NOT STEP on refrigerant lines. Broken lines can whip about and
release refrigerant, causing personal injury.
DO NOT climb over a chiller. Use platform, catwalk, or staging.
Follow safe practices when using ladders.
USE MECHANICAL EQUIPMENT (crane, hoist, etc.) to lift
or move inspection covers or other heavy components. Even if
components are light, use mechanical equipment when there is a risk
of slipping or losing your balance.
BE AWARE that certain automatic start arrangements CAN
ENGAGE THE VFD, TOWER FAN, OR PUMPS. Open the
disconnect ahead of the VFD, tower fans, or pumps.
USE only repair or replacement parts that meet the code requirements
of the original equipment.
DO NOT VENT OR DRAIN waterboxes containing industrial brines,
liquid, gases, or semisolids without the permission of your process
control group.
DO NOT LOOSEN waterbox cover bolts until the waterbox has been
completely drained.
DO NOT LOOSEN a packing gland nut before checking that the nut
has a positive thread engagement.
PERIODICALLY INSPECT all valves, fittings, and piping for
corrosion, rust, leaks, or damage.
PROVIDE A DRAIN connection in the vent line near each pressure
relief device to prevent a build-up of condensate or rain water.
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Catalog No. 04-53190015-01
Printed in U.S.A.
Form 19XRV-5SS
Pg 1
312
12-11
Replaces: 19XRV-2SS
CONTENTS
Page
High Discharge Temperature Control . . . . . . . . . . . . 46
Compressor Bearing Temperature. . . . . . . . . . . . . . . 46
Oil Sump Temperature and Pump Control . . . . . . . 46
Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Remote Start/Stop Controls . . . . . . . . . . . . . . . . . . . . . 47
Spare Safety and Spare Temperature Inputs. . . . . 47
Alarm (Trip) Output Contacts . . . . . . . . . . . . . . . . . . . . 47
Kilowatt Output. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Remote Reset of Alarms. . . . . . . . . . . . . . . . . . . . . . . . . 48
Condenser Pump Control . . . . . . . . . . . . . . . . . . . . . . . 48
Condenser Freeze Prevention . . . . . . . . . . . . . . . . . . . 48
Evaporator Freeze Protection . . . . . . . . . . . . . . . . . . . 48
Tower Fan Relay Low and High . . . . . . . . . . . . . . . . . . 48
Auto. Restart After Power Failure. . . . . . . . . . . . . . . . 49
Fast Power Source Transfers . . . . . . . . . . . . . . . . . . . . 49
Water/Brine Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
• RESET TYPE 1: 4 TO 20 mA TEMPERATURE RESET
• RESET TYPE 2: REMOTE TEMPERATURE RESET
• RESET TYPE 3
Surge Prevention. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
• HGBP OPTION =1
• HGBP OPTION =2
Surge Prevention Algorithm . . . . . . . . . . . . . . . . . . . . . 50
Surge Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Head Pressure Reference Output. . . . . . . . . . . . . . . . 51
VFD Start-Up Speed Control. . . . . . . . . . . . . . . . . . . . . 51
Lead/Lag Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
• 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
• 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 . . . . . . . . . . . . . . . 55
• ATTACHING TO OTHER CCN MODULES
Service Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
• 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57-59
Local Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Shutdown Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Automatic Soft Stop Amps Threshold . . . . . . . . . . . 58
Chilled Water Recycle Mode . . . . . . . . . . . . . . . . . . . . . 59
Safety Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
BEFORE INITIAL START-UP . . . . . . . . . . . . . . . . . . 59-77
Job Data Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Equipment Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Using the Optional Storage Tank
and Pumpout System . . . . . . . . . . . . . . . . . . . . . . . . . 59
Remove Shipping Packaging . . . . . . . . . . . . . . . . . . . . 59
Open Oil Circuit Valves . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Oil Charge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Tighten All Gasketed Joints and
Guide Vane Shaft Packing . . . . . . . . . . . . . . . . . . . . . 60
Check Chiller Tightness . . . . . . . . . . . . . . . . . . . . . . . . . 60
Refrigerant Tracer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Leak Test Chiller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Page
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . 1
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
ABBREVIATIONS AND EXPLANATIONS . . . . . . . . 4,5
CHILLER FAMILIARIZATION . . . . . . . . . . . . . . . . . . . . 5-7
Chiller Information Nameplate . . . . . . . . . . . . . . . . . . . . 5
System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Motor-Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Control Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Variable Frequency Drive . . . . . . . . . . . . . . . . . . . . . . . . . 6
Storage Vessel (Optional) . . . . . . . . . . . . . . . . . . . . . . . . 6
REFRIGERATION CYCLE . . . . . . . . . . . . . . . . . . . . . . . . . 8
MOTOR AND LUBRICATING OIL
COOLING CYCLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
VFD COOLING CYCLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
LUBRICATION CYCLE . . . . . . . . . . . . . . . . . . . . . . . . . 9,10
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Details. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Oil Reclaim System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
• PRIMARY OIL RECOVERY MODE
• SECONDARY OIL RECOVERY METHOD
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
STARTING EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . 10-14
Unit-Mounted VFD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
CONTROLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-57
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
• ANALOG SIGNAL
• DISCRETE SIGNAL
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
PIC III System Components . . . . . . . . . . . . . . . . . . . . . 15
• 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 . . . . . . . . . . . . . . . . . . . . . . . . 40
• CAPACITY CONTROL
• ECW CONTROL OPTION
• CONTROL POINT DEADBAND
• PROPORTIONAL BANDS
• DIFFUSER CONTROL
• DEMAND LIMITING
• CHILLER TIMERS AND STARTS COUNTER
• OCCUPANCY SCHEDULE
Safety Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Shunt Trip (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Default Screen Freeze . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Ramp Loading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Rampdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Capacity Override . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
2
CONTENTS (cont)
Page
REVIEW MAINTENANCE
SAFETY DEVICES AND PROCEDURES
CHECK OPERATOR KNOWLEDGE
REVIEW THE START-UP, OPERATION, AND
MAINTENANCE MANUAL
OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . 78-80
Operator Duties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Prepare the Chiller for Start-Up . . . . . . . . . . . . . . . . . 78
To Start the Chiller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Check the Running System . . . . . . . . . . . . . . . . . . . . . 78
To Stop the Chiller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
After Limited Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . 79
Preparation for Extended Shutdown . . . . . . . . . . . . 79
After Extended Shutdown . . . . . . . . . . . . . . . . . . . . . . . 79
Cold Weather Operation. . . . . . . . . . . . . . . . . . . . . . . . . 79
Manual Guide Vane Operation. . . . . . . . . . . . . . . . . . . 79
Refrigeration Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
PUMPOUT AND REFRIGERANT TRANSFER
PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81-84
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Operating the Optional Pumpout Unit . . . . . . . . . . . 81
• POSITIVE PRESSURE CHILLERS WITH
STORAGE TANKS
• CHILLERS WITH ISOLATION VALVES
• DISTILLING THE REFRIGERANT
GENERAL MAINTENANCE . . . . . . . . . . . . . . . . . . . .84,85
Refrigerant Properties . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Adding Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Removing Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Adjusting the Refrigerant Charge . . . . . . . . . . . . . . . 84
Refrigerant Leak Testing . . . . . . . . . . . . . . . . . . . . . . . . 84
Leak Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Test After Service, Repair, or Major Leak . . . . . . . . 84
• TESTING WITH REFRIGERANT TRACER
• TESTING WITHOUT REFRIGERANT TRACER
• TO PRESSURIZE WITH DRY NITROGEN
Repair the Leak, Retest, and Apply
Standing Vacuum Test . . . . . . . . . . . . . . . . . . . . . . . . 85
Checking Guide Vane Linkage . . . . . . . . . . . . . . . . . . 85
Trim Refrigerant Charge. . . . . . . . . . . . . . . . . . . . . . . . . 85
WEEKLY MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . 85
Check the Lubrication System . . . . . . . . . . . . . . . . . . 85
SCHEDULED MAINTENANCE . . . . . . . . . . . . . . . . 86-88
Service Ontime. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Inspect the Control Panel . . . . . . . . . . . . . . . . . . . . . . . 86
Check Safety and Operating Controls
Monthly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Changing Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Oil Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Oil Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
• TO CHANGE THE OIL
Refrigerant Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Oil Reclaim Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
VFD Refrigerant Strainer . . . . . . . . . . . . . . . . . . . . . . . . 87
Inspect Refrigerant Float System . . . . . . . . . . . . . . . 87
Inspect Relief Valves and Piping . . . . . . . . . . . . . . . . 87
Compressor Bearing and Gear
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Inspect the Heat Exchanger Tubes
and Flow Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
• COOLER AND OPTIONAL FLOW DEVICES
• CONDENSER AND OPTIONAL FLOW DEVICES
Water Leaks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Water Treatment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Inspect the VFD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Recalibrate Pressure Transducers . . . . . . . . . . . . . . 88
Page
Standing Vacuum Test . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Chiller Dehydration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Inspect Water Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Check Optional Pumpout Compressor
Water Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Check Relief Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Identify the VFD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
• IDENTIFYING THE DRIVE BY PART NUMBER
Input Power Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Checking the Installation . . . . . . . . . . . . . . . . . . . . . . . . 66
Inspect Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Ground Fault Troubleshooting . . . . . . . . . . . . . . . . . . 67
Carrier Comfort Network® Interface . . . . . . . . . . . . . 67
Power Up the Controls and
Check the Oil Heater . . . . . . . . . . . . . . . . . . . . . . . . . . 67
• SOFTWARE VERSION
Software Configuration . . . . . . . . . . . . . . . . . . . . . . . . . 68
Input the Design Set Points . . . . . . . . . . . . . . . . . . . . . 68
Input the Local Occupied Schedule
(OCCPC01S) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Input Service Configurations. . . . . . . . . . . . . . . . . . . . 68
• 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
• HAND CALCULATE VARIABLE PRIMARY FLOW
(VPF) SURGE PREVENTION CONFIGURATIONS
• CONFIGURE DIFFUSER CONTROL IF
NECESSARY
• MODIFY EQUIPMENT CONFIGURATION
IF NECESSARY
Perform a Control Test . . . . . . . . . . . . . . . . . . . . . . . . . . 72
• PRESSURE TRANSDUCER CALIBRATION
Check Optional Pumpout System
Controls and Compressor. . . . . . . . . . . . . . . . . . . . . 74
High Altitude Locations . . . . . . . . . . . . . . . . . . . . . . . . . 74
Charge Refrigerant Into Chiller . . . . . . . . . . . . . . . . . . 74
• CHILLER EQUALIZATION WITHOUT A
PUMPOUT UNIT
• CHILLER EQUALIZATION WITH
PUMPOUT UNIT
• TRIMMING REFRIGERANT CHARGE
INITIAL START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77,78
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Check Motor Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Check Oil Pressure and Compressor Stop . . . . . . 78
To Prevent Accidental Start-Up. . . . . . . . . . . . . . . . . . 78
Check Chiller Operating Condition . . . . . . . . . . . . . . 78
Instruct the Customer Operator . . . . . . . . . . . . . . . . . 78
• COOLER-CONDENSER
• OPTIONAL PUMPOUT STORAGE TANK AND
PUMPOUT SYSTEM
• MOTOR COMPRESSOR ASSEMBLY
• MOTOR COMPRESSOR LUBRICATION SYSTEM
• CONTROL SYSTEM
• AUXILIARY EQUIPMENT
• DESCRIBE CHILLER CYCLES
•
•
•
•
3
CONTENTS (cont)
CAUTION
Page
Optional Pumpout System Maintenance . . . . . . . . . 88
• OPTIONAL PUMPOUT COMPRESSOR OIL
CHARGE
• OPTIONAL PUMPOUT SAFETY CONTROL
SETTINGS
Ordering Replacement Chiller Parts . . . . . . . . . . . . . 88
TROUBLESHOOTING GUIDE . . . . . . . . . . . . . . . . 89-154
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Checking Display Messages. . . . . . . . . . . . . . . . . . . . . 89
Checking Temperature Sensors . . . . . . . . . . . . . . . . . 89
• RESISTANCE CHECK
• VOLTAGE DROP
• CHECK SENSOR ACCURACY
• DUAL TEMPERATURE SENSORS
Checking Pressure Transducers. . . . . . . . . . . . . . . . . 89
• COOLER CONDENSER PRESSURE TRANSDUCER
AND OPTIONAL WATERSIDE FLOW DEVICE
CALIBRATION
• TRANSDUCER REPLACEMENT
Control Algorithms Checkout Procedure . . . . . . . . 90
Control Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Control Modules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
• RED LED (Labeled as STAT)
• GREEN LED (Labeled as COM)
Notes on Module Operation . . . . . . . . . . . . . . . . . . . . 107
Chiller Control Module (CCM) . . . . . . . . . . . . . . . . . . 107
• INPUTS
• OUTPUTS
Replacing Defective Processor Modules . . . . . . . 108
• INSTALLATION
Gateway Status LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . 109
• DRIVE STATUS INDICATOR
• MS STATUS INDICATOR
• NET A STATUS INDICATOR
• NET B STATUS INDICATOR
Physical Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
APPENDIX A — LIQUIFLO™ 2 ICVC
PARAMETER INDEX. . . . . . . . . . . . . . . . . . . . . . 155-164
APPENDIX B — LEAD/LAG WIRING . . . . . . . . 165,166
APPENDIX C — MAINTENANCE SUMMARY
AND LOG SHEETS . . . . . . . . . . . . . . . . . . . . . . . 167-170
APPENDIX D — OPTIONAL BACNET
COMMUNICATIONS WIRING. . . . . . . . . . . . . . 171-177
INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
INITIAL START-UP CHECKLIST FOR
19XRV HERMETIC CENTRIFUGAL
LIQUID CHILLER . . . . . . . . . . . . . . . . . . . .CL-1 to CL-12
This unit uses a microprocessor control system. Do not
short or jumper between terminations on circuit boards or
modules; control or board failure may result.
Be aware of electrostatic discharge (static electricity) when
handling or making contact with circuit boards or module
connections. Always touch a chassis (grounded) part to
dissipate body electrostatic charge before working inside
the VFD enclosure.
Use extreme care when handling tools near boards and
when connecting or disconnecting terminal plugs. Circuit
boards can easily be damaged. Always hold boards by the
edges and avoid touching components and connections.
This equipment uses, and can radiate, radio frequency
energy. If not installed and used in accordance with the
instruction manual, it may cause interference to radio
communications. It has been tested and found to comply
with the limits for a Class A computing device pursuant to
Subpart J of Part 15 of FCC Rules, which are designed to
provide reasonable protection against such interference
when operated in a commercial environment. Operation of
this equipment in a residential area is likely to cause
interference, in which case the user, at his own expense,
will be required to take whatever measures may be
required to correct the interference.
Always store and transport replacement or defective boards
in anti-static shipping bag.
ABBREVIATIONS AND EXPLANATIONS
Frequently used abbreviations in this manual include:
CCM
CCN
CCW
CW
ECDW
ECW
EMS
HGBP
I/O
ICVC
LCD
LCDW
LCW
LED
OLTA
PIC III
RLA
SI
TXV
UPC
VFD
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
Chiller Control Module
Carrier Comfort Network®
Counterclockwise
Clockwise
Entering Condenser Water
Entering Chilled Water
Energy Management System
Hot Gas Bypass
Input/Output
International Chiller Visual Controller
Liquid Crystal Display
Leaving Condenser Water
Leaving Chilled Water
Light-Emitting Diode
Overload Trip Amps
Product Integrated Controls III
Rated Load Amps
International System of Units
Thermostatic Expansion Valve
Universal Protocol Card
Variable Frequency Drive
Words printed in all capital letters or in italics may be
viewed on the International Chiller Visual Controller (ICVC)
(e.g., LOCAL, CCN, ALARM, etc.).
Words printed in both all capital letters and italics can also
be viewed on the ICVC and are parameters (e.g., CONTROL
MODE, COMPRESSOR START RELAY, ICE BUILD
OPTION, etc.) with associated values (e.g., modes, temperatures, percentages, pressures, on, off, etc.).
Words printed in all capital letters and in a box represent
softkeys on the ICVC control panel (e.g., ENTER , EXIT ,
INCREASE , QUIT , etc.).
INTRODUCTION
Prior to initial start-up of the 19XRV unit, those involved in
the start-up, operation, and maintenance should be thoroughly
familiar with these instructions and other necessary job data.
This book is outlined to familiarize those involved in the
start-up, operation, and maintenance of the unit with the control system before performing start-up procedures. Procedures
in this manual are arranged in the sequence required for proper
chiller start-up and operation.
4
Factory-installed additional components are referred to as
options in this manual; factory-supplied but field-installed
additional components are referred to as accessories.
The chiller software part number of the 19XRV unit is
located on the back of the ICVC.
19XRV
52
51
CHILLER FAMILIARIZATION
(Fig. 1 and 2)
Chiller Information Nameplate — The information
nameplate is located on the right side of the chiller control
panel.
473
DG
H
64
–
Description
19XRV — Ultra High Efficiency Variable Speed
Hermetic Centrifugal Liquid Chiller
Special Order Indicator
– — Standard
S — Special Order
Cooler Size
20-22 (Frame 2 XRV)
30-32 (Frame 3 XRV)
35-37 (Frame 3 XRV)
40-42 (Frame 4 XRV)
45-47 (Frame 4 XRV)
50-54 (Frame 5 XRV)
5A-5C (Frame 5 XRV)*
55-59 (Frame 5 XRV)
5F-5H (Frame 5 XRV)*
5K-5R (Frame 5 XRV)
5T-5Z (Frame 5 XRV)
60-64 (Frame 6 XRV)
6K-6R (Frame 6 XRV)
65-69 (Frame 6 XRV)
6T-6Z (Frame 6 XRV)
70-74 (Frame 7 XRV)
7K-7R (Frame 7 XRV)
75-79 (Frame 7 XRV)
7T-7Z (Frame 7 XRV)
80-84 (Frame 8 XRV)
8K-8R (Frame 8 XRV)
85-89 (Frame 8 XRV)
8T-8Z (Frame 8 XRV)
Motor Voltage Code
Code Volts-Phase-Hertz
60 — 200-3-60
61 — 230-3-60
62 — 380-3-60
63 — 416-3-60
64 — 460-3-60
65 — 575-3-60
66 — 2400-3-60
67 — 3300-3-60
68 — 4160-3-60
69 — 6900-3-60
50 — 230-3-50
52 — 400-3-50
53 — 3000-3-50
54 — 3300-3-50
55 — 6300-3-50
5A — 10000-3-50
5B — 11000-3-50
6A — 11000-3-60
6B — 10000-3-60
Motor Efficiency Code
H — High Efficiency
S — Standard Efficiency
Condenser Size
20-22 (Frame 2 XRV)
30-32 (Frame 3 XRV)
35-37 (Frame 3 XRV)
40-42 (Frame 4 XRV)
45-47 (Frame 4 XRV)
50-54 (Frame 5 XRV)
55-59 (Frame 5 XRV)
60-64 (Frame 6 XRV)
65-69 (Frame 6 XRV)
70-74 (Frame 7 XRV)
75-79 (Frame 7 XRV)
80-84 (Frame 8 XRV)
85-89 (Frame 8 XRV)
Motor Code
Compressor Code
(First Digit Indicates Compressor Frame Size)**
MODEL NUMBER NOMENCLATURE
a19-1937
27 10 Q
19843
Week of Year
Unique Number
Year of Manufacture
Place of Manufacture
a19-1969
SERIAL NUMBER BREAKDOWN
* Refer to 19XRV Computer Selection Program for details on these sizes.
† Frame sizes with K-R and T-Z are with 1 in. OD evaporator tubing.
** For Frame 4 compressors, second digit will be a letter (example 4G3) on units equipped with
split ring diffuser.
††Refer to the 19XRV Computer Selection Program for motor code details.
Fig. 1 — 19XRV Identification
5
• shows the chiller operating condition and the alarm
shutdown conditions
• records the total chiller operating hours
• sequences chiller start, stop, and recycle under microprocessor control
• displays the status of the VFD
• provides access to other CCN (Carrier Comfort Network®)
devices and energy management systems
• languages pre-installed at factory include: English, Chinese,
Japanese, and Korean.
• International Language Translator (ILT) is available for
conversion of extended ASCII characters.
System Components — The components include the
cooler and condenser heat exchangers in separate vessels,
compressor-motor, lubrication package, control panel, and
VFD. All connections from pressure vessels have external
threads to enable each component to be pressure tested with a
threaded pipe cap during factory assembly.
Cooler — This vessel (also known as the evaporator) is
located underneath the compressor. The cooler is maintained at
lower temperature/pressure so evaporating refrigerant can
remove heat from water flowing through its internal tubes.
Condenser — The condenser operates at a higher
temperature/pressure than the cooler and has water flowing
through its internal tubes in order to remove heat from the
refrigerant.
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.
Storage Vessel (Optional) — There are 2 sizes of
storage vessels available. The vessels have double relief valves,
a magnetically-coupled dial-type refrigerant level gage, a
one-inch FPT drain valve, and a 1/2-in. male flare vapor connection for the pumpout unit.
NOTE: If a storage vessel is not used at the jobsite, factoryinstalled isolation valves on the chiller may be used to isolate
the chiller charge in either the cooler or condenser. An optional
pumpout system is used to transfer refrigerant from vessel to
vessel.
Control Panel — The control panel is the user interface
for controlling the chiller. It regulates the chiller’s capacity as
required to maintain proper leaving chilled water temperature.
The control panel:
• registers cooler, condenser, and lubricating system pressures
6
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)
2
1
2
3
4
5
6
7
8
9
3
6
4
19
5
7
—
—
—
—
—
—
—
—
—
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
Fig. 2 — Typical 19XRV Components
7
REFRIGERATION CYCLE
MOTOR AND LUBRICATING OIL
COOLING CYCLE
The compressor continuously draws refrigerant vapor from
the cooler at a rate set by the amount of guide vane opening or
compressor speed. As the compressor suction reduces the
pressure in the cooler, the remaining refrigerant boils at a fairly
low temperature (typically 38 to 42 F [3 to 6 C]). The energy
required for boiling is obtained from the water flowing through
the cooler tubes. With heat energy removed, the water becomes
cold enough to use in an air conditioning circuit or for process
liquid cooling.
After taking heat from the water, the refrigerant vapor is
compressed. Compression adds still more heat energy, and the
refrigerant is quite warm (typically 98 to 102 F [37 to 40 C])
when it is discharged from the compressor into the condenser.
Relatively cool (typically 65 to 90 F [18 to 32 C]) water
flowing into the condenser tubes removes heat from the refrigerant and the vapor condenses to liquid.
The liquid refrigerant passes through orifices into the
FLASC (Flash Subcooler) chamber (Fig. 3). Since the FLASC
chamber is at a lower pressure, part of the liquid refrigerant
flashes to vapor, thereby cooling the remaining liquid. The
FLASC vapor is recondensed on the tubes which are cooled by
entering condenser water. The liquid drains into a float chamber between the FLASC chamber and cooler. Here, a float
valve forms a liquid seal to keep FLASC chamber vapor from
entering the cooler. When liquid refrigerant passes through the
valve, some of it flashes to vapor in the reduced pressure on the
cooler side. In flashing, it removes heat from the remaining
liquid. The refrigerant is now at a temperature and pressure at
which the cycle began.
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
CONDENSER ISOLATION VALVE (OPTION)
ORIFICE FITTING
MOTOR
TRANSMISSION
DIFFUSER
GUIDE VANE
MOTOR
STATOR
MOISTURE/
FLOW
INDICATOR
ROTOR
ORIFICE
FITTING
GUIDE
VANES
OIL
PUMP
OIL
COOLER
IMPELLER
COMPRESSOR
OIL
FILTER
THERMOSTATIC
EXPANSION
VALVE
(TXV)
REFRIGERANT
VAPOR
REFRIGERANT
LIQUID/VAPOR
OIL
OPTIONAL
UNIT
MOUNTED
VFD
(VARIABLE
FREQUENCY
DRIVE)
HEAT
EXCHANGER
VFD COOLING
ORIFICE
REFRIGERANT
LIQUID
CHILLED
WATER
DISTRIBUTION
PIPE
COOLER ISOLATION
VALVE (OPTION)
a19-1851
Fig. 3 — Refrigerant Motor Cooling and Oil Cooling Cycles
8
can also be energized for testing purposes during a Control
Test.
Ramp loading can slow the rate of guide vane opening to
minimize oil foaming at start-up. If the guide vanes open
quickly, the sudden drop in suction pressure can cause any
refrigerant in the oil to flash. The resulting oil foam cannot be
pumped efficiently; therefore, oil pressure falls off and lubrication is poor. If oil pressure falls below 15 psid (103 kPad)
differential, the PIC III will shut down the compressor.
If the controls are subject to a power failure that lasts more
than 3 hours, the oil pump will be energized periodically when
the power is restored. This helps to eliminate refrigerant that
has migrated to the oil sump during the power failure. The
controls energize the pump for 30 seconds every 30 minutes
until the chiller is started.
VFD COOLING CYCLE
The unit-mounted variable frequency drive (VFD) is cooled
in a manner similar to the motor and lubricating oil cooling
cycle (Fig. 3).
If equipped with a unit-mounted VFD, the refrigerant line
that feeds the motor cooling and oil cooler also feeds the heat
exchanger on the unit-mounted VFD. Refrigerant is metered
through an orifice. The refrigerant leaving the heat exchanger
returns to the cooler.
LUBRICATION CYCLE
Summary — The oil pump, oil filter, and oil cooler make
up a package located partially in the transmission casing of the
compressor-motor assembly. The oil is pumped into a filter
assembly to remove foreign particles and is then forced into an
oil cooler heat exchanger where the oil is cooled to proper
operational temperatures. After the oil cooler, part of the flow
is directed to the gears and the high speed shaft bearings; the
remaining flow is directed to the motor shaft bearings. Oil
drains into the transmission oil sump to complete the cycle
(Fig. 4).
Oil Reclaim System — The oil reclaim system returns
oil lost from the compressor housing back to the oil reservoir
by recovering the oil from 2 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.
Details — Oil is charged into the lubrication system through
a hand valve. Two sight glasses in the oil reservoir permit oil
level observation. Normal oil level is between the middle of the
upper sight glass and the top of the lower sight glass when the
compressor is shut down. The oil level should be visible in at
least one of the 2 sight glasses during operation. Oil sump
temperature is displayed on the ICVC (International Chiller
Visual Controller) default screen. During compressor operation, the oil sump temperature ranges between 125 and 150 F
(52 and 66 C).
The oil pump suction is fed from the oil 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 84 to 88 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 46). 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
Bearings — The 19XRV compressor assemblies include
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.
9
REAR MOTOR
BEARING
FWD MOTOR
BEARING
OIL SUPPLY TO
FORWARD HIGH
SPEED BEARING
LABYRINTH
GAS LINE
MOTOR
COOLING LINE
OIL
FILTER
FLOW
SIGHT
GLASS
ISOLATION
VALVE
TXV BULB
PRESSURE
TRANSDUCER
OIL
PUMP
ISOLATION
VALVES
OIL
COOLER
OIL PUMP
MOTOR
FILTER
STRAINER
OIL
HEATER
EDUCTOR FILTER
SIGHT
GLASS
ISOLATION
VALVE
OIL SKIMMER
LINE
a19-1965
Fig. 4 — Lubrication System
Circuit breaker CB2 supplies 115-v power to the oil pump
control panel, oil heater, and portions of the VFD controls.
STARTING EQUIPMENT
All 19XRV units are equipped with a VFD to operate the
centrifugal hermetic compressor motor. A power panel controls
the oil pump, and various auxiliary equipment. The VFD and
power panel are the main field wiring interfaces for the installing contractor. The VFD is mounted directly on the chiller.
NOTE: This publication provides start-up and service information for the LiquiFlo™ 2.0 (LF2) VFDs. For information on
Std Tier VFDs, refer to associated Start-Up and Service
Instructions for the Rockwell PowerFlex 755 VFD or the
Eaton LCX 9000 VFD.
Three separate circuit breakers are inside the VFD. Circuit
breaker CB1 is the VFD circuit breaker. The disconnect switch
on the VFD front cover is connected to this breaker. Circuit
breaker CB1 supplies power to the VFD.
WARNING
Do not touch the power wiring or motor terminals while
voltage is present, or serious injury will result.
Unit-Mounted VFD — The 19XRV chiller is equipped
with a variable frequency drive motor controller mounted on
the condenser. See Fig. 5-7. This VFD is used with low voltage
motors between 380 and 460 vac. It reduces the starting current
inrush by controlling the voltage and frequency to the compressor motor. Once the motor has accelerated to minimum speed,
the PIC III modulates the compressor speed and guide vane
position to control chilled water temperature. The VFD is
further explained in the Controls section and Troubleshooting
Guide section, pages 15 and 89.
Operational parameters and fault codes are displayed relative to the drive. Refer to specific drive literature along with
troubleshooting sections. The display is also the interface for
entering specific chiller operational parameters. These parameters have been preprogrammed at the factory. An adhesive
backed label on the inside of the drive has been provided for
verification of the specific job parameters. See Initial Start-Up
Checklist section for details.
WARNING
The main circuit breaker (CB1) on the front of the VFD
disconnects the main VFD current only. Power is still energized for the other circuits. Two more circuit breakers
inside the VFD must be turned off to disconnect power to
the oil pump, PIC III controls, and oil heater.
10
OPTIONAL
METER
PACKAGE
a19-1718
442A AND 608A VFDs
a19-1725
900A AND 1200A VFDs
Fig. 5 — LF2 Variable Frequency Drive (VFD) External
11
1, 2
3
4
6
5
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Fuse Block, 30A, 600V, Class CC
Fuse, Class CC, 600V, 20A (3)
AC Contactor (3) — Pre-Charge
Input Conductor Assembly
Pre-Charge Resistor Assembly
Power Module Assembly
Power Module Namplate
Terminal Block, 10-Position (2)
Line Sync Board Cover
Line Sync PC Board Assembly
Fuse, Class CC, 600V, 1A (3)
Capacitor Bank Assembly
Fan, 115V (3)
Fuse, Class CC, 600V, 5A (1)
Fuse, Class CC, 600V, 20A (1)
Circuit Breaker, Control Power,
600V, 15A
17 — Transformer, 3k VA
18 — Circuit Breaker, 600V
19 — Lug, Ground, 2-600 MCM
19
18
17
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
16
13
14, 15, 1
11, 1
12
7 a19-1726
8
9, 10
442A AND 608A VFDs
3
2
1
4
5
6
7, 8
9
1
2
3
4
5
—
—
—
—
—
6 —
7 —
8 —
9 —
10 —
11 —
12 —
13 —
14 —
15 —
16 —
17 —
17
16
15, 7
14
12, 13, 7
11
10
900A AND 1200A VFDs
Fig. 6 — LF2 Variable Frequency Drive (VFD) Internal
12
Circuit Breaker, 600V
Lug, Ground, 2-600 MCM
Input Conductor Assembly
Capacitor Bank Assembly
Pre-Charge Resistor
Assembly
AC Contactor (3) —
Pre-Charge
Fuse Block, 30A, 600V,
Class CC
Fuse, Class CC, 600V,
20A (3)
Power Module Assembly
Power Module Namplate
Terminal Block,
10-Position (2)
Fuse, Class CC, 600V,
20A (1)
Fuse, Class CC, 600V,
5A (1)
Transformer, 3k VA
Fuse, Class CC, 600V,
1A (3)
Fan, 115V (3)
Circuit Breaker, Control
Power, 600V, 15A
a19-1727
1
2
5
3
4
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
—
—
—
—
—
—
—
—
—
Wire Harness Assembly, Gate Driver
Current Feedback Device, 1000 A
Wire Harness Assembly, Power Supply, Logic
80 W Power Supply Assembly
Terminal Block, 2-Position
Cable Assembly, 40-Pin
Cable Assembly, 30-Pin
Wire Harness Assembly, Power Supply, Upper Gate
Inverter Power Interface Assembly
10
11
12
13
14
15
16
17
18
—
—
—
—
—
—
—
—
—
Wire Harness Assembly, Power Supply, Lower Gate
Insulation Sheet
Rectifier Power Interface Assembly
Wire Harness Assembly, Current Feedback Device
Wire Harness Assembly, DC Bus Bleeder Resistors
Wire Harness Assembly, Line Sync
Inverter Control Assembly*
Standard I/O Option, 24 V Assembly
Rectifier Control Assembly*
19
20
21
22
23
24
25
26
—
—
—
—
—
—
—
—
AC Line I/O Assembly
Connector, Terminal Block, 32-Pin
NTC Assembly
Internal Fan
DPI Communications Interface Assembly
VFD Gateway
Wire Harness Assembly, Control Sync
Cable Assembly, 20-pin
*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.
442A AND 608A VFDs
Fig. 7 — LF2 Power Module Components
13
2
1
3
4
5
UNDER
TOP
COVER
18
17
16
2X
3
15
14
6X
13
a19-1728
6
Door Open
12
11
10
9
8
2X
7
a19-1729
Door Closed
1 — Wire Harness Assembly, Internal Fan
2 — Wire Harness Assembly, DC Power
3 — Wire Harness Assembly, Current Feedback
Device, Rectifier Side
4 — Wire Harness Assembly, Current Feedback
Device, Inverter Side
5 — Wire Harness Assembly, DC Bus Resistors
6 — Internal Fan, 24 VDC
7 — Cable, Mini DIN, 8 Pos., Male/Male,
1 Meter Long
8 — Cable Assembly, 40-Pin
9 — RS-485 Communications Assembly
10 — Cable Assembly, 20-Pin
11 — Combined Control PCB Assembly
12
13
14
15
16
17
18
—
—
—
—
—
—
—
Combined I/O PCB Assembly
Wire Harness Assembly, RTD, Inverter Side
Current Feedback Device, 2000A
Wire Harness Assembly, RTD, Rectifier Side
Wire Harness Assembly, Gate Driver
Combined Power PCB Assembly, 1215 Amps
Internal Fan, 24 VDC
900A AND 1200A VFDs
Fig. 7 — LF2 Power Module Components (cont)
14
fans to turn them on when required. It continually checks all
safeties to prevent any unsafe operating condition. It also regulates the oil heater while the compressor is off and regulates the
hot gas bypass valve, if installed. The PIC III controls provide
critical protection for the compressor motor and controls the
VFD. The PIC III can interface with the Carrier Comfort
Network® (CCN) system if desired. It can communicate with
other PIC I, PIC II, or PIC III equipped chillers and other CCN
devices.
The PIC III consists of 3 modules housed inside 3 major
components. The component names and corresponding control
voltages are listed below (also see Table 1):
• control panel
— all extra low-voltage wiring (24 v or less)
• power panel
— 115 vac control voltage (per job requirement)
— 115 vac power for oil heater and actuators
— up to 460 vac for oil pump power
• VFD cabinet
— chiller power wiring (per job requirement)
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.)
General — The 19XRV hermetic centrifugal liquid chiller
contains a microprocessor-based control panel that monitors
and controls all operations of the chiller. See Fig. 8 and 9. The
microprocessor control system matches the cooling capacity of
the chiller to the cooling load while providing state-of-the-art
chiller protection. The system controls the cooling load within
the set point plus the deadband by sensing the leaving chilled
water or brine temperature and regulating the inlet guide vane
via a mechanically linked actuator motor. The guide vane is a
variable flow pre-whirl assembly that controls the refrigeration
effect in the cooler by regulating the amount of refrigerant
vapor flow into the compressor. An increase in guide vane
opening increases capacity. A decrease in guide vane opening
decreases capacity. The microprocessor-based controls protect
the chiller by monitoring the digital and analog inputs and
executing capacity overrides or safety shutdowns, if required.
Table 1 — Major PIC III Components and
Panel Locations*
PIC III COMPONENT
International Chiller Visual Controller
(ICVC) and Display
Chiller Control Module (CCM)
Control Transformer Circuit Breakers
CB1, CB2
Oil Heater Contactor (1C)
Oil Pump Contactor (2C)
Hot Gas Bypass Relay (3C) (Optional)
Control Transformers (T1, T2, T3)
Temperature Sensors
Pressure Transducers
PIC III System Components — The chiller control
system is called the PIC III (Product Integrated Control III).
See Table 1. The PIC III controls the operation of the chiller by
monitoring all operating conditions. The PIC III can diagnose a
problem and let the operator know what the problem is and
what to check. It promptly positions the guide vanes to
maintain leaving chilled water temperature. It can interface
with auxiliary equipment such as pumps and cooling tower
COOLER CHARGING
VALVE (HIDDEN)
CONTROL
PANEL
Control Panel
Control Panel
Control Panel
Power Panel
Power Panel
Power Panel
Power Panel
See Fig. 8.
See Fig. 8.
*See Fig. 5-11.
GUIDE VANE
ACTUATOR
SPLIT RING
DIFFUSER
ACTUATOR
(OPTIONAL)
OIL SUMP
PRESSURE
TRANSDUCER
POWER
PANEL
OIL SUMP
TEMPERATURE
SENSOR
OIL PUMP
DISCHARGE
PRESSURE
COOLER
PRESSURE
TRANSDUCER
WATER
SENSOR
CABLES
WATER
SENSOR
CABLES
CONDENSER
PRESSURE
TRANSDUCER
CONDENSER
3-WAY SHUTOFF
VALVE
PANEL LOCATION
HGBP
ACTUATOR
(OPTIONAL)
CONDENSER CHARGING
VALVE (HIDDEN)
EVAPORATOR SATURATION
TEMPERATURE SENSOR
(ON BOTTOM OF COOLER)
VFD ENCLOSURE
Fig. 8 — Chiller Controls and Sensor Locations
15
VFD COOLING
SOLENOID
a19-1730
MOTOR TEMPERATURE
SENSOR CABLE
COMPRESSOR OIL DISCHARGE
PRESSURE CABLE
OIL RECLAIM
SIGHT GLASS
BEARING TEMPERATURE
SENSOR CABLE
COMPRESSOR OIL SUMP
PRESSURE CABLE
DIFFUSER PRESSURE
AND DIFFUSER ACTUATOR
CABLE (FRAME 4 & 5
COMPRESSOR ONLY)
COMPRESSOR OIL SUMP
TEMPERATURE CABLE
CABLE FROM
CONTROL PANEL
GUIDE VALVE
ACTUATOR CABLE
COMPRESSOR DISCHARGE
TEMPERATURE SENSOR
CABLE
OIL COOLER THERMOSTATIC
EXPANSION VALVE (TXV)
HIGH PRESSURE
SWITCH LOCATION
OIL COOLER THERMOSTATIC
EXPANSION VALVE (TXV) BULB
OIL HEATER TERMINAL
BOX
a19-1606
Fig. 9 — 19XRV Compressor Controls and Sensor Locations
INTERNATIONAL CHILLER VISUAL CONTROLLER
(ICVC) — The ICVC is the “brain” of the PIC III system. This
module contains all the operating software needed to control
the chiller. The ICVC is mounted to the control panel (Fig. 10)
and is the input center for all local chiller set points, schedules,
configurable functions, and options. The ICVC has a stop
button, an alarm light, four buttons for logic inputs, and a
backlight display. The backlight will automatically turn off
after 15 minutes of non-use. The functions of the four buttons
or “softkeys” are menu driven and are shown on the display
directly above the softkeys.
The viewing angle of the ICVC can be adjusted for optimum viewing. Remove the 2 bolts connecting the control panel
to the brackets attached to the cooler. Place them in one of the
holes to pivot the control panel forward to backward to change
the viewing angle. To change the contrast of the display, access
the adjustment on the back of the ICVC. See Fig. 10.
The ICVC features 4 factory programmed languages:
• English (default)
• Chinese
• Japanese
• Korean
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.
Table 2 — Identification Features of the ICVC
CONTROLLER
ICVC
COLOR CEPL No.
OTHER
OF
SOFTWARE
MARKINGS
PLATE (hardware)
“PIC III”
Marking
CEPL
CESR
on back
Metallic
130445-02 131350-0X
of green
circuit
board
CHILLER CONTROL MODULE (CCM) — This module is
located in the control panel. The CCM provides the input and
outputs necessary to control the chiller. This module monitors
refrigerant pressure, entering and leaving water temperatures,
and outputs control for the guide vane actuator, oil heaters, and
oil pump. The CCM is the connection point for optional
demand limit, chilled water reset, remote temperature reset,
and motor kilowatt output.
OIL HEATER CONTACTOR (1C) — This contactor is located in the power panel (Fig. 11) and operates the heater at
115 v. It is controlled by the PIC III to maintain oil temperature
during chiller shutdown. Refer to the control panel wiring
schematic.
OIL PUMP CONTACTOR (2C) — This contactor is located
in the power panel. It operates all 380 to 480-v oil pumps.
The PIC III energizes the contactor to turn on the oil pump as
necessary.
HOT GAS BYPASS CONTACTOR RELAY (3C)
(Optional) — This relay, located in the power panel, controls
the opening of the hot gas bypass valve. The PIC III energizes
the relay during low load, high lift conditions.
16
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 INTERNAL VIEW
CONTROL
PANEL
SIDE VIEW
REMOVABLE
BOLT
HINGE
a19-1610
a19-1742
CHILLER IDENTIFICATION NAMEPLATE
Fig. 10 — Control Panel
T1-24 VAC POWER TRANSFORMER
FOR HOT GAS BYPASS RELAY,
OIL PUMP CONTACTOR, AND
OIL HEATER CONTACTOR
T2-24 VAC POWER TRANSFORMER
FOR ICVC AND CCM
T3
T2
T1
T3-20 VAC POWER TRANSFORMER
FOR DATAPORT/DATALINK (OPTIONAL)
3C HOT GAS BYPASS
RELAY (OPTIONAL)
51
1 3
50
12
13
11
OIL HEATER
CONTACTOR
21
22
12
13
OIL PUMP
CONTACTOR
23
21
22
2 4
17
5 6
11
43
23
C
B
A
OIL HEATER CONDUIT
CONTROL PANEL
POWER CONDUIT
Fig. 11 — Power Panel
17
OPTIONAL HOT GAS
BYPASS CONDUIT
a19-1611
The second type of temperature sensor is a thermistor,
which is installed either in the motor windings or at the thrust
bearing within the compressor. Both of these have redundant
sensors such that if one fails, the other can be connected external to the machine. See Table 3 for a list of standard instrumentation sensors.
The PIC III control determines refrigerant temperature in
the condenser and evaporator from pressure in those vessels,
read from the corresponding pressure transducers. See Fig. 13.
The pressure values are converted to the equivalent saturation
temperatures for R-134a refrigerant. When the chiller is running, if the computed value for EVAPORATOR REFRIG
TEMP is greater than, or within 0.6 F (0.33 C) of the LEAVING CHILLED WATER temperature, its value is displayed as
0.6 F (0.33 C) below LEAVING CHILLED WATER temperature. When the chiller is running, if the computed value for
CONDENSER REFRIG TEMP is less than, or within 1.2 F
(0.67 C) of the LEAVING COND WATER temperature, its
value is displayed as 1.2 F (0.67 C) above LEAVING COND
WATER temperature.
CONTROL TRANSFORMERS (T1, T2) — These transformers convert incoming control voltage to 24 vac power for the
3 power panel contactor relays, CCM, and ICVC.
OPTIONAL TRANSFORMER (T3) — This transformer provides 20 vac control power to DataPort™/DataLINK™
modules.
SENSORS — Two types of temperature sensors are used:
Figure 12 shows a typical temperature sensor for which
sensor wells are used, in systems having an ICVC controller.
For this type, the sensor cable cannot be separated from the
sensor itself, but the sensor can be readily removed from the
well without breaking into the fluid boundary.
SHRINK WRAP
STRAIN RELIEF
1/8” NPT
THERMOWELL
a19-957
REMOVABLE
TEMPERATURE
SENSOR
Fig. 13 — Control Sensors
(Pressure Transducers, Typical)
a23-1624
Fig. 12 — Temperature Sensor Used
with Thermal Well
Table 3 — Standard Instrumentation Sensors
TYPE
Temperature
Pressure
Angular Position
Pressure Switch
Temperature Switch
LOCATION MONITORED
REMARKS
Entering chilled water
Leaving chilled water
Entering condenser water
Leaving condenser water
Evaporator saturation
Compressor discharge
Oil sump
Compressor thrust bearing
Motor winding
Evaporator
Condenser
Oil sump
Oil sump discharge
Diffuser (Compressor internal)
Entering chilled water (Optional)
Leaving chilled water (Optional)
Entering condenser water (Optional)
Leaving condenser water (Optional)
Guide vane actuator
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
Split ring diffuser actuator (Optional)
High condenser (discharge) pressure
Oil pump motor winding temperature
18
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 136. 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).
A Refrigerant Saturation Temperature sensor (thermistor) is
located in the base of the evaporator, sensing refrigerant
temperature directly. Evaporator and condenser water side
differential pressure transducers are not standard and are not
required. The ICVC software uses the evaporator saturation
refrigerant temperature in place of differential pressure flow
detection to provide evaporator freeze protection.
Approach temperatures are shown in the HEAT_EX screen.
EVAPORATOR APPROACH is defined as LEAVING
CHILLED WATER temperature minus EVAP SATURATION
TEMP (from the temperature sensor). CONDENSER APPROACH is defined as CONDENSER REFRIG TEMP
(derived from condenser pressure) minus LEAVING CONDENSER WATER temperature. When chiller is running, the
displayed value for either approach will not be less than 0.2 F
(0.1 C). If either approach value exceeds the value configured
in the SETUP1 screen, the corresponding Approach Alert message will be entered into the Alert History table.
FLOW DETECTION — Flow detection for the evaporator
and condenser is a required condition for start-up and used in
the freeze protection safety. Flow and no flow conditions are
detected from a combination of several measurements. The
usage of waterside differential pressure measurements is not
standard or required.
Positive determination of flow on the evaporator side is
made if the following conditions are true: (1) the EVAP SATURATION TEMP reads higher than 1° F (0.6 C) above the
EVAP REFRIG TRIPPOINT, and (2) EVAP REFRIG TEMP
(determined from the Evaporator Pressure sensor) is greater
than the EVAP REFRIG TRIPPOINT. (If the unit is in Pumpdown or Lockout mode, conditions (1) and (2) are not required
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
ICVC Operation and Menus (Fig. 14-20)
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 56.
NOTE: The date format on the default screen is MM-DD-YY
for English units and DD-MM-YY for SI metric units.
• Local Operation — In LOCAL mode, the PIC III accepts
commands from the ICVC only and uses the local time
occupancy schedule to determine chiller start and stop
times. The PIC III can be placed in the local operating mode
by pressing the LOCAL softkey. When RUN STATUS is
READY, the chiller will attempt to start up.
• CCN Operation — In CCN mode, the PIC III accepts input
from any CCN interface or module (with the proper authority) as well as from the local ICVC. The PIC III uses the
CCN time occupancy schedule to determine start and stop
times. The PIC III can be placed in the local operating mode
by pressing the CCN softkey. When RUN STATUS is
READY, the chiller will attempt to start up.
• OFF — The control is in OFF mode when neither the
LOCAL nor CCN softkey cue is highlighted. Pressing the
STOP key or an alarm will place the control in this mode.
The PIC III control must be in this mode for certain operations, such as performing a Control Test or accessing VFD
Configuration parameters.
ALARMS AND ALERTS — An alarm shuts down the compressor. An alert does not shut down the compressor, but it
notifies the operator that an unusual condition has occurred. An
alarm (*) or alert (!) is indicated on the STATUS screens on the
far right field of the ICVC display screen.
Alarms are indicated when the ICVC alarm light (!) flashes.
The primary alarm message is displayed on the default screen.
An additional, secondary message and troubleshooting information are sent to the ALARM HISTORY table.
19
When an alarm is detected, the ICVC default screen will
freeze (stop updating) at the time of alarm. The freeze enables
the operator to view the chiller conditions at the time of alarm.
The STATUS tables will show the updated information. Once
all alarms have been cleared (by pressing the RESET softkey), the default ICVC screen will return to normal operation.
• Press PREVIOUS to scroll the cursor bar up in order to
highlight a point or to view points above the current screen.
An alarm condition must be rectified before a RESET will
be processed. However, an alert will clear automatically as
soon as the associated condition is rectified.
ICVC MENU ITEMS — To perform any of the operations
described below, the PIC III must be powered up and have
successfully completed its self test. The self test takes place
automatically, after power-up.
Press the MENU softkey to view the list of menu structures: STATUS , SCHEDULE , SETPOINT , and
SERVICE . See Fig. 16.
• Press SELECT to view the next screen level (high-lighted
with the cursor bar), or to override (if allowable) the highlighted point value.
• Press EXIT to return to the previous screen level.
• The STATUS menu allows viewing and limited calibration
or modification of control points and sensors, relays and
contacts, and the options board.
• The SCHEDULE menu allows viewing and modification of
the local and CCN time schedules and Ice Build time schedules.
• The SETPOINT menu allows set point adjustments, such as
the entering chilled water and leaving chilled water set
points.
• The SERVICE menu can be used to view or modify information on the Alarm History, Control Test, Control Algorithm Status, Equipment Configuration, VFD Configuration
data, Equipment Service, Time and Date, Attach to Network Device, Log Out of Network Device, and ICVC Configuration screens. See Fig. 17.
Press the softkey that corresponds to the menu structure to
be viewed: STATUS , SCHEDULE , SETPOINT , or
SERVICE . To view or change parameters within any of these
menu structures, use the NEXT and PREVIOUS softkeys
to scroll down to the desired item or table. Use the SELECT
softkey to select that item. The softkey choices that appear next
depend on the selected table or menu. The softkey choices and
their functions are described below.
• Press INCREASE or DECREASE to change the highlighted point value.
PRIMARY STATUS
MESSAGE
SECONDARY
STATUS
MESSAGE
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.
DATE
RUNNING TEMP CONTROL
LEAVING CHILLED WATER
ALARM LIGHT
(ILLUMINATED
WHEN POWER ON)
•
•
COMPRESSOR
ON TIME
BLINKS CONTINUOUSLY
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
EACH KEY'S FUNCTION IS
DEFINED BY THE MENU DESCRIPTION
ON MENU LINE ABOVE
Fig. 14 — ICVC Default Screen
• Press ENTER to leave the selected decision or field and
save changes.
a19-1614
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
• Press NEXT to scroll the cursor bar down in order to
highlight a point or to view more points below the current
screen.
Fig. 15 — ICVC Service Screen
20
MENU
LINE
DEFAULT SCREEN
LOCAL
CCN
RESET
MENU
(SOFTKEYS)
Start Chiller In CCN Control
Start Chiller in Local Control
Clear Alarms
Access Main Menu
STATUS
SCHEDULE
SETPOINT
List the
Status Tables
SERVICE
1 1 1 1 (ENTER A 4-DIGIT PASSWORD) (VALUES SHOWN AT FACTORY DEFAULT)
List the Service Tables
• MAINSTAT
• VPF_STAT
• 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
Display The Setpoint Table
List the Schedules
EXIT
• Base Demand Limit
• LCW Setpoint
• ECW Setpoint
• Ice Build Setpoint
• Tower Fan High Setpoint
Select the Setpoint
SELECT
PREVIOUS
NEXT
SELECT
EXIT
Modify the Setpoint
INCREASE DECREASE
RELEASE
ENTER
RELEASE
ENTER
QUIT
ENTER
SELECT
EXIT
ENTER
QUIT
• OCCPC01S – LOCAL TIME SCHEDULE
• OCCPC02S – ICE BUILD TIME SCHEDULE
• OCCPC03S – CCN TIME SCHEDULE
Select a Schedule
SELECT
PREVIOUS
EXIT
NEXT
1
2
3
4
5
6
7
8
Override
Select a Time Period/Override
SELECT
PREVIOUS
NEXT
EXIT
Modify a Schedule Time
INCREASE DECREASE
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
a19-1988
SEE FIGURE 17
Fig. 16 — 19XRV Chiller Display Menu Structure (ICVC)
21
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.)
Display Alarm History
(The table holds up to 25 alarms
with the most recent alarm at
the top of the screen.)
CONTROL TEST
List the Control Tests
CONTROL ALGORITHM STATUS
List the Control Algorithm Status Tables
• CAPACITY (Capacity Control)
• SURGPREV (Surge Prevention)
• OVERRIDE (Override Status)
• LL_MAINT (Lead Lag Status)
• VFD_HIST (VFD Alarm History)
• LOADSHED
• CUR_ALARM (Current Alarm State)
• WSMDEFME (Water System Manager Control Status)
• OCCDEFCM (Time Schedule Status)
Select a Table
SELECT
PREVIOUS
EXIT
NEXT
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
OCCDEFM (Time Schedule Status)
Data Select Table
PREVIOUS
NEXT
SELECT
• CAPACITY (Capacity Control Algorithm)
• OVERRIDE (Override Status)
• LL_MAINT (LEADLAG Status)
• WSMDEFM2 (Water System Manager Control Status)
EXIT
OCCPC01S (Local Status)
OCCPC02S (CCN, ICE BUILD Status)
OCCPC03S (CCN Status)
EQUIPMENT CONFIGURATION
Maintenance Table Data
List the Equipment Configuration Tables
• 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
SELECT (USE ENTER) TO SCROLL DOWN
Fig. 17 — 19XRV Service Menu Structure
22
a19-1989
SERVICE MENU CONTINUED
FROM PREVIOUS PAGE
VFD CONFIG DATA
EQUIPMENT SERVICE
4 4 4 4 (ENTER A 4-DIGIT PASSWORD)
(VALUES SHOWN AT FACTORY DEFAULT)
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
Select a Service Table Parameter
SELECT
PREVIOUS
NEXT
EXIT
Modify a Service Table Parameter
INCREASE DECREASE
QUIT
ENABLE
DISABLE
QUIT
ENTER
(ANALOG VALUES)
ENTER
(DISCRETE VALUES)
TIME AND DATE
Display Time and Date Table:
• To Modify — Current Time
— Current Date
ENTER
INCREASE DECREASE
ATTACH TO NETWORK DEVICE
List Network Devices
• Local
• Device 6
• Device 1 • Device 7
• Device 2 • Device 8
• Device 3 • Attach to any Device
• Device 4
• Device 5
Select a Device
PREVIOUS
NEXT
SELECT
YES
NO
ENTER
— Day of Week
— Holiday Today
EXIT
(ANALOG VALUE)
EXIT
(DISCRETE VALUE)
ATTACH
Modify Device Address
INCREASE DECREASE
ENTER
EXIT
• Use to attach ICVC to another CCN network or device
• Attach to "LOCAL" to enter this machine
• To upload new tables
LOG OUT OF DEVICE
Default Screen
LOCAL
CCN
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
Fig. 17 — 19XRV Service Menu Structure (cont)
23
FORCING OPERATIONS
To Force (manually override) a Value or Status
1. From any point status screen, press NEXT
PREVIOUS to highlight the desired value.
TO VIEW STATUS (Fig. 18) — The status table shows the
actual value of overall chiller status such as CONTROL
MODE, RUN STATUS, AUTO CHILLED WATER RESET,
and REMOTE RESET SENSOR.
1. On the menu screen, press STATUS to view the list of
point status tables.
or
2. Press SELECT to select the highlighted value.
2. Press NEXT or PREVIOUS to highlight the desired
status table. The list of tables is:
MAINSTAT — Overall chiller status
VPF_STAT — Variable primary flow surge prevention
algorithm status
STARTUP — Status required to perform start-up of
chiller
COMPRESS — Status of sensors related to the
compressor
HEAT_EX — Status of sensors related to the heat
exchangers
POWER — Status of motor input power
VFD_STAT — Status of VFD
ICVC_PWD — Service menu password forcing access
screen
For Discrete Points — Press START or STOP to select the desired state.
For Analog Points — Press INCREASE
DECREASE to select the desired value.
or
3. Press ENTER to register the new value.
3. Press SELECT to view the desired point status table.
NOTE: When forcing or changing metric values, it is necessary to hold down the softkey for a few seconds in order to see
a value change, especially on kilopascal values.
To Remove a Force
1. On the point status table press NEXT or PREVIOUS
to highlight the desired value.
4. On the point status table, press NEXT or PREVIOUS
until the desired point is displayed on the screen.
19XRV_II MAINSTAT
Control Mode
Run Status
Start Inhibit Timer
Occupied?
System Alert/Alarm
Chiller Start/Stop
Remote Start Contact
Temperature Reset
Control Point
Chilled Water Temp
Active Demand Limit
Percent Line Current
POINT STATUS
OFF
Ready
0.0 Min
NO
NORMAL
STOP
Open
0.0 F
44.0 F
44.6 F
100%
0.0%
2. Press SELECT to access the highlighted value.
3. Press RELEASE to remove the force and return the
point to the PIC III’s automatic control.
a19-1615
Fig. 18 — Example of Status Screen
24
Force Indication — A forced value is indicated by
“SUPVSR,” “SERVC,” or “BEST” flashing next to the point
value on the STATUS table.
TIME SCHEDULE OPERATION (Fig. 19)
1. On the Menu screen, press SCHEDULE .
2. Press NEXT or PREVIOUS to highlight the desired
schedule.
OCCPC01S — LOCAL Time Schedule
OCCPC02S — ICE BUILD Time Schedule
OCCPC03S — CCN Time Schedule
a19-1638
Fig. 19 — Example of Time Schedule
Operation Screen
7. Press ENTER to register the values and to move horizontally (left to right) within a period.
3. Press SELECT to view the desired time schedule.
8. Press EXIT to leave the PERIOD or OVERRIDE.
4. Press NEXT or PREVIOUS to highlight the desired
period or override to change.
9. Either return to Step 4 to select another PERIOD or
OVERRIDE, or press EXIT again to leave the current
time schedule screen and save the changes.
5. Press SELECT to access the highlighted PERIOD or
OVERRIDE.
10. The Holiday Designation (HOLIDEF table) may be
found in the Service Operation section, page 56. The
month, day, and duration for the holiday must be
assigned. The Broadcast function in the BRODEF
table also must be enabled for holiday periods to
function.
TO VIEW AND CHANGE SET POINTS (Fig. 20)
1. To view the SETPOINT table, from the MENU screen
press SETPOINT .
6. a. Press INCREASE or DECREASE to change the
time values. OVERRIDE values are in one-hour
increments, up to 4 hours.
b. Press ENABLE to select days in the day-of-week
fields. Press DISABLE to eliminate days from the
period.
25
6. Press ENTER to save the changes and return to the previous screen.
2. There are 5 set points on this screen: BASE DEMAND
LIMIT, LCW SETPOINT (leaving chilled water set
point), ECW SETPOINT (entering chilled water set
point), ICE BUILD SETPOINT, and TOWER FAN
HIGH SETPOINT. Only one of the chilled water set
points can be active at one time. The set point that is
active is determined from the SERVICE menu. See the
Service Operation section, page 56. The ice build (ICE
BUILD) function is also activated and configured from
the SERVICE menu.
3. Press NEXT or PREVIOUS to highlight the desired
set point entry.
SERVICE OPERATION — To view the menu-driven programs available for Service Operation, see Service Operation
section, page 56. For examples of ICVC display screens, see
Table 4.
19XRV_II
SETPOINT
Base Demand Limit
Control Point
LCW Setpoint
ECW Setpoint
ICE BUILD Setpoint
Tower Fan High Setpoint
4. Press SELECT to modify the highlighted set point.
5. Press INCREASE or DECREASE to change the selected set point value.
SETPOINT SELECT
100%
50.0 F
60.0 F
40.0 F
85.0 F
a19-1619
Fig. 20 — Example of Set Point Screen
26
Table 4 — ICVC Display Data
6. Reference Point Names shown in these tables in all capital letters can be read by CCN and BS software. Of these capitalized
names, those preceded by a dagger (†) can also be changed
(that is, written to) by the CCN, BS, and the ICVC. Capitalized
Reference Point Names preceded by two asterisks (**) can be
changed only from the ICVC. Reference Point Names in lower
case type can be viewed by CCN or BS only by viewing the
whole table.
7. Alarms and Alerts: An asterisk (*) in the far right field of a ICVC
status screen indicates that the chiller is in an alarm state; an
exclamation point (!) in the far right field of the ICVC screen indicates an alert state. The * (or !) indicates that the value on that
line has exceeded (or is approaching) a limit. For more information on alarms and alerts, see the Alarms and Alerts section,
page 19.
LEGEND
CCN
— Carrier Comfort Network®
CHW
— Chilled Water
ECW
— Entering Chilled Water
HGBP — Hot Gas Bypass
ICVC
— International Chiller Visual Controller
LCW
— Leaving Chilled Water
mA
— Milliamps
P
— Pressure
PIC III — Product Integrated Controls III
PWM — Pulse Width Modulated
SRD
— Split Ring Diffuser
T
— Temperature
VFD
— Variable Frequency Drive
WSM — Water System Manager
IMPORTANT: The following notes apply to all Table 4
examples.
1. Only 12 lines of information appear on the chiller display screen
at any one time. Press the NEXT or PREVIOUS softkey to
highlight a point or to view items below or above the current
screen. Double click the NEXT softkey to page forward; press
the PREVIOUS softkey twice to page back.
2. To access the information shown in Examples 10 through 24,
enter a 4-digit password after pressing the SERVICE softkey. If
no softkeys are pressed for 15 minutes, the ICVC automatically
logs off (to prevent unrestricted access to PIC III controls) and
reverts to the default screen. If this happens, re-enter the password to access the tables shown in Examples 10 through 24.
3. Terms in the Description column of these tables are listed as
they appear on the chiller display screen.
4. The ICVC may be configured in English or Metric (SI) units using
the ICVC CONFIGURATION screen. See the Service Operation
section, page 56, for instructions on making this change.
5. The items in the Reference Point Name column do not appear on
the chiller display screen. They are data or variable names used
in CCN or Building Supervisor (BS) software. They are listed in
these tables as a convenience to the operator if it is necessary to
cross reference CCN/BS documentation or use CCN/BS programs. For more information, see the 19XRV CCN literature.
EXAMPLE 1 — CHILLER DISPLAY DEFAULT SCREEN
The following data is displayed in the Default screen.
DESCRIPTION
(PRIMARY MESSAGE)
(SECONDARY MESSAGE)
(DATE AND TIME)
Compressor Ontime
Entering Chilled Water
Leaving Chilled Water
Evaporator Temperature
Entering Condenser Water
Leaving Condenser Water
Condenser Temperature
Oil Pressure
Oil Sump Temp
Average Line Current
STATUS
UNITS
0-500000.0
–40-245
–40-245
–40-245
–40-245
–40-245
–40-245
0-420
–40-245
0-999
0-1
0-1
0-1
HOURS
DEG F
DEG F
DEG F
DEG F
DEG F
DEG F
PSI
DEG F
%
REFERENCE POINT NAME
(ALARM HISTORY)
C_HRS
ECW
LCW
ERT
ECDW
LCDW
CRT
OILPD
OILT
AMPS_%
CCN
LOCAL
RESET
NOTE: The last three entries are used to indicate operating mode to the PIC III. These values may be forced by the ICVC only.
27
DISPLAY
CHW IN
CHW OUT
EVAP REF
CDW IN
CDW OUT
COND REF
OILPRESS
OIL TEMP
AMPS%
Table 4 — ICVC Display Data (cont)
EXAMPLE 2 — MAINTSTAT DISPLAY SCREEN
To access this display from the ICVC default screen:
1. Press MENU .
2. Press STATUS ( MAINSTAT will be highlighted).
3. Press SELECT .


DESCRIPTION
Control Mode
Run Status
Start Inhibit Timer
Occupied?
System Alert/Alarm
*Chiller Start/Stop
*Remote Start Contact
Temperature Reset
*Control Point
Chilled Water Temp
*Active Demand Limit
Percent Line Current
Percent Line Kilowatts
Auto Demand Limit Input
Auto Chilled Water Reset
Remote Reset Sensor
Total Compressor Starts
Starts in 12 Hours
Compressor Ontime
*Service Ontime
Ice Build Contact
Emergency Stop
Alarm Relay
STATUS
NOTE 2
NOTE 3
0-15
0/1
1-3
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
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
NORMAL/ALARM
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
ALM
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 (1), Alert (2), Alarm (3).
5. All variables with capital letter point names are available for CCN read operation. Those shown with (*) support write operations for all CCN
devices.
EXAMPLE 3 — VPF STAT DISPLAY SCREEN
To access this display from the ICVC default screen:
1. Press MENU .
2. Press STATUS .
3. Scroll down to highlight VPF_STAT .
4. Press SELECT .
DESCRIPTION
**Target VFD Speed
Actual Guide Vane Pos
Diffuser Actuator
Condenser Refrig Temp
Calc Evap Sat Temp
Active Delta Tsat
Surge Line Delta Tsat
Chilled Water Delta T
Hot Gas Bypass Relay
Surge Prevention Active?
Surge Line High Offset
Surge/HGBP Delta Tsmin
Surge/HGBP IGVmin
Surge/HGBP Delta Tsmax
Surge/HGBP IGVmax
Surge Line Shape Factor
Surge Line Speed Factor
Surge Delta % Amps
Surge Time Period
STATUS
0-110
0-100
0-100
–40-245
–40-245
0-200
0-200
–40-245
0/1
0/1
0.1-3.0
0.0-150.0
0.0-110.0
0.0-150.0
0.0-110.0
–1.000-0.000
0.00-3.00
5-40
7-10
UNITS
%
%
%
DEG F
DEG F
^F
^F
^F
OFF/ON
NO/YES
^F
%
^F
%
%
min
POINT
VFD_OUT
GV_ACT
DIFF_ACT
CRT
ERT
DTS_A
DTS_C
CHW_DT
HGBYPASS
SHG_ACT
SP_HIGH
DTsatmin
GV_MIN
DTsatmax
GV_MAX
shapefac
VFD_POW
surge_a
surge_t
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.
312
28
Table 4 — ICVC Display Data (cont)
EXAMPLE 4 — STARTUP DISPLAY SCREEN
To access this display from the ICVC default screen:
1. Press MENU .
2. Press STATUS .
3. Scroll down to highlight STARTUP
4. Press SELECT .
.
DESCRIPTION
Actual Guide Vane Pos
**Chilled Water Pump
Chilled Water Flow
**Condenser Water Pump
Condenser Water Flow
Oil Pump Relay
** Oil Pump Delta P
Oil Sump Temp
VFD Start
Start Complete
Stop Complete
Target VFD Speed
Comp Motor RPM
Comp Motor Frequency
**Tower Fan Relay Low
**Tower Fan Relay High
Spare Safety Input
Shunt Trip Relay
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
NOTE 2
NOTE 2
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
%
RPM
Hz
OFF/ON
OFF/ON
ALARM/ NORMAL
OFF/ON
POINT
GV_ACT
CHWP
CHW_FLOW
CDP
CDW_FLOW
OILPUMP
OILPD
OILT
VFDSTART
START_OK
STOP_OK
VFD_OUT
CPR_RPM
VFD_FREQ
TFR_LOW
TFR_HIGH
SAFETY
TRIPR
NOTES:
1. All variables with CAPITAL LETTER point names are available for CCN read operation. Those shown with (**) shall support write operations
for the ICVC only.
2. Limits not defined for status point.
EXAMPLE 5 — COMPRESS DISPLAY SCREEN
To access this display from the ICVC default screen:
1. Press MENU .
2. Press STATUS .
3. Scroll down to highlight COMPRESS .
4. Press SELECT .
DESCRIPTION
Actual VFD Speed
Comp Motor RPM
Comp Motor Frequency
**Target VFD Speed
Actual Guide Vane Pos
Guide Vane Delta
**Target Guide Vane Pos
Oil Sump Temp
**Oil Pump Delta P
Comp Discharge Temp
Comp Thrust Lvg Oil Temp
Comp Thrust Brg Reset
Comp Thrust Brg Temp
Comp Motor Winding Temp
Spare Temperature 1
Spare Temperature 2
Oil Heater Relay
Diffuser Actuator
SRD Rotating Stall
Surge Protection Counts
STATUS
0.0-100.0
NOTE 2
NOTE 2
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
–40-245
–40-245
0/1
0-100
0-1
0-5
UNITS
%
RPM
Hz
%
%
%
%
DEG F
PSI
DEG F
DEG F
DEG F
DEG F
DEG F
DEG F
DEG F
OFF/ON
%
NO/YES
POINT
VFD_ACT
CPR_RPM
VFD_FREQ
VFD_OUT
GV_POS
GV_DELTA
GV_TRG
OILT
OILPD
CMPD
MTRB_OIL
TB_RESET
MTRB
MTRW
SPARE_T1
SPARE_T2
OILHEAT
DIFF_ACT
DIFFAULT
SPC
NOTES:
1. All variables with CAPITAL LETTER point names are available for CCN read operation. Those shown with (**) shall support write operations
for the ICVC only.
2. Limits not defined for status point.
29
Table 4 — ICVC Display Data (cont)
EXAMPLE 6 — HEAT_EX DISPLAY SCREEN
To access this display from the ICVC default screen:
1. Press MENU .
2. Press STATUS .
3. Scroll down to highlight HEAT_EX .
4. Press SELECT .
DESCRIPTION
**Chilled Water Delta P
Entering Chilled Water
Leaving Chilled Water
Chilled Water Delta T
Chill Water Pulldown/Min
Calc Evap Sat Temp
**Evaporator Pressure
Evap Refrig Liquid Temp
Evaporator Approach
**Condenser Water Delta P
Entering Condenser Water
Leaving Condenser Water
Condenser Refrig Temp
**Condenser Pressure
Condenser Approach
VFD Coolant Flow
Hot Gas Bypass Relay
Surge Prevention Active?
Active Delta P
Active Delta T
Surge/HGBP Delta T
Head Pressure Reference
STATUS
–6.7-420
–40-245
–40-245
–40-245
–20-20
–40-245
–6.7-420
–40-245
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
UNITS
PSI
DEG F
DEG F
^F
^F
DEG F
PSI
DEG F
^F
PSI
DEG F
DEG F
DEG F
PSI
^F
%
OFF/ON
NO/YES
PSI
^F
^F
%
POINT
CHWPD
ECW
LCW
CHW_DT
CHW_PULL
ERT
ERP
EST
EVAP_APP
CDWPD
ECDW
LCDW
CRT
CRP
COND_APP
VFD_FOUT
HGBYPASS
SHG_ACT
DP_A
DT_A
DT_C
HPR
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.
30
Table 4 — ICVC Display Data (cont)
EXAMPLE 7 — POWER DISPLAY SCREEN
To access this display from the ICVC default screen:
1. Press MENU .
2. Press STATUS .
3. Scroll down to highlight POWER .
4. Press SELECT .
DESCRIPTION
Percent Line Current
Average Line Current
Percent Line Voltage
Average Line Voltage
Line Power Factor
Line Kilowatts
Percent Line Kilowatts
Percent Load Current
Average Load Current
Motor Power Factor
Motor Kilowatts
Percent Motor Kilowatts
Motor Kilowatt Hours
Demand Kilowatts
Line Current Ph1(R)
Line Current Ph2 (S)
Line Current Ph3 (T)
Load Current Ph1 (U)
Load Current Ph2 (V)
Load Current Ph3 (W)
Line Voltage Ph1 (RS)
Line Voltage Ph2 (ST)
Line Voltage Ph3 (TR)
Ground Fault Current
Line Frequency
Rectifier Overload
Inverter Overload
Motor Overload
Line Current Imbalance
Motor Current Imbalance
Line Voltage Imbalance
Line Active Current
Line Reactive Current
Line Active Voltage
Line Reactive Voltage
DC Bus Voltage Reference
DC Bus Voltage
Flux Current
Torque Current
Inverter Temperature
Rectifier Temperature
VFD Dewpoint
VFD Enclosure Temp
VFD Cold Plate Temp
Humidity Sensor Input
Relative Humidity
VFD Coolant Flow
Actual VFD Speed
Comp Motor RPM
Comp Motor Frequency
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
0.0-100.0
0.0-300.0
0.0-300.0
0.0-5.0
0.0-100.0
0.0-100.0
0.0-100.0
NOTE 2
NOTE 2
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
DEG F
VOLTS
%
%
%
RPM
Hz
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
VFDDEWPT
VFD_ENCL
CP_TEMP
HUMID_SR
HUMIDITY
VFD_FOUT
VFD_ACT
CPR_RPM
VFD_FREQ
NOTES:
1. All variables with CAPITAL LETTER point names are available for CCN read operation. Those shown with (**) shall support write operations
for the ICVC only.
2. Limits not defined for status point.
31
Table 4 — ICVC Display Data (cont)
EXAMPLE 8 — VFD_STAT DISPLAY SCREEN
To access this display from the ICVC default screen:
1. Press MENU .
2. Press STATUS .
3. Scroll down to highlight VFD_STAT .
4. Press SELECT .
DESCRIPTION
VFD Fault Code
Single Cycle Dropout
Line Current Imbalance
Line Voltage Imbalance
Line Phase Reversal
High Line Voltage
Low Line Voltage
High DC Bus Voltage
Low DC Bus Voltage
Motor Current Imbalance
Motor Overload
Rectifier Overcurrent
Rectifier Overtemp
Rectifier Power Fault
Inverter Overcurrent
Inverter Overtemp
Inverter Power Fault
Ground Fault
Frequency Fault
VFD Power On Reset
Start Complete
Stop Complete
Condenser High Pressure
Motor Amps Not Sensed
Start Acceleration Fault
Stop Fault
VFD Start Inhibit
VFD Checksum Error
VFD Comm Fault
VFD Fault
VFD Gateway Version #
VFD Inverter Version #
VFD Rectifier Version #
STATUS
0-223
0/1
0/1
0/1
0/1
0/1
0/1
0/1
0/1
0/1
0/1
0/1
0/1
0/1
0/1
0/1
0/1
0/1
0/1
0/1
0/1
0/1
0/1
0/1
0/1
0/1
0/1
0/1
0/1
0/1
0-255
0-1000
0-1000
UNITS
NORMAL/ALARM
NORMAL/ALARM
NORMAL/ALARM
NORMAL/ALARM
NORMAL/ALARM
NORMAL/ALARM
NORMAL/ALARM
NORMAL/ALARM
NORMAL/ALARM
NORMAL/ALARM
NORMAL/ALARM
NORMAL/ALARM
NORMAL/ALARM
NORMAL/ALARM
NORMAL/ALARM
NORMAL/ALARM
NORMAL/ALARM
NORMAL/ALARM
NORMAL/ALARM
FALSE/TRUE
FALSE/TRUE
NORMAL/ALARM
NORMAL/ALARM
NORMAL/ALARM
NORMAL/ALARM
NORMAL/ALARM
NORMAL/ALARM
NORMAL/ALARM
NORMAL/ALARM
POINT
VFD_FLT
CYCLE_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 9 — 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 10 — 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.
32
Table 4 — ICVC Display Data (cont)
EXAMPLE 11 — CAPACITY 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 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
Comp Motor RPM
Comp Motor Frequency
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
NOTE 2
NOTE 2
0.2-2.0
40-100
DEG F
^F
^F
^F
^F
^F
%
%
%
%
%
RPM
Hz
%
%
ctrlpt
cperr
ecwdt
ecwres
lcwres
error
gvd
GV_TRG
GV_POS
VFD_OUT
VFD_ACT
CPR_RPM
VFD_FREQ
DEM_INH
DMDLIM
NOTES:
1. All variables with CAPITAL LETTER point names are available for CCN read operation. Those shown with (**) shall support write operations
for the ICVC only.
2. Limits not defined for status point.
EXAMPLE 12 — 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 Lvg Oil Temp
Comp Thrust Brg Reset
Comp Thrust Brg Temp
Comp Thrust Brg Alert
Comp Thrust Brg Trip
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
–40-245
–40-245
165-185
160-185
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
DEG F
DEG F
DEG F
^F
^F
DEG F
POINT
MTRW
MT_OVER
CRP
CP_OVER
ERT
ERT_OVER
CMPD
CD_ALERT
MTRD_OIL
TB_RESET
MTRB
TB_ALERT
TB_ALARM
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.
33
312
Table 4 — ICVC Display Data (cont)
EXAMPLE 13 — SURGPREV 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 SURGPREV .
Press SELECT .
DESCRIPTION
Active Region
Surge Prevention Active?
Actual Guide Vane Pos
Active Delta Tsat
Surge Line Delta Tsat
HGBP On Delta T
HGBP Off Delta T
Guide Vane Delta
Target Guide Vane Pos
Target VFD Speed
Speed Change in Effect
VFD Speed Factor
Surge Counts
Surge Protection Counts
Ramp Loading Active
VFD Rampdown Active
HGBP/VFD Active
VFD Load Factor
Hot Gas Bypass Relay
Surge Limit/HGBP Option
Override Inhibit Active
Override Decrease Active
STATUS
0-2
0/1
0-100
0-150
0-150
0.5-10.0
1.5-20.0
–2.0-2.0
0-100
0-100
0-5
0.000-1.000
0-99
0-4
0/1
0/1
0-2
0.00-1.20
0/1
0-2
0/1
0/1
UNITS
No/Yes
%
^F
^F
^F
^F
%
%
%
No/Yes
No/Yes
Off/On
No/Yes
No/Yes
POINT
ACT_REG
SHG_ACT
GV_POS
DTS_A
DTS_C
HGBP_ON
HGBP_OFF
GV_DELTA
GV_OUT
VFD_TRG
SPD_CHG
VFD_SPD
SC
SPC
RAMP_ACT
VFD_RAMP
HGBP_VFD
VFD_RAT
HGBYPASS
HGBP_OPT
VANE_INH
VANE_DEC
NOTE: All variables with CAPITAL LETTER point names are available for CCN read operation; forcing shall not be supported on maintenance
screens.
EXAMPLE 14 — LL_MAINT DISPLAY SCREEN
To access this display from the ICVC default screen:
1. Press MENU .
2. Press SERVICE .
3. Scroll down to highlight CONTROL ALGORITHM STATUS .
4. Press SELECT .
5. Scroll down to highlight LL_MAINT.
6. Press SELECT .
DESCRIPTION
STATUS
UNITS
POINT
LeadLag Control
LEADLAG: Configuration
NOTE 1
leadlag
Current Mode
NOTE 2
llmode
Load Balance Option
0/1
DSABLE/ENABLE
loadbal
LAG START Time
2-60
MIN
lagstart
LAG STOP Time
2-60
MIN
lagstop
Prestart Fault Time
2-30
MIN
preflt
PULLDOWN Time
0-30
MIN
pulltime
Pulldown: Delta T / Min
x.xx
^F
pull_dt
Satisfied?
0/1
NO/YES
pull_sat
LEAD CHILLER in Control
0/1
NO/YES
leadctrl
LAG CHILLER: Mode
NOTE 3
lagmode
Run Status
NOTE 4
lagstat
Start/Stop
NOTE 5
lag_s_s
Recovery Start Request
0/1
NO/YES
lag_rec
STANDBY CHILLER: Mode
NOTE 3
stdmode
Run Status
NOTE 4
stdstat
Start/Stop
NOTE 5
Std_s_s
Recovery Start Request
0/1
NO/YES
std_rec
Spare Temperature 1
–40-245
DEG F
SPARE_T1
Spare Temperature 2
–40-245
DEG F
SPARE_T2
NOTES:
1. DISABLE, LEAD, LAG, STANDBY, INVALID
2. DISABLE, LEAD, LAG, STANDBY, RECOVERY, CONFIG
3. Reset, Off, Local, CCN
4. Timeout, Ready, Recycle, Prestart, Startup, Ramping, Running, Demand, Override, Shutdown, Trippout, Pumpdown, Lockout, Ctl Test
5. Stop, Start, Retain
6. All variables with CAPITAL LETTER point names are available for CCN read operation; forcing shall not be supported on maintenance screens.
34
Table 4 — ICVC Display Data (cont)
EXAMPLE 15 — VFD_HIST DISPLAY SCREEN
To access this display from the ICVC default screen:
1. Press MENU .
2. Press SERVICE .
3. Scroll down to highlight CONTROL ALGORITHM STATUS .
4. Press SELECT .
5. Scroll down to highlight VFD_HIST .
6. Press SELECT .
DESCRIPTION
VFD FAULT HISTORY
Values at Last Fault:
Line Current Ph1(R)
Line Current Ph2(S)
Line Current Ph3(T)
Load Current Ph1(U)
Load Current Ph2(V)
Load Current Ph3(W)
Line Voltage Ph1(RS)
Line Voltage Ph2(ST)
Line Voltage Ph3(TR)
Ground Fault Current
Line Frequency
Line Power Factor
Line Current Imbalance
Line Voltage Imbalance
Motor Power Factor
Motor Current Imbalance
Motor Overload
Line Active Current
Line Reactive Current
Line Active Voltage
Line Reactive Voltage
DC Bus Voltage
DC Bus Voltage Reference
Flux Current
Torque Current
Inverter Temperature
Rectifier Temperature
VFD Enclosure Temp
VFD Cold Plate Temp
Actual VFD Speed
Comp Motor RPM
Comp Motor Frequency
Chiller Fault State
VFD Fault Code
STATUS
UNITS
0.0-99999.0
0.0-99999.0
0.0-99999.0
0.0-99999.0
0.0-99999.0
0.0-99999.0
0.0-99999.0
0.0-99999.0
0.0-99999.0
0.0-999.0
0.0-99.0
0.00-2.00
0.0-100.0
0.0-100.0
0.00-2.00
0.0-100.0
0.0-100.0
0.0-99999.0
0.0-99999.0
0.0-99999.0
0.0-99999.0
0.0-99999.0
0.0-99999.0
0.0-99999.0
0.0-99999.0
0.0-300.0
0.0-300.0
0.0-300.0
0.0-300.0
0.0-100.0
NOTE 2
NOTE 2
200-225
200-225
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
%
RPM
Hz
POINT
LNAMPS1H
LNAMPS2H
LNAMPS3H
LDAMPS1H
LDAMPS2H
LDAMPS3H
LNVOLT1H
LNVOLT2H
LNVOLT3H
GF_AMPSH
LINEFRQH
LINE_PFH
LN_IMBIH
LN_IMBVH
MOTORPFH
MT_IMBIH
MOTOROVH
AMPSACTH
AMPS_REH
VOLTACTH
VOLT_REH
BUSVOLTH
BUS_REFH
FLUXAMPH
TORQAMPH
INVTEMPH
RECTEMPH
VFDENCLH
CP_TEMPH
VFD_ACTH
CPR_RPMH
VFDFREQH
VFDSTATH
VFD_FLTH
NOTES:
1. All variables with CAPITAL LETTER point names are available for CCN read operation; forcing shall not be supported on maintenance
screens.
2. Limits not defined for status point.
EXAMPLE 16 — WSMDEFME 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 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.
35
Table 4 — ICVC Display Data (cont)
EXAMPLE 17 — NET_OPT 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 CONFIGURATION .
Press SELECT .
Scroll down to highlight NET_OPT .
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
POINT
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
NOTE: No variables are available for CCN read or write operation.
EXAMPLE 18 — VFD_CONF DISPLAY SCREEN
To access this display from the ICVC default screen:
1. Press MENU .
2.
3.
4.
5.
Press SERVICE .
Scroll down to highlight VFD CONFIG DATA .
Press SELECT .
Enter password (4444 Factory Default).
6. Scroll down to highlight VFD_CONF .
7. Press SELECT .
DESCRIPTION
Motor Nameplate Voltage
Compressor 100% Speed
Line Freq=60 Hz? (No=50)
* Rated Line Voltage
* Rated Line Amps
* Rated Line Kilowatts
* Motor Rated Load KW
* Motor Rated Load Amps
Motor Nameplate Amps
Motor Nameplate RPM
Motor Nameplate KW
Inverter PWM Frequency (0=4 k Hz, 1=2 k Hz)
Skip Frequency 1
Skip Frequency 2
Skip Frequency 3
Skip Frequency Band
Line Voltage % Imbalance
Line Volt Imbalance Time
Line Current % Imbalance
Line Current Imbal Time
Motor Current % Imbalance
Motor Current Imbal Time
Increase Ramp Time
Decrease Ramp Time
Single Cycle Dropout
STATUS
346-480
45.0-62.0
0/1
346-600
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.
36
Table 4 — ICVC Display Data (cont)
EXAMPLE 19 — 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
Low Load HGBP=2
Minimum Load Point
Surge/HGBP Delta Tsmin
Surge/HGBP IGVmin
Full Load Point
Surge/HGBP Delta Tsmax
Surge/HGBP IGVmax
Surge Line Shape Factor
Surge Line Speed Factor
Surge Line High Offset
Surge/HGBP Deadband
Low Load HGBP
HGBP On Delta T
HGBP Off Delta T
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
Refrigerant Leak Option
Refrigerant Leak Alarm mA
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
%
0/1/2
POINT
astart
r_contac
softstop
DEFAULT
DSABLE
DSABLE
100
srg_hgbp
0
0.0-150.0
0.0-110.0
^F
%
DTsatmin
GV_MIN
45
5.0
0.0-150.0
0.0-110.0
–1.000-0.000
0.00-3.00
0.1-3.0
0.5-3
^F
%
^F
DTsatmax
GV_MAX
shapefac
VFD_POW
SP_HIGH
hbg_db
70
5.0
–0.040
1.85
1.0
1
0.5-10.0
1.0-10.0
^F
^F
hgb_ton
hgb_toff
2.0
4.0
5-20
7-10
%
MIN
surge_a
surge_t
10
8
0/1
0-2
DSABLE/ENABLE
ibopt
ibterm
DSABLE
0
0/1
0/1
4-20
DSABLE/ENABLE
DSABLE/ENABLE
mA
ibrecyc
LEAK_EN
LEAK_MA
DSABLE
DSABLE
20
20-85
20-85
0-100
PSI
PSI
%
HPDPO
HPDP100
HPDPMIN%
25
50
0
NOTE: No variables are available for CCN read or write operation.
37
Table 4 — ICVC Display Data (cont)
EXAMPLE 20 — SETUP1 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 SETUP1 .
Press SELECT .
DESCRIPTION
Comp Motor Temp Override
Cond Press Override
Rectifier Temp Override
Inverter Temp Override
Comp Discharge Alert
Comp Thrust Brg Alert
Comp Thrust Brg Trip
Thrust Brg Reset Factor
STATUS
150-200
90-165
155-170
155-170
125-200
165-185
165-185
1.0-3.0
UNITS
DEG F
PSI
DEG F
DEG F
DEG F
DEG F
DEG F
POINT
MT_OVER
CP_OVER
REC_OVER
INV _OVER
CD_ALERT
TB_ALERT
TB_TRIP
TB_POWER
DEFAULT
200
125
160
160
200
175
185
1.4
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
Flow Delta P Display
Evap Flow Delta P Cutout
Cond Flow Delta P Cutout
Cond Hi Flow Alarm Opt
Cond Hi Flow Del P Limit
Water Flow Verify Time
Oil Press Verify Time
Recycle Control
Restart Delta T
Shutdown Delta T
0-1
0.5 - 50.0
0.5 - 50.0
0/1
0.5 - 50.0
0.5-5
15-300
DSABLE/ENABLE
PSI
PSI
DSABLE/ENABLE
PSI
MIN
SEC
FLOWDISP
EVAP_CUT
COND_CUT
COND_ALM
COND_VAL
WFLOW_T
OILPR_T
DSABLE
5.0
5.0
DSABLE
50.0
5
40
2.0-10.0
0.5-4.0
DEG F
DEG F
rcycr_dt
rcycs_dt
5
1
Spare Alert/Alarm Enable
Disable=0, Lo=1/3,Hi=2/4
Spare Temp #1 Enable
0-4
sp1_en
Spare Temp #1 Limit
-40-245
DEG F
sp1_lim
Spare Temp #2 Enable
0-4
sp2_en
Spare Temp #2 Limit
-40-245
DEG F
sp2_lim
NOTE: No variables are available for CCN read operation; forcing shall not be supported on service screens.
0
245
0
245
EXAMPLE 21 — 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
Guide Vane Travel Limit
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
VFD Start Speed
VFD Surge Line Gain
VFD Encl Temp Correction
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
65-100
2.0-3.5
-40.0-20.0
%
%
%
%
%
%
vfd_gain
vfd_step
vfd_min
vfd_max
vfd_strt
vfd_slg
vfd_corr
0.75
2
70
100
100
2.0
0.0
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.
312
38
Table 4 — ICVC Display Data (cont)
EXAMPLE 22 — LEADLAG 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 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
PULLDOWN 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
1-30
0/1
25-75
1-236
DSABLE/ENABLE
DSABLE/ENABLE
%
MIN
MIN
MIN
MIN
DSABLE/ENABLE
%
POINT
DEFAULT
leadlag
0
loadbal
commsens
lag_per
lag_add
lagstart
lagstop
preflt
pulldown
stndopt
stnd_per
stnd_add
DSABLE
DSABLE
50
92
10
10
5
2
DSABLE
50
93
NOTE: No variables are available for CCN read or write operation.
EXAMPLE 23 — RAMP_DEM 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 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
VFD Overload Decrease
VFD Overload Delta
Demand Watts Interval
STATUS
0/1
UNITS
0/1
5-20
3-15
40-100
0/1
25-50
3-15
5-60
%
%
DSABLE/ENABLE
%
%
MIN
POINT
ramps1ct
DEFAULT
1
dem_src
0
kw_ramp
dem_app
dem_20ma
dem_sel
vfd_dec
vfd_delt
dw_int
10
10
40
DSABLE
30
5
15
NOTE: No variables are available for CCN read or write operation.
EXAMPLE 24 — TEMP_CTL 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 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
0-3
^F
^F
^F
restd_1
restd_2
deg_chw
res_sel
10
0
5
0
39
PIC III System Functions
Table 5 — Guide Vane Delta Modes
IMPORTANT: Words not part of paragraph headings and
printed in all capital letters can be viewed on the ICVC
(e.g., LOCAL, CCN, RUNNING, ALARM, etc.). Words
printed both in all capital letters and italics can also be
viewed on the ICVC and are parameters (CONTROL
MODE, TARGET GUIDE VANE POS, etc.) with associated
values (e.g., modes, temperatures, pressures, percentages,
on, off, enable, disable, etc.). Words printed in all capital letters and in a box represent softkeys on the ICVC (e.g.,
ENTER and EXIT ). See Table 4 for examples of the type
of information that can appear on the ICVC screens. Figures
14-20 give an overview of ICVC operations and menus.
GUIDE VANE
DELTA
NORMAL
CONTROL
MODE
IGV
VFD
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
—
Normal Control mode occurs when ACTIVE DELTA T
> SURGE/HGBP DELTA T.
Surge Prevention Mode occurs when ACTIVE DELTA T
 SURGE/HGBP DELTA T.
The VFD GAIN parameter allows for additional adjustment
of the VFD response. Increasing VFD GAIN will increase the
rate of speed change.
Generally for the case of line voltage equaling motor voltage (460 volts), VFD output (motor) current is a few percent
higher than line current at full speed (60 Hz). As drive speeds
decrease from maximum, drive output voltage decreases
linearly with output frequency, and motor current continues to
increase relative to line current.
The TARGET VFD SPEED, ACTUAL VFD SPEED and the
VFD GAIN can be viewed and modified in the CAPACITY
display screen. The TARGET VFD SPEED can be manually
overridden by the operator from the COMPRESS screen. The
VFD MINIMUM SPEED, VFD MAXIMUM SPEED, VFD
GAIN and VFD INCREASE STEP can be selected and modified in the SETUP2 display screen. TARGET and ACTUAL
VFD SPEED can be viewed in the COMPRESS screen.
ECW CONTROL OPTION — If this option is enabled, the
PIC III uses the ENTERING CHILLED WATER temperature to
modulate the vanes instead of the LEAVING CHILLED
WATER temperature. The ECW CONTROL OPTION may be
viewed on the TEMP_CTL screen, which is accessed from the
EQUIPMENT SERVICE screen.
CONTROL POINT DEADBAND — This is the tolerance
range on the chilled water/brine temperature control point. If
the water temperature goes outside the CHILLED WATER
DEADBAND, the PIC III opens or closes the guide vanes until
the temperature is within tolerance. The PIC III may be configured with a 0.5 to 2 F (0.3 to 1.1 C) deadband. CHILLED
WATER DEADBAND may be viewed or modified on the
SETUP1 screen, which is accessed from the EQUIPMENT
SERVICE table.
For example, a 1 F (0.6 C) deadband setting controls the
water temperature within ±0.5 F (0.3 C) of the control point.
This may cause frequent guide vane movement if the chilled
water load fluctuates frequently. A value of 1 F (0.6 C) is the
default setting.
A deadband is a span of measurement in which a controller
takes no action. In the PIC controls it is a temperature range
centered on the CONTROL POINT. If the LEAVING
CHILLED WATER TEMP falls within the CHILLED WATER
DEADBAND, the guide vanes will not move.
The purpose of the deadband is to prevent slight fluctuations in ENTERING CHILLED WATER TEMPERATURE
from keeping the guide vanes in constant movement.
Adjusting The Deadband — The default setting of the
CHILLED WATER DEADBAND, is 1°F, which is 0.5°F above
and below the CONTROL POINT. The CONTROL POINT setting range is 0.5 to 2° F. If temperature control is satisfactory
and the guide vanes are stable, do not change the setting.
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 49) 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 on page 41.
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.
40
X
X
X
°F
48.2
48
47.8
47.6
47.4
47.2
SET POINT = 47
46.8
46.6
46.4
X
X
X
X
X
X
X
X
X
X
X
EXAMPLE 1
EXAMPLE 2
EXAMPLE 3
a19-1957
Fig. 21 — Transient Example of ECW Gain
41
3
2.5
2
1.5
1
0.5
0
-0.5
-1
TOTAL ERROR
PROPORTIONAL BANDS and LCW DEADBAND should be
adjusted satisfactorily.
Increase the ECW GAIN if the ENT CHILLED WATER
TEMP drifts away from the ECW SETPOINT. Reduce the
ECW GAIN if the ENT CHILLED WATER TEMP swings
above and below the ECW SETPOINT. Because the water must
travel around the entire loop before the controls receive feedback on the effect of the LCW CONTROL POINT, the chilled
water loop should be given the opportunity to stabilize before
the gain is adjusted. The following example shows how the Entering Chilled Water Control works to move the vanes based on
the rate of change of the ENT CHILLED WATER TEMP as
well as the by the difference between ENT CHILLED WATER
TEMP and ECW SETPOINT.
Effect of Proportional Entering Chilled Water Band (ECW
Gain) (See Fig. 21)
Error = the contribution of the ECW control to the total error that inputs to the guide vane control. Positive error drives
the vanes open. Negative error drives the vanes closed.
ECW set point = 47 F
ECW = Entering Chilled Water
ECW-10 = Entering Chilled Water 10 seconds previous
Example 1 — The first section of Fig. 21 shows the entering
water dropping with a constant rate. The ECW algorithm is
reducing its effort to open the guide vanes. After the entering
water temperature drops below the setpoint the error drops
below zero and thus is trying to close the vanes.
Example 2 — The second section shows the water temperature
dropping but at a decreasing rate as shown by the reduction in
the difference between ECW and ECW-10. The error value is
leveling at zero but takes a dip because the entering water temperature drops below the set point.
Example 3 — The third section of Fig. 21 shows the entering
chilled water temperature increasing. Again the error starts to
level off or drop as the temperature change over 10 seconds
becomes smaller.
When very close temperature control is required, as for
some process applications, the deadband may be reduced.
When constant small load changes occur in a system and
the vanes will not stabilize, increase the size of the deadband.
The deadband must always be smaller than the allowable drift
in leaving water temperature.
PROPORTIONAL BANDS — The proportional bands control how far the guide vanes will move in response to a specific
change in leaving water temperature. Increasing the proportional band increases the amount that the water temperature
must move away from the control point in order to move the
guide vanes a specific amount. Decreasing the proportional
band allows the vanes to move the same amount with a smaller
change in water temperature.
If the proportional band is too large, the leaving water temperature will increase or decrease slowly enough that the temperature moves away from the control point by an unacceptable amount. A proportional band set too low will cause the
leaving temperature to overshoot the control point and cause
the guide vanes to “hunt.”
The PIC controls have separate proportional bands for increasing and decreasing capacity. The PROPORTIONIONAL
INCREASE BAND should be set as described above. The PROPORTIONIONAL DECREASE BAND should be set at a typically smaller value than the increasing band so that the guide
vanes can close quickly enough on a sudden drop in load to
prevent a low temperature safety trip.
Proportional Entering Chilled Water Gain — When Entering
Chilled Water Control is enabled the controls are resetting the
Leaving Chilled Water (LCW) control point every 10 seconds
in order to keep the ENTERING CHILLED WATER TEMP at
the ENTERING CHILLED WATER (ECW) SETPOINT.
The ECW GAIN affects the size of the LCW CONTROL
POINT change in proportion to the difference between the
ECW SETPOINT and ECW TEMPERATURE.
NOTE: Before enabling the ENTERING CHILLED WATER
CONTROL and before tuning the ECW GAIN, the LCW
E C W (°F )
E C W -10 sec
E rror, G ain = 1
E rror, G ain = 3
(displayed in the MAINSTAT screen). LINE KILOWATTS is
measured by the VFD, and the MOTOR RATED LOAD kW
value (100% rated kW) is set in the VFD_CONF table.
If the DEMAND LIMIT SOURCE (percent line current)
exceeds the ACTIVE DEMAND LIMIT by 5% or less, increases in guide vane opening will be prevented. If the DEMAND LIMIT SOURCE (percent line current) exceeds the
ACTIVE DEMAND LIMIT by more than 5%, the guide vanes
will be forced to close. Also, as the DEMAND LIMIT
SOURCE approaches the ACTIVE DEMAND LIMIT from a
lower value, allowable capacity increases become increasingly
more limited, beginning when the DEMAND LIMIT
SOURCE is within the DEMAND LIMIT PROP BAND (configurable in the RAMP_DEM table).
Demand Limit Control Option — The demand limit control
option (20 mA DEMAND LIMIT OPT) is externally
controlled by a 4 to 20 mA signal from an energy management
system (EMS). The option is set up on the RAMP_DEM
screen. When enabled, 4 mA will set ACTIVE DEMAND
LIMIT to 100% of the DEMAND LIMIT SOURCE (regardless of the value of BASE DEMAND LIMIT), and 20 mA will
set ACTIVE DEMAND LIMIT to the value configured as
“20MA DEMAND LIMIT OPT” in the RAMP_DEM table.
Wire the auto demand limit input to terminals J5-1 (–) and
J5-2 (+) on the CCM. In order to use a 1 to 5 vdc input instead
of 4 to 20 mA, install a 25-ohm resistor in series with the + lead
at terminal J5-2.
A DEMAND KILOWATTS monitoring feature is also
available. This feature provides a display of average demand
(power) in kilowatts (in the POWER screen). This value is
continuously updated and averaged over the preceding time
interval specified as DEMAND WATTS INTERVAL in the SERVICE / EQUIPMENT SERVICE/RAMP_DEM screen.
CHILLER TIMERS AND STARTS COUNTER —
The
PIC III maintains two run time clocks: COMPRESSOR
ONTIME and SERVICE ONTIME. COMPRESSOR
ONTIME indicates the total lifetime compressor run hours.
SERVICE ONTIME is a resettable timer that can be used to
indicate the hours since the last service visit or any other event.
A separate counter tallies compressor starts as TOTAL COMPRESSOR STARTS. All of these can be viewed on the
MAINSTAT screen on the ICVC. Both ontime counters roll
over to 0 at 500,000 hours. Manual changes to SERVICE
ONTIME from the ICVC are permitted at any time. If the controller is replaced, one opportunity, before the first startup with
the new controller, is provided to set COMPRESSOR
ONTIME and TOTAL COMPRESSOR STARTS to the last
readings retained with the prior controller. The SERVICE
ONTIME timer can register up to 32,767 hours before it rolls
over to zero.
The chiller also maintains a start-to-start timer and a
stop-to-start timer. These timers limit how soon the chiller
can be started. START INHIBIT TIMER is displayed on
the MAINSTAT screen. See the Start-Up/Shutdown/Recycle
Sequence section, page 57, for more information on this topic.
OCCUPANCY SCHEDULE — The chiller schedule, described in the Time Schedule Operation section (page 25), determines when the chiller can run. Each schedule consists of from
1 to 8 occupied or unoccupied time periods, set by the operator.
The chiller can be started and run during an occupied time period (when OCCUPIED? is set to YES on the MAINSTAT display screen). It cannot be started or run during an unoccupied
time period (when OCCUPIED? is set to NO on the MAINSTAT display screen). These time periods can be set for each
day of the week and for holidays. The day begins with 0000
hours and ends with 2400 hours. The default setting for OCCUPIED? is YES, unless an unoccupied time period is in effect.
2 mA
(0%)
Full 4 mA
Open (0.2%)
surge more likely
Control Output
(Actuator Position)
DIFFUSER POSITION
Pinion Shaft Clockwise Rotation
DIFFUSER CONTROL — On all units with Frame 5 compressors and those Frame 4 compressors with the variable (split
ring) diffuser option, the PIC III adjusts the diffuser actuator
position (DIFFUSER ACTUATOR on the COMPRESS screen)
based on the ACTUAL GUIDE VANE POSITION. This is
done in accordance with a compressor build-specific “schedule”
entered in the SETUP2 screen. The schedule consists of guide
vane and diffuser positions for three points (designated as the
25%, 50%, and 75% Load Points). In order for the schedule to
be valid, the guide vane values must be ascending and the diffuser values must be descending for the three points. Diffuser
actuator output is controlled by a 4 to 20 mA output from CCM
terminals J8-3(+) and J8-4(–). Figure 22 shows the relationship
between diffuser-related parameters for a typical build.
75 % Load Point
surge less likely
50 % Load Point
rotating stall
less likely
Full
Closed
approx.
20 mA*
(100%)
25 % Load Point
0%
* Diffuser full Span mA.

50 %
78 %
GUIDE VANE OPENING (%)
a19-1620
Fig. 22 — Diffuser Control
Diffuser control output is enabled whenever the DIFFUSER
OPTION is enabled, whether the machine is running or not. As
shown in Fig. 22, 0% output corresponds to a full open diffuser.
The minimum closed position (25% Load Point value) will be
at less than 100% for most diffusers (depending upon the
model). This coordinated guide vane-diffuser operation may be
tested in the Control Test selection “IGV & SRD Actuator.”
Note that the diffuser actuator should NOT be forced to a greater percent than the configured 25% Load Point (maximum)
value. The diffuser opening can be incremented from fully open
to completely closed. A 0% setting is fully open; a 100% setting
is completely closed. To obtain the proper settings for Diffuser
Control, contact a Carrier Engineering representative.
DEMAND LIMITING — The PIC III controls provide a
feature for limiting AVERAGE LINE CURRENT or LINE
KILOWATTS (demand) by limiting capacity via guide vane
control. The limit applied is called ACTIVE DEMAND
LIMIT, which is equal to a BASE DEMAND LIMIT value
(set in the SETPOINTS Screen, page 26, default value 100%),
or that determined by AUTO DEMAND LIMIT INPUT (an
optional 4 to 20 mA input, described below). ACTIVE
DEMAND LIMIT may also be forced to be different from
BASE DEMAND LIMIT by manually overriding the value
(forcing) from the MAINSTAT screen or writing a value via a
CCN network device, or controlled by another chiller in Lead
Lag operation (see page 51).
The demand limit may be based on either line current or
kW, as indicated by DEMAND LIMIT SOURCE in the
EQUIPMENT SERVICE/RAMP_DEM table. The default is 0,
for demand limiting based on AVERAGE LINE CURRENT
(percent of RATED LINE AMPS, as displayed on the default
screen). Setting DEMAND LIMIT SOURCE to 1 makes
demand limiting based on PERCENT LINE KILOWATTS
312
42
If the PIC III control initiates a safety shutdown, it displays
the reason for the shutdown (the fault) on the ICVC display
screen along with a primary and secondary message, and blinks
the alarm light on the control panel. The alarm is stored in
memory and can be viewed on the ALARM HISTORY and
VFD_HIST screens on the ICVC, along with a message for
troubleshooting. If the safety shutdown was also initiated by a
fault detected in the VFD, the conditions at the time of the fault
will be stored in VFD_HIST.
To give more precise information or warnings on the
chiller’s operating condition, the operator can define alert
limits on various monitored inputs in the SETUP1 screen.
A partial list of protective safety and alert limits is provided
in Table 6. A complete list of alarm and alert messages is provided in the Troubleshooting Guide section, page 89.
These schedules can be set up to follow a building’s
occupancy schedule, or the chiller can be set so to run 100% of
the time, if the operator wishes. The schedules also can be
bypassed by forcing the CHILLER START/STOP parameter on
the MAINSTAT screen to START. For more information on
forced starts, see Local Start-Up, page 57.
The schedules also can be overridden to keep the chiller in
an occupied state for up to 4 hours, on a one time basis. See the
Time Schedule Operation section, page 25.
Figure 19 shows a schedule for a typical office building
with a 3-hour, off-peak, cool-down period from midnight to
3 a.m., following a weekend shutdown. Holiday periods are in
an unoccupied state 24 hours per day. The building operates
Monday through Friday, 7:00 a.m. to 6:00 p.m., and Saturdays
from 6:00 a.m. to 1:00 p.m. This schedule also includes the
Monday midnight to 3:00 a.m. weekend cool-down schedule.
NOTE: This schedule is for illustration only and is not
intended to be a recommended schedule for chiller operation.
Whenever the chiller is in the LOCAL mode, it uses
Occupancy Schedule 01 (OCCPC01S). When the chiller is in
the ICE BUILD mode, it uses Occupancy Schedule 02
(OCCPC02S). When the chiller is in CCN mode, it uses
Occupancy Schedule 03 (OCCPC03S).
The CCN SCHEDULE NUMBER is configured on the
NET_OPT display screen, accessed from the EQUIPMENT
CONFIGURATION table. See Table 4, Example 17. SCHEDULE NUMBER can be changed to any value from 03 to 99. If
this number is changed on the NET_OPT screen, the operator
must go to the ATTACH TO NETWORK DEVICE screen to upload new number into the SCHEDULE screen. See Fig. 17.
Safety Controls — The PIC III monitors all safety control inputs and, if required, shuts down the chiller or limits the
guide vanes to protect the chiller from possible damage from
any of the following conditions:
• high bearing temperature
• high motor winding temperature
• high discharge temperature
• low discharge superheat*
• low oil pressure
• low cooler refrigerant temperature/pressure
• condenser high pressure or low pressure
• inadequate water/brine cooler and condenser flow
• high, low, or loss of voltage
• ground fault
• voltage imbalance
• current imbalance
• excessive motor acceleration time
• lack of motor current signal
• excessive motor amps
• excessive compressor surge
• temperature and transducer faults
• VFD power faults
• VFD over temperature
• dew formation on the VFD cold plate
*Superheat is the difference between saturation temperature
and sensible temperature. The high discharge temperature
safety measures only sensible temperature.
VFD faults or optional protective devices within the VFD
can shut down the chiller.
Shunt Trip (Option) — A main circuit breaker shunt trip
may be provided on a VFD. Other VFDs are equipped with a
“gate-kill” feature which disables the VFD output transistors
providing the same emergency shutdown function as a circuit
breaker shunt trip. Shunt trips can be initated from either ICVC
or the VFD.
When a shunt trip is provided, it is wired from a discreet
output in the VFD which is activated by the ICVC or by logic
in the VFD. The following conditions will initiate a shunt trip
or Gate Kill:
• Motor locked rotor amps limit exceeded.
• VFD locked rotor amps rating exceeded.
• Ground fault or phase-to-phase current fault limit
exceeded on the load side of the drive. The LiquiFlo™ 2
drive also has these safeties on the line side.
• Significant motor current detected more than 20 seconds
after a shutdown or otherwise when the chiller is off.
Other drive-specific conditions or features may energize
the shunt trip. The shunt trip feature can be tested using the
Control Test feature.
Default Screen Freeze — When the chiller is in an alarm
state, the default ICVC display “freezes,” that is, it stops updating.
The first line of the ICVC default screen displays a primary alarm
message; the second line displays a secondary alarm message.
The ICVC default screen freezes to enable the operator to
see the conditions of the chiller at the time of the alarm. If the
value in alarm is one normally displayed on the default screen,
it flashes between normal and reverse contrast. The ICVC
default screen remains frozen until the condition that caused
the alarm is remedied by the operator. Use ICVC display and
alarm shutdown record sheet (page CL-12) to record all values
from default screen freeze.
Knowledge of the operating state of the chiller at the time an
alarm occurs is useful when troubleshooting. Additional chiller
information can be viewed on the status screens and the
VFD_HIST screen. Troubleshooting information is recorded in
the ALARM HISTORY table, which can be accessed from the
SERVICE menu.
To determine what caused the alarm, the operator should read
both the primary and secondary default screen messages, as well
as the alarm history. The primary message indicates the most
recent alarm condition. The secondary message gives more
detail on the alarm condition. Since there may be more than one
alarm condition, another alarm message may appear after the
first condition is cleared. Check the ALARM HISTORY screen
for additional help in determining the reasons for the alarms.
Once all existing alarms are cleared (by pressing the RESET
softkey), the default ICVC display returns to normal operation.
CAUTION
If compressor motor overload or a motor ground fault
occurs, check the motor for grounded or open phases
before attempting a restart.
43
Table 6 — Protective Safety Limits and Control Settings
MONITORED PARAMETER
Temperature Sensors Out of Range
Pressure Transducers Out of Range
High Compressor Discharge Temperature
ALARM/
ALERT
260-271,
140,141
260-271
231
167
103
High Motor Temperature
233
102
Compressor Thrust Bearing Temperature

101
234
Low Evaporator Temperature
(Freeze Protection)
LIMIT
.06 > Voltage Ratio > .98 or – 40 F >
Temperature>245 F for 3 seconds
Preset Alarm, Voltage Ratio=Input Voltage/
Voltage Reference(5 Volts)
Preset Alarm, Voltage Ratio=Input Voltage/
.06 > Voltage Ratio > .98 for 3 seconds
Voltage Reference(5 Volts)
COMP DISCHARGE TEMP > 220 F
Preset Alarm, Configure COMP DISCHARGE
(104.4 C)
ALERT in SETUP1 screen
COMP DISCHARGE TEMP > COMP DISCHARGE Configure COMP DISCHARGE ALERT in SETUP1
ALERT
screen
COMP DISCHARGE TEMP > COMP DISCHARGE Prestart Alert, Configure COMP DISCHARGE
ALERT – 10 F (5.6 C)
ALERT in SETUP1 screen
COMP MOTOR WINDING TEMP > 220 F
Preset Alarm, Configure COMP MOTOR TEMP
(104 C)
OVERRIDE in SETUP1 screen
COMP MOTOR WINDING TEMP > COMP MOTOR Prestart Alert, Configure COMP MOTOR TEMP
TEMP OVERRIDE – 10 F (5.6 C)
OVERRIDE in SETUP1 screen
COMP THRUST BRG TEMP > COMP THRUST
Preset Alert, Configure COMP THRUST BRG
BRG ALERT – 10 F (5.6 C)
ALERT in SETUP1 screen
COMP THRUST BRG TEMP > COMP THRUST
Preset Alarm
BRG TRIP
Transducer Voltage Fault
239
Chiller in RECYCLE SHUTDOWN and EVAP
TEMP< EVAP REFRIG TRIPPOINT + 1 F
EVAP REFRIG TEMP < 33 F (water) and
EVAP APPROACH > EVAP APPROACH ALERT
0° F (–17.8 C) < EVAP REFRIG TEMP
< 40 F (4.4 C) (brine) and EVAP APPROACH
> EVAP APPROACH ALERT
EVAPORATOR REFRIG TEMP < 33 F
+ REFRIG OVERRIDE DELTA T (water)
EVAPORATOR REFRIG TEMP < EVAP REFRIG
TRIPPOINT (brine)
5.5 VDC < Voltage Reference < 4.5 VDC
High Condenser Pressure — Control
235
CONDENSER PRESSURE > 165 PSI
Switch
207
Prestart
106
High Pressure Switch Open (165 ± 5 PSIG) &
VFD START = YES
CONDENSER PRESSURE > COND PRESS
OVERRIDE – 20 PSI
CONDENSER PRESSURE > 145 PSI
Chiller in PUMPDOWN mode and CONDENSER
REFRIG TEMP < CONDENSER FREEZE POINT
Energizes condenser pump relay if CONDENSER
REFRIG TEMP < CONDENSER FREEZE POINT.
Deenergizes condenser pump relay when
CONDENSER REFRIG TEMP > CONDENSER
FREEZE POINT + 5 F (2.8 C) and ENTERING
COND LIQUID > CONDENSER FREEZE POINT
OIL PRESSURE DELTA P < 13 PSID and
VFD START = TRUE
OIL PRESSURE DELTA P < 18 PSID and startup
complete after OIL PRESS VERIFY TIME elapsed
OIL PRESSURE DELTA P < 18 PSID and startup
complete
OIL PRESSURE DELTA P > 4 PSI immediately
before oil pump turned on
OIL SUMP TEMP < 150 F and OIL SUMP TEMP <
EVAP REFRIG TEMP + 50 F (27.8 C)
Line voltage > approximately 528 V, limits are
calculated by VFD
PERCENT LINE VOLTAGE > Overvoltage
threshold
DC BUS VOLTAGE < approximately 408 V,
limits are calculated by a VFD
PERCENT LINE VOLTAGE < Undervoltage
threshold
243
232
104
Low Condenser Pressure
(Freeze Protection)
244
154
Oil — Low Pressure
228
Low Pressure
Low Pressure
142
Pressure Sensor Fault
227
Low Temperature
105
Line Voltage — High
High
108
Low
212/146
Low
107
Imbalance
216
Line Current — Single Cycle Dropout
Imbalance
Power — Line Frequency Out of Range
ICVC Power on Reset
312
211/145
LINE VOLTAGE IMBALANCE > LINE VOLTAGE
% IMBALANCE
210/144
Line Voltage on 2 Phases < 50% for 1 Cycle
209/143
LINE CURRENT IMBALANCE>LINE CURRENT
% IMBALANCE
222
214/148
COMMENTS
47 Hz < LINE FREQUENCY < 63 Hz
Loss of control power to ICVC for excessive time
period
44
Preset Alarm, configure EVAP REFRIG
TRIPPOINT in SETUP1 screen
Preset Alarm, Configure EVAP APPROACH
ALERT in SETUP1 screen
Configure EVAP REFRIG TRIP POINT and
CHILLED MEDIUM in SETUP1 screen
Prestart Alert, Configure REFRIG OVERRIDE
DELTA T in SETUP1 screen
Prestart Alert, Configure EVAP REFRIG TRIPPOINT and CHILLED MEDIUM in SETUP1 screen
Preset Alarm
Preset Alarm, Configure COND PRESS
OVERRIDE in SETUP1 screen
Preset Alarm, Switch closes at 110 ± – PSIG
Prestart Alert, Configure COND PRESS
OVERRIDE in SETUP1 screen
Prestart Alert
Preset Alarm, Configure CONDENSER FREEZE
POINT in SETUP1 screen.
Configure CONDENSER FREEZE POINT in
SETUP1 screen
Preset Alarm
Preset Alarm, Configure OIL PRESS VERIFY
TIME in SETUP1 screen
Preset Alert
Preset Alarm
Prestart Alert
Preset Alarm/Alert
Preset Prestart Alert
Preset Alarm/Alert
Preset Prestart Alert
Configure LINE VOLTAGE % IMBALANCE and
LINE VOLT IMBALANCE TIME in VFD CONF
screen
Preset Alarm
Configure LINE CURRENT % IMBALANCE and
LINE CURRENT IMBALANCE TIME in
VFD_CONF screen
Preset Alarm
Preset Alarm
Table 6 — Protective Limits and Control Settings (cont)
MONITORED PARAMETER
ALARM/ALERT
LIMIT
> 5 surge events within SURGE TIME PERIOD
and VFD SPEED > 90%
> 5 surge events within SURGE TIME PERIOD
and VFD SPEED < 90%
Motor — Surge
238
Surge
236
Current Imbalance
225
Overload Trip
217
Excessive Amps
208
Acceleration Fault
203
PERCENT LOAD CURRENT > 95% and
VFDSTART = TRUE for 5 to 40 sec
Amps Not Sensed
202
PERCENT LOAD CURRENT < 5% for 3 seconds
and VFD START=TRUE for 20 sec
Starts Limit Exceeded
100
Low Chilled Water Flow
229
Low Cond Water Flow
230
High Approach — Evaporator
162
Condenser
163
VFD — High VFD Speed
245
Failure to Stop
204
Rectifier — High Temperature
218
110
Overcurrent
241
Power Fault
200
Inverter — High Temperature
219
111
Power Fault
Inductor — Overtemperature Switch
DC Bus Voltage — High
Low
Ground Fault
Optional Limits — Spare Temperature
Guide Vane Position
286
201
256
205/166
215
220
158,159,
248,249
253
MOTOR CURRENT IMBALANCE > MOTOR
CURRENT % IMBALANCE
Any LOAD CURRENT PHASE > 108% for
Excessive Time Period
PERCENT LOAD CURRENT > 110% for 30 sec.
More than 8 starts in 12 hours
CHILLED LIQUID FLOW = FALSE after CHILLED
WATER PUMP = ON & WATER FLOW VERIFY
TIME elapsed
COND WATER FLOW = FALSE after COND
WATER PUMP = ON & WATER FLOW VERIFY
TIME elapsed
EVAPORATOR APPROACH > EVAP APPROACH
ALERT and startup complete
CONDENSER APPROACH > COND APPROACH
ALERT and startup complete
ACTUAL VFD SPEED > VFD SPEED OUTPUT
+ 10%
240
Humidity — Dew Prevention
255
Sensor Fault
168
Optional Alarm, Configure WATER FLOW VERIFY
TIME in SETUP1 screen
Optional Alarm, Configure WATER FLOW VERIFY
TIME in SETUP1 screen
Configure EVAP APPROACH ALERT in SETUP1
screen
Configure COND APPROACH ALERT in SETUP1
screen
Preset Alarm, Must be outside +10% threshold for
75 sec.
Preset Alarm, PERCENT LOAD CURRENT =
PERCENT LOAD CURRENT >15% and
AVERAGE LOAD CURRENT/MOTOR RATED
VFDSTART = NO for 20 sec
LOAD AMPS
Preset Alarm, Configure RECTIFIER TEMP
RECTIFIER TEMPERATURE limit exceeded
OVERRIDE in SETUP1 screen
RECTIFIER TEMPERATURE > RECTIFIER TEMP Prestart Alert, Configure RECTIFIER TEMP
OVERRIDE –20 F (11.1 C)
OVERRIDE in SETUP1 screen
Rectifier current limit exceeded
Preset Alarm
IGBT current limit exceeded or a fault was detected Preset Alarm
in the rectifier
Preset Alarm, Configure INVERTER TEMP
INVERTER TEMPERATURE limit exceeded
OVERRIDE in SETUP1 screen
INVERTER TEMPERATURE > INVERTER TEMP Prestart Alert, Configure INVERTER TEMP
OVERRIDE –20 F (11.1 C)
OVERRIDE in SETUP1 screen
Inverter current limit exceeded
Preset Alarm
IGBT current limit exceeded
Preset Alarm
Preset Alarm, Temperature switch in reactor has
Inductor temperature limit exceeded
opened
DC BUS VOLTAGE Limit Exceeded
Preset Alarm/Alert
DC BUS VOLTAGE < 407 VDC at 400/480 V
Preset Alarm
Line Side Voltage
GROUND FAULT CURRENT > 7% of Drive Rated
Preset Alarm
Amps Sensed
Optional Alarm/Alert, Configure SPARE TEMP
SPARE TEMPERATURE > SPARE TEMP LIMIT
ENABLE and SPARE TEMP LIMIT in SETUP1
screen
ACTUAL GUIDE VANE POS > 4% after 4 minutes Preset Alarm
of closing
ACTUAL GUIDE VANE POSITION < .045 volts
Preset Alarm
after startup complete
ACTUAL GUIDE VANE POSITION > 3.15 volts
after startup complete
ACTUAL GUIDE VANE POSITION < –1% after
startup complete
ACTUAL GUIDE VANE POSITION > 103% after
startup complete
Low Discharge Superheat
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
DISCHARGE SUPERHEAT < SUPERHEAT
REQUIRED –3 F (1.7 C) for 60 seconds
Preset Alarm
Preset Alarm
Preset Alarm
Preset Alarm, DISCHARGE SUPERHEAT = COMP
DISCHARGE TEMP – CONDENSER REFRIG
TEMP
VFD COOLANT FLOW = 0% and VFD COLD
PLATE TEMPERATURE < Tdewpoint + 0.5 F
(0.3 C) or VFD COOLANT FLOW = 0% and there is Preset Alarm
a Rectifier Overtemperature or Inverter Overtemperature Alarm
HUMIDITY SENSOR INPUT > 4.5 V or
Preset Alert
HUMIDITY SENSOR INPUT < 0.5 V
45
Ramp Loading — The ramp loading control slows down
the rate at which the compressor loads up. This control can prevent the compressor from loading up during the short period of
time when the chiller is started and the chilled water loop has to
be brought down to CONTROL POINT. This helps reduce
electrical demand charges by slowly bringing the chilled water
to CONTROL POINT. The total power draw during this period
remains almost unchanged.
There are several methods of ramp loading with the PIC III.
Ramp loading can be based on LEAVING CHILLED WATER,
ENTERING CHILLED WATER, PERCENT LINE CURENT,
or PERCENT MOTOR KILOWATTS. PULLDOWN RAMP
TYPE is selected from the RAMP__DEM screen.
1. Temperature ramp loading (TEMP PULLDOWN DEG/
MIN) limits the degrees per minute rate at which either
LEAVING CHILLED WATER or ENTERING CHILLED
WATER temperature decreases. This rate is configured by
the operator on the TEMP_CTL screen.
NOTE: If chiller control power has been off for 3 hours or
more, the next start-up (only) will follow temperature ramp
loading using the minimum rate regardless of the ramp loading
method and rate which are configured in the screens. This is
used to maximize oil reclaim during start-up.
2. Motor load ramp loading (AMPS OR KW RAMP %/
MIN) limits the rate at which the compressor motor current or compressor motor load increases. The AMPS OR
KW RAMP %/MIN rate is configured by the operator
on the RAMP_DEM screen in line current or motor
kilowatts.
If kilowatts is selected for the DEMAND LIMIT SOURCE,
the MOTOR RATED LOAD KILOWATTS must be entered in
the VFD_CONF screen.
The TEMP PULLDOWN DEG/MIN may be viewed or
modified on the TEMP_CTL screen which is accessed from
the EQUIPMENT SERVICE screen. PULLDOWN RAMP
TYPE, DEMAND LIMIT SOURCE, and AMPS OR KW RAMP
%/MIN may be viewed or modified on RAMP_DEM screen.
Whenever the motor current demand limit set point
(ACTIVE DEMAND LIMIT) is reached, it activates a capacity
override, again, with a 2-step process. Exceeding 110% of the
rated load amps for more than 30 seconds will initiate a safety
shutdown.
The high compressor lift (surge prevention) set point will
cause a capacity override as well. When the surge prevention
set point is reached, the controller normally will only prevent
the guide vanes from opening. If so equipped, the hot gas
bypass valve will open instead of holding the vanes. The hot
gas bypass will only open if the compressor is at 100% speed.
See the Surge Prevention Algorithm section, page 50.
High Discharge Temperature Control — If the
COMP DISCHARGE TEMP increases above 160 F (71.1 C),
the guide vanes are proportionally opened to increase gas flow
through the compressor. If the LEAVING CHILLED WATER
temperature decreases 5 F (2.8 C) below the control set point
temperature, as a result of opening the guide vanes, the PIC III
will bring the chiller into the recycle mode.
 Compressor Bearing Temperature — The thrust
bearing temperature (MTRB) is a calculated value which is the
temperature of the oil leaving the bearing plus an internal increment calculated with the THRUST BRG RESET FACTOR. The
Comp Thrust Bearing Reset is calculated using the rate of
change of the oil leaving the bearing. If the oil temperature is
stable the COMP THRUST BRG TEMP equals the COMP
THRUST LVG OIL TEMP. As the oil temperature rises, the
COMP THRUST BRG RESET is calculated to account for any
lag between actual bearing temperature and the temperature of
the leaving oil.
In the SETUP1 screen an adjustment called the THRUST
BRG RESET FACTOR is an adjustment to the COMP THRUST
BRG TEMP calculation. The default value is 1.4 and will normally be left at that value unless other wise advised by Carrier
Service Engineering.
Oil Sump Temperature and Pump Control — The oil sump temperature is regulated by the PIC III,
Rampdown — The Rampdown control applies to VFD
equipped chillers. At machine startup the VFD speed is set to
“Start Speed” which is the lower of VFD MAXIMUM SPEED
or the configured value of VFD START SPEED. VFD START
SPEED is configured on the SETUP2 screen. After Ramp
Loading is complete the control begins to reduce the VFD
speed. Speed reduction continues until the leaving water temperature is within the control point dead band and any condition is reached that would require the VFD speed to hold or increase. The chiller is then out of Rampdown and running in
normal capacity control.
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).
Capacity Override — Capacity overrides can prevent
some safety shutdowns caused by exceeding the motor amperage limit, low evaporator temperature safety limit, high motor
temperature safety limit, and high condenser pressure limit. In
all cases, there are two stages of compressor capacity control
applied by guide vane operation:
1. When the value of interest crosses the First Stage Set
Point into the Override Region, the guide vanes are
prevented from opening further, and the status line on the
ICVC indicates the reason for the override. Normal
capacity control operation is restored when the value
crosses back over the First Stage Set point, leaving the
Override Region. See Table 7.
2. When the value of interest is in the Override Region and
further crosses the Second Stage Set Point, the guide
vanes are closed until the value meets the Override
Termination Condition. The PIC III controls resume
normal capacity control operation after the override
termination condition has been satisfied. (In the case of
high discharge superheat, there is an intermediate stage.)
312
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
46
the certified drawings for further details on contact ratings. The
contacts must have 24 vac dry contact rating.
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.
Spare Safety and Spare Temperature Inputs —
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 51.
Remote Start/Stop Controls — A remote device, such
as a timeclock that uses a set of contacts, may be used to start
and stop the chiller. However, the device should not be programmed to start and stop the chiller in excess of 2 or 3 times
every 12 hours. If more than 8 starts in 12 hours (the STARTS
IN 12 HOURS parameter on the MAINSTAT screen) occur,
(not counting either recycle restarts or auto. restarts after power
failure) an excessive starts alarm displays, preventing the chiller from starting. The operator must press the RESET softkey
on the ICVC to override the starts counter and start the chiller.
If the chiller records 12 starts (excluding recycle starts) in a
sliding 12-hour period, it can be restarted only by pressing the
RESET softkey followed by the LOCAL or CCN softkey.
This ensures that, if the automatic system is malfunctioning,
the chiller will not repeatedly cycle on and off. If the AUTO
RESTART OPTION in the OPTIONS screen and the REMOTE
CONTACTS OPTION are enabled, the REMOTE CONTACTS
must be closed in order for the chiller to restart following a
power failure. If the automatic restart after a power failure option (AUTO RESTART OPTION on the OPTIONS screen) is
not activated when a power failure occurs, and if the remote
contact is closed, the chiller will indicate an alarm because of
the loss of voltage.
The contacts for remote start are wired into terminals 23 and
24 of the low voltage terminal strip in the VFD enclosure. See
Alarm (Trip) Output Contacts — One set of alarm
contacts is provided in the VFD. The contact ratings are
provided in the certified drawings. The contacts are located on
terminals 9 and 10 of the TB2 field wiring terminal strip in the
VFD enclosure.
Table 7 — Capacity Overrides Table
OVERRIDE
CONDITION
View/Modify on
ICVC Screen
High Condenser Pressure
(COND PRESS OVERRIDE)
SETUP1
High Motor Temperature
(COMP MOTOR TEMP
OVERRIDE)
SETUP1
Low Evaporator Temperature
(REFRIG OVERRIDE
DELTA T)
SETUP1
FIRST STAGE SET POINT
Override Default
Configurable
Value
Range
CONDENSER
90
to
165 psig
PRESSURE
(621 to 1138 kPa)
>125 psig (862 kPa)
COMP MOTOR
150 to 200 F
WINDING TEMP
(66 to 93 C)
> 200 F (93 C)
EVAPORATOR
REFRIG TEMP
< EVAP REFRIG
TRIPPOINT + 3 F
(1.7 C)
2 to 5 F
(1.1 to 2.8 C)
SECOND STAGE SET POINT
OVERRIDE TERMINATION
Value
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
CONDENSER PRESSURE
< CONDENSER PRESS
OVERRIDE – 1 PSI (6.9 kPa)
COMPR MOTOR WINDING
TEMP < COMP MOTOR TEMP
OVERRIDE – 2 F (1.1 C)
EVAP REFRIG TEMP
> EVAP REF OVERRIDE TEMP
+ 2 F (1.1 C)
0.5 - 2.0 F
(0.3 - 1.1 C)
30 - 170 psid
(207 - 1172 kPad)
0.5 - 20 F
(0.3 - 11.1 C)
50 - 170 psid
(345 - 1172 kPad)
None
ACTIVE DELTA T > SURGE/
HGBP DELTA T + SURGE/HGBP
DEADBAND
Automatic
0 to 100%
None
Press RELEASE softkey after
selecting TARGET GUIDE VANE
POS
COMPRESS
Automatic
VFD MINIMUM
SPEED to 100%
Motor Load
(ACTIVE DEMAND LIMIT)
MAINSTAT
Automatic
40 to 100%
Low Discharge Superheat
OVERRIDE
Min T1: 1.5 F (0.8 C)
High Compressor Lift
(SURGE/HGBP DELTA T,P)
OPTIONS
Min P1: 50 psid
(345 kPa)
Max T2: 10 F (5.6 C)
Max P2: 85 psid
(586 kPad)
Manual Guide Vane Target
(TARGET GUIDE VANE POS)
Manual Speed Control
(TARGET VFD SPEED)
High Rectifier Temperature
(RECTIFIER TEMP
OVERRIDE)
High Inverter Temperature
(INVERTER TEMP
OVERRIDE)
COMPRESS
SETUP1
SETUP1
ACTUAL SUPERHEAT < SUPERHEAT
REQUIRED for
conditions
RECTIFIER
TEMPERATURE >
160 F (71 C)
INVERTER
TEMPERATURE >
160 F (71 C)
None
155 to 170 F
(68 to 77 C)
155 to 170 F
(68 to 77 C)
47
Forced TARGET VFD SPEED
cannot override either a
capacity inhibit or a capacity
decrease command generated by
the PIC III
ACTIVE DEMAND LIMIT
> Set Point + 5%
Press RELEASE softkey after
selecting TARGET VFD SPEED
ACTIVE DEMAND LIMIT
< Set Point – 2%
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)
TEMP was more than 5 F (2.7 C) above the CONDENSER
FREEZE POINT, the same low temperature condition will
generate Alarm State 244 and the CONDENSER WATER
PUMP will be energized. In either case, the fault state will clear
and the pump will turn off when the CONDENSER REFRIG
TEMP is more than 5 F (2.7 C) above the CONDENSER
FREEZE POINT and the entering condenser water temperature
is greater than the CONDENSER FREEZE POINT. If the chiller is in Recycle Shutdown Mode when the condition occurs,
the controls will transition to a non-recycle shutdown.
Kilowatt Output — An output is available on the CCM
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 chiller’s 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 5°F (2.8°C) above the CONTROL POINT.
When the unit is off, if the EVAPORATOR REFRIG TEMP
is less than the EVAP REFRIG 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.
Remote Reset of Alarms — A standard feature of the
PIC III controls is the ability to reset a chiller in a shutdown
alarm state from a remote location. If the condition which
caused the alarm has cleared the chiller, the chiller can be
placed back into a normal CCN operating mode when the
REMOTE RESET OPTION (ICVC_PWD menu) is set to
ENABLE. A variety of Carrier Comfort Network® software
systems including ComfortVIEW™ or Network Service
Tool™ can access the PIC III controls and reset the displayed
alarm. Third party software from building automation systems
(BAS) or energy management systems (EMS) can also access
the PIC III controls through a Carrier DataLINK™ module and
reset the fault displayed. Both methods would access the
ICVC_PWD screen and force the RESET ALARM? point to
YES to reset the fault condition. If the PIC III controls have determined that it is safe to start the chiller, the CCN MODE?
point (ICVC_PWD screen) can be forced to YES to place the
chiller back into normal CCN operating mode. The only exceptions are the following alarms that cannot be reset from a
remote location: Alarm/Alert STATE 100, 200, 201, 204, 206,
217-220, 233, 234, 247, and 259. To view alarm codes, refer to
Troubleshooting Guide, Checking Display Messages, page 89.
After the alarm has been reset, the PIC III control will increment the STARTS IN 12 HOURS counter by one upon restart. If
the limit of 8 starts in a 12-hour period is reached (Prestart/
Alert state 100), this must be reset at the local chiller control
panel (ICVC).
Tower Fan Relay Low and High — Low condens-
er water temperature can cause the chiller to shut down when
refrigerant temperature is low. The tower fan relays, located in
the VFD, are controlled by the PIC III to energize and deenergize as the pressure differential between cooler and condenser
vessels changes. This prevents low condenser water temperature and maximizes chiller efficiency. The tower fan relay can
only accomplish this if the relay has been added to the cooling
tower temperature controller.
TOWER FAN RELAY LOW is turned on whenever the
condenser water pump is running, flow is verified, and the
difference between cooler and condenser pressure is more than
30 psid (207 kPad) for entering condenser water temperature
greater than 65 F (18.3 C).
TOWER FAN RELAY LOW is turned off when the condenser pump is off, flow is stopped, or the EVAP REFRIGERANT
TEMP is less than the EVAP REF OVERRIDE TEMP for
ENTERING CONDENSER WATER temperature less than
62 F (16.7 C), or the difference between the CONDENSER
PRESSURE and EVAPORATOR PRESSURE is less than
25 psid (172.4 kPad) for ENTERING CONDENSER water less
than 80 F (27 C).
TOWER FAN RELAY HIGH is turned on whenever
the condenser water pump is running, flow is verified and
the difference between EVAPORATOR PRESSURE and
CONDENSER PRESSURE is more than 35 psid (241.3 kPa)
for ENTERING COND WATER temperature greater than the
TOWER FAN HIGH SETPOINT (SETPOINT menu, default
75 F [23.9 C]).
The TOWER FAN RELAY HIGH is turned off when the
condenser pump is off, flow is stopped, or the EVAPORATOR
REFRIG TEMP is less than the EVAP REF OVERRIDE TEMP
and ENTERING CONDENSER WATER is less than 70 F
(21.1 C), or the difference between EVAPORATOR PRESSURE and CONDENSER PRESSURE is less than 28 Psid
(193 kPa), and ENTERING CONDENSER WATER temperature is less than TOWER FAN HIGH SETPOINT minus 3 F
(–16.1 C).
Condenser Pump Control — The chiller will moni-
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.
Condenser Freeze Prevention — This control algo-
rithm helps prevent condenser tube freeze-up by energizing the
condenser pump relay. The PIC III controls the pump and, by
starting it, helps to prevent the water in the condenser from
freezing. The PIC III can perform this function whenever the
chiller is not running except when it is either actively in pumpdown or in pumpdown/lockout with the freeze prevention
disabled.
When the chiller is off and CONDENSER REFRIG TEMP
is less than the CONDENSER FREEZE POINT, the
CONDENSER WATER PUMP will be energized (Alert State
154) However, if the chiller is in pump down, and when it
entered pump down mode, the CONDENSING REFRIG
48
types of chilled water or brine reset are available and can be
viewed or modified on the TEMP_CTL screen, which is
accessed from the EQUIPMENT SERVICE table.
The ICVC default screen indicates when the chilled water
reset is active. TEMPERATURE RESET on the MAINSTAT
screen indicates the amount of reset. The CONTROL POINT
will be determined by adding the TEMPERATURE RESET to
the SETPOINT.
To activate a reset type, access the TEMP_CTL screen and
input all configuration information for that reset type. Then,
input the reset type number (1, 2, or 3) in the SELECT/
ENABLE RESET TYPE input line.
RESET TYPE 1: 4 to 20 mA (1 to 5 vdc) TEMPERATURE
RESET — Reset Type 1 is an “automatic” reset utilizing a 4 to
20 mA or 1 to 5 vdc analog input signal provided from any
external sensor, controller, or other device which is appropriately configured. Reset Type 1 permits up to ±30 F (±16.7 C)
of reset to the chilled water set point. Inputs are wired to terminals J5-3 (–) and J5-4 (+) on the CCM (for 4-20 mA input). In
order to utilize a 1 to 5 vdc input, a 250 ohm resistor must be
wired in series with the + input lead (J5-4). For either input
type, SW2 DIP switches should be set in the ON (up) position.
Inputs equivalent to less than 4 mA result in no reset, and
inputs exceeding 20 mA are treated as 20 mA.
RESET TYPE 2: REMOTE TEMPERATURE RESET —
Reset Type 2 is an automatic chilled water temperature reset
based on a remote temperature sensor input signal. Reset type 2
permits ± 30 F (± 16 C) of automatic reset to the set point based
on a temperature sensor wired to the CCM module (see wiring
diagrams or certified drawings). The temperature sensor must
be wired to terminal J4-13 and J4-14. To configure Reset Type
2, enter the temperature of the remote sensor at the point where
no temperature reset will occur (REMOTE TEMP –> NO RESET). Next, enter the temperature at which the full amount of
reset will occur (REMOTE TEMP –> FULL RESET). Then,
enter the maximum amount of reset required to operate chiller
(DEGREES RESET). Reset Type 2 can now be activated.
RESET TYPE 3 — Reset Type 3 is an automatic chilled water
temperature reset based on cooler temperature difference.
Reset Type 3 adds ± 30 F (± 16 C) based on the temperature
difference between the ENTERING CHILLED WATER and
LEAVING CHILLED WATER temperature.
To configure Reset Type 3, enter the chilled water temperature difference (the difference between entering and leaving
chilled water) at which no temperature reset occurs (CHW
DELTA T –> NO RESET). This chilled water temperature difference is usually the full design load temperature difference.
Next, enter the difference in chilled water temperature at which
the full amount of reset occurs (CHW DELTA T –> FULL RESET). Finally, enter the amount of reset (DEGREES RESET).
Reset Type 3 can now be activated.
The TOWER FAN RELAY LOW and TOWER FAN RELAY
HIGH parameters are accessed from the STARTUP screen.
IMPORTANT: A field-supplied water temperature control
system for condenser water should be installed. The system
should maintain the leaving condenser water temperature
at a temperature that is at least 20 F (11 C) above the leaving chilled water temperature.
CAUTION
The tower fan relay control is not a substitute for a condenser water temperature control. When used with a water
temperature control system, the tower fan relay control can
be used to help prevent low condenser water temperatures.
Auto. Restart After Power Failure — This option
may be enabled or disabled and may be viewed or modified
on the OPTIONS screen, which is accessed from the
EQUIPMENT CONFIGURATION table. If the AUTO
RESTART OPTION is enabled, the chiller will start up automatically after a power failure has occurred, generating one of the
following faults: single cycle dropout (if enabled), line current
imbalance, high line voltage, low line voltage, low DC bus
voltage, high DC bus voltage, VFD power on reset, and ICVC
power on reset (alerts 143-148, 165, and 166). With this feature
enabled, these faults are treated as alerts instead of alarms, so
start-up proceeds as soon as the condition is rectified. The 15
and 1-minute start inhibit timers are ignored during this type of
start-up, and the STARTS IN 12 HOURS counter is not
incremented.
When power is restored after the power failure and if the
compressor had been running, the oil pump will energize
for one minute before energizing the cooler pump. AUTO
RESTART will then continue like a normal start-up.
If power to the ICVC module has been off for more than
3 hours or the timeclock has been set for the first time, start the
compressor with the slowest TEMP PULLDOWN DEG/MIN
rate possible in order to minimize oil foaming.
The oil pump is energized occasionally during the time the
oil is being brought up to proper temperature in order to eliminate refrigerant that has migrated to the oil sump during the
power failure. The pump turns on for 30 seconds at the end of
every 30-minute period until the chiller is started.
Fast Power Source Transfers — When the the electrical system is being prepared to transfer power from generator power back to utility power or vice-versa, and the power
transfer is an open transition type, and time to transfer is less
than 5 seconds, the chiller should be stopped before the transfer
occurs and restarted after the transfer has been completed. If
the chiller is not stopped before the transfer occurs, alarms on
the chiller can occur that must be manually reset, such as a circuit breaker trip.
To accomplish shutdown and restart automatically, a set of
dry contacts should be opened 30 to 60 seconds before the
transfer occurs, then closed after the transfer is complete to restart the chiller. The contacts must be wired to the Remote
START/STOP contact in the starter or VFD (See the field wiring diagrams) and the Remote Start contact configuration must
be enabled.
If power transfers take 5 seconds or longer, the chiller Auto
Restart after Power Failure feature (if enabled) will automatically restart the chiller.
Water/Brine Reset — Chilled water capacity control is
based on achieving and maintaining a CONTROL POINT
temperature, which is the sum of the LCW SET POINT or ECW
SETPOINT (from the SETPOINT screen) and a Water/Brine
Reset value, if any. CONTROL POINT is limited to a minimum
of 35 F (+1.7 C) for water, or 10 F (–12.2 C) for brine. Three
Surge Prevention — A surge condition occurs when the
lift becomes so high that the gas flow across the impeller reverses. This condition can eventually cause chiller damage.
The surge prevention algorithm notifies the operator that chiller
operating conditions are marginal and to take action to help
prevent chiller damage such as lowering entering condenser
water temperature.
The surge prevention algorithm is an operator-configurable
feature that can determine if lift conditions are too high for the
compressor and then take corrective action. Lift is defined as
the difference between the saturated temperature at the impeller
eye and at the impeller discharge. The maximum lift a particular impeller wheel can perform varies with the gas flow across
the impeller and the size of the wheel.
Variable Primary Flow Surge prevention is the current standard for both constant and variable primary flow chilled water
systems. Variable Primary Flow Surge Prevention does not re-
49
The surge line constructed from the SURGE/HGBP DELTA
T and SURGE/HGBP DELTA P points is based on full load
conditions and 100% compressor speed. As ACTUAL VFD
SPEED is reduced, the SURGE/HGBP DELTA P values are
automatically reduced so that the surge line duplicates the compressor lift capability at the reduced speed. If the actual operating point (lift vs. load) goes above the surge prevention line
then the controls enter SURGE PREVENTION mode.
Changing the VFD SURGE LINE GAIN adjusts the rate at
which the surge line is adjusted in response to changes in ACTUAL VFD SPEED. Increasing VFD SURGE LINE GAIN reduces the size of the SURGE PREVENTION “on” area.
When the controls enter SURGE PREVENTION mode the
first response is to increase ACTUAL VFD SPEED and increase the lift capability of the compressor while preventing the
guide vanes from opening further. Should the compressor reach
100% ACTUAL VFD SPEED and still be in the surge prevention region, the controls will energize the HOT GAS BYPASS
RELAY (if the SURGE LIMIT/HGBP OPTION is configured
for Hot Gas Bypass).
If load decreases while the chiller is in SURGE PREVENTION mode the ACTUAL GUIDE VANE POSITION will close
but the ACTUAL VFD SPEED will not decrease.
ACTIVE REGION as found on the SURGPREV screen is
based on how far into the surge prevention area that the load
point has moved. This is used to determine the size of the speed
boost to the VFD.
NOTE: If upon ramp-up, a chiller with VFD tends to go to full
speed before guide vanes open fully, it is an indication that the
lift at low load is excessive, and the operating point moved
directly into the surge prevention region. In this case, investigate the ability of the condenser cooling means (e.g., cooling
tower) to provide cooling water in accordance with the design
load/entering condenser water temperature schedule.
A surge condition occurs when the lift becomes so high the
gas flow across the impeller reverses. This condition can eventually cause chiller damage. When enabled, the Surge Prevention Algorithm will adjust either the inlet guide vane (IGV)
position or compressor speed to maintain the compressor at a
safe distance from surge while maintaining machine efficiency.
If the surge condition degrades then the algorithm will move
aggressively away from surge. This condition can be identified
when the SURGE/HGBP ACTIVE? on the HEAT_EX display
screen displays a YES.
quire a measurement of COOLER DELTA T and is thus unaffected by changes in flow. With Variable Primary Flow Surge
Prevention there is no difference in field configuration between
constant and variable flow water systems.
The controls calculate the conditions at which the compressor will surge based on operating conditions and configured
values entered into the OPTIONS screen.
The configurations as used by the controls would plot out
on a graph as a curved line. If the present operating conditions
plot at or above this line, surge prevention is turned on.
The way in which surge prevention functions will differ
with the presence or absence of hot gas bypass.
HGBP OPTION = 1 — The HGBP is only energized if a
SURGE PROTECTION COUNT is registered, the ACTIVE
DELTA T falls below the SURGE/HGBP DELTA T or the VFD
LOAD FACTOR approaches 1.0 and it is not possible to increase VFD speed. The VFD speed cannot increase when the
VFD TARGET SPEED is equal to VFD MAXIMUM SPEED or
if the VFD TARGET SPEED is FORCED to a fixed value.
HGBP OPTION = 2 — This option energizes the HOT GAS
BYPASS RELAY solely based on the ACTIVE DELTA T (actual temperature difference between the LEAVING CHILLED
WATER and ENTERING CHILLED WATER). Evaluation of
the ACTIVE DELTA T begins at the completion of ramp loading. The hot gas bypass valve is energized if the ACTIVE DELTA T is less than the HGBP ON DELTA T. The hot gas bypass
relay will be turned off when the ACTIVE DELTA T is greater
than or equal to the sum of HGBP ON DELTA T plus HGBP
OFF DELTA T See Fig. 23. The HGBP ON DELTA T must be
set to a value larger than the minimum delta T to which the
chiller can unload.
HGBP OFF
DELTA T
HGBP Off As ACTIVE
DELTA T Decreases
∆P
HGBP
Off
HGBP
On
HGBP On As ACTIVE
DELTA T Increases
Surge Protection — The PIC III monitors surge, which
HGBP ON
DELTA T
results in a fluctuation on the compressor motor amperage.
Each time the fluctuation in amperage exceeds an operatorspecified limit (SURGE DELTA % AMPS) plus a load correction factor, both SURGE COUNTS are incremented by one
and the VFD will increase in speed provided that it is not already operating at VFD MAXIMUM SPEED or that the VFD
TARGET SPEED is forced. If the VFD cannot increase in
speed because the VFD is already at maximum speed of the
target speed is forced then the SURGE PROTECTION
COUNTS are also incremented by one. If more than 4 SURGE
PROTECTION COUNTS occur within an operator-specified
time (SURGE TIME PERIOD) and the ACTUAL VFD
SPEED is greater than 90% then the PIC III declares an Excessive Compressor Surge Alarm (238) and the chiller is shut
down. If more than four SURGE PROTECTION COUNTS
occur within the SURGE TIME PERIOD and the ACTUAL
VFD SPEED is less than 90% then the chiller is shut down on a
Excessive Compressor Surge / Low Speed Alarm (236). Both
SURGE COUNTS and SURGE PROTECTION COUNTS are
decreased by one if no surges occur within the SURGE TIME
PERIOD.
On chillers with VFDs, if a SURGE COUNT is registered
and the ACTUAL VFD SPEED is less than the VFD MAXIMUM SPEED, then TARGET VFD SPEED will be increased
∆T
LEGEND
ECW
— Entering Chilled Water
HGBP
— Hot Gas Bypass
LCW
— Leaving Chilled Water
a19-1864
P = (Condenser Pressure) – (Cooler Pressure)
T = (ECW) – (LCW)
Fig. 23 — Hot Gas Bypass/Surge
Prevention (Option 2)
Surge Prevention Algorithm — This is an operator
configurable feature that can determine if lift conditions are too
high for the compressor and then take corrective action. Lift is
defined as the difference between the saturated temperature at
the impeller eye and at the impeller discharge. The maximum
lift a particular impeller wheel can perform varies with the gas
flow through the impeller and the diameter of the impeller.
With a VFD the lift capability and the position of the surge line
also vary with ACTUAL VFD SPEED.
50
the compressor, if possible, while adjusting the guide vane position until a stable operating point with improved chiller efficiency is attained.
Following a start command, the PIC III controls internally
set the VFD TARGET SPEED to the smaller of the VFD
MAXIMUM SPEED or the VFD START SPEED. Provided
that the chiller has sufficient capacity, the VFD will continue to
run at the startup speed during Ramp Loading until the chilled
water temperature falls within the CHILLED WATER DEADBAND surrounding the set point. RAMP LOADING ACTIVE
in the SURGPREV screen will indicate YES during Ramp
Loading. The GUIDE VANE DELTA will be equal to zero
when the chilled water temperature is in the CHILLED WATER DEADBAND. The VFD speed will then be ramped
down at one half of the VFD GAIN rate until, surge conditions
are encountered, the VFD MINIMUM SPEED is reached, the
ACTUAL GUIDE VANE POS reaches the GUIDE VANE
TRAVEL LIMIT, or the TARGET VFD SPEED is forced.
VFD RAMPDOWN ACTIVE in the SURGPREV screen will
indicate YES during the rampdown process. The VFD speed
will be regulated by standard capacity control and surge prevention algorithms at the conclusion of the rampdown process.
by the amount configured in the VFD INCREASE STEP parameter. The VFD will not decrease in speed if SURGE
COUNTS is greater than zero.
The threshold at which a current fluctuation is interpreted as
a surge can be adjusted from the OPTIONS screen. The portion
of the surge threshold attributable to current fluctuations can be
changed by scrolling to the SURGE DELTA % AMPS parameter and adjusting it with the INCREASE or DECREASE softkeys. The default setting is 10 %. The SURGE TIME PERIOD
can be adjusted from the OPTIONS screen. Scroll to the
SURGE TIME PERIOD parameter and use the INCREASE or
DECREASE softkey to adjust the surge count time interval.
The default setting is 8 minutes.
SURGE PROTECTION COUNTS are displayed in the
COMPRESS screen. Both SURGE PROTECTION COUNTS
and SURGE COUNTS are displayed in the SURGPREV
screen.
Head Pressure Reference Output (See Fig. 24) —
The PIC III control outputs a 4 to 20 mA signal for the
configurable Delta P (CONDENSER PRESSURE minus
EVAPORATOR PRESSURE) reference curve shown in Fig. 24.
The DELTA P AT 100% (chiller at maximum load condition
default at 50 psi), DELTA P AT 0% (chiller at minimum load
condition default at 25 psi) and MINIMUM OUTPUT points
are configurable in the EQUIPMENT SERVICE-OPTIONS
table. When configuring this output ensure that minimum requirements for oil pressure and proper condenser FLASC orifice performance are maintained. The 4 to 20 mA output from
VFD TB1 terminals 17 and 18 may be useful as a reference
signal to control a tower bypass valve, tower speed control,
condenser pump speed control, etc. Note that it is up to the site
design engineering agent to integrate this analog output with
any external system device(s) to produce the desired effect.
Carrier does not make any claim that this output is directly usable to control any specific piece of equipment (that is, without
further control elements or signal conditioning), although it
may be.
The head pressure reference output will be on whenever the
condenser pump is operating. It may also be manually operated
in CONTROLS TEST. When the head pressure differential is
less than the value entered for DELTA P AT 0%, the output will
be maintained at 4 mA.
Lead/Lag Control — The lead/lag control system auto-
matically starts and stops a lag or second chiller in a 2-chiller
water system. A third chiller can be added to the lead/lag
system as a standby chiller to start up in case the lead or lag
chiller in the system has shut down during an alarm condition
and additional cooling is required. Refer to Fig. 16 and 17 for
menu, table, and screen selection information.
NOTE: The lead/lag function can be configured on the LEADLAG screen, which is accessed from the SERVICE menu and
EQUIPMENT SERVICE table. See Table 4, Example 20.
Lead/lag status during chiller operation can be viewed on the
LL_MAINT display screen, which is accessed from the
SERVICE menu and CONTROL ALGORITHM STATUS
table. See Table 4, Example 14.
Lead/Lag System Requirements:
• all chillers in the system must have software capable of performing the lead/lag function
• water pumps MUST be energized from the PIC III controls
• water flows should be constant
• the CCN time schedules for all chillers must be identical
Operation Features:
• 2 chiller lead/lag
• addition of a third chiller for backup
• manual rotation of lead chiller
• load balancing (if configured)
• staggered restart of the chillers after a power failure
• chillers may be piped in parallel or in series chilled water
flow
COMMON POINT SENSOR USAGE AND INSTALLATION — Lead/lag operation does not require a common
chilled water point sensor. However, common point sensors
(Spare Temp #1 and #2) may be added to the CCM module, if
desired.
NOTE: If the common point sensor option is chosen on a
chilled water system, each chiller should have its own common
point sensor installed. Each chiller uses its own common point
sensor for control when that chiller is designated as the lead
chiller. The PIC III cannot read the value of common point
sensors installed on the other chillers in the chilled water
system.
If leaving chilled water control (ECW CONTROL OPTION
is set to 0 [DSABLE] TEMP_CTL screen) and a common
point sensor is desired (COMMON SENSOR OPTION in
LEADLAG screen selected as 1) then the sensor is wired in
Spare Temp #1 position on the CCM (terminals J4-25 and
J4-26).
DELTA P
AT 100%
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%)
Fig. 24 — Head Pressure Reference Output
VFD Start-Up Speed Control — Immediately accelerating to a high VFD speed improves the ability of the compressor to compensate for some start-up environments that exceed condenser water design conditions. The 19XRV chillers
initially accelerate to high VFD speed and then gradually slow
51
displayed. The lead/lag maintenance screen (LL_MAINT) displays the message ‘INVALID CONFIG’ in the LEADLAG:
CONFIGURATION and CURRENT MODE fields.
The lead chiller responds to normal start/stop controls such
as the occupancy schedule, a forced start or stop, and remote
start contact inputs. After completing start-up and ramp
loading, the PIC III evaluates the need for additional capacity.
If additional capacity is needed, the PIC III initiates the start-up
of the chiller configured at the LAG ADDRESS. If the lag
chiller is faulted (in alarm) or is in the OFF or LOCAL modes,
the chiller at the STANDBY ADDRESS (if configured) is
requested to start. After the second chiller is started and is
running, the lead chiller monitors conditions and evaluates
whether the capacity has been reduced enough for the lead
chiller to sustain the system alone. If the capacity is reduced
enough for the lead chiller to sustain the CONTROL POINT
temperatures alone, then the operating lag chiller is stopped.
If the lead chiller is stopped in CCN mode for any reason
other than an alarm (*) condition, the lag and standby chillers
are also stopped. If the configured lead chiller stops for an
alarm condition, the configured lag chiller takes the lead
chiller’s place as the lead chiller, and the standby chiller serves
as the lag chiller.
The PRESTART FAULT TIMER provides a timeout if
there is a prestart alert condition that prevents a chiller from
starting in a timely manner. If the configured lead chiller does
not complete its start-up before the PRESTART FAULT
TIMER (a user-configured value) elapses, then the lag chiller
starts, and the lead chiller shuts down. The lead chiller then
monitors the lag, acting as the lead, for a start request. The
PRESTART FAULT TIMER parameter is on the LEADLAG
screen, which is accessed from the EQUIPMENT SERVICE
table of the SERVICE menu.
If the lag chiller does not achieve start-up before the
PRESTART FAULT TIMER elapses, the lag chiller stops, and
the standby chiller is requested to start, if configured and ready.
Standby Chiller Configuration and Operation — A chiller is
designated as a standby chiller when its LEADLAG: CONFIGURATION value on the LEADLAG screen is set to “3.” The
standby chiller can operate as a replacement for the lag chiller
only if one of the other two chillers is in an alarm (*) condition
(as shown on the ICVC panel). If both lead and lag chillers
are in an alarm (*) condition, the standby chiller defaults to
operate in CCN mode and will operate based on its configured
CCN occupancy schedule and remote contacts input.
Lag Chiller Start-Up Requirements — Before the lag chiller
can be started, the following conditions must be met:
1. The lag chiller status indicates it is in CCN mode and is
not in an alarm condition. If the current lag chiller is in an
alarm condition, the standby chiller becomes the active
lag chiller, if it is configured and available.
2. Lead chiller ramp loading must be complete.
3. The configured LAG STOP TIMER entry has elapsed.
The LAG STOP TIMER starts when the lead chiller ramp
loading is completed or when a lag chiller stops. The
LAG STOP TIMER entry is on the LEADLAG screen.
4. Lead chiller ACTIVE DEMAND LIMIT (see the MAINSTAT screen) value must be greater than 95% of full load
amps.
5. Lead chilled water temperature must be greater than the
CONTROL POINT temperature (see the MAINSTAT
screen) plus 1/2 the CHILLED WATER DEADBAND
temperature (see the SETUP1 screen).
NOTE: The chilled water temperature sensor may be the
leaving chilled water sensor, the return water sensor, the
common supply water sensor, or the common return water sensor, depending on which options are configured
and enabled.
If the entering chilled water control option (ECW CONTROL OPTION) is enabled (configured in TEMP_CTL
screen) and a common point sensor is desired (COMMON
SENSOR OPTION in LEADLAG screen selected as 1) then
the sensor is wired in Spare Temp #2 position on the CCM
(terminals J4-27 and J4-28).
When installing chillers in series, either a common point
sensor should be used (preferred), or the LEAVING CHILLED
WATER sensor of the upstream chiller must be moved into the
leaving chilled water pipe of the downstream chiller. In this
application the COMMON SENSOR OPTION should only be
enabled for the upstream chiller if that chiller is configured as
the Lead.
If ENTERING CHILLED WATER control is required on
chillers piped in series, either the common point return chilled
water sensor should be used (preferred), or the LEAVING
CHILLED WATER sensor of the downstream chiller must be
relocated to the LEAVING CHILLED WATER pipe of the
upstream chiller. In this application, the COMMON SENSOR
OPTION should only be enabled for the downstream chiller if
that chiller is configured as the lead. Note that ENTERING
CHILLED WATER control is not recommended for chillers
installed in series due to potential control stability problems.
To properly control the LEAVING CHILLED WATER
TEMPERATURE when chillers are piped in parallel, the water
flow through the shutdown chiller(s) should be isolated so that
no water bypass around the operating chiller occurs. However,
if water bypass around the operating chiller is unavoidable, a
common point sensor in the mixed LEAVING CHILLED
WATER piping should be provided and enabled for the Lead
chiller.
CHILLER COMMUNICATION WIRING — Refer to the
chiller’s Installation Instructions, Carrier Comfort Network®
Interface section for information on chiller communication
wiring.
LEAD/LAG OPERATION — The PIC III not only has the
ability to operate 2 chillers in lead/lag, but it can also start a
designated standby chiller when either the lead or lag chiller is
faulted and capacity requirements are not met. The lead/lag
option only operates when the chillers are in CCN mode. If any
other chiller configured for lead/lag is set to the LOCAL or
OFF modes, it will be unavailable for lead/lag operation.
Lead/Lag Chiller Configuration and Operation
• A chiller is designated the lead chiller when its LEADLAG:
CONFIGURATION value on the LEADLAG screen is set
to “1.”
• A chiller is designated the lag chiller when its LEADLAG:
CONFIGURATION value is set to “2.”
• A chiller is designated as a standby chiller when its LEADLAG: CONFIGURATION value is set to “3.”
• A value of “0” disables the lead/lag designation of a chiller.
This setting should also be used when “normal” operation
without regard to lead/lag rules is desired (in LOCAL or
CCN mode).
When configuring the LAG ADDRESS value on the
LEADLAG screen of chiller “A” enter the address of the
chiller on the system which will serve as lag when/if chiller
“A” is configured as lead. For example, if you are configuring
chiller A, enter the address for chiller B as the lag address. If
you are configuring chiller B, enter the address for chiller A as
the lag address. This makes it easier to rotate the lead and lag
chillers. Note that only the lag and standby chiller addresses
specified in the configured lead chiller's table are relevant at a
given time.
If the address assignments in the LAG ADDRESS
and STANDBY ADDRESS parameters conflict, the lead/lag
function is disabled and an alert (!) message displays. For
example, if the LAG ADDRESS matches the lead chiller’s
address, the lead/lag will be disabled and an alert (!) message
52
6. Lead chiller temperature pulldown rate (TEMP PULLDOWN DEG/MIN on the TEMP_CTL screen) of the
chilled water temperature is less than 0.5 F (0.27 C) per
minute for a cumulative duration greater than the PULLDOWN TIMER setting in the LEAD/LAG screen.
When all the above requirements have been met, the lag
chiller is commanded to a STARTUP mode (indicated by
“CONTRL” flashing next to the CHILLER START/STOP parameter in the MAINSTAT screen). The PIC III control then
monitors the lag chiller for a successful start. If the lag chiller
fails to start, the standby chiller, if configured, is started.
Lead/Lag Pulldown Timer Operation — Some lead/lag chiller applications with large chilled liquid loop volumes must accommodate intermittent slugs of warm ENTERING
CHILLED WATER for short time periods. This type of transient condition can result when a control valve rapidly opens to
allow flow through a previously isolated branch or zone within
the chilled liquid system. A PULLDOWN TIMER can be configured to delay starting the lag chiller so it does not excessively cycle on and off for short time periods when intermittent
slugs of warm ENTERING CHILLED WATER pass through
the chillers. A larger PULLDOWN TIMER entry gives the
warm slug of water more time to pass through the chillers before the lag chiller can start.
The chiller CONTROL POINT can be configured to either
LEAVING CHILLED WATER or ENTERING CHILLED
WATER temperature. The PIC controls monitor the temperature pulldown rate of the CHILLED WATER and display the
result as CHILL WATER PULLDOWN/MIN in the
HEAT_EX screen. Samples of the CHILLED WATER temperature are taken once every 10 seconds and compared against
the previous CHILLED WATER sample. A positive value of
CHILL WATER PULLDOWN/MIN indicates that the
CHILLED WATER temperature is decreasing between successive samples. If CHILL WATER PULLDOWN/MIN rate is a
minimum of 0.5 degrees F per minute then the PULLDOWN:
SATISFIED parameter in the LL_MAINT screen displays
YES, otherwise, the PULLDOWN: SATISFIED parameter
displays NO.
If the lead chiller is unable to achieve the CONTROL
POINT, the lag chiller will not start unless the lead chiller is unable to maintain a CHILL WATER PULLDOWN/MIN rate of
0.5 degrees F per minute for a time period equal to the number
of minutes entered in the PULLDOWN TIMER parameter.
PULLDOWN TIME in the LL_MAINT screen displays the remaining delay left before the lag chiller is allowed to start
based on the pulldown timer. PULLDOWN TIME will count
down starting at the value entered in PULLDOWN TIMER
under the following conditions:
Ramp Loading is Complete
AND
PULLDOWN: SATISFIED = NO
The lag chiller pulldown start condition is met when PULLDOWN TIME lapses to 0.0 min.
If PULLDOWN: SATISFIED changes to YES as the
PULLDOWN TIME is counting down to zero, the PULLDOWN TIME will start to count back up provided that the
CHILLED WATER temperature has not fallen to less than the
CONTROL POINT plus one half of the CHILLED WATER
DEADBAND. The PULLDOWN TIME will start to count
back down again should PULLDOWN: SATISFIED change
back to NO. The PULLDOWN TIME will be immediately reset to the value entered in the PULLDOWN TIMER parameter
if the CHILLED WATER temperature decreases to less than
the CONTROL POINT plus one half of the CHILLED WATER DEADBAND.
Lag Chiller Shutdown Requirements — The following conditions must be met in order for the lag chiller to be stopped.
1. Lead chiller AVERAGE LINE CURRENT or MOTOR
PERCENT KILOWATTS (on the MAINSTAT screen) is
less than the lead chiller percent capacity.
NOTE: Lead Chiller Percent Capacity = 115 – LAG %
CAPACITY. The LAG % CAPACITY parameter is on the
LEADLAG screen, which is accessed from the EQUIPMENT SERVICE table on the SERVICE menu.
2. The lead chiller chilled water temperature is less than the
CONTROL POINT temperature (see the MAINSTAT
screen) plus 1/2 the CHILLED WATER DEADBAND
temperature (see the SETUP1 screen).
3. The configured LAG STOP TIMER entry has elapsed.
The LAG STOP TIMER starts when the lead chiller
chilled water temperature is less than the chilled water
CONTROL POINT plus 1/2 of the CHILLED WATER
DEADBAND and the lead chiller compressor motor load
(MOTOR PERCENT KILOWATT or AVERAGE LINE
CURRENT on the MAINSTAT screen) is less than the
Lead Chiller Percent Capacity.
NOTE: Lead Chiller Percent Capacity = 115 – LAG %
CAPACITY. The LAG % CAPACITY parameter is on the
LEADLAG screen, which is accessed from the EQUIPMENT
SERVICE table on the SERVICE menu.
FAULTED CHILLER OPERATION — If the lead chiller
shuts down because of an alarm (*) condition, it stops communicating to the lag and standby chillers. After 30 seconds, the
lag chiller becomes the acting lead chiller and starts and stops
the standby chiller, if necessary.
If the lag chiller goes into alarm when the lead chiller is also
in alarm, the standby chiller reverts to a stand-alone CCN
mode of operation.
If the lead chiller is in an alarm (*) condition (as shown on
the ICVC panel), press the RESET softkey to clear the alarm.
The chiller is placed in CCN mode. The lead chiller communicates and monitors the RUN STATUS of the lag and standby
chillers. If both the lag and standby chillers are running, the
lead chiller does not attempt to start and does not assume the
role of lead chiller until either the lag or standby chiller shuts
down. If only one chiller is running, the lead chiller waits for a
start request from the operating chiller. When the configured
lead chiller starts, it assumes its role as lead chiller.
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) chiller’s 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
chiller’s compressor motor load value MOTOR PERCENT
KILOWATTS or AVERAGE LINE CURRENT on the
53
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 parameter’s 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.
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).
MAINSTAT screen). This value has limits of 40% to 100%. In
addition, the CONTROL POINT for the lag chiller must be
modified to a value of 3 F (1.67 C) less than the lead chiller’s
CONTROL POINT value. If the LOAD BALANCE OPTION is
disabled, the ACTIVE DEMAND LIMIT and the CONTROL
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.
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 19.
• The ICE BUILD SETPOINT can be configured from the
SETPOINT display, which is accessed from the PIC III
main menu. See Table 4, Example 10.
• 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 25, 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.
54
When the ATTACH TO NETWORK DEVICE screen is
accessed, information can not be read from the ICVC on any
device until one of the devices listed on that screen is attached.
The ICVC erases information about the module to which it was
attached to make room for information on another device.
Therefore, a CCN module must be attached when this screen is
entered.
To attach any CCN device, highlight it using the SELECT
softkey and press the ATTACH softkey. The message
“UPLOADING TABLES, PLEASE WAIT” displays. The
ICVC then uploads the highlighted device or module. If
the module address cannot be found, the message “COMMUNICATION FAILURE” appears. The ICVC then reverts back
to the ATTACH TO DEVICE screen. Try another device or
check the address of the device that would not attach. The
upload process time for each CCN module is different. In
general, the uploading process takes 1 to 2 minutes. Before
leaving the ATTACH TO NETWORK DEVICE screen, select
the LOCAL device. Otherwise, the ICVC will be unable to
display information on the local chiller.
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
CONTACTS are open and the ICE BUILD RECYCLE is
set to DSABLE (0). In this case, the ICE BUILD
CONTACTS provide ice level termination control. The
contacts are used to stop the ice build function when a
time period on the ice build schedule (OCCPC02S) is set
for ice build operation. The remote contacts can still be
opened and closed to start and stop the chiller when a
specific time period on the ice build schedule is not set for
ice build.
4. Entering Chilled Water Temperature and ICE BUILD
Contacts — Ice Build operation terminates when the ICE
BUILD TERMINATION parameter is set to 2 (BOTH)
and the conditions described above in items 2 and 3 for
ENTERING CHILLED WATER temperature and ICE
BUILD CONTACTS have occurred.
NOTE: It is not possible to override the CHILLER START/
STOP, CONTROL POINT, and ACTIVE DEMAND LIMIT
variables from CCN devices (with a priority 4 or greater)
during the ice build period. However, a CCN device can
override these settings during 2-chiller lead/lag operation.
RETURN TO NON-ICE BUILD OPERATIONS — The ice
build function forces the chiller to start, even if all other schedules indicate that the chiller should stop. When the ice build
function terminates, the chiller returns to normal temperature
control and start/stop schedule operation. The CHILLER START/
STOP and CONTROL POINT return to normal operation. If the
CHILLER START/STOP or CONTROL POINT has been forced
(with a device of less than 4 priority) before the ice build function started, when the ice build function ends, the previous forces
(of less than 4 priority) are not automatically restored.
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.
NOTE: The ICVC will not automatically reattach to the local
module on the chiller. Press the ATTACH softkey to attach to
the LOCAL device and view the chiller operation.
Attach to Network Device Control — The Service
menu includes the ATTACH TO NETWORK DEVICE
screen. From this screen, the operator can:
• enter the time schedule number (if changed) for
OCCPC03S, as defined in the NET_OPT screen
• attach the ICVC to any CCN device, if the chiller has been
connected to a CCN network. This may include other PICcontrolled chillers.
• upgrade software
Figure 25 shows the ATTACH TO NETWORK DEVICE
screen. The LOCAL parameter is always the ICVC module
address of the chiller on which it is mounted. Whenever the
controller identification of the ICVC changes, the change is
reflected automatically in the BUS and ADDRESS columns
for the local device. See Fig. 17. Default address for local
device is BUS 0 ADDRESS 1.
a19-1743
Fig. 25 — Example of Attach to Network
Device Screen
55
password and, from the SERVICE menu, highlight LOG OUT
OF NETWORK DEVICE and press the SELECT softkey.
The ICVC default screen will now be displayed.
Service Operation — An overview of the tables and
screens available for the SERVICE function is shown in
Fig. 17.
TO ACCESS THE SERVICE SCREENS — When the SERVICE screens are accessed, a password must be entered.
1. From the main MENU screen, press the SERVICE
softkey. The softkeys now correspond to the numerals 1,
2, 3, 4.
TIME BROADCAST ENABLE — The first displayed line,
“Time Broadcast Enable,” in the SERVICE/EQUIPMENT
CONFIGURATION/BRODEF screen, is used to designate the
local chiller as the sole time broadcaster on a CCN network
(there may only be one). If there is no CCN network present
and/or there is no designated time broadcaster on the network,
current time and date, Daylight Saving Time (DST), and holidays as configured in the local chiller’s control will be applied.
If a network is present and one time broadcaster on the network
has been enabled, current time and date, DST, and holiday
schedules as configured in the controls of the designated time
broadcaster will be applied to all CCN devices (including chillers) on the network.
HOLIDAY SCHEDULING (Fig. 26) — Up to 18 different
holidays can be defined for special schedule consideration.
There are two different screens to be configured.
First, in the SERVICE/EQUIPMENT CONFIGURATION/
HOLIDAYS screen, select the first unused holiday entry
(HOLDY01S, for example). As shown in Fig. 26, enter a number for Start Month (1 = January, 2 = February, …, 12 = December), a number for Start Day (1 - 31), and Duration in days (0 99). By default there are no holidays set up. Second, in the occupancy Schedule tables, specify and enable (by setting “X” under
the “H” column) run time period(s) which will apply to all holidays. (Refer to Fig. 19.) A run time period which is enabled for
holidays may be applied to one or more non-holiday days of the
week as well. This may be done for the local (table
OCCPC01S), Ice Build (OCCPC02S), and/or CCN
(OCCPC03S) schedule(s). If the chiller is on a CCN network,
the active holiday definition will be that configured in the
device designated at the sole time broadcaster (if one is so
enabled). See the TIME BROADCAST ENABLE section.
The broadcast function must be activated for the holidays
configured on the HOLIDEF screen to work properly.
Access the BRODEF screen from the EQUIPMENT
CONFIGURATION table and select ENABLE to activate the
function. Note that when the chiller is connected to a CCN
Network, only one chiller or CCN device can be configured as
the broadcast device. The controller that is configured as the
broadcaster is the device responsible for transmitting holiday,
time, and daylight-savings dates throughout the network.
To access the BRODEF screen, see the SERVICE menu
structure, Fig. 18.
To view or change the holiday periods for up to 18 different
holidays, perform the following operation:
1. At the Menu screen, press SERVICE to access the
Service menu.
2. Press the four digits of the password, one at a time. An asterisk (*) appears as each digit is entered.
NOTE: The initial factory-set password is 1-1-1-1. If the
password is incorrect, an error message is displayed.
If this occurs, return to Step 1 and try to access the
SERVICE screens again. If the password is correct, the
softkey labels change to:
NOTE: The SERVICE screen password can be changed by
entering the ICVC CONFIGURATION screen under SERVICE menu. The password is located at the bottom of the
menu.
The ICVC screen displays the following list of available
SERVICE screens:
• Alarm History
• Alert History
• Control Test
• Control Algorithm Status
• Equipment Configuration
• VFD Config Data
• Equipment Service
• Time and Date
• Attach to Network Device
• Log Out of Device
• ICVC Configuration
See Fig. 18 for additional screens and tables available from
the SERVICE screens listed above. Use the EXIT softkey to
return to the main MENU screen.
2. If not logged on, follow the instructions for Attach to
Network Device or To Log Out. Once logged on, press
NEXT until Equipment Configuration is highlighted.
NOTE: To prevent unauthorized persons from accessing the
ICVC service screens, the ICVC automatically signs off and
password-protects itself if a key has not been pressed for
15 minutes. The sequence is as follows. Fifteen minutes after
the last key is pressed, the default screen displays, the ICVC
screen light goes out (analogous to a screen saver), and the
ICVC logs out of the password-protected SERVICE menu.
Other screen and menus, such as the STATUS screen can be
accessed without the password by pressing the appropriate
softkey.
TO LOG OUT OF NETWORK DEVICE — To access this
screen and log out of a network device, from the default ICVC
screen, press the MENU and SERVICE softkeys. Enter the
3. Once Equipment Configuration is highlighted, press
SELECT to access.
4. Press NEXT until HOLIDAYS is highlighted. This is
the Holiday Definition table.
5. Press SELECT to enter the Data Table Select screen.
This screen lists 18 holiday tables.
6. Press NEXT to highlight the holiday table that is to be
viewed or changed. Each table is one holiday period,
starting on a specific date, and lasting up to 99 days.
56
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.
7. Press SELECT to access the holiday table. The Configuration Select table now shows the holiday start month
and day, and how many days the holiday period will last.
8. Press NEXT or PREVIOUS to highlight the month,
day, or duration.
9. Press SELECT to modify the month, day, or duration.
10. Press INCREASE or DECREASE to change the
selected value.
NOTE: The time schedule is said to be “occupied” if the
OCCUPIED ? parameter on the MAINSTAT screen is set to
YES. For more information on occupancy schedules, see the
sections on Time Schedule Operation (page 25), Occupancy
Schedule (page 42), and To Prevent Accidental Start-Up
(page 78), and Fig. 18.
If the OCCUPIED ? parameter on the MAINSTAT screen
is set to NO, the chiller can be forced to start as follows. From
the default ICVC screen, press the MENU and STATUS
softkeys. Scroll to highlight MAINSTAT. Press the SELECT
softkey. Scroll to highlight CHILLER START/STOP. Press the
START softkey to override the schedule and start the chiller.
11. Press ENTER to save the changes.
12. Press EXIT to return to the previous menu.
DAYLIGHT SAVING TIME CONFIGURATION — The
BRODEF table also defines Daylight Saving Time (DST)
changes. This feature is by default enabled, and the settings
should be reviewed and adjusted if desired. The following
line-item entries are configurable for both DST “Start” and
“Stop,” and they are defined in Table 8.
To disable the Daylight Savings Time function simply enter
0 minutes for “Start Advance” and “Stop Back.”
Table 8 — Daylight Saving Time Values
ITEM
Month
Day of Week
Week
Time
Advance/Back
NOTE: The chiller will continue to run until this forced start is
released, regardless of the programmed schedule. To release
the forced start, highlight CHILLER START/STOP from the
MAINSTAT screen and press the RELEASE softkey. This
action returns the chiller to the start and stop times established
by the schedule.
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 7, 2011, is Day 4 Week
1, but April 8, 2011, is Day 5 Week 2.
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).
The chiller may also be started by overriding the time schedule. From the default screen, press the MENU and
SCHEDULE softkeys. Scroll down and select the current
schedule. Select OVERRIDE, and set the desired override time.
Another condition for start-up must be met for chillers that
have the REMOTE CONTACTS OPTION on the EQUIPMENT SERVICE screen set to ENABLE. For these chillers,
the REMOTE START CONTACT parameter on the MAINSTAT screen must be CLOSED. From the ICVC default
screen, press the MENU and STATUS softkeys. Scroll to
highlight MAINSTAT and press the SELECT softkey. Scroll
down the MAINSTAT screen to highlight REMOTE START
CONTACT and press the SELECT softkey. Then, press the
CLOSE softkey. To end the override, select REMOTE
CONTACTS INPUT and press the RELEASE softkey.
Once local start-up begins, the PIC III performs a series of
pre-start tests to verify that all pre-start alerts and safeties are
within the limits shown in Table 7. The RUN STATUS parameter on the MAINSTAT screen line now reads PRESTART. If a
test is not successful, the start-up is delayed or aborted. If the
tests are successful, the CHILLED WATER PUMP relay energizes, and the RUN STATUS line now reads STARTUP. See
Table 9.
Five seconds later, the CONDENSER WATER PUMP relay
energizes. Thirty seconds later, the PIC III monitors the chilled
water and condenser water flow devices and waits until the
WATER FLOW VERIFY TIME (operator-configured, default
5 minutes) expires to confirm flow. After flow is verified, the
chilled water temperature is compared to CONTROL POINT
plus 1/2 CHILLED WATER DEADBAND. If the temperature is
less than or equal to this value, the PIC III turns off
the CONDENSER WATER PUMP relay and goes into a
RECYCLE mode.
a19-1624
Fig. 26 — Example of Holiday Period Screen
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
57
• a recycle condition is present (see Chilled Water Recycle
Mode section)
• the time schedule has gone into unoccupied mode
• the chiller protective limit has been reached and chiller is in
alarm
• the start/stop status is overridden to stop from the CCN network or the ICVC
When a stop signal occurs, the shutdown sequence first
stops the compressor by deactivating the VFD output to the
motor. A status message of “SHUTDOWN IN PROGRESS,
COMPRESSOR DEENERGIZED” is displayed, and the
compressor ontime and service ontime stop. The guide vanes
are then brought to the closed position. The oil pump relay and
the chilled water/brine pump relay shut down 60 seconds after
the compressor stops. The condenser water pump shuts down
at the same time if the ENTERING CONDENSER WATER
temperature is greater than or equal to 115 F (46.1 C) and
the CONDENSER REFRIG TEMP is greater than the
CONDENSER FREEZE POINT plus 5 F (–15.0 C). The
stop-to-start timer now begins to count down. If the
start-to-start timer value is still greater than the value of the
start-to-stop timer, then this time displays on the ICVC.
Certain conditions that occur during shutdown can change
this sequence.
• If the AVERAGE LINE CURRENT is greater than 5%
after shutdown, the oil pump and chilled water pump
remain energized and the alarm is displayed.
• 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).
NOTE: The 19XRV units are not available with factoryinstalled chilled water or condenser water flow devices (available as an accessory for use with the CCM control board).
If the water/brine temperature is high enough, the start-up
sequence continues and checks the guide vane position. If the
guide vanes are more than 4% open, the start-up is delayed
until the PIC III closes the vanes. If the vanes are closed and
the oil pump pressure is less than 4 psi (28 kPa), the oil pump
relay energizes. The PIC III then waits until the oil pressure
(OIL PRESS VERIFY TIME, operator-configured, default of
40 seconds) reaches a maximum of 18 psi (124 kPa). After oil
pressure is verified, the PIC III waits 40 seconds, and the VFD
energizes to start the compressor.
Compressor ontime and service ontime timers start, and the
compressor STARTS IN 12 HOURS counter and the number of
starts over a 12-hour period counter advance by one.
Failure to verify any of the requirements up to this point will
result in the PIC III aborting the start and displaying the applicable pre-start mode of failure on the ICVC default screen. A
pre-start failure does not advance the STARTS IN 12 HOURS
counter. Any failure after the VFD has energized results in a
safety shutdown, advances the starts in 12 hours counter by
one, and displays the applicable shutdown status on the ICVC
display. The minimum time to complete the entire prestart
sequence is approximately 185 seconds.
Automatic Soft Stop Amps Threshold — The soft
stop amps threshold feature closes the guide vanes of the
compressor automatically if a non-recycle, non-alarm stop
signal occurs before the compressor motor is deenergized.
Any time the compressor is directed to STOP (except in the
cases of a fault or recycle shutdown), the guide vanes are
directed to close, and the compressor shuts off when any of the
following is true:
• AVERAGE LINE CURRENT (%) drops below the SOFT
STOP AMPS THRESHOLD
• ACTUAL GUIDE VANE POSITION drops below 4%
• 4 minutes have elapsed
• the STOP button is pressed twice
If the chiller enters an alarm state or if the compressor enters
a RECYCLE mode, the compressor deenergizes immediately.
To activate the soft stop amps threshold feature, scroll to the
bottom of OPTIONS screen on the ICVC. Use the
INCREASE or DECREASE softkey to set the SOFT STOP
AMPS THRESHOLD parameter to the percent of amps at
which the motor will shut down. The default setting is 100%
amps (no soft stop). The range is 40 to 100%.
a19-765
A
— START INITIATED: Pre-start checks are made; evaporator pump
started.
B — Condenser water pump started (5 seconds after A).
C — Water flows verified (30 seconds to 5 minutes maximum after B).
Chilled water temperatures checked against control point. Guide
vanes checked for closure. Oil pump started; tower fan control
enabled.
D — Oil pressure verified (15 seconds minimum, 300 seconds maximum
after C).
E — Compressor motor starts; compressor ontime and service ontime
start, 15-minute inhibit timer starts (10 seconds after D), total compressor starts advances by one, and the number of starts over a
12-hour period advances by one.
F — SHUTDOWN INITIATED — Compressor motor stops; compressor
ontime and service ontime stop, and 1-minute inhibit timer starts.
G — Oil pump and evaporator pumps deenergized (60 seconds after F).
Condenser pump and tower fan control may continue to operate if
condenser pressure is high. Evaporator pump may continue if in
RECYCLE mode.
O/A — Restart permitted (both inhibit timers expired: minimum of 15 minutes after E; minimum of 1 minute after F).
When the soft stop amps threshold feature is being applied,
a status message, “SHUTDOWN IN PROGRESS, COMPRESSOR UNLOADING” displays on the ICVC.
The soft stop amps threshold function can be terminated and
the compressor motor deenergized immediately by pressing the
STOP button twice.
Fig. 27 — Control Sequence
Shutdown Sequence — Chiller shutdown begins if
any of the following occurs:
• the STOP button is pressed for at least one second (the
alarm light blinks once to confirm the stop command)
58
Table 9 — Prestart Checks
QUANTITY CHECKED
STARTS IN 12 HOURS
COMP THRUST BRG TEMP
COMP MOTOR WINDING TEMP
COMP DISCHARGE TEMP
EVAPORATOR REFRIG TEMP
OIL SUMP TEMP
CONDENSER PRESSURE
PERCENT LINE VOLTAGE
PERCENT LINE VOLTAGE
ACTUAL GUIDE VANE POS
RECTIFIER TEMPERATURE
INVERTER TEMPERATURE
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)
ALERT STATE IF FALSE
100
101
102
103
104
105
106
107
108
109
110
111
(RECYCLE CONTROL) RESTART DELTA T on the SETUP1
table to lengthen the time between restarts.
The chiller should not be operated below design minimum
load without a hot gas bypass installed.
Chilled Water Recycle Mode — The chiller may
cycle off and wait until the load increases to restart when the
compressor is running in a lightly loaded condition. This
cycling is normal and is known as “recycle.” A recycle shutdown is initiated when any of the following conditions are true:
• LEAVING CHILLED WATER temperature (or ENTERING
CHILLED WATER temperature, if the ECW CONTROL
OPTION is enabled) is more than 5 F (2.8 C) below the
CONTROL POINT.
• LEAVING CHILLED WATER temperature (or ENTERING
CHILLED WATER temperature, if the ECW CONTROL
OPTION is enabled) is below the CONTROL POINT, and
the chilled water temperature difference is less than the
(RECYCLE CONTROL) SHUTDOWN DELTA T (configured in the EQUIPMENT SERVICE/SETUP1 table).
• the LEAVING CHILLED WATER temperature is within 3 F
(1.7 C) of the EVAP REFRIG TRIPPOINT.
NOTE: Recycle shutdown will not occur if the CONTROL
POINT has been modified (e.g., by a chilled water reset input)
within the previous 5 minutes of operation.
Also, chilled water recycle logic does not apply to Ice Build
operation (refer to page 54).
When the chiller is in RECYCLE mode, the chilled water
pump relay remains energized so the chilled water temperature
can be monitored for increasing load. The recycle control uses
RESTART DELTA T to check when the compressor should be
restarted. This is an operator-configured function which
defaults to 5 F (2.8 C). This value can be viewed or modified
on the SETUP1 table. The compressor will restart when the
chiller is:
• in LCW CONTROL and the LEAVING CHILLED WATER
temperature is greater than the CONTROL POINT plus the
(RECYCLE CONTROL) RESTART DELTA T.
• in ECW CONTROL and the ENTERING CHILLED WATER
temperature is greater than the CONTROL POINT plus the
(RECYCLE CONTROL) RESTART DELTA T.
Once these conditions are met, the compressor initiates a
start-up with a normal start-up sequence.
An alert condition may be generated if 5 or more recycle
start-ups occur in less than 4 hours. Excessive recycling can
reduce chiller life; therefore, compressor recycling due to
extremely low loads should be reduced.
To reduce compressor recycling, use the time schedule to
shut the chiller down during known low load operation period,
or increase the chiller load by running the fan systems. If the
hot gas bypass is installed, adjust the values to ensure that hot
gas is energized during light load conditions. Increase the
Safety Shutdown — A safety shutdown is identical to
a manual shutdown with the exception that, during a safety
shutdown, the ICVC displays the reason for the shutdown, the
alarm light blinks continuously, and the spare alarm contacts
are energized.
After a safety shutdown, the RESET softkey must be pressed
to clear the alarm. If the alarm condition is still present, the alarm
light continues to blink. Once the alarm is cleared, the operator
must press the CCN or LOCAL softkeys to restart the chiller.
BEFORE INITIAL START-UP
Job Data Required
• list of applicable design temperatures and pressures (product data submittal)
• chiller certified prints
• starting equipment details and wiring diagrams
• diagrams and instructions for special controls or options
• pumpout unit instructions
Equipment Required
• mechanic’s tools (refrigeration) including T30 torx
• True RMS digital multimeter with clamp-on current probe
or True RMS digital clamp-on meter rated for at least 480
vac or 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
Using the Optional Storage Tank and Pumpout System — Refer to Chillers with Storage Tanks sec-
tion, page 82 for pumpout system preparation, refrigerant
transfer, and chiller evacuation.
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.
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.
59
through the oil charging valve located near the bottom of the
transmission housing (Fig. 2). The oil must be pumped from
the oil container through the charging valve due to higher
refrigerant pressure. The pumping device must be able to lift
from 0 to 200 psig (0 to 1380 kPa) or above unit pressure. Oil
should only be charged or removed when the chiller is shut
down.
Tighten All Gasketed Joints and Guide Vane
Shaft Packing — Gaskets and packing normally relax by
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.
a19-658
Fig. 28 — Typical Wet-Bulb Type
Vacuum Indicator
Oil Charge — 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 option —
12 gal (45 L)
• Frame 5 compressor — 18 gal (67.8 L)
The chiller is shipped with oil in the compressor. When the
sump is full, the oil level should be no higher than the middle
of the upper sight glass, and minimum level is the bottom
of the lower sight glass (Fig. 2). If oil is added, it must meet
Carrier’s specification for centrifugal compressor use as
described in the Oil Specification section. Charge the oil
Check Chiller Tightness — Figure 29 outlines the
proper sequence and procedures for leak testing.
The 19XRV chillers are shipped with the refrigerant
contained in the condenser shell and the oil charge in the
compressor. The cooler is shipped with a 15 psig (103 kPa)
refrigerant charge. Units may be ordered with the refrigerant
shipped separately, along with a 15 psig (103 kPa) nitrogenholding charge in each vessel.
To determine if there are any leaks, the chiller should be
charged with refrigerant. Use an electronic leak detector to
check all flanges and solder joints after the chiller is pressurized. If any leaks are detected, follow the leak test procedure.
Table 10 — Bolt Torque Requirements, Foot Pounds
BOLT SIZE
(in.)
1/
5/
3/
7/
8
16
1/
9/
4
16
2
16
5/
8
3/
4
7/
8
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
60
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
a19-1625
61
Fig. 29 — 19XRV Leak Test Procedures
If the chiller is spring isolated, keep all springs blocked in
both directions to prevent possible piping stress and damage
during the transfer of refrigerant from vessel to vessel during
the leak test process, or any time refrigerant is being
transferred. Adjust the springs when the refrigerant is in operating condition and the water circuits are full.
3.
4.
Refrigerant Tracer — Carrier recommends the use of an
environmentally acceptable refrigerant tracer for leak testing
with an electronic detector or halide torch.
Ultrasonic leak detectors can also be used if the chiller is
under pressure.
5.
WARNING
Do not use air or oxygen as a means of pressurizing
the chiller. Mixtures of HFC-134a and air can undergo
combustion.
6.
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 82.
7.
8.
WARNING
9.
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.
h. Slowly raise the system pressure to a maximum of
160 psig (1103 kPa) but no less than 35 psig
(241 kPa) for HFC-134a by adding refrigerant.
Proceed with the test for small leaks (Steps 3-9).
Check the chiller carefully with an electronic leak detector, halide torch, or soap bubble solution.
Leak Determination — If an electronic leak detector
indicates a leak, use a soap bubble solution, if possible, to
confirm. Total all leak rates for the entire chiller. Leakage
at rates greater than 0.1% of the total charge per year must
be repaired. Note the total chiller leak rate on the start-up
report.
If no leak is found during the initial start-up procedures,
complete the transfer of refrigerant gas from the pumpout
storage tank to the chiller (see Transfer Refrigerant from
Pumpout Storage Tank to Chiller section, page 82).
Retest for leaks.
If no leak is found after a retest:
a. Transfer the refrigerant to the pumpout storage
tank and perform a standing vacuum test as
outlined in the Standing Vacuum Test section,
below.
b. If the chiller fails the standing vacuum test, check
for large leaks (Step 2b).
c. If the chiller passes the standing vacuum test,
dehydrate the chiller. Follow the procedure in
the Chiller Dehydration section. Charge the chiller
with refrigerant (see Transfer Refrigerant from
Pumpout Storage Tank to Chiller section,
page 82).
If a leak is found after a retest, pump the refrigerant back
into the pumpout storage tank or, if isolation valves are
present, pump the refrigerant into non-leaking vessel (see
Pumpout and Refrigerant Transfer Procedures section).
Transfer the refrigerant until the chiller pressure is at
18 in. Hg (40 kPa absolute).
Repair the leak and repeat the procedure, beginning from
Step 2h, to ensure a leak-tight repair. (If the chiller is
opened to the atmosphere for an extended period, evacuate it before repeating the leak test.)
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 82) 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 83. 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.
c. Leak test chiller as outlined in Steps 3-9.
2. If the pressure readings are abnormal for the chiller
condition:
a. Prepare to leak test chillers shipped with refrigerant (Step 2h).
b. Check for large leaks by connecting a nitrogen bottle
and raising the pressure to 30 psig (207 kPa). Soap
test all joints. If the test pressure holds for 30 minutes,
prepare the test for small leaks (Steps 2g-h).
c. Plainly mark any leaks that are found.
d. Release the pressure in the system.
e. Repair all leaks.
f. Retest the joints that were repaired.
g. After successfully completing the test for large
leaks, remove as much nitrogen, air, and moisture
as possible, given the fact that small leaks may be
present in the system. This can be accomplished by
following the dehydration procedure, outlined in
the Chiller Dehydration section, page 65.
62
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
10
STORAGE
TANK LIQUID
VALVE
7
OIL
SEPARATOR
LIQUID LINE
SERVICE
VALVE
PUMPOUT
COMPRESSOR
= SERVICE VALVE ON
CHILLER (FIELD
SUPPLIED)
= SERVICE VALVE ON
PUMPOUT UNIT
PUMPOUT
CONDENSER
2
3
4
5
= MAINTAIN AT LEAST 2 FT (610mm) CLEARANCE AROUND
STORAGE TANK FOR SERVICE AND OPERATION WORK.
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
7
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
3
4
5
PUMPOUT
CONDENSER
WATER SUPPLY
AND RETURN
a19-1722
Fig. 31 — Typical Optional Pumpout System Piping Schematic without Storage Tank
63
Table 11A — HFC-134a Pressure —
Temperature (F)
TEMPERATURE,
F
0
2
4
6
8
10
12
14
16
18
20
22
24
26
28
30
32
34
36
38
40
42
44
46
48
50
52
54
56
58
60
62
64
66
68
70
72
74
76
78
80
82
84
86
88
90
92
94
96
98
100
102
104
106
108
110
112
114
116
118
120
122
124
126
128
130
132
134
136
138
140
Table 11B — HFC-134a Pressure —
Temperature (C)
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
64
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
and condenser must meet job requirements. Measure the
pressure drop across the cooler and the condenser.
Chiller Dehydration — Dehydration is recommended if
the chiller has been open for a considerable period of time, if
the chiller is known to contain moisture, or if there has been a
complete loss of chiller holding charge or refrigerant pressure.
CAUTION
Water must be within design limits, clean, and treated to
ensure proper chiller performance and reduce the potential
of tube damage due to corrosion, scaling, or erosion.
Carrier assumes no responsibility for chiller damage resulting from untreated or improperly treated water.
CAUTION
Do not start or megohm-test the compressor motor or oil
pump motor, even for a rotation check, if the chiller is
under dehydration vacuum. Insulation breakdown and
severe damage may result.
Dehydration can be done at room temperatures. Using a
cold trap (Fig. 32) may substantially reduce the time required
to complete the dehydration. The higher the room temperature,
the faster dehydration takes place. At low room temperatures, a
very deep vacuum is required to boil off any moisture. If low
ambient temperatures are involved, contact a qualified service
representative for the dehydration techniques required.
Perform dehydration as follows:
1. Connect a high capacity vacuum pump (5 cfm [.002 m3/s]
or larger is recommended) to the refrigerant charging
valve (Fig. 2). Tubing from the pump to the chiller should
be as short in length and as large in diameter as possible to
provide least resistance to gas flow.
2. Use an absolute pressure manometer or a wet bulb
vacuum indicator to measure the vacuum. Open the
shutoff valve to the vacuum indicator only when taking a
reading. Leave the valve open for 3 minutes to allow the
indicator vacuum to equalize with the chiller vacuum.
3. If the entire chiller is to be dehydrated, open all isolation
valves (if present).
4. With the chiller ambient temperature at 60 F (15.6 C) or
higher, operate the vacuum pump until the manometer
reads 29.8 in. Hg vac, ref 30 in. bar. (0.1 psia)
(–100.61 kPa) or a vacuum indicator reads 35 F (1.7 C).
Operate the pump an additional 2 hours.
Do not apply a greater vacuum than 29.82 in. Hg vac
(757.4 mm Hg) or go below 33 F (.56 C) on the wet bulb
vacuum indicator. At this temperature and pressure,
isolated pockets of moisture can turn into ice. The slow
rate of evaporation (sublimation) of ice at these low
temperatures and pressures greatly increases dehydration
time.
5. Valve off the vacuum pump, stop the pump, and record
the instrument reading.
6. After a 2-hour wait, take another instrument reading. If
the reading has not changed, dehydration is complete. If
the reading indicates vacuum loss, repeat Steps 4 and 5.
7. If the reading continues to change after several attempts,
perform a leak test up to the maximum 160 psig
(1103 kPa) pressure. Locate and repair the leak, and
repeat dehydration.
a19-661
Fig. 32 — Dehydration Cold Trap
Check Optional Pumpout Compressor Water
Piping — If the optional pumpout storage tank and/or
pumpout system are installed, check to ensure the pumpout
condenser water has been piped in. Check for field-supplied
shutoff valves and controls as specified in the job data. Check
for refrigerant leaks on field-installed piping. See Fig. 30
and 31.
Check Relief Valves — Be sure the relief valves have
been piped to the outdoors in compliance with the latest edition
of ANSI/ASHRAE Standard 15 and applicable local safety
codes. Piping connections must allow for access to the valve
mechanism for periodic inspection and leak testing.
The 19XRV relief valves are set to relieve at the 185 psig
(1275 kPa) chiller design pressure.
Identify the VFD — The LiquiFlo™ 2.0 AC drive is a
PWM (Pulse Width Modulated), liquid-cooled drive that
provides vector and general purpose regulation for a wide
range of applications. Identify the drive from the Drive Part
Number on the drive’s nameplate (Fig. 33) and the model
number matrix in (Fig. 34).
NOTE: This publication provides start-up and service information for the LiquiFlo™ 2.0 (LF2) VFDs. For information on
Std Tier VFDs, refer to associated Start-Up and Service
Instructions for the Rockwell PowerFlex 755 VFD or the
Eaton LCX 9000 VFD.
The VFD is designed to operate in the following environmental conditions:
CONDITION
Ambient Temperature
(outside NEMA 1 enclosure)
Storage Temperature
(ambient)
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.
Piping systems must be properly vented with no stress on
waterbox nozzles and covers. Water flows through the cooler
Humidity
65
SPECIFICATION
32 to 122 F (0 to 50 C)
-40 to 149 F (-40 to 65 C)
5% to 95%
(non-condensing)
Input Power Wiring — All wiring should be installed in
conformance with applicable local, national, and international
codes. Use grommets, when hubs are not provided, to guard
against wire chafing.
Use the following steps to connect AC input power to the
main input circuit breaker:
1. Turn off, lockout, and tag the input power to the drive.
2. Remove the input wiring panel and drill the required
number of openings in the top of the drive enclosure.
Take care that metal chips do not enter the enclosure.
3. Wire the AC input power leads by routing them through
the openings to the main input circuit breaker.
a19-1723
CAUTION
Do not route control wiring carrying 30 v or less within a
conduit carrying 50 v or higher. Failure to observe this
precaution could result in electromagnetic interference in
the control wiring.
Fig. 33 — VFD Nameplate
LF20
0608CC
R
4. Connect the three-phase AC input power leads (per job
specification) to the appropriate input terminals of the
circuit breaker.
5. Tighten the AC input power terminals to the proper
torque as specified on the input circuit breaker.
LF20 = LiquiFlo 2.0
Continuous Ampere Rating
and Frame Size
Coolant Method
R = refrigerant R134a
Checking the Installation — Use the following in-
a19-1629
structions to verify the condition of the installation:
1. Turn off, lockout, and tag the input power to the drive.
2. Wait a minimum of 5 minutes for the DC bus to discharge.
3. All wiring should be installed in conformance with the
applicable local, national, and international codes (e.g.,
NEC/CEC).
4. Remove any debris, such as metal shavings, from the
enclosure.
5. Check that there is adequate clearance around the
machine.
6. Verify that the wiring to the terminal strip and the power
terminals is correct.
7. Verify that all of the VFD power module circuit board
connectors are fully engaged and taped in place.
8. Check that the wire size is within terminal specifications
and that the wires are tightened properly.
9. Check that specified branch circuit protection is installed
and correctly rated.
10. Check that the incoming power is within ± 10% of chiller
nameplate voltage.
11. Verify that a properly sized ground wire is installed and a
suitable earth ground is used. Check for and eliminate any
grounds between the power leads. Verify that all ground
leads are unbroken.
Fig. 34 — Identifying the Drive Model Number
IDENTIFYING THE DRIVE BY PART NUMBER — Each
AC drive can be identified by its assembly number. See
Fig. 33. This number appears on the shipping label and on the
drive’s nameplate. LiquiFlo™ 2.0 AC power module can be
identified by its model number. See Fig. 34. This number
appears on the shipping label and on the power module’s
nameplate. Power ratings are provided in Table 12.
WARNING
BE AWARE that certain automatic start arrangements can
engage the VFD. Open the disconnect ahead of the VFD in
addition to shutting off the chiller or pump. Failure to do so
could result in serious personal injury or death from electric shock.
WARNING
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.
Table 12 — Drive Assembly and Power Module Ratings
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.
66
MAX
OUTPUT
CURRENT
AT 4 kHz*
(AMPS)
442
608
1169
2. With the tester connected to the motor leads, take
10-second and 60-second megohm readings as follows:
Tie terminals 1, 2, and 3 together and test between the
group and ground.
3. Divide the 60-second resistance reading by the 10-second
reading. The ratio, or polarization index, must be one or
higher. Both the 10 and 60-second readings must be at
least 50 megohms.
If the readings are unsatisfactory, repeat the test at the
motor with the power leads disconnected. Satisfactory
readings in this second test indicate the fault is in the
power leads.
Inspect Wiring
WARNING
Do not check the voltage supply without proper equipment
and precautions. Serious personal injury may result. Follow
power company recommendations.
CAUTION
Do not apply any kind of test voltage, even for a rotation
check, if the chiller is under a dehydration vacuum. Insulation breakdown and serious damage may result.
Carrier Comfort Network® Interface — The Carrier
1. Examine the wiring for conformance to the job wiring
diagrams and all applicable electrical codes.
2. Connect a voltmeter across the power wires to the VFD
and measure the phase to phase and phase to ground
voltage. Compare this reading to the voltage rating on the
compressor and VFD nameplates.
3. Compare the ampere rating on the VFD enclosure
nameplate to the rating on the compressor nameplate.
4. The VFD must be wired to components and terminals
required for PIC III refrigeration control. Check line side
power and for control components shown on the Certified
Prints. The VFD must share control of cooler and condenser liquid pumps and cooling tower fans.
5. Check the phase to phase and phase to ground line
voltage to the VFD, power panel, and optional pumpout
compressor. Compare voltages against nameplate values.
6. Ensure that fused disconnects or circuit breakers have
been supplied to the VFD and optional pumpout unit.
7. Ensure all electrical equipment and controls are properly
grounded in accordance with the job drawings, certified
drawings, and all applicable electrical codes.
8. Ensure the customer's contractor has verified proper operation of the pumps, cooling tower fans, and associated
auxiliary equipment. This includes ensuring motors are
properly lubricated and have proper electrical supply and
proper rotation.
9. Tighten all wiring connections on the high and low
voltage terminal blocks in the VFD enclosure below the
control panel.
10. Inspect the power panel and VFD enclosure to ensure that
the contractor has used the knockouts to feed the wires
into the back of the enclosures. Wiring into the top of the
enclosures can allow debris to fall into the enclosures.
Clean and inspect the interior of the power panel and
VFD enclosure if this has occurred.
Comfort Network (CCN) communication bus wiring is
supplied and installed by the electrical contractor. It consists of
shielded, 3-conductor cable with drain wire.
The system elements are connected to the communication
bus in a daisy chain arrangement. The positive pin of each
system element communication connector must be wired to the
positive pins of the system element on either side of it. The
negative pins must be wired to the negative pins. The signal
ground pins must be wired to the signal ground pins. See
installation manual.
NOTE: Conductors and drain wire must be 20 AWG
(American Wire Gage) minimum stranded, tinned copper.
Individual conductors must be insulated with PVC, PVC/
nylon, vinyl, Teflon, or polyethylene. An aluminum/polyester
100% foil shield and an outer jacket of PVC, PVC/nylon,
chrome vinyl, or Teflon with a minimum operating temperature range of –4 F to 140 F (–20 C to 60 C) is required. See
table below for cables that meet the requirements.
MANUFACTURER
Alpha
American
Belden
Columbia
CABLE NO.
2413 or 5463
A22503
8772
02525
When connecting the CCN communication bus to a system
element, a color code system for the entire network is recommended to simplify installation and checkout. The following
color code is recommended:
SIGNAL
TYPE
+
Ground
–
WARNING
CCN BUS
CONDUCTOR
INSULATION
COLOR
Red
White
Black
CCN
TERMINAL
CONNECTION
ICVC PLUG J1
PIN NO.
RED (+)
WHITE (G)
BLACK (–)
1
2
3
Power Up the Controls and Check the Oil
Heater — Ensure that an oil level is visible in the compres-
Do not apply power unless a qualified Carrier technician is
present. Serious personal injury may result.
sor before energizing the controls. A circuit breaker in the
VFD energizes the oil heater and the control circuit. When first
powered, the ICVC should display the default screen within a
short period of time.
The oil heater is energized by powering the control circuit.
This should be done several hours before start-up to minimize
oil-refrigerant migration. The oil heater is controlled by the
PIC III and is powered through a contactor in the power panel.
A separate circuit breaker powers the heater and the control
circuit. This arrangement allows the heater to energize when
the main motor circuit breaker is off for service work or
extended shutdowns. The oil heater relay status (OIL HEATER
RELAY) can be viewed on the COMPRESS table on the ICVC.
Oil sump temperature can be viewed on the ICVC default
screen.
Ground Fault Troubleshooting — Follow this pro-
cedure only if ground faults are declared by the chiller controls.
Test the chiller compressor motor and its power lead
insulation resistance with a 500-v insulation tester such as a
megohmmeter.
1. Open the VFD main disconnect switch and follow
lockout/tagout rules.
CAUTION
The motor leads must be disconnected from the VFD
before an insulation test is performed. The voltage
generated from the tester can damage the VFD.
67
the screen to SI units as required, and change the password if
desired.
TO CHANGE THE PASSWORD — The password may be
changed from the ICVC CONFIGURATION screen.
1. Press the MENU and SERVICE softkeys. Enter the
current password and highlight ICVC CONFIGURATION. Press the SELECT softkey. Only the last
5 entries on the ICVC CONFIG screen can be changed:
BUS NUMBER, ADDRESS, BAUD RATE, US IMP/
METRIC, and PASSWORD.
SOFTWARE VERSION — The software part number is
labeled on the backside of the ICVC module. The software
version also appears on the ICVC configuration screen as the
last two digits of the software part number.
Software Configuration
WARNING
Do not operate the chiller before the control configurations
have been checked and a Control Test has been
satisfactorily completed. Protection by safety controls
cannot be assumed until all control configurations have
been confirmed.
2. Use the ENTER softkey to scroll to PASSWORD. The
first digit of the password is highlighted on the screen.
As the 19XRV unit is configured, all configuration settings
should be written down. A log, such as the one shown on pages
CL-1 to CL-12, provides a list for configuration values.
3. To change the digit, press the INCREASE or
DECREASE softkey. When the desired digit is seen,
press the ENTER softkey.
Input the Design Set Points — Access the ICVC set
point screen and view/modify the BASE DEMAND LIMIT set
point, and either the LCW SETPOINT or the ECW SETPOINT. The PIC III can control a set point to either the leaving
or entering chilled water. This control method is set in the
EQUIPMENT SERVICE (TEMP_CTL) table.
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
the
Local
Occupied
Schedule
(OCCPC01S) — Access the schedule OCCPC01S screen
CAUTION
on the ICVC and set up the occupied time schedule according
to the customer’s requirements. If no schedule is available, the
default is factory set for 24 hours occupied, 7 days per week including holidays.
For more information about how to set up a time schedule,
see the Controls section, page 15.
The CCN Occupied Schedule (OCCPC03S) should be configured if a CCN system is being installed or if a secondary
time schedule is needed.
NOTE: The default CCN Occupied Schedule OCCPC03S is
configured to be unoccupied.
Be sure to remember the password. Retain a copy
for future reference. Without the password, access to the
SERVICE menu will not be possible unless the
ICVC_PSWD menu on the STATUS screen is accessed by
a Carrier representative.
TO CHANGE THE ICVC DISPLAY FROM ENGLISH TO
METRIC UNITS — By default, the ICVC displays information in English units. To change to metric units, access the
ICVC CONFIGURATION screen:
1. Press the MENU and SERVICE softkeys. Enter the
password and highlight ICVC CONFIGURATION. Press
the SELECT softkey.
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,
date, and day of the week. The HOLIDAY parameter should
only be configured to YES if the present day is a holiday.
NOTE: Because a schedule is integral to the chiller control
sequence, the chiller will not start until the time and date have
been set.
NOTE: The date format is MM-DD-YY for English units and
DD-MM-YY format for SI metric units.
CHANGE ICVC CONFIGURATION IF NECESSARY —
From the SERVICE table, access the ICVC CONFIGURATION screen. From there, view or modify the ICVC CCN
address, change to English or SI units, and change the
password. If there is more than one chiller at the jobsite,
change the ICVC address on each chiller so that each chiller
has its own address. Note and record the new address. Change
2. Use the ENTER softkey to scroll to US IMP/METRIC.
3. Press the softkey that corresponds to the units desired for
display on the ICVC (e.g., US or METRIC).
CHANGE LANGUAGE — By default, the ICVC displays
information in English. To change to another Language, access
the ICVC CONFIGURATION screen:
1. Press the MENU and SERVICE softkeys. Enter the
password and highlight ICVC CONFIGURATION. Press
the SELECT softkey.
2. Use the ENTER softkey to scroll to LID LANGUAGE.
3. Press the INCREASE or DECREASE softkey until the
desired language is displayed. Press ENTER to confirm
desired language.
MODIFY CONTROLLER IDENTIFICATION IF NECESSARY — The ICVC module ADDRESS can be changed from
the ICVC CONFIGURATION screen. Change this address for
each chiller if there is more than one chiller at the jobsite. Write
the new address on the ICVC module for future reference.
INPUT EQUIPMENT SERVICE PARAMETERS IF NECESSARY — The EQUIPMENT SERVICE table has six
service tables.
68
• Rated Line Voltage — Nominal line voltage selected for the
job site.
• Rated Line Amps — Line current required for the chiller to
run at the design point.
• Rated Line Kilowatts — Line power required for the chiller
to run at the design point.
• Motor Rated Load kW — Power consumed by the motor
when running at the chiller design point.
• Motor Rated Load Amps — Motor current required for the
chiller to run at the design point.
• Motor Nameplate Amps — Motor nameplate full load
amps.
• Motor Nameplate RPM — Rated speed of the motor when
running at motor nameplate rated frequency, rated current,
and rated voltage.
• Motor Nameplate kW — Motor nameplate rated power.
• Inverter PWM Frequency — Sets the carrier frequency for
the pulse width modulation output.
NOTE: Other parameters on these screens are normally left at
the default settings; however, they may be changed by the
operator as required. The voltage and current imbalance level
and imbalance persistence time on the VFD_CONF table can
be adjusted to increase or decrease the sensitivity of these fault
conditions. Increasing time or persistence decreases sensitivity.
Decreasing time or persistence increases sensitivity to the fault
condition.
NOTE: Some of the parameters can be changed only when the
drive is stopped.
VERIFY VFD CONFIGURATION AND CHANGE
PARAMETERS IF NECESSARY (Fig. 35)
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.
WARNING
It is the operator’s responsibility to distribute access to the
ICVC passwords. Carrier is not responsible for unauthorized access violations within the operator’s organization.
Failure to observe this warning could result in bodily
injury.
HAND CALCULATE VARIABLE PRIMARY FLOW
(VPF) SURGE PREVENTION CONFIGURATIONS —
The configurations entered determine the Surge Prevention line
that the controls use to raise the speed of the VFD if the compressor operating point nears this line.
Calculate ΔP maximum and ΔP minimum using 2 point
method shown in sections below. If the original selection configuration points are available, use ΔP1 and ΔP4 from that selection as ΔP maximum and ΔP minimum. If the original selection configuration was for a 2 point surge line, use ΔP1 and
ΔP2.
Use the default values for the following configurations:
• Surge / HGBP IGV min. = 5.0
• Surge / HGBP IGV max = 100.0
• Surge Line Shape Factor = -0.040
• Surge Line Speed Factor = 1.85
• Surge Line High Offset = 1.0
• Surge/ HGBP Deadband = 1
Calculate Maximum Load — To calculate the maximum load
points, use the design load condition data. If the chiller full load
cooler temperature difference is more than 15 F (8.3 C),
estimate the refrigerant suction and condensing temperatures at
this difference. Use the proper saturated pressure and temperature for the particular refrigerant used.
Suction Temperature:
42 F (5.6 C) = 37 psig (255 kPa) saturated
refrigerant pressure (HFC-134a)
Condensing Temperature:
98 F (36.7 C) = 120 psig (1827 kPa) saturated
refrigerant pressure (HFC-134a)
:
a19-1626
INTERNAL
EXTERNAL
Fig. 35 — Machine Electrical Data Nameplate
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.
69
Maximum Load T2:
54 – 44 = 10º F (12.2 – 6.7 = 5.5º C)
Maximum Load P2:
120 – 37 = 83 psid (827 – 255 = 572 kPad)
To avoid unnecessary surge prevention, add about 10 psid
(70 kPad) to P2 from these conditions:
T2 = 10º F (5.5º C)
P2 = 93 psid (642 kPad)
Calculate Minimum Load — To calculate the minimum load
conditions, estimate the temperature difference the cooler will
have at 10% load, then estimate what the suction and condensing temperatures will be at this point. Use the proper saturated
pressure and temperature for the particular refrigerant used.
Suction Temperature:
43 F (6.1 C) = 38 psig (262 kPa) saturated
refrigerant pressure (HFC-134a)
Condensing Temperature:
70 F (21.1 C) = 71 psig (490 kPa) saturated
refrigerant pressure (HFC-134a)
Minimum Load T1 (at 20% Load): 2 F (1.1 C)
Minimum Load P1:
71 – 38 = 33 psid (490 – 262 = 228 kPad)
NOTE: The preceding two values produce the full load point
of the surge prevention line.
• Surge Line Shape Factor determines the curvature of the
line mainly in the low load zone. (See Fig. 38.)
• Surge Line Speed Factor determines how much the surge
line moves to accommodate lower compressor speed. As
compressor speed drops the ΔT values on the surge prevention line decrease. Increasing the Speed Factor causes
Surge Prevention to activate sooner as the compressor
speed drops. (See Fig. 39.)
• Surge Line High Offset determines the ΔT increase
beyond the surge prevention line where the high stage of
Surge Prevention takes effect. The high stage produces
larger RPM increase steps. This is not likely to require
adjustment at the jobsite other than to ensure that it
matches the value supplied with the machine selection
• Surge/HGBP Deadband controls the amount the ACTIVE
DELTA TSAT must drop below the Surge Prevention to
de-activate Surge Prevention.
40
35
30
Again, to avoid unnecessary surge prevention, add 20 psid
(140 kPad) at P1 from these conditions:
T1 = 2 F (1.1 C)
P1 = 53 psid (368 kPad)
Calculate Surge/ HGBP Delta Tsmin — Convert design suction temp to pressure using an R-134a pressure/temperature
chart.
Min. Cond. Pressure = (suction pressure) + (ΔP minimum)
Convert Min. Cond. Pressure to Min. Cond. Temperature
using a saturation pressure/temperature chart for R-134a.
Surge / HGBP Tsmin = (Min. Cond. Temp.) – (design suction temperature)
Calculate Surge/ HGBP Delta Tsmax
Max. Cond. Pressure = (suction pressure) + (ΔP maximum)
Convert Max. Cond. Pressure to Max. Cond. Temperature
using a saturation pressure/temperature chart for R-134a.
Surge / HGBP Tsmax = (Max. Cond. Temp) – (design suction temperature)
VPF Surge Prevention Configurations are defined as
follows:
• Surge/HGBP Delta Tsmin is the minimum difference
between cooler and condenser saturation temperatures.
(See Fig. 36.)
• Surge/HGBP IGVmin is the lowest position of the guide
vanes that affects Surge prevention. This is not likely to
require adjustment at the jobsite other than to ensure that
it matches the value supplied with the machine selection.
These values produce the minimum load point of the Surge
Prevention line:
• Surge/HGBP Delta Tsmax is the maximum difference
between cooler and condenser saturation temperatures.
(See Fig. 37.)
• Surge/HGBP IGVmax is the highest position of the
guide vanes that affects Surge prevention. This is not
likely to require adjustment at the jobsite other than to
ensure that it matches the value supplied with the
machine selection.
Tsmin=30
Delta Tsat
25
Tsmin=40
20
15
Tsmin=50
10
5
0
0
10
20
30
40
50
60
70
80
90
100
110
GV_POS
a19-1959
Fig. 36 — Effect of SURGE/HGBP DELTA TSMIN
on Surge Prevention
45
40
35
Tsmax=60
Delta Tsat
30
25
Tsmax=70
20
15
Tsmax=80
10
5
0
0
10
20
30
40
50
60
GV_POS
70
80
90
100
110
a19-1960
Fig. 37 — Effect of SURGE/HGBP DELTA TSMAX
on Surge Prevention
70
• ACTUAL GUIDE VANE POSITION
• AVERAGE LINE CURRENT
The ACTIVE DELTA Tsat and the SURGE LINE DELTA
TSAT can be monitored on the VPF_STAT screen. When
DELTA TSAT exceeds SURGE LINE DELTA TSAT surge
prevention will occur.
If ACTUAL GUIDE VANE POSITION is less than 30%,
then increase SURGE/HGBP DELTA TSMIN in steps of 2º F
until one of the three conditions listed above no longer applies.
Do not change SURGE/HGBP DELTA TSMAX.
If ACTUAL GUIDE VANE POSITION is greater than
60%, then increase SURGE/HGBP DELTA TSMAX in steps
of 2º F until cooling capacity is reached or one of conditions
listed above no longer applies. Do not change SURGE/HGBP
DELTA TSMIN.
If ACTUAL GUIDE VANE POSITION is more than 30%
AND less than 60%, then:
1. Increase SURGE/HGBP DELTA TSMIN in steps of 2º F.
2. Increase SURGE/HGBP DELTA TSMAX in steps of
2º F.
3. Repeat Steps 1 and 2 until one of the conditions listed
above no longer applies.
NOTE: DELTA TSMIN should seldom need to be increased
more than 10 degrees above the selection program value. Likewise, DELTA TSMAX rarely requires more than a 2 degree
increase.
If surge is encountered then the surge line is probably too
optimistic or high. Note following parameters from ICVC at
surge:
• EVAPORATOR REFRIGERANT TEMP
• EVAPORATOR PRESSURE
• CONDENSER REFRIG TEMP
• CONDENSER PRESSURE
• ACTUAL GUIDE VANE POSITION
• AVERAGE LINE CURRENT
If ACTUAL GUIDE VANE POSITION is less than 30%,
go to Step 1. If ACTUAL GUIDE VANE POSITION is greater
than 60%, then go to Step 3.
1. Do not change SURGE LINE SHAPE FACTOR from
the value selected by Chiller Builder (ECAT). Decrease
SURGE/HGBP DELTA TSMIN in 1° F steps up to 5
times. Monitor chiller for surge.
2. If ACTUAL GUIDE VANE POSITION is still less than
30 and step 1 failed, then increase the value of SURGE
LINE SHAPE FACTOR in steps of 0.01 up to 2 times.
For example, if surge is encountered when shape factor is
–0.06, increase the SURGE LINE SHAPE FACTOR to
–0.05. If this does not solve the problem, go to Step 5,
even if ACTUAL GUIDE VANE POSITION is less than
30%.
3. Do not change SURGE LINE SHAPE FACTOR from
the value selected by Chiller Builder (ECAT). Decrease
SURGE/HGBP DELTA TSMAX by 1°F Steps up to 5
times. Monitor chiller for surge.
4. If ACTUAL GUIDE VANE POSITION is greater than
60% and Step 3 failed to eliminate surge, then set
SURGE/HGBP DELTA TSMAX to 5° F below the value
specified by Chiller Builder (ECAT). Increase the value
of the SURGE LINE SHAPE FACTOR in steps of 0.01
up to 2 times. For example, if surge is encountered when
the SURGE LINE SHAPE FACTOR is –0.06, increase
the SURGE LINE SHAPE FACTOR to –0.05. If this
does not solve the problem, go to Step 5, even if ACTUAL GUIDE VANE POSITION is greater than 60%.
5. If ACTUAL GUIDE VANE POSITION is greater than
30% but less than 60% or if Step 2 failed (with ACTUAL
GUIDE VANE POSITION less than 30) or if Step 4
60.00
55.00
50.00
Shape factor
= -0.020
45.00
Delta Tsat
40.00
35.00
Shape factor
= -0.040
30.00
25.00
20.00
Shape factor
= -0.050
15.00
10.00
5.00
0.00
0
10
20
30
40
50
60
70
80
90
100
GV_POS
110
a19-1961
Fig. 38 — Effect of SURGE LINE SHAPE FACTOR
on Surge Prevention
40.00
35.00
Speed Factor
=1.60
30.00
Delta Tsat
25.00
Speed Factor
=1.85
20.00
15.00
Speed Factor
=2.00
10.00
5.00
0.00
0
10
20
30
40
50
60
70
80
90
100
110
GV_POS
a19-1962
Fig. 39 — Effect of SURGE LINE SPEED FACTOR
on Surge Prevention
Fine Tuning VPF Surge Prevention — Figures 36-39 show
how the parameters defined below will affect the configured
surge line.
NOTE: Before tuning surge prevention check for VFD speed
limitation or capacity overrides. If the source of low capacity is
found in one of these places, do not proceed with an attempt to
tune the Surge Prevention configurations.
If capacity is not reached
and
1. ACTUAL GUIDE VANE POSITION < GUIDE VANE
TRAVEL RANGE
and
2. SURGE PREVENTION ACTIVE = YES
and
3. PERCENT LINE CURRENT < 100%
then the surge line is probably too conservative.
Note the following parameters from ICVC when maximum
AVERAGE LINE CURRENT achieved:
• EVAPORATOR REFRIGERANT TEMP
• EVAPORATOR PRESSURE
• CONDENSER REFRIG TEMP
• CONDENSER PRESSURE
71
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. 40.
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.
failed (with ACTUAL GUIDE VANE POSITION greater than 60), then perform this step. Do not change
SURGE LINE SHAPE FACTOR from the value specified by Chiller Builder (ECAT). Reset SURGE/HGBP
DELTA TSMIN and SURGE/HGBP DELTA TSMAX to
the value specified by Chiller Builder (ECAT). Decrease
SURGE/HGBP DELTA TSMIN and SURGE/HGBP
DELTA TSMAX in steps of 1° F up to 5 times. Monitor
chiller for surge.
CONFIGURE DIFFUSER CONTROL IF NECESSARY — If the compressor is equipped with a variable
diffuser, (size 4 or 5 compressor) access the SETUP2 screen.
Scroll to DIFFUSER CONTROL and press the ENABLE
softkey. Compare the diffuser and guide vane values (GUIDE
VANE 25% LOAD PT, GUIDE VANE 50% LOAD PT, GUIDE
VANE 75% LOAD PT, DIFFUSER 25% LOAD POINT,
DIFFUSER 50% LOAD POINT, DIFFUSER 75% LOAD
POINT) to the values located on the label inside the control
panel above the ICVC. See Fig. 10.
Compressors with variable diffuser control have actuators
tested and stamped with the milliamp (mA) value that results in
100% actuator rotation. This value is configured on the
SETUP2 screen. It is labeled DIFFUSER FULL SPAN mA.
Further adjustments can be made if response to surge prevention or protection is not functioning as desired. VFD GAIN
and VFD INCREASE STEP can be adjusted to allow for more
aggressive changes in speed when surge prevention or protection is active.
MODIFY EQUIPMENT CONFIGURATION IF NECESSARY — The EQUIPMENT SERVICE table has screens to
select, view, or modify parameters. Carrier’s certified drawings
have the configuration values required for the jobsite. Modify
these values only if requested.
EQUIPMENT SERVICE Screen Modifications — Change
the values on these screens according to specific job data. See
the certified drawings for the correct values. Modifications can
include:
• Chilled water reset (CHW SETPT RESET VALUE)
• Entering chilled water control (ECW CONTROL OPTION)
• 4 to 20 mA demand limit (DEMAND LIMIT AT 20 mA)
• AUTO RESTART OPTION (Enable/Disable)
• REMOTE CONTACT OPTION (Enable/Disable)
Owner-Modified CCN Tables — The following EQUIPMENT CONFIGURATION screens are described for reference
only.
OCCDEFCS — The OCCDEFCS screen contains the Local
and CCN time schedules, which can be modified here or on the
SCHEDULE screen as described previously.
HOLIDAYS — From the HOLIDAYS screen, the days of the
year that holidays are in effect can be configured. See the
holiday paragraphs in the Controls section for more details.
BRODEF — The BRODEF screen defines the start and end of
daylight savings time. By default this feature is enabled. Enter
the dates for the start and end of daylight savings if required
for your location. Note that for Day of Week, 1 represents
Monday. Start Week and Stop Week refer to the instance of the
selected Day of Week during the selected month and year. To
disable the feature, change “Start Advance” and “Stop Back”
times to 0 (minutes). In the BRODEF table the user may also
identify a chiller as the time broadcaster for a CCN network.
There should be only one device on a CCN network which is
designated as the Time Broadcaster.
ALARM ROUTING — This is in the table SERVICE–>
EQUIPMENT CONFIGURATION–>NET_OPT under the
heading Alarm Configuration. Alarm Routing consists of an
8-bit binary number. Only bits 1, 2, and 4 (counting from the
left, first) are used. The others do not matter. The bits can be
set by any device which can access and change configuration
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
1
1
0
1
0
0
a19-1627
0
0
unused
NOTE: If your CCN does not contain ComfortWORKS® controls or a
Building Supervisor, Autodial Gateway, or APIM to serve as an
alarm acknowledger, set all digits in this decision to 0 in order to
prevent unnecessary activity on the CCN Communication Bus.
Allowable Entries
00000000 to 11111111
0 = Disabled, 1 = Enabled
Default Value
10000000
Fig. 40 — Alarm Control and Alarm Routing
Perform a Control Test — Check the safety controls
status by performing an automated control test. Access the
CONTROL TEST table and select a test to be performed
function. See Table 13.
The Automated Control Test checks all outputs and inputs
for function. In order to successfully proceed with the controls
test, the compressor should be off, no alarms showing, and voltage should be within ±10% of Nameplate value. The compressor can be put in OFF mode by pressing the STOP push button
on the ICVC. Each test asks the operator to confirm the operation is occurring and whether or not to continue. If an error occurs, the operator can try to address the problem as the test is
being done or note the problem and proceed to the next test.
NOTE: Enter guide vane calibration to calibrate guide vane
actuator feedback potentiometer input on CCM (Plug J4 upper
terminals 9 and 10).
NOTE: If during the control test, the guide vanes do not open,
verify the low pressure alarm is not active. (An active low
pressure alarm causes the guide vanes to close.)
NOTE: The oil pump test will not energize the oil pump if
cooler pressure is below –5 psig (–35 kPa).When the control
test is finished or the EXIT softkey is pressed, the test stops,
and the CONTROL TEST menu displays. If a specific automated test procedure is not completed, access the particular
control test to test the function when ready. The CONTROL
TEST menu is described in Table 13.
72
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 transducer’s 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.
Table 13 — Control Test Menu Functions
TESTS TO BE
DEVICES TESTED
PERFORMED
1. CCM Thermistors Entering Chilled Water
Leaving Chilled Water
Entering Condenser Water
Leaving Condenser Water
Evap Saturation Temp
Comp Discharge Temp
Comp Thrust Brg Temp
Oil Sump Temp
Comp Motor Winding Temp
Spare Temperature 1
Spare Temperature 2
Remote Reset Sensor
2. CCM Pressure
Evaporator Pressure
Transducers
Condenser Pressure
Oil Pump Delta P
Chilled Water Delta
Condenser Water Delta P
Transducer Voltage Ref
Humidity Sensor Input
Relative Humidity
3. Pumps
Oil Pump — Confirm Pressure
Chilled Water — Confirm Flow and Delta P
Condenser Water — Confirm Delta P
4. Discrete
Oil Heater Relay
Outputs
Hot Gas Bypass Relay
Tower Fan Relay Low
Tower Fan Relay High
VFD Coolant Solenoid
Alarm Relay
Shunt Trip Relay
5. IGV & SRD
Open/Close
Actuator
If present, split ring diffuser will operate in
coordination with the guide vanes per configured schedule.
6. Head Pressure
Increase/Decrease 4-20 mA output
Output
7. Diffuser Actuator* Open/Close (independent of guide vanes)
8. Pumpdown
When using pumpdown/lockout, observe
Lockout
freeze up precautions when removing
charge:
Instructs operator which valves to close and
when.
Starts chilled water and condenser water
pumps and requests flow confirmation.
Monitors
Evaporator pressure
Condenser pressure
Evaporator temperature during
pumpout procedures
Turns pumps off after pumpdown.
Locks out compressor.
9. Terminate
Starts pumps and monitors flows.
Lockout
Instructs operator which valves to
open and when.
Monitors
Evaporator pressure
Condenser pressure
Evaporator temperature during
charging process
Terminates compressor lockout.
10. Guide Vane
Automatic, displays guide vane position sigCalibration
nal voltage. This test is required before first
startup with new Actuator or Controller.
If the ICVC fails to accept the zero point calibration, the
value will not change to 0.0 and the display will show “Higher
Force In Effect”. This indicates that the sensor voltage is out of
the acceptable range. For each single value transducer there are
3 terminals at the CCM: 0 vdc (low), “sensor” voltage, and
5.00 vdc (high). With a base supply voltage of 5.00 volts, the
acceptable range of voltage taken between the low and sensor
terminals for zero point calibration is 0.40 to 0.55 v. For each
transducer differential pair there are two 3-terminal sets at the
CCM. With a base supply voltage of 5.00 volts, the acceptable
range of voltage taken between the sensor terminal for the high
end transducer (water inlet or oil pump discharge) and the
sensor terminal for the low end transducer (water outlet or oil
sump) for zero point calibration is –0.065 to +0.085 v. If this
occurs with a differential pair, one possible remedy is to swap
the high end (e.g., inlet) and low end (e.g., outlet) transducers.
In most cases this puts the sensor voltage within the acceptable
range.
High End Calibration — High end calibration can be performed between 25 and 250 psig (173 and 1724 kPa), comparing the pressure readings in the ICVC display to an accurate refrigeration gage. While it normally will have a negligible effect, it may improve transducer accuracy over the full pressure
range. High end calibration is not recommended for transducer
differential pairs. Pressure can be provided by attaching a regulated 250 psig (1724 kPa) pressure source, such as from a nitrogen cylinder, to the transducer.
Access the HEAT_EX screen under the STATUS menu,
and the CONDENSER PRESSURE or EVAPORATOR
PRESSURE to the reference pressure gage. To change the displayed reading, press the SELECT key to highlight the associated line in the display, then the INCREASE or DECREASE
key to set the new value, then the ENTER key. Generally, the
value can be changed to any value within ±15% of a nominal
value.
*Diffuser tests function only on size 4 and 5 compressor with diffuser
control enabled.
NOTE: During any of the tests, an out-of-range reading will have an
asterisk (*) next to the reading and a message will be displayed if
diffuser control is enabled.
PRESSURE TRANSDUCER CALIBRATION — The
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
NOTE: Prior calibrations may have shifted the present
pre-calibration value from the center of this range. In this case,
the limit of acceptable new values will be less than 15% in one
direction.
73
CHILLER EQUALIZATION WITHOUT A PUMPOUT
UNIT
If the ICVC fails to accept the high end calibration, the
value will not change and the display will show “Higher Force
In Effect.” This indicates that the sensor voltage is out of the
acceptable range for the entered value. If this occurs with a
differential pair, one possible remedy is to swap the high end
(inlet) and low end (outlet) transducers. In most cases this puts
the sensor voltage within the acceptable range.
Each transducer is supplied with 5 vdc power from the
CCM. Pressure transducer readings are derived from voltage
ratio, not absolute voltage, which compensates for any
reference voltage variation. If this power supply fails, a
transducer voltage reference alarm is generated. If transducer
readings are suspected of being faulty, check the supply
voltage, measured between the high and low (first and third)
terminals of any transducer 3 terminal connection at the CCM.
This is also displayed in CONTROL TEST under CCM
PRESSURE TRANSDUCERS.
CAUTION
When equalizing refrigerant pressure in the 19XRV chiller
after service work or during the initial chiller start-up, do
not use the discharge isolation valve to equalize. Either the
motor cooling isolation valve or a charging hose (connected between the refrigerant charging valves on top of
the cooler and condenser) should be used as the equalization valve. Damage to the float valve could result.
To equalize the pressure differential on a 19XRV chiller
with the refrigerant isolated in one of the heat exchangers, use
the terminate lockout function of the CONTROL TEST on the
SERVICE menu. This helps to turn on pumps and advises the
operator on proper procedures.
The following steps describe how to equalize refrigerant
pressure in an isolated 19XRV chiller without a pumpout unit.
1. Access terminate lockout function on the CONTROL
TEST screen.
2. IMPORTANT: Turn on the chilled water and condenser water pumps to prevent freezing.
Check Optional Pumpout System Controls
and Compressor — Controls include an on/off switch,
a 0.5-amp fuse, the compressor overloads, an internal thermostat, a compressor contactor, refrigerant low pressure cut-out,
and a refrigerant high pressure cutout. The high pressure cutout
is factory set to open at 185 psig (1276 kPa) and reset at
140 psig (965 kPa). The low pressure cutout is factory set to
open at 7 psia (–15.7 in. HG) and close at 9 psia (–11.6 in. HG).
Ensure the water-cooled condenser has been connected. Ensure
oil is visible in the compressor sight glass. Add oil if necessary.
See the Pumpout and Refrigerant Transfer Procedures and
Optional Pumpout System Maintenance sections, pages 81 and
88, 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.
3. Slowly open the motor cooling isolation valve. The
chiller’s cooler and condenser pressures will gradually
equalize. This process takes approximately 15 minutes.
4. Once the pressures have equalized, the cooler isolation
valve, the condenser isolation valve, and the hot gas isolation valve may now be opened. Refer to Fig. 30 and 31,
for the location of the valves.
WARNING
Whenever turning the discharge isolation valve, be sure to
reattach the valve locking device. This prevents the valve
from opening or closing during service work or during
chiller operation, which could result in serious personal
injury.
Charge Refrigerant into Chiller
CAUTION
The transfer, addition, or removal of refrigerant in spring
isolated chillers may place severe stress on external piping
if springs have not been blocked in both up and down
directions. Failure to block springs in both up and down
directions could result in severe personal injury and equipment damage.
CHILLER EQUALIZATION WITH PUMPOUT UNIT —
The following steps describe how to equalize refrigerant
pressure on an isolated 19XRV chiller using the pumpout unit.
1. Access the terminate lockout function on the CONTROL
TEST screen.
2. IMPORTANT: Turn on the chilled water and condenser water pumps to prevent freezing.
CAUTION
Always operate the condenser and chilled water pumps
during charging operations to prevent freeze-ups. Damage
could result to equipment if condenser and chilled water
pumps are not operated during pumpdown or charging.
3. Open valve 4 on the pumpout unit and open valves 1a and
1b on the chiller cooler and condenser, Fig. 30 and 31.
Slowly open valve 2 on the pumpout unit to equalize the
pressure. This process takes approximately 15 minutes.
4. Once the pressures have equalized, the discharge isolation valve, cooler isolation valve, optional hot gas bypass
isolation valve, and the refrigerant isolation valve can be
opened. Close valves 1a and 1b, and all pumpout unit
valves.
The full refrigerant charge on the 19XRV chiller will vary
with chiller components and design conditions, as indicated on
the job data specifications. An approximate charge may be determined by adding the condenser charge to the cooler charge
as listed in Table 14A and 14B.
The standard 19XRV chiller is shipped with the refrigerant
already charged in the vessels. However, the 19XRV chiller
may be ordered with a nitrogen holding charge of 15 psig
(103 kPa). Evacuate the nitrogen from the entire chiller, and
charge the chiller from refrigerant cylinders.
74
Table 14A — Refrigerant (HFC-134a) Charge with Compressor End Entering Cooler Water
CODE
20
21
22
30
31
32
35
36
37
40
41
42
45
46
47
50
51
52
53
54
55
56
57
58
59
5A
5B
5C
5F
5G
5H
5K
5L
5M
5P
5Q
5R
5T
5U
5V
5X
5Y
5Z
60
61
62
63
64
65
66
67
68
69
MACHINE CHARGE
English
Metric (SI)
Refrigerant
Refrigerant
Weight (lb)
Weight (kg)
Cooler
Condenser
Cooler
Condenser
345
225
156
102
385
225
175
102
435
225
197
102
350
260
159
118
420
260
191
118
490
260
222
118
400
310
181
141
480
310
218
141
550
310
249
141
560
280
254
127
630
280
286
127
690
280
313
127
640
330
290
150
720
330
327
150
790
330
358
150
750
400
340
181
840
400
381
181
900
400
408
181
900
400
409
182
900
400
409
182
870
490
395
222
940
490
426
222
980
490
445
222
980
490
445
222
980
490
445
222
500
—
227
—
520
—
236
—
550
—
249
—
550
—
249
—
570
—
259
—
600
—
272
—
673
—
306
—
706
—
321
—
742
—
337
—
641
—
291
—
678
—
308
—
709
—
322
—
768
—
349
—
801
—
364
—
843
—
383
—
730
—
331
—
769
—
349
—
805
—
365
—
940
420
426
191
980
420
445
191
1020
420
463
191
1020
420
463
191
1020
420
463
191
1020
510
463
231
1060
510
481
231
1090
510
494
231
1090
510
495
232
1090
510
495
232
English
CODE
6K
6L
6M
6P
6Q
6R
6T
6U
6V
6X
6Y
6Z
70
71
72
73
74
75
76
77
78
79
7K
7L
7M
7P
7Q
7R
7T
7U
7V
7X
7Y
7Z
80
81
82
83
84
85
86
87
88
89
8K
8L
8M
8P
8Q
8R
8T
8U
8V
8X
8Y
8Z
75
MACHINE CHARGE
Metric (SI)
Refrigerant
Weight (lb)
Cooler
Condenser
760
797
828
725
764
798
863
905
941
823
868
906
1220
1340
1440
1440
1440
1365
1505
1625
1625
1625
1047
1132
1214
1002
1087
1167
1194
1292
1403
1142
1240
1347
1500
1620
1730
1730
1730
1690
1820
1940
1940
1940
1385
1484
1589
1334
1430
1535
1580
1694
1814
1522
1632
1752
—
—
—
—
—
—
—
—
—
—
—
—
780
780
780
780
780
925
925
925
925
925
—
—
—
—
—
—
—
—
—
—
—
—
720
720
720
720
720
860
860
860
860
860
—
—
—
—
—
—
—
—
—
—
—
—
Refrigerant
Weight (kg)
Cooler
Condenser
345
362
376
329
347
362
392
411
427
374
394
411
553
608
653
654
654
619
683
737
738
738
475
514
551
455
493
530
542
587
637
518
563
612
680
735
785
785
785
767
826
880
881
881
629
674
721
606
649
697
717
769
824
691
741
795
—
—
—
—
—
—
—
—
—
—
—
—
354
354
354
354
354
420
420
420
420
420
—
—
—
—
—
—
—
—
—
—
—
—
327
327
327
327
327
390
390
390
390
390
—
—
—
—
—
—
—
—
—
—
—
—
Table 14B — Refrigerant (HFC-134a) Charge with Drive End Entering Cooler Water
CODE
20
21
22
30
31
32
35
36
37
40
41
42
45
46
47
50
51
52
53
54
55
56
57
58
59
5A
5B
5C
5F
5G
5H
5K
5L
5M
5P
5Q
5R
5T
5U
5V
5X
5Y
5Z
60
61
62
63
64
65
66
67
68
69
MACHINE CHARGE
English
Metric (SI)
Refrigerant
Refrigerant
Weight (lb)
Weight (kg)
Cooler
Condenser
Cooler
Condenser
416
252
189
114
459
252
208
114
505
252
229
114
510
308
232
140
565
308
257
140
626
308
284
140
577
349
262
158
639
349
290
158
709
349
322
158
726
338
330
153
783
338
355
153
840
338
381
153
821
383
373
174
874
383
397
174
949
383
431
174
897
446
407
202
974
446
442
202
1021
446
464
202
1010
446
459
202
987
446
448
202
1014
504
460
229
1101
504
500
229
1154
504
524
229
1143
504
519
229
1116
504
507
229
491
—
223
—
510
—
232
—
532
—
242
—
553
—
251
—
575
—
261
—
600
—
272
—
673
—
306
—
706
—
321
—
742
—
337
—
641
—
291
—
678
—
308
—
709
—
322
—
768
—
349
—
801
—
364
—
843
—
383
—
730
—
331
—
769
—
349
—
805
—
365
—
1091
479
495
217
1150
479
522
217
1202
479
546
217
1202
479
546
217
1178
479
535
217
1241
542
563
246
1309
542
594
246
1369
542
622
246
1359
542
617
246
1332
542
605
246
CODE
6K
6L
6M
6P
6Q
6R
6T
6U
6V
6X
6Y
6Z
70
71
72
73
74
75
76
77
78
79
7K
7L
7M
7P
7Q
7R
7T
7U
7V
7X
7Y
7Z
80
81
82
83
84
85
86
87
88
89
8K
8L
8M
8P
8Q
8R
8T
8U
8V
8X
8Y
8Z
76
MACHINE CHARGE
English
Metric (SI)
Refrigerant
Refrigerant
Weight (lb)
Weight (kg)
Cooler
Condenser
Cooler
Condenser
760
—
345
—
797
—
362
—
828
—
376
—
725
—
329
—
764
—
347
—
798
—
362
—
863
—
392
—
905
—
411
—
941
—
427
—
823
—
374
—
868
—
394
—
906
—
411
—
1409
840
640
381
1539
840
699
381
1646
840
747
381
1622
840
736
381
1584
840
719
381
1599
950
726
431
1747
950
793
431
1869
950
849
431
1849
950
839
431
1806
950
820
431
1047
—
475
—
1132
—
514
—
1214
—
551
—
1002
—
455
—
1087
—
493
—
1167
—
530
—
1194
—
542
—
1292
—
587
—
1403
—
637
—
1142
—
518
—
1240
—
563
—
1347
—
612
—
1700
836
772
380
1812
836
823
380
1928
836
875
380
1877
836
852
380
1840
836
835
380
1927
945
875
429
2054
945
933
429
2186
945
992
429
2142
945
972
429
2099
945
953
429
1385
—
629
—
1484
—
674
—
1589
—
721
—
1334
—
606
—
1430
—
649
—
1535
—
697
—
1580
—
717
—
1694
—
769
—
1814
—
824
—
1522
—
691
—
1632
—
741
—
1752
—
795
—
4. Oil is at the proper level in the reservoir sight glasses.
5. Oil reservoir temperature is above 140 F (60 C) or above
refrigerant temperature plus 50 F (28 C).
6. Valves in the evaporator and condenser water circuits are
open.
NOTE: If the pumps are not automatic, ensure water is
circulating properly.
CAUTION
Ensure that the condenser and chilled water pumps are
operating whenever charging, transferring, or removing
refrigerant from the chiller. Failure to do so could result in
serious personal injury or equipment damage.
Use the CONTROL TEST terminate lockout function to
monitor conditions and start the pumps.
If the chiller has been shipped with a holding charge, the
refrigerant is added through the pumpout charging connection
(Fig. 30 and 31, valve 1b). First evacuate the nitrogen holding
charge from the chiller vessels. Charge the refrigerant as a gas
until the system pressure exceeds 35 psig (141 kPa) for
HFC-134a. After the chiller is beyond this pressure the refrigerant should be charged as a liquid until all the recommended
refrigerant charge has been added. The charging valve (Fig. 30
and 31, valve 1a or 1b) can be used to charge liquid to the cooler or condenser. Do not charge liquid through the liquid line
service valve.
TRIMMING REFRIGERANT CHARGE — The 19XRV unit
is shipped with the correct charge for the design duty of the
chiller. On most 19XRV chillers the design LTD (Leaving
Temperature Difference) between the leaving chilled water
temperature and the cooler refrigerant temperature is so low
that the traditional method of trimming the charge to achieve a
minimum LTD is not practical. In the case where leaks have
been found and corrected and the LTD is greater than about 4 F
(2.2 C) above design, add refrigerant until the full load design
LTD is approached, and then charge for proper oil return at low
load. (A high cooler LTD can also be caused by dirty tubes,
water box division plate bypass, a partially closed liquid isolation valve, or a sticking float valve.)
If low load oil loss is experienced, operate the chiller at low
load with the guide vanes nearly closed and observe the flow
through the sight glass in the oil skimmer line. Under low load
operation one should be able to see a flow of bubbly oil and
refrigerant in the sight glass. If there is no visible flow, add
refrigerant. If the sight glass shows a flow of nearly clear fluid,
remove refrigerant.
The preferred location at which refrigerant should be added
directly into the chiller is through the service valve at the top of
the condenser. If that valve is not accessible due to presence of
an attached pumpdown unit which does not have a storage
tank, add charge through the valve connected to the side of the
condenser drain float sump. Adding charge through the drain
valve at the base of the chiller (off the liquid line) is NOT
recommended.
The full refrigerant charge on the 19XRV chiller will vary
with chiller components and design conditions, as indicated on
the job data specifications. An approximate charge may be determined by adding the condenser charge to the cooler charge
as listed in Tables 14A and 14B.
CAUTION
Do not permit water or brine that is warmer than 110 F
(43 C) to flow through the cooler or condenser. Refrigerant
overpressure may discharge through the relief valves and
result in the loss of refrigerant charge, damaging the chiller.
7. Access the CONTROL TEST screen. Scroll down on the
TERMINATE LOCKOUT option. Press the SELECT (to
enable the chiller to start) and answer YES to reset unit to
operating mode. The chiller is locked out at the factory in
order to prevent accidental start-up.
Check Motor Rotation
1. Engage the control power circuit breaker (CB2) located
inside the left hand side of the VFD enclosure.
2. Finally close the main motor disconnect (CB1) on the
front of the VFD enclosure.
3. The VFD checks for proper phase rotation as soon as
power is applied to the VFD and the PIC III controls
power up. The controls do not permit a start if the phase
rotation is not correct.
4. An alarm message will appear on the ICVC if the phase
rotation is incorrect. If this occurs, reverse any 2 of the 3
incoming power leads to the VFD and reapply power.
The motor is now ready for a rotation check.
5. After the default screen status message states ‘Ready to
Start’ press the LOCAL softkey. The PIC III control
performs start-up checks.
6. When the VFD is energized and the motor begins to turn,
check for clockwise motor rotation. See Fig. 41.
CAUTION
Do not check motor rotation during coastdown. Rotation
may have reversed during equalization of vessel pressures.
a19-1326
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.
Preparation — Before starting the chiller, verify:
1. Power is on to the VFD, oil pump relay, oil heater relay,
and the chiller control panel.
2. Cooling tower water is at proper level and at-or-below
design entering temperature.
3. Chiller is charged with refrigerant and all refrigerant and
oil valves are in their proper operating positions.
Fig. 41 — Correct Motor Rotation
77
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.
Check Oil Pressure and Compressor Stop
1. When the motor is at full speed, note the OIL PRESSURE reading on the ICVC default screen. Normal
19XRV oil pressure readings are between 18 and 30 psid
(124 to 207 kPad). The oil pressure should be between 18
and 40 psid (124 to 276 kPad) on Frame 3 compressors
equipped with rolling element bearings.
2. Press the Stop button and listen for any unusual sounds
from the compressor as it coasts to a stop.
To Prevent Accidental Start-Up — A chiller STOP
override setting may be entered to prevent accidental start-up
during service or whenever necessary. Access the MAINSTAT
screen and using the NEXT or PREVIOUS softkeys,
highlight the CHILLER START/STOP parameter. Override the
current START value by pressing the SELECT softkey. Press
the STOP softkey followed by the ENTER softkey. The
word SUPVSR! displays on the ICVC indicating the override
is in place.
OPERATING INSTRUCTIONS
Operator Duties
To restart the chiller, the STOP override setting must be
removed. Access the MAINSTAT screen and using NEXT
or PREVIOUS softkeys highlight CHILLER START/STOP.
The 3 softkeys that appear represent 3 choices:
•
•
•
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.
START — forces the chiller ON
STOP — forces the chiller OFF
RELEASE — puts the chiller under remote or schedule
control
To return the chiller to normal control, press the
RELEASE softkey followed by the ENTER softkey. For
more information, see Local Start-Up, page 57.
The default ICVC screen message line indicates which
command is in effect.
Prepare the Chiller for Start-Up — Follow the steps
described in the Initial Start-Up section, page 77.
To Start the Chiller
Check Chiller Operating Condition — Check to be
1. Start the water pumps, if they are not automatic.
2. On the ICVC default screen, press the LOCAL or
CCN softkey to start the system. If the chiller is in the
OCCUPIED mode and the start timers have expired, the
start sequence will start. Follow the procedure described
in the Start-Up/Shutdown/Recycle Sequence section,
page 57.
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.
Check the Running System — After the compres-
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
78
5.
6.

7.
8.
be up to 10 psid (69 kPad) higher for Frame 3 compressors equipped with rolling element bearings.
The moisture indicator sight glass on the refrigerant
motor cooling line should indicate refrigerant flow and a
dry condition.
The condenser pressure and temperature varies with the
chiller design conditions. Typically the pressure will
range between 60 and 135 psig (390 to 950 kPa) with a
corresponding temperature range of 60 to 105 F (15 to
41 C). The condenser entering water temperature should
be controlled below the specified design entering
water temperature to save on compressor kilowatt
requirements.
Cooler pressure and temperature also will vary with the
design conditions. Typical pressure range will be between
29.5 and 40.1 psig (203.4 and 276.4 kPa), with temperature ranging between 34 and 45 F (1.1 and 7.2 C).
The compressor may operate at full capacity for a short
time after the pulldown ramping has ended, even though
the building load is small. The active electrical demand
setting can be overridden to limit the compressor IkW, or
the pulldown rate can be decreased to avoid a high
demand charge for the short period of high demand
operation. Pulldown rate can be based on load rate or
temperature rate and is accessed on the EQUIPMENT
SERVICE screen, RAMP_DEM table (Table 4,
Example 23).
After Extended Shutdown — Ensure the water sys-
tem drains are closed. It may be advisable to flush the water
circuits to remove any soft rust which may have formed. This
is a good time to brush the tubes and inspect the Schrader
fittings on the waterside flow devices for fouling, if necessary.
Check the cooler pressure on the ICVC default screen and
compare it to the original holding charge that was left in the
chiller. If (after adjusting for ambient temperature changes) any
loss in pressure is indicated, check for refrigerant leaks. See
Check Chiller Tightness section, page 60.
Recharge the chiller by transferring refrigerant from the
pumpout storage tank (if supplied). Follow the Pumpout and
Refrigerant Transfer Procedures section, page 81. Observe
freeze-up precautions.
Carefully make all regular preliminary and running system
checks. Perform a Control Test before start-up. If the compressor oil level appears abnormally high, the oil may have
absorbed refrigerant. Ensure that the oil temperature is above
140 F (60 C) or above the cooler refrigerant temperature plus
50 F (27 C).
Cold Weather Operation — When the entering con-
denser water temperature drops very low, the operator should
automatically cycle the cooling tower fans off to keep the
temperature up. Piping may also be arranged to bypass the
cooling tower. The PIC III controls have a low limit tower fan
output that can be used to assist in this control (terminals 5 and
6 on the TB2 hazardous voltage field wiring terminal strip).
To Stop the Chiller
Manual Guide Vane Operation — It is possible to
manually operate the guide vanes in order to check control
operation or to control the guide vanes in an emergency. Manual operation is possible by overriding the target guide vane
position. Access the COMPRESS screen on the ICVC and
scroll down to highlight TARGET GUIDE VANE POS. To
control the position, use the INCREASE or DECREASE
softkey to adjust to the percentage of guide vane opening that is
desired. Zero percent is fully closed; 100% is fully open. To
release the guide vanes to automatic control, press the
RELEASE softkey.
Similarly, the TARGET VFD SPEED can be manually set
in the COMPRESS screen. The target value is still limited to be
between configured VFD MINIMUM SPEED and VFD
MAXIMUM SPEED. Once speed is manually set in this manner, capacity control changes are directed to modulate the
guide vanes.
NOTE: Manual control mode overrides the configured pulldown ramp rate during start-up and permits the guide vanes to
open at a faster rate. The PIC III controls will close the guide
vanes if the motor current exceeds the ACTIVE DEMAND
LIMIT or capacity override limits. The guide vanes will
also close if the chilled water temperature falls below the
CONTROL POINT. For descriptions of capacity overrides and
set points, see the Controls section.
1. The occupancy schedule starts and stops the chiller
automatically once the time schedule is configured.
2. By pressing the STOP button for one second, the alarm
light blinks once to confirm the button has been pressed.
The compressor will then follow the normal shutdown
sequence as described in the Shutdown Sequence,
Start-Up/Shutdown/Recycle Sequence section, page 57.
The chiller will not restart until the CCN or LOCAL
softkey is pressed. The chiller is now in the OFF control
mode.
IMPORTANT: Do not attempt to stop the chiller by opening
an isolating knife switch. High intensity arcing may occur.
Do not restart the chiller until the problem is diagnosed
and corrected.
After Limited Shutdown — No special preparations
should be necessary. Follow the regular preliminary checks and
starting procedures.
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.
Refrigeration Log — A refrigeration log (as shown in
Fig. 42) is a convenient checklist for routine inspection and
maintenance and provides a continuous record of chiller
performance. It is also an aid when scheduling routine maintenance and diagnosing chiller problems.
Keep a record of the chiller pressures, temperatures, and liquid levels on a sheet similar to the one in Fig. 42. Automatic
recording of PIC III data is possible by using CCN devices
such as the Data Collection module and a Building Supervisor.
Contact your Carrier representative for more information.
79
312
80
TIME
Press. Temp
In
Out
GPM
Pressure
Water
COOLER
DATE
Refrigerant
MODEL NO.
Plant
In
Out
Temp
Press. Temp
Refrigerant
In
Out
GPM
Pressure
Water
CONDENSER
SERIAL NO.
In
Pressure
Sump
Temp
Oil
COMPRESSOR
Level
Fig. 42 — Refrigeration Log
Out
Temp
Thrust
Bearing
Temp
MOTOR RLA
Average Average
Average Inverter Rectifier
VFD
Line
Line
Line
Load
Temp Coolant
Current Voltage Kilowatts Current Temp
Flow
VFD
REFRIGERATION LOG CARRIER 19XRV HERMETIC CENTRIFUGAL REFRIGERATION MACHINE
OPERATOR
INITIALS
REMARKS
under all operating conditions and during shutdown. If oil is
low, add oil as described under Optional Pumpout System
Maintenance section, page 88. The pumpout unit control
wiring schematic is detailed in Fig. 43.
To read refrigerant pressures during pumpout or leak testing:
1. The ICVC display on the chiller control panel is suitable
for determining refrigerant-side pressures and low (soft)
vacuum. To assure the desired range and accuracy when
measuring evacuation and dehydration, use a quality
vacuum indicator or manometer. This can be placed on
the Schrader connections on each vessel (Fig. 8) by
removing the pressure transducer.
2. To determine pumpout storage tank pressure, a 30 in. Hg
vacuum -0-400 psi (-101-0-2769 kPa) gage is attached to
the storage tank.
3. Refer to Fig. 30, 31, and 44 for valve locations and
numbers.
PUMPOUT AND REFRIGERANT
TRANSFER PROCEDURES
Preparation — The 19XRV chiller may come equipped
with an optional pumpout storage tank, pumpout system, or
pumpout compressor. The refrigerant can be pumped for service work to either the chiller compressor vessel or chiller condenser vessel by using the optional pumpout system. If a
pumpout storage tank is supplied, the refrigerant can be isolated in the storage tank. The following procedures describe
how to transfer refrigerant from vessel to vessel and perform
chiller evacuations.
CAUTION
Always run the chiller cooler and condenser water pumps
and always charge or transfer refrigerant as a gas when the
chiller pressure is less than 35 psig (241 kPa). Below these
pressures, liquid refrigerant flashes into gas, resulting in
extremely low temperatures in the cooler/condenser tubes
and possibly causing tube freeze-up.
CAUTION
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.
WARNING
During transfer of refrigerant into and out of the optional
storage tank, carefully monitor the storage tank level gage.
Do not fill the tank more than 90% of capacity to allow for
refrigerant expansion. Overfilling may result in damage to
the tank or personal injury.
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.
CAUTION
CAUTION
Do not mix refrigerants from chillers that use different
compressor oils. Compressor damage can result.
Always run chiller cooler and condenser water pumps and
always charge or transfer refrigerant as a gas when chiller
vessel pressure is less than 35 psig (241 kPa). Below these
pressures, liquid refrigerant flashes into gas, resulting in
extremely low temperatures in the cooler/condenser tubes
and possibly causing tube freeze-up.
Operating the Optional Pumpout Unit — Oil
should be visible in the pumpout unit compressor sight glass
C
2 OL
C
2 OL
C
2 OL
L1
FIELD
POWER
SUPPLY
L2
MTR-1
L3
GND
L1
8
H1
C
FU
GND
HTR
MTR
NC
OL
SS
X2
FU3
0.5A
HIGH PRESSURE
SAFETY
NC OPEN > 185psig
1
X2
2
3
LOW PRESSURE CONTROL
NC OPEN < 7 psia (-15.7 in. HG)
CLOSE > 9 psia (-11.6 in. HG)
LEGEND
— Contactor
— Fuse
— Ground
— Heater
— Motor
— Normally Closed
— Overload
— Selector Switch
6
SS-1
OFF
AUTO ON
2
CRANKCASE HEATER
240-600v
27-40 WATT
7
H4
CONTROL POWER
TRANSFORMER X1
XFMR-1
69 VA
2
HTR-1
0.25A
FU1
0.25A
FU2
L2
PUMP OUT
COMPRESSOR
4
5
C
X2
Fig. 43 — Pumpout Unit Wiring Schematic
81
a23-1615
CONTROL
PANEL
VALVE
CONDITION
FRAME
ASSEMBLY
1a
1b
2
3
C
4
C
5
6
7
C
10
C
11
g. Turn on pumpout condenser water.
h. Run the pumpout compressor in manual mode until
the storage tank pressure reaches 5 psig (34 kPa),
18 in. Hg vacuum (41 kPa absolute).
i. Turn off the pumpout compressor.
j. Close valves 1a, 1b, 2, 5, and 6.
VALVE
2
VALVE
3
VALVE
4
VALVE
CONDITION
COMPRESSOR
OIL
HEATER
LEAVING
WATER
CONDENSER
OIL FILL
FITTING
OIL
SEPARATOR
a23-1546
VALVE
CONDITION
Fig. 44 — Pumpout Unit
Transfer Refrigerant from Pumpout Storage Tank to Chiller
During transfer of refrigerant into and out of the 19XRV
storage tank, carefully monitor the storage tank level gage.
Do not fill the tank more than 90% of capacity to allow for
refrigerant expansion. Overfilling may result in damage to
the tank and personal injury.
VALVE
CONDITION
1b
2
C
3
4
C
5
C
6
7
C
10
C
VALVE
CONDITION
1a
1b
2
C
3
4
C
5
6
7
10
4
C
5
C
6
C
7
C
10
C
11
1a
1b
2
C
3
4
C
5
C
6
7
C
10
C
11
1a
1b
2
C
3
4
C
5
6
7
10
11
1a
1b
2
3
C
4
C
5
6
7
10
11
b. Run the pumpout compressor in automatic mode
until vacuum switch is satisfied and compressor
stops. Close valves 7 and 10.
VALVE
CONDITION
1a
1b
2
3
C
4
C
5
6
7
C
10
C
11
10
C
11
c. Turn off the pumpout compressor.
11
3. Remove any remaining refrigerant.
a. Turn on chiller water pumps.
b. Turn on pumpout condenser water.
c. Place valves in the following positions:
d. Gradually crack open valve 5 to increase chiller
pressure to 35 psig (241 kPa). Slowly feed refrigerant to prevent freeze-up.
e. Open valve 5 fully after the chiller pressure rises
above the freezing point of the refrigerant. Let the
storage tank and chiller pressure equalize. Open
refrigerant charging valve 7 and storage tank
charging valve 10 to let liquid refrigerant drain into
the chiller.
VALVE
CONDITION
3
C
2. Transfer the remaining liquid.
a. Turn off pumpout condenser water. Place valves in
the following positions:
1. Equalize refrigerant pressure.
a. Turn on chiller water pumps and monitor chiller
pressures.
b. Close pumpout and storage tank valves 2, 4, 5, and
10, and close refrigerant charging valve 7; open
chiller isolation valve 11 and any other chiller
isolation valves, if present.
c. Open pumpout and storage tank valves 3 and 6;
open chiller valves 1a and 1b.
1a
2
C
b. Slowly open valve 5 and refrigerant charging
valves 7 and 10 to allow liquid refrigerant to drain
by gravity into the storage tank.
WARNING
VALVE
CONDITION
1b
C
k. Turn off pumpout condenser water.
Transfer the Refrigerant from Chiller to Pumpout Storage
Tank
1. Equalize refrigerant pressure.
a. Valve positions:
VALVE
5
ENTERING
WATER
1a
C
VALVE
CONDITION
1a
1b
2
C
3
4
5
C
6
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.
f. Close valves 1a, 1b, 3, 4, and 6.
11
2. Transfer remaining refrigerant.
a. Close valve 5 and open valve 4. Turn off the
pumpout condenser water, and turn on the
pumpout compressor in manual mode to push
liquid refrigerant out of the storage tank. Monitor
the storage tank level until the tank is empty.
b. Close refrigerant charging valves 7 and 10.
c. Turn off the pumpout compressor.
d. Turn off the chiller water pumps.
e. Close valves 3 and 4.
f. Open valves 2 and 5.
VALVE
CONDITION
1a
C
1b
C
2
C
3
C
4
C
5
C
6
C
g. Turn off the pumpout condenser water.
82
7
C
10
C
11
c. Equalize the refrigerant in the chiller cooler and
condenser.
d. Turn off chiller water pumps and pumpout condenser water.
e. Turn on pumpout compressor to push refrigerant
out of the chiller condenser.
f. When all liquid is out of the chiller condenser,
close valve 11 and any other liquid isolation valves
on the chiller.
g. Turn off the pumpout compressor.
2. Evacuate gas from chiller condenser vessel.
a. Turn on chiller water pumps.
b. Make sure that liquid line service valves 3 and 4
are closed and valves 2 and 5 are open.
4. Establish vacuum for service. To conserve refrigerant,
operate the pumpout compressor as described in Step 3e
until the chiller pressure is reduced to 18 in. Hg
vacuum (41 kPa absolute).
This operation can be done in Automatic or On mode.
In Automatic mode, the compressor will stop automatically at approximately 15 in. Hg vacuum (51 kPa
absolute).
CHILLERS WITH ISOLATION VALVES — The valves referred to in the following instructions are shown in Fig. 31 and
44. Valve 7 remains closed.
Transfer All Refrigerant to Chiller Condenser Vessel
1. Push refrigerant into chiller condenser vessel.
a. Turn on the chiller water pumps and monitor the
chiller pressure.
b. Valve positions:
VALVE
CONDITION
1a
1b
2
3
C
4
C
5
VALVE
CONDITION
11
1a
1b
2
C
3
4
5
C
VALVE
CONDITION
11
C
VALVE
CONDITION
1b
C
2
C
3
C
VALVE
CONDITION
4
C
5
C
1a
1b
2
3
C
4
C
5
4
C
5
11
C
1a
C
1b
C
2
C
3
C
4
C
5
C
11
C
1a
1b
2
C
3
4
C
5
C
11
C
1a
1b
2
C
3
4
C
5
11
C
7. Close valves 1a, 1b, 3, and 5.
8. Open chiller isolation valve 11 and any other isolation
valves, if present.
11
C
g. Turn off pumpout condenser water.
h. Turn off chiller water pumps and lock out chiller
compressor.
Transfer All Refrigerant to Chiller Cooler Vessel
1. Push refrigerant into the chiller cooler vessel.
a. Turn on the chiller water pumps and monitor the
chiller pressure.
b. Valve positions:
VALVE
CONDITION
3
C
4. Crack open valve 5, gradually increasing pressure in the
evacuated chiller vessel to 35 psig (241 kPa). Feed refrigerant slowly to prevent tube freeze-up.
5. Leak test to ensure chiller vessel integrity.
6. Open valve 5 fully.
d. Close valve 1a.
e. Turn off pumpout compressor.
f. Close valves 1b, 3, and 4.
1a
C
2
h. Turn off pumpout condenser water.
i. Turn off chiller water pumps and lock out chiller
compressor.
Return Chiller to Normal Operating Conditions
1. Be sure that the chiller vessel that was opened has been
evacuated.
2. Turn on chiller water pumps.
3. Open valves 1a, 1b, and 3.
b. Turn on pumpout condenser water.
c. Run pumpout compressor until the chiller cooler
vessel pressure reaches 18 in. Hg vacuum (41 kPa
absolute). Monitor pressures on the chiller control
panel and on refrigerant gages.
This operation can be done in Automatic or On
mode. In Automatic mode, the compressor will
stop automatically at approximately 15 in. Hg
vacuum (51 kPa absolute).
VALVE
CONDITION
1b
c. Turn on pumpout condenser water.
d. Run the pumpout compressor until the chiller condenser reaches 18 in. Hg vacuum (41 kPa absolute)
in Manual or Automatic mode. Monitor pressure at
the chiller control panel and refrigerant gages.
e. Close valve 1b.
f. Turn off pumpout compressor.
g. Close valves 1a, 2, and 5.
c. Equalize the refrigerant in the chiller cooler and
condenser.
d. Turn off chiller water pumps and pumpout condenser water supply.
e. Turn on pumpout compressor to push liquid out of
the chiller cooler vessel.
f. When all liquid has been pushed into the chiller
condenser vessel, close the cooler refrigerant isolation valve (11).
g. Turn on the chiller water pumps.
h. Turn off the pumpout compressor.
2. Evacuate gas from chiller cooler vessel.
a. Close liquid line service valves 2 and 5; open
valves 3 and 4.
VALVE
CONDITION
1a
VALVE
CONDITION
1a
C
1b
C
2
C
3
C
4
C
5
C
11
9. Turn off chiller water pumps.
DISTILLING THE REFRIGERANT
1. Transfer the refrigerant from the chiller to the pumpout
storage tank as described in the Transfer the Refrigerant
from Chiller to Pumpout Storage Tank section.
2. Equalize the refrigerant pressure.
a. Turn on chiller water pumps and monitor chiller
pressures.
11
83
b. Close pumpout and storage tank valves 2, 4, 5, and
10, and close chiller charging valve 7; open chiller
isolation valve 11 and any other chiller isolation
valves, if present.
c. Open pumpout and storage tank valves 3 and 6;
open chiller valves 1a and 1b.
VALVE
CONDITION
1a
1b
2
C
3
4
C
5
C
6
7
C
10
C
Removing Refrigerant — If the optional pumpout sys-
tem is used, the 19XRV refrigerant charge may be transferred
to a pumpout storage tank or to the chiller condenser or cooler
vessels. Follow the procedures in the Pumpout and Refrigerant
Transfer Procedures section when transferring refrigerant from
one vessel to another.
Adjusting the Refrigerant Charge — If the addition or removal of refrigerant is required to improve chiller
performance, follow the procedures given under the Trim
Refrigerant Charge section, page 85.
11
d. Gradually crack open valve 5 to increase chiller
pressure to 35 psig (241 kPa). Slowly feed refrigerant to prevent freeze-up.
e. Open valve 5 fully after the chiller pressure rises
above the freezing point of the refrigerant. Let the
storage tank and chiller pressure equalize.
3. Transfer remaining refrigerant.
a. Close valve 3.
b. Open valve 2.
VALVE
CONDITION
1a
1b
2
3
C
4
C
5
6
7
C
10
C
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.
Leak Rate — It is recommended by ASHRAE that chillers
11
be taken off line immediately and repaired if the refrigerant
leak rate for the entire chiller is more than 10% of the operating
refrigerant charge per year.
In addition, Carrier recommends that leaks totalling less
than the above rate, but more than a rate of 0.1% of the total
charge per year, should be repaired during annual maintenance
or whenever the refrigerant is transferred for other service
work.
c. Turn on pumpout condenser water.
d. Run the pumpout compressor until the storage tank
pressure reaches 5 psig (34 kPa), 18 in. Hg vacuum
(41 kPa absolute) in Manual or Automatic mode.
e. Turn off the pumpout compressor.
f. Close valves 1a, 1b, 2, 5, and 6.
g. Turn off pumpout condenser water.
VALVE
CONDITION
1a
C
1b
C
2
C
3
C
4
C
5
C
6
C
7
C
10
C
Test After Service, Repair, or Major Leak — If
all the refrigerant has been lost or if the chiller has been opened
for service, the chiller or the affected vessels must be pressure
tested and leak tested. Refer to the Leak Test Chiller section to
perform a leak test.
11
4. Drain the contaminants from the bottom of the storage
tank into a container. Dispose of contaminants safely.
WARNING
Refrigerant HFC-134a should not be mixed with air or
oxygen and pressurized for leak testing. In general, this
refrigerant should not be present with high concentrations
of air or oxygen above atmospheric pressures, because the
mixture can undergo combustion, which could result in
serious personal injury or death.
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.
TESTING WITH REFRIGERANT TRACER — Use an environmentally acceptable refrigerant as a tracer for leak test
procedures. Use dry nitrogen to raise the machine pressure to
leak testing levels.
TESTING WITHOUT REFRIGERANT TRACER — Another method of leak testing is to pressurize with nitrogen only and
to use a soap bubble solution or an ultrasonic leak detector to
determine if leaks are present.
TO PRESSURIZE WITH DRY NITROGEN
NOTE: Pressurizing with dry nitrogen for leak testing should
not be done if the full refrigerant charge is in the vessel
because purging the nitrogen is very difficult.
1. Connect a copper tube from the pressure regulator on the
cylinder to the refrigerant charging valve. Never apply
full cylinder pressure to the pressurizing line. Follow the
listed sequence.
2. Open the charging valve fully.
3. Slowly open the cylinder regulating valve.
4. Observe the pressure gage on the chiller and close the
regulating valve when the pressure reaches test level. Do
not exceed 140 psig (965 kPa).
5. Close the charging valve on the chiller. Remove the
copper tube if it is no longer required.
DANGER
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.
Adding Refrigerant — Follow the procedures described in Trim Refrigerant Charge section, page 85.
CAUTION
Always use the compressor pumpdown function in the
Control Test table to turn on the cooler pump and lock out
the compressor when transferring refrigerant. Liquid refrigerant may flash into a gas and cause water in the heater
exchanger tubes to freeze when the chiller pressure is
below 35 psig (241 kPa) for HFC-134a, resulting in equipment damage.
84
Repair the Leak, Retest, and Apply Standing
Vacuum Test — After pressurizing the chiller, test for
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 sections
on page 86. 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.
leaks with an electronic halide leak detector, soap bubble
solution, or an ultrasonic leak detector. Bring the chiller back to
atmospheric pressure, repair any leaks found, and retest.
After retesting and finding no leaks, apply a standing
vacuum test. Then dehydrate the chiller. Refer to the Standing
Vacuum Test and Chiller Dehydration section (pages 63 and
66) in the Before Initial Start-Up section.
Checking Guide Vane Linkage — When the chiller
is off, the guide vanes are closed and the actuator mechanism is
in the position shown in Fig. 45. Slack in the guide vane actuator’s drive chain can only be removed with the guide vane
actuator fully closed and the chiller shut down. Complete the
following steps to adjust chain tension and position:
1. Remove the two set screws in the guide vane actuator
sprocket.
2. Loosen the guide vane actuator’s holddown bolts.
3. Pull the guide vane actuator away from the suction housing along the slotted holes in the actuator bracket.
4. Rotate the guide vane sprocket fully clockwise and
spot-drill the guide vane actuator shaft. Spot-drilling is
necessary when the guide vane actuator sprocket set
screws on the guide vane actuator shaft need to be
re-seated. (Remember: Spot-drill and tighten the first set
screw before spot-drilling for the second set screw.)
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 82.
Refer to the Trimming Refrigerant Charge section on
page 77.
GUIDE VANE
ACTUATOR
SHAFT
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
Fig. 45 — Guide Vane Actuator Linkage
85
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.
Service Ontime — The ICVC will display a SERVICE
ONTIME value on the MAINSTAT screen. This value should
be reset to zero by the service person or the operator each time
major service work is completed so that the time between
service can be viewed and tracked.
Oil Specification — If oil is added, it must meet the fol-
lowing Carrier specifications:
Oil Type for units using R-134a . . . . . . . . . . . . . . . . . .Inhibited
polyolester-based synthetic
compressor oil formatted for
use with HFC, gear-driven,
hermetic compressors.
ISO Viscosity Grade. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
The polyolester-based oil (P/N: PP23BZ103) may be
ordered from a local Carrier representative.
Inspect the Control Panel — Maintenance consists of
general cleaning and tightening of connections. Vacuum the
cabinet to eliminate dust build-up. If the chiller control
malfunctions, refer to the Troubleshooting Guide section for
control checks and adjustments.
CAUTION
Ensure power to the VFD is off when cleaning and
tightening connections inside the VFD enclosure. Failure
to disconnect power could result in electrocution.
 Oil Changes — Carrier recommends that a yearly oil
analysis be performed to determine when to change oil and
when to perform a compressor inspection. However, if yearly
analysis is not performed or available, the time between oil
changes should be no longer than 5 years.
Check Safety and Operating Controls
Monthly — Check values of monitored parameters (see
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 level’s 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.
Changing Oil Filter — Change the oil filter on a
yearly basis or when the chiller is opened for repairs. The
19XRV chiller has an isolatable oil filter so that the filter
may be changed with the refrigerant remaining in the
chiller. Early 19XRV compressors were designed with the
oil filter housing attached to the oil pump. The following
procedure applies to later 19XRV compressors which have
the oil filter separate from the oil pump.
1. Ensure the compressor is off and the disconnect for the
compressor is open.
2. Disconnect the power to the oil pump.
3. Close the oil filter isolation valves located behind power
panel on top of oil pump assembly.
4. Close the isolation valves located on both ends of the oil
filter. Have rags and a catch basin available to collect oil
spillage.
5. Equalize the filter’s higher internal pressure to ambient
by connecting an oil charging hose to the Schrader valve
on the oil filter housing. Collect the oil-refrigerant mixture which is discharged.
6. Remove the oil filter assembly by loosening the hex nuts
on both ends of the filter assembly.
7. Insert the replacement filter assembly with the arrow on
the housing pointing away from the oil pump.
8. Rotate the assembly so that the Schraeder drain valve is
oriented at the bottom, and tighten the connection nut on
each end to a torque of approximately 30 ft-lb (41 N-m).
Refrigerant Filter — A refrigerant filter/drier, located on
the refrigerant cooling line to the motor, should be changed
once a year or more often if filter condition indicates a need for
more frequent replacement. Change the filter by closing the
filter isolation valves (see Fig. 4) and slowly opening the flare
fittings with a wrench and back-up wrench to relieve the pressure. A moisture indicator sight glass is located beyond this
filter to indicate the volume and moisture in the refrigerant. If
the moisture indicator indicates moisture, locate the source of
water immediately by performing a thorough leak check.
Oil Reclaim Filter — The oil reclaim system has a
strainer on the eductor suction line, a strainer on the discharge
pressure line, and a filter on the cooler scavenging line.
Replace the filter once per year or more often if filter condition
indicates a need for more frequent replacement. Change the
filter by closing the filter isolation valves and slowly opening
the flare fitting with a wrench and back-up wrench to relieve
the pressure. Change the strainers once every 5 years or whenever refrigerant is evacuated from the cooler.
CAUTION
The oil filter housing is at a high pressure. Relieve this
pressure slowly. Failure to do so could result in serious personal injury.
9. Evacuate the filter housing by placing a vacuum pump on
the charging valve. Follow the normal evacuation procedures. Shut the charging valve when done and reconnect
312
86
signs of corrosion or scale. Replace a sensor or Schrader fitting
if corroded or remove any scale if found.
CONDENSER AND OPTIONAL FLOW DEVICES —
Since this water circuit is usually an open-type system, the
tubes may be subject to contamination and scale. Clean the
condenser tubes with a rotary tube cleaning system at least
once per year and more often if the water is contaminated.
Inspect the entering and leaving condenser water sensors and
flow devices for signs of corrosion or scale. Replace the sensor
or Schrader fitting if corroded or remove any scale if found.
Higher than normal condenser pressures, together with the
inability to reach full refrigeration load, usually indicate dirty
tubes or air in the chiller. If the refrigeration log indicates a rise
above normal condenser pressures, check the condenser refrigerant temperature against the leaving condenser water temperature. If this reading is more than what the design difference is
supposed to be, the condenser tubes may be dirty or water flow
may be incorrect. Because HFC-134a is a high-pressure refrigerant, air usually does not enter the chiller.
During the tube cleaning process, use brushes specially
designed to avoid scraping and scratching the tube wall.
Contact a Carrier representative to obtain these brushes. Do not
use wire brushes.
VFD Refrigerant Strainer — A refrigerant strainer is
located in the 5/8 in. line that supplies refrigerant to the VFD.
The strainer should be replaced once a year or more often if the
strainer condition indicates a need for more frequent replacement. Change the filter by closing the refrigerant cooling line
isolation valves. Refrigerant pressure can be relieved through
access valves on the strainer housing. Tighten 5/8 in. flare nuts
to 55 to 66 ft-lb (75 to 89 Nm).
Inspect Refrigerant Float System — Perform this
inspection every 5 years or when the condenser is opened for
service.
1. Transfer the refrigerant into the cooler vessel or into a
pumpout storage tank.
2. Remove the float access cover.
3. Clean the chamber and valve assembly thoroughly. Be
sure the valve moves freely. Ensure that all openings are
free of obstructions.
4. Examine the cover gasket and replace if necessary.
See Fig. 46 for a view of the float valve design. For linear
float valve designs, inspect the orientation of the float slide pin.
It must be pointed toward the bubbler tube for proper operation.
Inspect Relief Valves and Piping — The relief valves
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.
CAUTION
Hard scale may require chemical treatment for its prevention or removal. Consult a water treatment specialist for
proper treatment.
Water Leaks — The refrigerant moisture indicator on the
refrigerant motor cooling line (Fig. 2) indicates whether there
is water leakage during chiller operation. Water leaks should be
repaired immediately.
CAUTION
The chiller must be dehydrated after repair of water leaks.
See Chiller Dehydration section, page 65.
Compressor Bearing and Gear Maintenance —
1
The key to good bearing and gear maintenance is proper
lubrication. Use the proper grade of oil, maintained at
recommended level, temperature, and pressure. Inspect the
lubrication system regularly and thoroughly.
Excessive bearing wear can sometimes be detected through
increased vibration or increased bearing temperature. Gears,
babbitted journal, and thrust bearings should be examined approximately every five years for signs of wear based on the results of the annual oil analysis. To inspect the bearings, a complete compressor teardown is required. Only a trained service
technician should remove and examine the bearings. The frequency of examination is determined by the hours of chiller operation, load conditions during operation, and the condition of
the oil and the lubrication system. Rolling element bearings
(Frame 3 compressor high speed shaft only) cannot be field inspected; excessive vibration is the primary sign of wear or
damage. If either symptom appears, contact an experienced
and responsible service organization for assistance.
2
3
4
5
6
Inspect the Heat Exchanger Tubes and Flow
Devices
7
a23-1632
8
COOLER AND OPTIONAL FLOW DEVICES — Inspect
and clean the cooler tubes at the end of the first operating season. Because these tubes have internal ridges, a rotary-type
tube cleaning system is needed to fully clean the tubes. Inspect
the tubes’ condition to determine the scheduled frequency for
future cleaning and to determine whether water treatment in the
chilled water/brine circuit is adequate. Inspect the entering and
leaving chilled water temperature sensors and flow devices for
1
2
3
4
5
6
7
8
—
—
—
—
—
—
—
—
LEGEND
Refrigerant Inlet from FLASC Chamber
Linear Float Assembly
Float Screen
Bubbler Line
Float Cover
Bubbler Line Connection
Refrigerant Outlet to Cooler
Gasket
Fig. 46 — 19XRV Float Valve Design
87
Troubleshooting Guide section. Oil differential pressure (OIL
PUMP DELTA P on the COMPRESS screen) should be zero
whenever the compressor is off.
Water Treatment — Untreated or improperly treated
water may result in corrosion, scaling, erosion, or algae. The
services of a qualified water treatment specialist should be
obtained to develop and monitor a treatment program.
Optional Pumpout System Maintenance — For
pumpout unit compressor maintenance details, refer to the
19XR Positive Pressure Storage System Installation, Start-Up,
and Service Instructions.
OPTIONAL
PUMPOUT
COMPRESSOR
OIL
CHARGE — Use oil conforming to Carrier specifications
for reciprocating compressor usage. Oil requirements are as
follows:
ISO Viscosity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 or 220
Carrier Part Number. . . . . . . . . . . . PP23BZ103 or PP23BZ104
The total oil charge is 13 oz. (0.5 L)
Oil should be visible in the pumpout compressor sight glass
both during operation and at shutdown. Always check the oil
level before operating the pumpout compressor. Before adding
changing oil, relieve the refrigerant pressure through the access
valves.
Relieve refrigerant pressure and add oil to the pumpout unit
as follows:
1. Close service valves 2 and 4.
2. Run the pumpout compressor in Automatic mode for one
minute or until the vacuum switch is satisfied and compressor shuts off.
3. Move the pumpout selector switch to OFF. Pumpout
compressor shell should now be under vacuum.
4. Oil can be added to the shell with a hand oil pump
through the access valve in the compressor base.
NOTE: The compressor access valve has a self-sealing fitting
which will require a hose connection with a depressor to open.
OPTIONAL PUMPOUT SAFETY CONTROL SETTINGS
(Fig. 47) — The optional pumpout system high-pressure
switch opens at 185 psig (1276 kPa) and closes at 140 psig
(965 kPa). Check the switch setting by operating the pumpout
compressor and slowly throttling the pumpout condenser
water.
Ordering Replacement Chiller Parts — When
ordering Carrier specified parts, the following information
must accompany an order:
• chiller model number and serial number
• name, quantity, and part number of the part required
• delivery address and method of shipment.
CAUTION
Water must be within design flow limits, clean, and treated
to ensure proper chiller performance and reduce the potential of tube damage due to corrosion, scaling, erosion, and
algae. Carrier assumes no responsibility for chiller damage
resulting from untreated or improperly treated water.
Inspect the VFD
CAUTION
The motor leads must be disconnected from the VFD
before an insulation test is performed. The voltage
generated from the tester can damage the VFD or drive
components.
WARNING
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.
WARNING
The disconnect on the VFD front panel does not deenergize
all internal circuits. Open all internal and remote disconnects before servicing the VFD.
WARNING
Never open isolating knife switches while equipment is
operating. Electrical arcing can cause serious injury.
Periodically vacuum or blow off accumulated debris on internal VFD enclosure components with a high-velocity, lowpressure blower.
Power connections on newly installed VFDs may relax
and loosen after a month of operation. Turn power off and
retighten. Recheck annually thereafter.
CONTACTOR
TERMINAL
STRIP
FUSES
SWITCH
CAUTION
Loose power connections can cause voltage spikes, overheating, malfunctioning, or failures.
Recalibrate Pressure Transducers — Once a year,
the pressure transducers should be checked against a pressure
gage reading. Check all eight transducers: the 2 oil differential
pressure transducers, the condenser pressure transducer, the
cooler pressure transducer, the diffuser pressure transducer (only for compressors equipped with split ring diffusers), and the
optional waterside pressure transducer pairs (consisting of 4
flow devices: 2 cooler, 2 condenser).
Note the evaporator and condenser pressure readings on the
HEAT_EX screen on the ICVC (EVAPORATOR PRESSURE
and CONDENSER PRESSURE). Attach an accurate set of
refrigeration gages to the cooler and condenser Schrader
fittings. Compare the two readings. If there is a difference in
readings, the transducer can be calibrated as described in the
a19-1569
TRANSFORMER
Fig. 47 — Pumpout Control Box (Interior)
88
RESISTANCE CHECK — Turn off the control power and,
from the module, disconnect the terminal plug of the sensor in
question. With a digital ohmmeter, measure sensor resistance
between receptacles as designated by the wiring diagram. The
resistance and corresponding temperature are listed in
Table 18A or 18B. Check the resistance of both wires to
ground. This resistance should be infinite.
VOLTAGE DROP — The voltage drop across any energized
sensor can be measured with a digital voltmeter while the
control is energized. Table 18A or 18B lists the relationship
between temperature and sensor voltage drop (volts dc
measured across the energized sensor). Exercise care when
measuring voltage to prevent damage to the sensor leads,
connector plugs, and modules. Sensors should also be checked
at the sensor plugs. Check the sensor wire at the sensor for
5 vdc if the control is powered on.
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 chiller’s 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.
CAUTION
Relieve all refrigerant pressure or drain the water before
replacing temperature sensors or thermowells threaded into
the refrigerant pressure boundary. Failure to do so could
result in personal injury and equipment damage.
CHECK SENSOR ACCURACY — Place the sensor in a
medium of known temperature and compare that temperature
to the measured reading. The thermometer used to determine
the temperature of the medium should be of laboratory quality
with 0.5 F (.25 C) graduations. The sensor in question should
be accurate to within 2 F (1.2 C).
See Fig. 8 for sensor locations. The sensors are immersed
directly in the refrigerant or water circuits. The wiring at each
sensor is easily disconnected by unlatching the connector.
These connectors allow only one-way connection to the sensor.
When installing a new sensor, apply a pipe sealant or thread
sealant to the sensor threads.
DUAL TEMPERATURE SENSORS — For servicing convenience, there are 2 sensors each on the bearing and motor
temperature sensors. If one of the sensors is damaged, the other
can be used by simply moving a wire. The number 2 terminal
in the sensor terminal box is the common line. To use the
second sensor, move the wire from the number 1 position to the
number 3 position.
Checking Display Messages — The first area to
check when troubleshooting the 19XRV is the ICVC display. If
the alarm light is flashing, check the primary and secondary
message lines on the ICVC default screen (Fig. 14). These
messages will indicate where the fault is occurring. These
messages contain the alarm message with a specified code. For
a complete list of possible alarm and alert messages, see
Table 16. This code or state appears with each alarm and alert
message. The ALARM and ALERT HISTORY tables on the
ICVC SERVICE menu also contains a message to further
expand on the fault description. For a complete list of VFD
Fault Code Descriptions and corrective actions, see Table 17.
NOTE: The date format in these tables is MM/DD/YY.
If the alarm light starts to flash while accessing a menu
screen, press the EXIT softkey to return to the default screen
to read the alarm message. The STATUS screen can also be accessed to determine where an alarm exists.
Checking Pressure Transducers — There are 6
factory-installed pressure transducers, with inputs available for
optional cooler and condenser waterside differential pressure
transducers. The ICVC software will display a default reading
of 26 psi during start-up and operation. An additional transducer, factory installed in the bottom of the cooler barrel, will read
as EVAPORATOR SATURATION TEMP on the HEAT_EX
DISPLAY screen. This provides additional protection against a
loss of water flow condition.
These pressure transducers can be calibrated if necessary. It
is not usually necessary to calibrate at initial start-up.
However, at high altitude locations, it is necessary to calibrate
the transducers to ensure the proper refrigerant temperature/
pressure relationship. Each transducer is supplied with 5 vdc
power from the CCM. If the power supply fails, a transducer
voltage reference alarm occurs. If the transducer reading is
suspected of being faulty, check the TRANSDUCER VOLTAGE REF supply voltage. It should be 5 vdc ±.5 v displayed in
CONTROL TEST under CCM PRESSURE TRANSDUCERS. If the TRANSDUCER VOLTAGE REF is correct, the
transducer should be recalibrated or replaced.
Also check that inputs on CCM J5-1 through J5-6 have not
been grounded and are not receiving anything other than a 4 to
20 mA signal.
A “C” to the right of a parameter’s value means that there is
a communications fault on that channel.
Checking Temperature Sensors — All temperature
sensors are thermistor-type sensors. This means that the
resistance of the sensor varies with temperature. All sensors
have the same resistance characteristics. If the controls are on,
determine sensor temperature by measuring voltage drop; if the
controls are powered off, determine sensor temperature by
measuring resistance. Compare the readings to the values listed
in Table 18A or 18B.
89
high altitude locations must be compensated for, so the
chiller temperature/pressure relationship is correct.
COOLER CONDENSER PRESSURE TRANSDUCER
AND OPTIONAL WATERSIDE FLOW DEVICE CALIBRATION — Calibration can be checked by comparing the
pressure readings from the transducer to an accurate refrigeration gage reading. These readings can be viewed or calibrated
from the HEAT_EX screen on the ICVC. The transducer can
be checked and calibrated at 2 pressure points. These calibration points are 0 psig (0 kPa) and between 25 and 250 psig
(173 and 1724 kPa). To calibrate these transducers:
1. Shut down the compressor, cooler, and condenser pumps.
NOTE: There should be no flow through the heat
exchangers.
2. Disconnect the transducer in question from its Schrader
fitting for cooler or condenser transducer calibration. For
oil pressure or flow device calibration, leave the transducer in place.
NOTE: If the cooler or condenser vessels are at
0 psig (0 kPa) or are open to atmospheric pressure, the
transducers can be calibrated for zero without removing the transducer from the vessel.
3. Access the HEAT_EX screen and view the particular
transducer reading (the EVAPORATOR PRESSURE or
CONDENSER PRESSURE parameter on the HEAT_EX
screen). To calibrate oil pressure or liquidside flow
device, view the particular reading (CHILLED WATER
DELTA P and CONDENSER WATER DELTA P on the
HEAT_EX screen, and OIL PUMP DELTA P on the
COMPRESS screen). It should read 0 psi (0 kPa). If the
reading is not 0 psi (0 kPa), but within ± 5 psi (35 kPa),
the value may be set to zero by pressing the SELECT
softkey while the appropriate transducer parameter is
highlighted on the ICVC screen. Then press the ENTER
softkey. The value will now go to zero. No high end
calibration is necessary for OIL PRESSURE DELTA P or
flow devices.
The PIC III does not allow calibration if the transducer is
too far out of calibration. In this case, a new transducer must be
installed and re-calibrated. If calibration problems are encountered on the OIL PRESSURE DELTA P channel, sometimes
swapping the compressor oil discharge pressure transducer and
the oil sump pressure transducer will offset an adverse transducer tolerance stack up and allow the calibration to proceed.
TRANSDUCER REPLACEMENT — Since the transducers
are mounted on Schrader-type fittings, there is no need to
remove refrigerant from the vessel when replacing the transducers. Disconnect the transducer wiring. Do not pull on the
transducer wires. Unscrew the transducer from the Schrader
fitting. When installing a new transducer, do not use pipe sealer
(which can plug the sensor). Put the plug connector back on the
sensor and snap into place. Check for refrigerant leaks.
WARNING
Be sure to use a back-up wrench on the Schrader fitting
whenever removing a transducer, since the Schrader fitting
may back out with the transducer, causing an uncontrolled
loss of refrigerant and possible injury to personnel.
Control Algorithms Checkout Procedure — One
of the tables on the ICVC SERVICE menu is CONTROL
ALGORITHM STATUS. The maintenance screens may be
viewed from the CONTROL ALGORITHM STATUS table to
see how a particular control algorithm is operating.
These maintenance screens show different tables that are
very useful in helping to determine how the control temperature is calculated and guide vane positioned and also for
observing the reactions from load changes, control point overrides, hot gas bypass, surge prevention, etc. See Table 15.
Table 15 — Control Algorithm Status Tables
TABLE
If the transducer value is not within the calibration
range, the transducer returns to the original reading. If
the pressure is within the allowed range (noted above),
check the voltage ratio of the transducer. To obtain the
voltage ratio, divide the voltage (dc) input from the
transducer by the TRANSDUCER VOLTAGE REF
supply voltage signal (displayed in CONTROL TEST
menu in the PRESSURE TRANSDUCERS screen) or
measure across the positive (+ red) and negative
(– black) leads of the transducer. For example, the
condenser transducer voltage reference is measured
at CCM terminals J2-4 and J2-6, the condenser transducer voltage input. The input to reference voltage
ratio must be between 0.80 and 0.11 for the software to
allow calibration. Pressurize the transducer until the
ratio is within range. Then attempt calibration again.
4. A high pressure point can also be calibrated between 25
and 250 psig (172.4 and 1723.7 kPa) by attaching a regulated 250 psig (1724 kPa) pressure (usually from a
nitrogen cylinder). The high pressure point can be
calibrated by accessing the appropriate transducer parameter on the HEAT_EX screen, highlighting the parameter,
pressing the SELECT softkey, and then using the
INCREASE or DECREASE softkeys to adjust the
value to the exact pressure on the refrigerant gage. Press
the ENTER softkey to finish the calibration. Pressures at
CAPACITY
OVERRIDE
SURGPREV
LL_MAINT
EXPANDED
NAME
Capacity
Control
Override
Status
Surge Prevention Status
LEAD/LAG
Status
OCCDEFCM
Time
Schedules
Status
WSMDEFME
Water
System
Manager
Status
VFD Alarm
History
Loadshed
LOADSHED
Status
Current
CUR_ALARM
Alarm Status
VFD_HIST
HEAT_EX*
DESCRIPTION
This table shows all values used to
calculate the chilled water/brine
control point.
Details of all chilled water control
override values.
Displays all information used or
supplied by the surge prevention
algorithm.
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
Surge and
control algorithm status is viewed
HGBP Status from this screen. All values related
to this control are displayed.
*The HEAT_EX screen is under the STATUS menu.
90
Terminate Lockout feature ends the Pumpdown/Lockout after
the pumpdown procedure is reversed and refrigerant is added.
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
LEGEND TO TABLES 16A-16J
CCN
CCM
DPI
ICVC
PIC III
TXV
VFD
VFG
—
—
—
—
—
—
—
—
Carrier Comfort Network®
Chiller Control Module
Drive Peripheral Interface
International Chiller Visual Control
Product Integrated Controls III
Thermostatic Expansion Valve
Variable Frequency Drive
Variable Frequency (Drive) Gateway
Table 16 — Alarm and Alert Messages
A. MANUAL STOP
PRIMARY MESSAGE
SECONDARY MESSAGE
PROBABLE CAUSE/REMEDY
MANUALLY STOPPED — PRESS
CCN OR LOCAL TO START
TERMINATE PUMPDOWN MODE
TO SELECT CCN OR LOCAL
SHUTDOWN IN PROGRESS
COMPRESSOR UNLOADING
SHUTDOWN IN PROGRESS
COMPRESSOR DEENERGIZED
ICE BUILD
OPERATION COMPLETE
SHUTDOWN IN PROGRESS
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
SECONDARY MESSAGE
READY TO START IN XX MIN
UNOCCUPIED MODE
READY TO START IN XX MIN
REMOTE CONTACT OPEN
READY TO START IN XX MIN
STOP COMMAND IN EFFECT
READY TO START IN XX MIN
OCCUPIED MODE
READY TO START IN XX MIN
REMOTE CONTACT CLOSED
READY TO START IN XX MIN
START COMMAND IN EFFECT
READY TO START IN XX MIN
RECYCLE RESTART PENDING
READY TO START
UNOCCUPIED MODE
READY TO START
REMOTE CONTACT OPEN
READY TO START
STOP COMMAND IN EFFECT
READY TO START
READY TO START
OCCUPIED MODE
REMOTE CONTACT CLOSED
READY TO START
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
SECONDARY MESSAGE
RECYCLE RESTART PENDING
OCCUPIED MODE
RECYCLE RESTART PENDING
REMOTE CONTACT CLOSED
RECYCLE RESTART PENDING
START COMMAND IN EFFECT
RECYCLE RESTART PENDING
ICE BUILD MODE
91
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.
Table 16 — Alarm and Alert Messages (cont)
D. PRE-START ALERTS: These alerts only delay start-up. When alert is corrected, the start-up will continue. No reset is
necessary.
ICVC FAULT
STATE
PRIMARY
MESSAGE
PRESTART
ALERT
SECONDARY
MESSAGE
STARTS LIMIT
EXCEEDED
101
PRESTART
ALERT
HIGH BEARING
TEMPERATURE
102
PRESTART
ALERT
HIGH MOTOR
TEMPERATURE
103
PRESTART
ALERT
HIGH
DISCHARGE
TEMP
104
PRESTART
ALERT
LOW
REFRIGERANT
TEMP
105
PRESTART
ALERT
LOW OIL
TEMPERATURE
106
PRESTART
ALERT
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
100
PRIMARY CAUSE
ADDITIONAL CAUSE/REMEDY
100Excessive compressor starts
(8 in 12 hours).
Depress the RESET softkey if additional start
is required. Reassess start-up requirements.
Check oil heater for proper operation.
Check for low oil level, partially closed oil sup101Comp Thrust Brg Temp [VALUE] ply valves, clogged oil filters.
exceeded limit of [LIMIT]*.
Check the sensor wiring and accuracy.
Check Comp Thrust Brg Alert setting in
SETUP1 screen.
Check motor sensors for wiring and accuracy.
Check motor cooling line for proper operation,
or restrictions.
102Comp Motor Winding Temp
Check for excessive starts within a short time
[VALUE] exceeded limit of [LIMIT]*.
span.
Check Comp Motor Temperature Override
setting in SETUP1 screen.
Allow discharge sensor to cool.
Check sensor wiring and accuracy.
103Comp Discharge Temp [VALUE]
Check for excessive starts.
exceeded limit of [LIMIT]*.
Check Comp Discharge Alert setting in
SETUP1 screen.
Check transducer wiring and accuracy.
Check for low chilled fluid supply
104Evaporator Refrig Temp [VALUE] temperatures.
exceeded limit of [LIMIT]*.
Check refrigerant charge.
Check Refrig Override Delta T in SETUP1
screen.
105Oil Sump Temp [VALUE]
Check oil heater contactor/relay and power.
exceeded limit of [LIMIT]*.
Check oil level and oil pump operation.
Check transducer wiring and accuracy.
106Condenser Pressure [VALUE]
Check for high condenser water
exceeded limit of [LIMIT]*.
temperatures.
Check high condenser pressure switch wiring.
Check voltage supply.
107Percent Line Voltage [VALUE]
Check voltage transformers and switch gear.
exceeded limit of [LIMIT]*.
Consult power utility if voltage is low.
Check voltage supply.
108Percent Line Voltage [VALUE]
Check power transformers.
exceeded limit of [LIMIT]*.
Consult power utility if voltage is high.
Press STOP button on ICVC and perform
Guide Vane Calibration in Controls Test
109Actual Guide Vane Pos
screen.
Calibration Required Before Startup.
Check guide vane actuator feedback
potentiometer.
Check that VFD refrigerant isolation valves
are open.
110Rectifier Temperature [VALUE]
Check VFD refrigerant cooling solenoid and
exceeded limit of [LIMIT]*.
refrigerant strainer.
Check for proper VFD cooling fan operation
and blockage.
Check that VFD refrigerant isolation valves
are open.
111Inverter Temperature [VALUE]
Check VFD refrigerant cooling solenoid and
exceeded limit of [LIMIT]*.
refrigerant strainer.
Check for proper VFD cooling fan operation
and blockage.
*[LIMIT] is shown on the ICVC as temperature, pressure, voltage, etc., predefined or selected by the operator as an override or an alert. [VALUE] is
the actual pressure, temperature, voltage, etc., at which the control tripped.
E. START-UP IN PROGRESS
PRIMARY MESSAGE
STARTUP IN PROGRESS
STARTUP IN PROGRESS
STARTUP IN PROGRESS
AUTORESTART IN
PROGRESS
AUTORESTART IN
PROGRESS
AUTORESTART IN
PROGRESS
SECONDARY MESSAGE
OCCUPIED MODE
REMOTE CONTACT CLOSED
CAUSE/REMEDY
Chiller is starting. Time schedule is Occupied.
Chiller is starting. Remote contacts are Enabled and Closed.
Chiller is starting. Chiller START/STOP in MAINSTAT manually forced to
START COMMAND IN EFFECT
start.
OCCUPIED MODE
Chiller is starting after power failure. Time schedule is Occupied.
Chiller is starting after power failure. Remote contacts are Enabled and
Closed.
Chiller is starting after power failure. Chiller START/STOP on MAINSTAT
START COMMAND IN EFFECT
screen manually forced to start.
REMOTE CONTACT CLOSED
92
Table 16 — Alarm and Alert Messages (cont)
F. NORMAL RUN
PRIMARY MESSAGE
RUNNING — RESET ACTIVE
RUNNING — RESET ACTIVE
SECONDARY MESSAGE
BY 4-20 mA SIGNAL
REMOTE TEMP SENSOR
RUNNING — RESET ACTIVE
CHW TEMP DIFFERENCE
RUNNING — TEMP CONTROL
RUNNING — TEMP CONTROL
RUNNING — TEMP CONTROL
RUNNING — DEMAND LIMITED
RUNNING — DEMAND LIMITED
RUNNING — DEMAND LIMITED
RUNNING — DEMAND LIMITED
RUNNING — DEMAND LIMITED
LEAVING CHILLED WATER
ENTERING CHILLED WATER
TEMPERATURE RAMP LOADING
BY DEMAND RAMP LOADING
BY LOCAL DEMAND SETPOINT
BY 4-20 mA SIGNAL
BY CCN SIGNAL
BY LOADSHED/REDLINE
RUNNING — TEMP CONTROL
HOT GAS BYPASS
RUNNING — DEMAND LIMITED
RUNNING — TEMP CONTROL
BY LOCAL SIGNAL
ICE BUILD MODE
RUNNING — DEMAND LIMITED
MOTOR LOAD CURRENT
RUNNING — DEMAND LIMITED
VFD LINE CURRENT
RUNNING — TEMP CONTROL
IN VFD RAMPDOWN
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.
Post-startup, speed reducing, and guide vanes opening to reach
normal operating state.
G. NORMAL RUN WITH OVERRIDES
ICVC FAULT
STATE
PRIMARY
MESSAGE
SECONDARY
MESSAGE
PRIMARY CAUSE
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.
120
RUN CAPACITY
LIMITED
HIGH CONDENSER
PRESSURE
120Condenser Pressure
[VALUE] exceeded limit of
[LIMIT]*.
121
RUN CAPACITY
LIMITED
HIGH MOTOR
TEMPERATURE
121Comp Motor Winding
Temp [VALUE] exceeded
limit of [LIMIT]*.
122
RUN CAPACITY
LIMITED
LOW EVAP REFRIG
TEMP
122Evaporator Refrig
Temp [VALUE] exceeded
limit of [LIMIT]*.
123
RUN CAPACITY
LIMITED
HIGH COMPRESSOR LIFT
123Surge Prevention
Override: Lift Too High For
Compressor
124
RUN CAPACITY
LIMITED
125
RUN CAPACITY
LIMITED
MANUAL GUIDE
VANE
TARGET
LOW DISCHARGE
SUPERHEAT
126
RUN CAPACITY
LIMITED
HIGH RECTIFIER
TEMP
126Rectifier Temperature
[VALUE] exceeded limit of
[LIMIT]*.
127
RUN CAPACITY
LIMITED
MANUAL SPEED
CONTROL
No Alert message.
Chiller is not in automatic temperature control.
HIGH INVERTER
TEMP
128Inverter Temperature
[VALUE] exceeded limit of
[LIMIT]*.
Check Inverter Temp Override in SETUP1 screen.
Check that VFD refrigerant isolation valves are
open.
Check VFD refrigerant cooling solenoid.
Check for proper VFD cooling fan operation and
blockage.
128
RUN CAPACITY
LIMITED
124Run Capacity Limited:
Manual Guide Vane Target.
No Alert message.
*[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
Table 16 — Alarm and Alert Messages (cont)
H. OUT-OF-RANGE SENSOR
ICVC FAULT
STATE
PRIMARY
MESSAGE
260
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
MESSAGE
PRIMARY CAUSE
ADDITIONAL CAUSE/REMEDY
Check sensor resistance or voltage drop.
Check for proper wiring.
Check for disconnected or shorted wiring.
261Sensor Fault: Check
Check sensor resistance or voltage drop.
ENTERING CHILLED
Entering Chilled Water
Check for proper wiring.
WATER
Sensor.
Check for disconnected or shorted wiring.
Check sensor wiring.
262Sensor Fault: Check
Check for disconnected or shorted wiring.
CONDENSER PRESSURE
Condenser Pressure Sensor.
Check for condensation in transducer
connector.
Check sensor wiring.
EVAPORATOR
263Sensor Fault: Check
Check for disconnected or shorted wiring.
PRESSURE
Evaporator Pressure Sensor.
Check for condensation in transducer
connector.
Check sensor resistance or voltage drop.
COMPRESSOR BEARING 264Sensor Fault: Check
Check for proper wiring.
TEMP
Comp Thrust Brg Temp Sensor. Check for disconnected or shorted wiring.
265Sensor Fault: Check
Check sensor resistance or voltage drop.
COMPRESSOR MOTOR
Comp Motor Winding Temp
Check for proper wiring.
TEMP
Sensor.
Check for disconnected or shorted wiring.
Check sensor resistance or voltage drop.
266Sensor Fault: Check
Check for proper wiring.
COMP DISCHARGE TEMP
Comp Discharge Temp Sensor. Check for disconnected or shorted wiring.
Check sensor resistance or voltage drop.
267Sensor Fault: Check Oil
Check for proper wiring.
OIL SUMP TEMP
Sump Temp Sensor.
Check for disconnected or shorted wiring.
Check sensor resistance or voltage drop.
268Sensor Fault: Check Oil
Check for proper wiring.
COMP OIL PRESS DIFF
Pump Delta P Sensor.
Check for disconnected or shorted wiring.
Check sensor wiring and accuracy.
Check for disconnected or shorted wiring.
269Sensor Fault: Check
If pressure transducers are not installed,
CHILLED WATER FLOW
Chilled Water Delta P Sensor.
check for presence of resistors and jumpers
on lower CCM terminal block J3.
Check sensor wiring and accuracy.
Check for disconnected or shorted wiring.
270Sensor
Fault:
Check
COND WATER FLOW
If pressure transducers are not installed,
Cond Water Delta P Sensor.
check for presence of resistors and jumpers
on lower CCM terminal block J3.
Check sensor resistance or voltage drop.
271Sensor Fault: Check
EVAP SATURATION TEMP Evap Saturation Temp Sensor. Check for proper wiring.
Check for disconnected or shorted wiring.
LEAVING CHILLED WATER 260Sensor Fault: Check
Leaving Chilled Water Sensor.
94
Table 16 — Alarm and Alert Messages (cont)
I. CHILLER PROTECTIVE LIMIT FAULTS
ICVC FAULT
STATE
200
201
202
203
204
205
206
207
208
209
210
211
212
213
214
215
216
217
218
219
PRIMARY
MESSAGE
SECONDARY
MESSAGE
RECTIFIER POWER
PROTECTIVE LIMIT FAULT
PRIMARY CAUSE
200Rectifier Power Fault:
Check VFD Status.
PROTECTIVE LIMIT INVERTER POWER FAULT 201Inverter Power Fault:
Check VFD Status.
202Motor Amps Not
MOTOR AMPS NOT
Sensed — Average Load
PROTECTIVE LIMIT SENSED
Current [VALUE].
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
203Motor Acceleration Fault
start-up.
— Average Load Current
Check Motor Rated Load Amps in VFD_CONF
[VALUE].
screen. Reduce unit pressure if possible.
204VFD
Shutdown
Fault:
VFD Circuit Board malfunction.
FAILURE TO STOP VFD SHUTDOWN FAULT
Check Inverter Power Unit.
Call Carrier Service.
Verify phase to phase and phase to ground line
205High DC Bus Voltage:
voltage. Monitor AC line for high transient voltPROTECTIVE LIMIT HIGH DC BUS VOLTAGE
[VALUE] exceeded limit of
age conditions. VFD Circuit Board malfunction.
[LIMIT]*.
Call Carrier Service.
206VFD Fault Code:
See VFD Fault Code description and corrective
PROTECTIVE LIMIT VFD FAULT
[VALUE]; Check VFD Fault
action.
Code List.
Check Compressor Discharge High Pressure
switch wiring and accuracy.
207High
Cond
Pressure
Check for high condenser water temperatures,
HIGH CONDENSER
trip. [VALUE] exceeded Switch
PROTECTIVE LIMIT
low water flow, fouled tubes.
PRESSURE
Trippoint.
Check for division plate/gasket bypass.
Check for noncondensables in refrigerant.
208Percent
Load
Current
Check Motor Rated Load Amps in VFD_CONF
EXCESSIVE MOTOR
[VALUE] exceeded limit of
screen. Percent Load Current > 110%.
PROTECTIVE LIMIT
AMPS
[LIMIT]*.
Check Motor Rated Load Amps setting.
Check phase to phase and phase to ground
209Line Current Imbalpower distribution bus voltage.
LINE CURRENT
ance: Check VFD Fault HisPROTECTIVE LIMIT
Check Line Current % Imbalance in VFD_CONF
IMBALANCE
tory for Values.
screen. Consult power company.
210Single Cycle Line Volt- Temporary loss of voltage. Disable Single Cycle
PROTECTIVE LIMIT LINE VOLTAGE DROPOUT
age Dropout.
Dropout in VFD_CONF screen.
211High Percent Line Volt- Check phase to phase and phase to ground disPROTECTIVE LIMIT HIGH LINE VOLTAGE
age [VALUE].
tribution bus voltage. Consult power company.
212Low
Percent
Line
VoltCheck phase to phase and phase to ground disPROTECTIVE LIMIT LOW LINE VOLTAGE
age [VALUE].
tribution bus voltage. Consult power company.
Temporary loss of VFD control voltage. Check
213VFD Module Power-On
VFD control power breaker, transformer and
PROTECTIVE LIMIT VFD MODULE RESET
Reset When Running.
fuses.
Check phase to phase and phase to ground distribution bus voltage.
214Control Power Loss
Check VFD fuses.
PROTECTIVE LIMIT POWER LOSS
When Running.
Check 24 vac power supply to ICVC.
Consult power company.
215Low DC Bus Voltage:
Verify phase-to-phase and phase-to-ground line
PROTECTIVE LIMIT LOW DC BUS VOLTAGE
[VALUE] exceeded limit of
voltage. VFD Circuit Board malfunction.
[LIMIT]*.
Call Carrier Service.
216Line Voltage ImbalCheck phase-to-phase and phase-to-ground
PROTECTIVE LIMIT LINE VOLTAGE
ance. Check VFD Fault Hisdistribution bus voltage. Increase Line Voltage
IMBALANCE
tory for Values.
% Imbalance in VFD_CONF screen.
Any phase current > 106% RLA. Can result from
significant load side current imbalance when
running at full load.
217Motor Overload Trip;
Check entering condenser water temperature
PROTECTIVE LIMIT MOTOR OVERLOAD TRIP
Check VFD configurations.
and water flow rate.
Check Motor Rated Load Amps in VFD_CONF
screen.
Check that VFD refrigerant isolation valves are
open.
218VFD Rectifier Temp
Check VFD refrigerant cooling solenoid and
VFD RECTIFIER
Exceeded: Check Cooling and refrigerant strainer.
PROTECTIVE LIMIT OVERTEMP
VFD Config.
Check for proper VFD cooling fan operation and
blockage.
Check that VFD refrigerant isolation valves are
open.
219VFD Inverter Temp
Check VFD refrigerant cooling solenoid and
VFD INVERTER
Exceeded: Check Cooling and refrigerant strainer.
PROTECTIVE LIMIT OVERTEMP
VFD Config.
Check for proper VFD cooling fan operation and
blockage.
FAILURE TO START MOTOR ACCELERATION
FAULT
*[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.
95
Table 16 — Alarm and Alert Messaged (cont)
I. CHILLER PROTECTIVE LIMIT FAULTS (cont)
ICVC FAULT
STATE
PRIMARY
MESSAGE
SECONDARY
MESSAGE
220
PROTECTIVE LIMIT GROUND FAULT
221
PROTECTIVE LIMIT UNUSED
222
PROTECTIVE LIMIT
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
220Ground Fault Trip;
Check Motor and Current
Sensors.
ADDITIONAL CAUSE/REMEDY
Check for condensation on motor terminals.
Check motor power leads for phase to phase or
phase to ground shorts. Disconnect motor from
VFD and megger motor.
Call Carrier Service.
221UNUSED
222Line Frequency —
If operating from a generator, check generator
LINE FREQUENCY TRIP [VALUE] exceeded limit of
size and speed.
[LIMIT]; Check Power Supply. Check utility power supply.
Check VFD communication wiring and
223Loss of SIO Comm with
connectors on VFD Gateway and DPI board.
WITH VFD GATEWAY
VFD Gateway: Check VFG
Check for compatibility between ICVC and
MODULE
Module and Power.
Gateway software.
Check VFD communication wiring and
VFD COMMUNICATIONS 224Loss of DPI Comm with connectors.
VFD Gateway: Check VFG to Check status lights on DPI Communications
FAULT
VFD Comm.
Interface Board.
Call Carrier Service.
225Motor Current ImbalCheck Motor Current % Imbalance in
MOTOR CURRENT
ance: Check VFD Fault
VFD_CONF screen.
IMBALANCE
History for Values.
226Line Phase Reversal:
Reverse connections of any two line conductors
LINE PHASE REVERSAL
Check Line Phases.
to circuit breaker.
Check transducer wiring and accuracy.
227Oil Pressure Delta P
Check power supply to pump.
OIL PRESS SENSOR
[VALUE]
(Pump
Off):
Check
Check pump operation.
FAULT
Pump/Transducers.
Check transducer calibration.
Check transducer wiring and accuracy.
Check power supply to pump.
Check pump operation.
228Low Operating Oil
Check oil level.
LOW OIL PRESSURE
Pressure [VALUE]: Check Oil Check for partially closed service valves.
Pump and Filter.
Check oil filters.
Check for foaming oil at start-up.
Check transducer calibration.
Perform pump control test.
Check optional transducer calibration and
wiring.
Check Evaporator Refrigerant Temperature
229Low Chilled Water Flow;
LOW CHILLED WATER
Check Switch/Delta P Config sensor.
Check chilled water valves.
FLOW
& Calibration.
Check for evaporator saturation temperature
< 34 F if not in Pumpdown Lockout mode. Place
unit in Pumpdown mode before removing
charge.
Perform pump control test.
230Low Condenser Water Check optional transducer calibration and
LOW CONDENSER
Flow; Check Switch/Delta P
wiring.
WATER FLOW
Config & Calibration.
Check condenser water valves.
Check for condenser pressure > 130 PSIG.
Check for closed compressor discharge isolation valve.
Check if chiller was operating in surge.
231Comp Discharge Temp Check sensor resistance or voltage drop.
Check for proper wiring.
HIGH DISCHARGE TEMP [VALUE] Exceeded Limit of
Check for proper condenser flow and
[LIMIT]*.
temperature.
Check compressor discharge isolation valve.
Check for proper inlet guide vane and optional
diffuser actuator operation.
Check for proper refrigerant charge.
Check float valve operation.
Check for closed condenser liquid line isolation
valve. If problem occurs at high load, check for
low condenser pressure which causes inade232Evaporator Refrig Temp quate flasc orifice differential pressure.
LOW REFRIGERANT
[VALUE] exceeded limit of
Check for proper water flow and temperature.
TEMP
[LIMIT]*.
Confirm that condenser water enters bottom row
of condenser tubes first.
Check Evaporator Refrigerant Temperature
sensor.
Check for division plate gasket bypass.
Check for fouled tubes.
*[LIMIT] is shown on the ICVC as the temperature, pressure, voltage, etc., set point predefined or selected by the operator as an override, alert, or
alarm condition. [VALUE] is the actual pressure, temperature, voltage, etc., at which the control tripped.
96
Table 16 — Alarm and Alert Messages (cont)
I. CHILLER PROTECTIVE LIMIT FAULTS (cont)
ICVC FAULT
STATE
PRIMARY
MESSAGE
SECONDARY
MESSAGE
PRIMARY CAUSE
233Comp Motor Winding
Temp [VALUE] exceeded
limit of [LIMIT]*.
233
HIGH MOTOR
PROTECTIVE LIMIT TEMPERATURE
234
PROTECTIVE LIMIT
235
PROTECTIVE LIMIT HIGH CONDENSER
PRESSURE
236
PROTECTIVE LIMIT
237
PROTECTIVE LIMIT SPARE SAFETY
DEVICE
238
PROTECTIVE LIMIT
EXCESSIVE COMPR
SURGE
238Compressor Surge:
Check condenser water temp
and flow.
239
PROTECTIVE LIMIT
TRANSDUCER
VOLTAGE FAULT
239Transducer Voltage Ref
[VALUE] exceeded limit of
[LIMIT]*.
240
LOW DISCHARGE
PROTECTIVE LIMIT SUPERHEAT
241
PROTECTIVE LIMIT
RECTIFIER
OVERCURRENT
242
LOSS OF
COMMUNICATION
WITH CCM MODULE
243
POTENTIAL
FREEZE-UP
EVAP PRESS/TEMP
TOO LOW
243Evaporator Refrig
Temp [VALUE] exceeded
limit of [LIMIT]*.
244
POTENTIAL
FREEZE-UP
COND PRESS/TEMP
TOO LOW
244Condenser Refrig
Temp [VALUE] exceeded
limit of [LIMIT]*.
HIGH BEARING
TEMPERATURE
COMPRESS SURGE/
LOW SPEED
234Comp Thrust Brg Temp
[VALUE] exceeded limit of
[LIMIT]*.
235Condenser Pressure
[VALUE] exceeded limit of
[LIMIT]*.
236Compressor Surge:
Check condenser water temp
and flow.
237Spare Safety Device.
240Check for Oil in Or
Overcharge of Refrigerant.
241Rectifier Overcurrent
Fault: Check VFD Status.
242Loss of Communication With CCM, Check
Comm. Connectors.
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.
97
Table 16 — Alarm and Alert Messages (cont)
I. CHILLER PROTECTIVE LIMIT FAULTS (cont)
ICVC FAULT
STATE
PRIMARY
MESSAGE
SECONDARY
MESSAGE
245
PROTECTIVE LIMIT HIGH VFD SPEED
246
PROTECTIVE LIMIT INVALID DIFFUSER
CONFIG.
247
DIFFUSER POSITION
PROTECTIVE LIMIT FAULT
248
PROTECTIVE LIMIT
249
SPARE TEMPERATURE
PROTECTIVE LIMIT #2
250
UNUSED
SPARE TEMPERATURE
#1
UNUSED
PRIMARY CAUSE
ADDITIONAL CAUSE/REMEDY
245Actual VFD Speed
exceeded limit of Target VFD
Speed + 10%.
246Diffuser Control Invalid
Configuration: Check SETUP2
Entries.
Actual VFD Speed on COMPRESS screen must
not exceed Target VFD Speed by more than
10%.
247Diffuser Position Fault:
Check Guide Vane/Diffuser
Actuator.
248Spare Temperature #1
[VALUE] exceeded limit of
[LIMIT]*.
249Spare Temperature #2
[VALUE] exceeded limit of
[LIMIT]*.
250Unused State.
Check 25%, 50%, and 75% Guide Vane and Diffuser Load Point entries in SETUP2 screen.
Confirm that Diffuser Option in SETUP 2 screen
has not been Enabled if compressor does not
have a split ring diffuser. May indicate rotating
stall condition.
Check rotating stall transducer wiring accuracy
and sealing.
Check diffuser schedule and guide vane schedule in SETUP2 screen.
Check for proper operation of diffuser and inlet
guide vane actuators including inlet guide vane
calibration.
Check diffuser actuator coupling for rotational
slip.
Check RC snubber on CCM J4-23 and J4-24.
Check 4.3k ohm resistor between CCM terminals J3-7 and J3-8.
Check for electrical noise in CCM Diffuser Pressure wiring. Do not continue to operate compressor except for diagnostic purposes.
Check Spare Temperature Enable and Spare
Temperature Limit in SETUP1 Screen.
Check Spare Temperature Enable and Spare
Temperature Limit in SETUP1 Screen.
251
PROTECTIVE LIMIT VFD CONFIG CONFLICT
251VFD Config Conflict
(VFD Uploaded): Verify to
Reset Alarm.
The VFD_CONF table in the Gateway does not
match that which is in the ICVC. This is a normal
fault if an ICVC has been uploaded with software when it was not attached to the CCM.
Enter VFD_CONF screen and then exit
VFD_CONF screen by pressing EXIT then
CANCEL. Re-enter the VFD_CONF screen,
press EXIT then SAVE. Parameters stored in
the Gateway will be uploaded into the ICVC.
Confirm valid settings in VFD_CONF screen.
252
PROTECTIVE LIMIT VFD CONFIG CONFLICT
252VFD Config Conflict
(VFD Downloaded): Verify to
Reset Alarm.
The VFD_CONF table in the Gateway does not
match that which is in the ICVC.
253Guide Vane Fault
[VALUE]. Check Calibration.
Enter CONTROL TEST and execute Guide
Vane Calibration.
Check CCM guide vane feedback terminals J4-9
and J4-10.
Check guide vane feedback potentiometer.
Alarm before start indicates guide vane opening
is not less than 4%. Alarm running indicates
guide vane position is < -1% or > 103%, or feedback voltage is < .045 or > 3.15 VDC.
253
PROTECTIVE LIMIT GUIDE VANE
CALIBRATION
254
254Checksum Error:
PROTECTIVE LIMIT VFD CHECKSUM ERROR Press Reset to Restore
Configuration
255
PROTECTIVE LIMIT VFD DEW PREVENTION
256
PROTECTIVE LIMIT INDUCTOR OVERTEMP
257
PROTECTIVE LIMIT VFD START INHIBIT
258
UNUSED STATE
UNUSED
Actual VFD checksum does not match calculated value.
VFD COLDPLATE TEMP is too close to dew
point based on VFD ENCLOSURE TEMP and
RELATIVE HUMIDITY in POWER screen.
255Dew Prevention - Cool- Check for moisture in VFD enclosure.
ant Too Cold. Check Solenoid Check Humidity Sensor in CONTROLS TEST.
& Cond T.
Check for contamination on CCM J3-7 and J3-9
Humidity Sensor.
Check that VFD refrigerant cooling modulating
valve is closing.
256Inductor Overtemp Trip Check Temp Switch and Cool- Check for cooling fan air flow obstructions.
ing Fans.
The VFD Start Inhibit is derived from the Alarm
257VFD Start Inhibit: Check bit being set in the VFD. The conditions causing
VFD Diagnostic Parameters
the alarm must be corrected in the VFD to
212/214.
enable subsequent starts and operation. See
VFD parameters 212/214.
258Unused.
*[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.
98
Table 16 — Alarm and Alert Messages (cont)
I. CHILLER PROTECTIVE LIMIT FAULTS (cont)
ICVC FAULT
STATE
PRIMARY
MESSAGE
259
SECONDARY
MESSAGE
CCN OVERRIDE
PROTECTIVE LIMIT STOP
282
INVALID VFD CONPROTECTIVE LIMIT FIG
282Line Frequency
[VALUE] Exceeded Configuration Range.
283
INVALID VFD CONPROTECTIVE LIMIT FIG
283Compressor 100%
Speed Config Ranges: 50=Hz
45-52; 60 Hz=55-62.
284
VFD GATEWAY
COMPATIBILITY
CONFLICT
285
VFD GATEWAY
COMPATIBILITY
CONFLICT
286
PROTECTIVE LIMIT
INVERTER
OVERCURRENT
PRIMARY CAUSE
259CCN Emergency/
Override Stop.
284VFD Gateway Compatibility Conflict: Check VFG/
VFD Versions.
285VFD Gateway Compatibility Conflict: Check VFG/
ICVC Versions.
286Inverter Overcurrent
Fault: Check VFD Status.
ADDITIONAL CAUSE/REMEDY
CCN has signaled the chiller to stop.This fault must be
manually reset from the default screen of the ICVC.
LINE FREQUENCY in POWER screen must be maintained between 45-52 Hz if LINE FREQ=60Hz? is set
to NO(50 Hz). LINE 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
STATE
PRIMARY
MESSAGE
SECONDARY
MESSAGE
LEAVING COND
WATER TEMP
ENTERING COND
WATER TEMP
PRIMARY CAUSE
140Sensor Fault: Check
Leaving Cond Water Sensor.
141Sensor Fault: Check
Entering Cond Water Sensor.
140
SENSOR ALERT
141
SENSOR ALERT
142
LOW OIL
CHECK OIL FILTER
PRESSURE ALERT
142Low Oil Pressure Alert.
Check Oil Filter.
143
AUTORESTART
PENDING
LINE CURRENT
IMBALANCE
143Line Current Imbalance: Check VFD Fault History for Values.
144
AUTORESTART
PENDING
LINE VOLTAGE
DROP OUT
144Single Cycle Line
Voltage Dropout.
AUTORESTART
PENDING
AUTORESTART
PENDING
HIGH LINE VOLTAGE
147
AUTORESTART
PENDING
VFD MODULE
RESET
147->VFD Module Power-On
Reset When Running.
148
AUTORESTART
PENDING
POWER LOSS
148Control Power-Loss
When Running.
145
146
149
MACHINE ALERT
150
SENSOR ALERT
145High Percent Line
Voltage [VALUE].
LOW LINE VOLTAGE 146Low Percent Line
Voltage [VALUE].
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.
COND HI FLOW ALARM OPT is disabled and CONDENSER WATER DELTA P has exceeded configured
limit. Check FLOW DELTA P DISPLAY and COND HI
FLOW DEL P LIMIT in SETUP1 screen. Check
optional condenser water pressure transducer wiring
149->High
Flow:
Condenser
and accuracy. Confirm that 5 V reference signal is
HIGH COND WATER
Water Delta P [VALUE]
available between CCM J3-19 and J3-21 and J3-22
FLOW
Exceeded Limit of [LIMIT]*.
and J3-24. Check for disconnected, grounded, or
shorted wiring. If pressure transducers are not
installed, check for presence of resistors and jumpers
CCM terminals J3-19 through J3-24. See Chiller Controls Schematic if flow switches are used.
Check sensor resistance or voltage drop.
150Comp Thrust Brg Temp Check for proper wiring.
HIGH BEARING
[VALUE] exceeded limit of
Check for partially closed service valves.
TEMPERATURE
[LIMIT]*.
Check oil cooler TXV.
Check oil level and oil temperature.
*[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.
99
Table 16 — Alarm and Alert Messages (cont)
J. CHILLER ALERTS (cont)
ICVC FAULT
STATE
PRIMARY
MESSAGE
SECONDARY
MESSAGE
PRIMARY CAUSE
151High Condenser Pressure [VALUE]: Pump Energized to Reduce Pressure.
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.
151
CONDENSER
PUMP RELAY
PRESSURE ALERT ENERGIZED
152
RECYCLE ALERT
EXCESSIVE RECYCLE
STARTS
152Excessive recycle
starts.
153
no message:
ALERT
only
no message; ALERT only
153Lead/Lag DisabledConfig: Duplicate Chiller
Address.
Illegal chiller address configuration in Lead/Lag
screen. Both chillers require a different address.
154Condenser freeze up
prevention.
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.
154
POTENTIAL
FREEZE-UP
COND PRESS/TEMP
TOO LOW
155
OPTION SENSOR
FAULT
REMOTE RESET
SENSOR
156
OPTION SENSOR
FAULT
AUTO CHILLED WATER
RESET
157
OPTION SENSOR
FAULT
AUTO DEMAND LIMIT
INPUT
158
SENSOR ALERT
SPARE TEMPERATURE
#1
159
SENSOR ALERT
SPARE TEMPERATURE
#2
161
LOSS OF
COMMUNICATION
WITH WSM
161WSM Cool Source —
Loss of Communication.
162
SENSOR ALERT
EVAPORATOR
APPROACH
162Evaporator Approach
[VALUE] Exceeded Limit of
[LIMIT]*.
163
SENSOR ALERT
163Condenser Approach
CONDENSER APPROACH [VALUE] Exceeded Limit of
[LIMIT]*.
164
VFD SPEED ALERT LOW VFD SPEED
165
AUTORESTART
PENDING
166
AUTORESTART
PENDING
167
SYSTEM ALERT
168
SENSOR ALERT
LOW DC BUS VOLTAGE
155Sensor Fault/Option
Disabled: Remote Reset
Sensor.
156Sensor Fault/Option
Disabled: Auto Chilled Water
Reset.
157Sensor Fault/Option
Disabled: Auto Demand Limit
Input.
158Spare Temperature 1
[VALUE] exceeded limit of
[LIMIT]*.
159Spare Temperature 2
[VALUE] exceeded limit of
[LIMIT]*.
164Actual VFD Speed
exceeded limit of Target VFD
Speed –10%.
165Low DC Bus Voltage:
[VALUE] Exceeded Limit of
[LIMIT]*.
166High DC Bus Voltage:
[VALUE] Exceeded Limit of
[LIMIT]*.
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.
Verify phase to phase and phase to ground line
voltage. Monitor AC line for high transient voltage conditions.
Check sensor resistance or voltage drop.
167Comp Discharge Temp Check for proper wiring.
HIGH DISCHARGE TEMP [VALUE] exceeded limit of
Check for excessive starts.
[LIMIT]*.
Check Comp Discharge Alert setting in SETUP1
screen.
Check humidity sensor wiring on CCM connecHUMIDITY SENSOR
168Sensor Fault: Check
tors J3 and J5. CCM switch SW2-1 must be in
INPUT
Humidity Sensor Input Sensor. “OFF” position.
Check Humidity Sensor Input in Controls Test.
HIGH DC BUS 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.
100
Table 17 — Fault Code Descriptions and Corrective Actions
Fault Type indicates if the fault is:
1 — Auto-resettable
2 — Non-resettable
3 — User-configurable
4 — Normal Fault
VFD FAULT
FAULT TYPE
CODE
2
Auxiliary Input 1
3
Power Loss 1, 3
4
UnderVoltage 1, 3
5
OverVoltage 1
7
Motor Overload 1, 3
8
Invtr Base Temp 1
9
Invtr IGBT Temp 1
12
HW OverCurrent 1
13
Ground Fault 1
24
Decel Inhibit 3
25
OverSpeed Limit 1
29
Analog In Loss 1, 3
33
Auto Rstrt Tries 3
35
Current FBK Lost 4
36
SW OverCurrent 1
37
Motor I Imbalance
DPI
EPROM
FLA
IGBT
I/O
NP
—
—
—
—
—
—
DESCRIPTION
ACTION
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).
Check remote wiring.
Monitor the incoming AC line for low voltage or
line power interruption.
215
Monitor the incoming AC line for low voltage or
power interruption.
215
Monitor the AC line for high line voltage or
DC bus voltage exceeded maximum value. transient conditions. Bus overvoltage can also
be caused by motor regeneration. Extend the
decel time or install dynamic brake option.
Internal electronic overload trip.
An excessive motor load exists. Reduce load

so drive output current does not exceed the

current set by Motor NP FLA (42).
Enable/disable with Fault Config 1 (238).
Check for proper temperature and flow rate of
Base temperature exceeded limit.
coolant.
Output transistors have exceeded their
Check for proper temperature and flow rate of
maximum operating temperature.
coolant.
Check programming. Check for excess load,
The drive output current has exceeded the improper DC boost setting, DC brake volts set
too high or other causes of excess
hardware current limit.
current.
A current path to earth ground in excess of
7% of drive rated amps has been detected Check the motor and external wiring to the
drive output terminals for a grounded
at one or more of the drive output 
condition.
terminals.
a. Verify input voltage is within drive specified
limits.
The drive is not following a commanded
b. Verify system ground impedance follows
deceleration because it is attempting to
proper grounding techniques.
limit bus voltage.
c. Disable bus regulation and/or add dynamic
brake resistor and/or extend deceleration
time.
Functions such as slip compensation or
bus regulation have attempted to add an
Remove excessive load or overhauling condioutput frequency adjustment greater than tions or increase Overspeed Limit (83).
that programmed in Overspeed Limit (83).
An analog input is configured to fault on
a. Check parameters.
signal loss. A signal loss has occurred.
b. Check for broken/loose connections at
inputs.
Configure with Anlg In 1, 2 Loss (324, 327).
Drive unsuccessfully attempted to reset a
fault and resume running for the proCorrect the cause of the fault and manually
grammed number of Auto Rstrt Tries (174). clear.
Enable/disable with Fault Config 1 (238).
The magnitude of motor current feedback
was less than 5% of the configured Motor
Nameplate Amps for the time configured in Verify connection of current feedback device
the Motor Imbalance Time. Detection of
and motor terminals. If fault repeats replace
this fault is disabled when the Motor Imbal- current feedback devices and/or power supply.
ance Time is set to the maximum value of
10.0 seconds.
The drive output current has exceeded the Check for excess load, improper DC boost setsoftware current.
ting. DC brake volts set too high.
Phase current displayed in Imbalance Display (221) > percentage set in Imbalance Clear fault.
Limit (49) for time set in Imbalance Time
(50).
LEGEND
Drive Peripheral Interface
Erasable, Programmable, Read-Only
Full Load Amps
Insulated Gate Bipolar Transistor
Inputs/Outputs
Nameplate
NOTE: Reliance parameter numbers are indicated by ( ).
101
ICVC FAULT
STATE
206
205
217
219
219
286
220
204
206
206
206
206
286
225
Table 17 — Fault Code Descriptions and Corrective Actions (cont)
Fault Type indicates if the fault is:
1 — Auto-resettable
2 — Non-resettable
3 — User-configurable
4 — Normal Fault
VFD FAULT
FAULT TYPE
CODE
38
Phase U to Grnd
39
Phase V to Grnd
40
Phase W to Grnd
41
42
43
Phase UV Short
Phase VW Short
Phase UW Short
48
Params Defaulted
63
Shear Pin 3
64
Drive OverLoad
70
HW Fault 4
71- 75
Port 1-5 Net Loss
76
Peripheral Fault at
DPI Port 6
77
78
79
80
81- 85
87
100
101
102
103
104
105
DPI
EPROM
FLA
IGBT
I/O
NP
—
—
—
—
—
—
ACTION
ICVC FAULT
STATE
Check the wiring between the drive and
motor.
Check motor for grounded phase.
Replace drive.
220
Excessive current has been detected
between these two output terminals.
a. Check the motor and drive output terminal
wiring for a shorted condition.
b. Replace drive.
246
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.).
a. Clear the fault or cycle power to the drive.
b. Program the drive parameters as needed.
206
Check load requirements and Current Lmt Val
(148) setting.
206
Reduce load or extend Accel Time (140).
286
a. Cycle power.
b. Call Carrier service.
206
DESCRIPTION
a.
A phase-to-ground fault has been detected
between the drive and motor in this phase. b.
c.
a. Check communication board for proper
connection to external network.
b. Check external wiring to module on port.
206
206
The drive autotuning default is Calculate,
IR Volts Range
and the value calculated for IR Drop Volts
is not in the range of acceptable values.
The value for flux amps determined by the
FluxAmpsRef Rang autotune procedure exceeds the programmed Motor NP FLA (42).
Motor did not come up to speed in the allotExcessive Load
ted time.
The autotune procedure was canceled by
AutoTune Aborted
the user.
DPI port stopped communicating.
An attached peripheral with control capabilities via Logic Source Sel (89) (or OIM
Port 1-5 DPI Loss
control) was removed.
The fault code indicates the offending port
number (81 = port 1, etc.).
Ixo voltage calculated from motor nameIxo Voltage Range
plate 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
The checksum read from the EPROM does
not match the checksum calculated from
Pwr Brd Chksum1
the EPROM data.
The checksum read from the board does
Pwr Brd Chksum2
not match the checksum calculated.
LEGEND
Drive Peripheral Interface
Erasable, Programmable, Read-Only
Full Load Amps
Insulated Gate Bipolar Transistor
Inputs/Outputs
Nameplate
NOTE: Reliance parameter numbers are indicated by ( ).
102
Re-enter motor nameplate data.
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).
206
206
206
Restart procedure.
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
Re-enter motor nameplate data.
206
a. Press reset.
b. Reload user set if used.
206
Press reset.
206
Clear the fault or cycle power to the drive.
206
a. Cycle power to the drive.
b. If problem persists, replace drive.
206
Table 17 — Fault Code Descriptions and Corrective Actions (cont)
Fault Type indicates if the fault is:
1 — Auto-resettable
2 — Non-resettable
3 — User-configurable
4 — Normal Fault
VFD FAULT
CODE
FAULT TYPE
DESCRIPTION
ACTION
121
Drive rating information stored on the
Incompat MCB-PB 2 power board is incompatible with the Main
Control board.
Replaced MCB-PB 2 Main Control board was replaced and
parameters were not programmed.
I/O Board Mismatch
Incorrect I/O board identified.
4
I/O Board Comm
Loss of communication to I/O board.
Loss 2
122
I/O Board Fail
Board failure.
Inverter Dsat
U, V, W
High current was detected in an IGBT.
Inverter
OverCurrent
U, V, W
High current was detected in an IGBT.
106
107
120
200
201
202
203
204
205
Inverter section of power structure hardInverter Unused Bit 4 ware reported unexpected fault.
Invtr Gate Kill
Inverter gate kill contact is open.
206
207
208
209
210
211
212
213
214
216
217
a. Press reset.
b. Reprogram parameters.
Restore I/O board to original configuration, or,
if new configuration is desired, reset fault.
206
Cycle power.
206
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.
206
a. Verify proper motor data is entered.
b. Reduce current limit.
286
206
201
Check wiring harness.
206
Close gate kill contact.
207, 235
a. Check for loose connection in IGBT wire
harness.
b. Check IGBTs.
200
Rectifier IOC 
R, S, T
Rectifier overcurrent.
a. Verify proper motor data is entered.
b. Reduce current limit.
241
Reactor Temp
Temperature switch in reactor opened.
Check for proper temperature and fan
operation.
206
Check wiring harness.
206
Check for grounded input wiring.
220
Rectifier IGBT Temp
Excessive calculated IGBT temperature.
219
Rectifier IT
Overload
Short-term current rating of rectifier
exceeded.
220
Rectifier I2T
Overload
Long-term current rating of rectifier
exceeded.
221
Ride Thru Abort
Input power loss timed out.
222
High AC Line
Input line voltage is too high.
223
Low DC Bus
The bus voltage is too low.
224
Rctfr Over Volt
The bus voltage is too high.
—
—
—
—
—
—
206
High current was detected in an IGBT.
218
DPI
EPROM
FLA
IGBT
I/O
NP
Load compatible version files into drive.
Rectifier Dsat 
R, S, T
Rectifier HW Unused Rectifier section of power structure hard4
ware reported unexpected fault.
Rectifier Ground
Excessive ground current measured.
Fault
Excessive rectifier temperatured
Rectifier Base Temp
measured.
215
ICVC FAULT
STATE
LEGEND
Drive Peripheral Interface
Erasable, Programmable, Read-Only
Full Load Amps
Insulated Gate Bipolar Transistor
Inputs/Outputs
Nameplate
NOTE: Reliance parameter numbers are indicated by ( ).
103
Check for proper temperature and flow rate of
coolant.
Check for proper temperature and flow rate of
coolant.
Low input voltage can result in increased current load. Provide proper input voltage to the
drive.
Low input voltage can result in increased current load. Provide proper input voltage to the
drive.
a. Verify input power and connections.
b. Check Line Sync board.
c. Check AC Line I/O board.
Reduce input voltage to meet specification of
480 ±10%.
Verify proper input voltage.
Monitor the AC line for high line voltage or
transient conditions. Bus overvoltage can also
be caused by motor regeneration. Extend the
decel time or install dynamic brake option.
218
218
212
212
210
211
215
205
Table 17 — Fault Code Descriptions and Corrective Actions (cont)
Fault Type indicates if the fault is:
1 — Auto-resettable
2 — Non-resettable
3 — User-configurable
4 — Normal Fault
VFD FAULT
CODE
FAULT TYPE
DESCRIPTION
ACTION
Input Amp
Imbalance
Input Volt
Imbalance
Input phase current imbalance exceeded
limits.
227
AC Line Lost
Input power Lost.
228
Line Frequency
225
226
Rectifier
Checksum
Inverter HW
Unknown 4
Rectifier HW 
Unknown 4
229
230
231
Input voltage imbalance exceeded limits.
Line frequency not in the range of
47-63 Hz.
The checksum read from the board does
not match the checksum calculated.
Inverter section of power structure hardware reported unexpected fault.
Rectifier portion of power structure hardware reported unexpected fault.
A fault was detected in the rectifier other
than one specifically decoded.
232
Rctfr Not OK
233
Precharge closed
Precharge was closed when it should be
open.
234
Precharge open
Precharge was open when it should be
closed.
Drive rating information stored on the
power board is incompatible with the Main
Control board.
The checksum read from the board does
not match the checksum calculated.
Loss of communication to I/O board.
Board failure.
The rectifier did not regulate to the desired
bus voltage within the defined time.
235
Rctfr Pwr Board
236
Rctfr I/O Board
237
Not At Voltage 4
238
Rectified Not Log 
In 4
239
Power Phased ACB 4 Input power is phased ACB rather than
ABC.
DPI
EPROM
FLA
IGBT
I/O
NP
—
—
—
—
—
—
Rectifier took too long to connect to
inverter.
LEGEND
Drive Peripheral Interface
Erasable, Programmable, Read-Only
Full Load Amps
Insulated Gate Bipolar Transistor
Inputs/Outputs
Nameplate
NOTE: Reliance parameter numbers are indicated by ( ).
104
ICVC FAULT
STATE
Check for loose connection in input power
wiring.
Check for problem in input power
distribution.
a. Verify proper input voltage.
b. Check line sync board and fuse.
c. Check AC line I/O board.
d. Verify connection between boards.
Verify connection between AC Line Sync and
AC Line I/O boards.
a. Restore defaults.
b. Reload user set if used.
209
Check wiring harness.
206
Check wiring harness.
206
Look at rectifier parameter 243 to see fault
code.
a. Check AUX contacts on precharge.
b. Check input bit 0 in rectifier parameter 216
to view status of input.
c. Check wiring.
d. Check precharge resistors and fuses.
a. Check AUX contacts on precharge.
b. Check input bit 0 in rectifier parameter 216
to view status of input.
c. Check wiring.
d. Check precharge resistors and fuses.
a. Load compatible version files into drive.
b. Cycle power to the drive.
c. If problem persists, replace drive.
a. Cycle power.
b. If fault repeats, replace I/O board.
Replace rectifier power board and/or rectifier
control board.
a. Check the cabling between the communications interface and the two control boards.
b. Connect one DPI device at a time to see if
one of the DPI devices is causing the
problem.
c. Replace the communications interface.
d. Replace the rectifier control board.
Switch two of the input power phases.
216
210
222
206
200
206
206
206
206
206
206
206
Table 18A — Thermistor Temperature (F) vs. Resistance/Voltage Drop
TEMPERATURE
(F)
–25
–24
–23
–22
–21
–20
–19
–18
–17
–16
–15
–14
–13
–12
–11
–10
–9
–8
–7
–6
–5
–4
–3
–2
–1
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
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
105
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
Table 18B — Thermistor Temperature (C) vs. Resistance/Voltage Drop
TEMPERATURE
(C)
–33
–32
–31
–30
–29
–28
–27
–26
–25
–24
–23
–22
–21
–20
–19
–18
–17
–16
–15
–14
–13
–12
–11
–10
–9
–8
–7
–6
–5
–4
–3
–2
–1
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
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
106
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
CCM is accomplished through the SIO (Sensor Input/
Output) bus, which is a phone cable. The communication
between the CCM and VFD is accomplished through the
sensor bus, which is a 3-wire cable.
2. If a green LED is on continuously, check the communication wiring. If a green LED is off, check the red LED
operation. If the red LED is normal, check the module
address switches (SW1). See Fig. 48 and 49. Confirm all
switches are in OFF position.
All system operating intelligence resides in the ICVC.
Some safety shutdown logic resides in the Gateway in
case communications are lost between the VFD and
ICVC. Outputs are controlled by the CCM and VFD as
well.
3. Power is supplied to the modules within the control panel
via the 24-vac T1 and T2 transformers. The transformers
are located within the power panel.
In the power panel, T1 supplies power to the compressor
oil heater, and optional hot gas bypass, and T2 supplies
power to both the ICVC and CCM.
T3 provides 24-v power to the optional DataPort™ or
DataLINK™ modules.
Power is connected to Plug J1 on each module.
Control Modules
CAUTION
Turn controller power off before servicing controls. This
ensures safety and prevents damage to the controller.
The ICVC and CCM modules perform continuous diagnostic evaluations of the hardware to determine its condition.
Proper operation of all modules is indicated by LEDs
(light-emitting diodes) located on the circuit board of the ICVC
and CCM.
There is one green LED located on the CCM board, and one
red LED located on the ICVC and CCM boards respectively.
RED LED (Labeled as STAT) — If the red LED:
• Blinks continuously at a 2-second interval, the module is
operating properly
• Is lit continuously, there is most likely a hardware fault that
requires replacing the module
• Is off continuously, the power should be checked
• Blinks 3 times per second, a software error has been discovered and the module must be replaced
If there is no input power, check the fuses and circuit breaker.
If the fuse is good, check for a shorted secondary of the transformer or, if power is present to the module, replace the module.
GREED LED (Labeled as COM) — These LEDs indicate
the communication status between different parts of the controller and the network modules and should blink continuously.
Chiller Control Module (CCM) (Fig. 49)
INPUTS — Each input channel has 2 or 3 terminals. Refer to
individual chiller wiring diagrams for the correct terminal
numbers for a specific application.
OUTPUTS — Output is 24 vac. There are 2 terminals per
output. Refer to the chiller wiring diagram for a specific
application for the correct terminal numbers.
Notes on Module Operation
1. The chiller operator monitors and modifies configurations in the microprocessor by using the 4 softkeys and
the ICVC. Communications between the ICVC and the
MODULE PART NUMBER
SOFTWARE PART NUMBER
CCN INTERFACE
CONNECTION
DATALINK OR
DATAPORT MODULE (OPTION)
ICVC
CONTRAST
ADJUSTMENT
BACK OF ICVC
J7 SIO
J1 POWER/
CCN
J8 SERVICE
SW1
a19-1633
Fig. 48 — Rear of ICVC (International Chiller Visual Controller)
107
J11
DISCRETE
OUTPUTS
J12
DISCRETE
OUTPUTS
SW1 SIO ADDRESS
DIP SWITCH SET
ALL TO “OFF”
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
Fig. 49 — Chiller Control Module (CCM)
Replacing Defective Processor Modules —
The module replacement part number is printed on a small
label on the rear of the ICVC module. The chiller model and
serial numbers are printed on the chiller nameplate located on
an exterior corner post. The proper software is factory-installed
by Carrier in the replacement module. When ordering a
replacement chiller visual control (ICVC) module, specify the
complete replacement part number, full chiller model number,
and chiller serial number. The installer must configure the new
module to the original chiller data. Follow the procedures
described in the Software Configuration section on page 68.
3.
WARNING
4.
5.
6.
Electrical shock can cause personal injury. Disconnect all
electrical power before servicing.
INSTALLATION
1. Verify the existing ICVC module is defective by using the
procedure described in the Troubleshooting Guide
section, page 89, and the Control Modules section,
page 107. Do not select the ATTACH TO NETWORK
DEVICE table if the ICVC indicates a communication
failure.
2. Data regarding the ICVC configuration should have been
recorded and saved. This data must be reconfigured into
the new ICVC. If this data is not available, follow the
procedures described in the Software Configuration
section. If the module to be replaced is functional, configurations may also be copied manually. The data sheets on
pages CL-3 and CL-11 are provided for this purpose.
Default values are shown so that only deviations from
these need to be recorded.
7.
8.
108
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,
Board is mounted on the front of the VFD power module in a
vertical orientation.
release the force on SERVICE ONTIME after the desired
value has been set.
9. Perform the guide vane calibration procedure (in Control
Test). Check and recalibrate pressure transducer readings.
Check that the CURRENT TIME and DATE in the TIME
AND DATE screen are correct.
DPI Communications Interface Board Status LEDs — VFD
status can be determined from the status LEDs on the DPI
Communications Interface Board shown in Fig. 50. The DPI
Gateway Status LEDs — The RS485 VFD Gateway
provides a communication link between the CCM and ICVC
SIO bus to the VFD Drive Peripheral Interface (DPI) board.
The SIO bus communicates with the Gateway through VFD
connector A32. See Fig. 51.
The Gateway has four status indicators on the top side of the
module.
DPI COMMUNICATIONS INTERFACE BOARD
INVERTER LED
RECTIFIER LED
a19-1634
INVERTER STATUS LIGHT
COLOR
STATE
Flashing
Steady
Green
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.
Flashing
Yellow
Red
Red Inverter
Green Rectifier
RECTIFIER STATUS LIGHT
COLOR
STATE
Flashing
Steady
Green
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.
Flashing
Yellow
Red
Red Inverter
Green Rectifier
INVERTER AND RECTIFIER CONTROL BOARD FAILURE STATUS LIGHT PATTERNS
COLOR
DESCRIPTION
Red/Green Alternating Control board application firmware may be corrupt. Call Carrier Service.
Yellow/Green/Red
Control board RAM failure or control board firmware may be corrupt. Call Carrier Service.
Repeating Pattern
Fig. 50 — DPI Communications Interface Board Status LEDs
109
Table 20 — MS Status Indicator: State Definitions
DPI RIBBON
CABLE CONNECTOR
STATE
CAUSE
The Gateway is not
powered.
Off
NODE ADDRESS
TENS DIGIT = 0
(DO NOT
CHANGE)
Flashing Recoverable Fault
Red
Condition
DATA
RATE = PGM
(DO NOT
CHANGE)
Solid
Red
The module has failed
the hardware test.
The Gateway is operaFlashing
tional. No I/O data is
Green
being transferred.
The Gateway is operaSolid
tional and transferring
Green
I/O data.
A32
TERMINAL BLOCK
NODE ADDRESS
ONES DIGIT = 1
(DO NOT CHANGE)
NUMBER
1
2
3
4
STATUS
INDICATOR
DRIVE
MS
NET A
NET B
Table 21 — NET A Status Indicator:
State Definitions
DESCRIPTION
DPI Connection Status
Module Status
Serial Communication Status
Serial Communication Traffic Status
STATE
NOTE: If all status indicators are off, the Gateway is not receiving
power.
CAUSE
CORRECTIVE ACTION
The module is not pow• Securely connect the
ered or is not properly
Gateway ribbon cable to
connected to the
the drive DPI board.
network.
• Attach the RS485 cable in
First incoming network
Gateway to the connector.
command not yet 
• Apply power to the drive.
recognized.
Off
Fig. 51 — Gateway Status LEDs
Flashing Network has timed out.
Red
The Gateway has
detected an error that
Solid
has made it incapable
Red
of communication on
the network.
Online to network, but
Flashing not producing or conGreen
suming I/O information.
The module is properly
Solid
connected and commuGreen
nicating on the network.
DRIVE STATUS INDICATOR — The DRIVE status indicator is on the right side of the Gateway. See Table 19.
Table 19 — DRIVE Status Indicator
CAUSE
The Gateway is not
powered or is not conOff
nected properly to the
drive.
The Gateway is not
Flashing
receiving a ping mesRed
sage from the drive.
Solid
Red
The drive has refused
an I/O connection from
the Gateway.
The Gateway is connected to a product that
Orange does not support Rockwell Automation DPI
communications.
The Gateway is estabFlashing lishing an I/O connecGreen
tion to the drive or the
I/O has been disabled.
The Gateway is propSolid
erly connected and is
Green
communicating with the
drive.
No action required.
NET A STATUS INDICATOR — The NET A status indicator is the third LED from the right of the Gateway. See
Table 21.
a23-1618
STATE
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.
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.
Cycle power to the drive.
Check node address and
data rate switch positions on
the front of the Gateway.
Cycle power to the drive.
No action required. The LED
will turn solid green when
communication resumes.
No action required.
NET B STATUS INDICATOR — The NETB status indicator
is the left LED on the Gateway. See Table 22.
Table 22 — NET B Status Indicator:
State Definitions
STATE
Off
• Check wires leading to the
A32 terminal block.
• Check that A32 terminal
block is fully engaged.
Solid or
Blinking
Green
Normal behavior.
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.
Physical Data — Tables 23A-30 and Fig. 52-62 provide
additional information on component weights, compressor fits
and clearances, physical and electrical data, and wiring schematics for the operator’s convenience during troubleshooting.
NOTE: This publication provides start-up and service information for the LiquiFlo™ 2.0 (LF2) VFDs. For information on
Std Tier VFDs, refer to associated Start-Up and Service
Instructions for the Rockwell PowerFlex 755 VFD or the
Eaton LCX 9000 VFD.
No action required.
MS STATUS INDICATOR — The MS status indicator is the
second LED from the right of the Gateway. See Table 20.
110
CAUTION
WARNING
Before rigging the compressor, disconnect all wires entering the power panel.
Do not attempt to disconnect flanges while the machine is
under pressure. Failure to relieve pressure can result in personal injury or damage to the unit.
Table 23A — 19XR Heat Exchanger Data — Drive End Entering Cooler Water
ENGLISH
CODE
Dry Rigging Weight
(lb)*
METRIC (SI)
Dry Rigging Weight
(kg)*
Machine Charge
Refrigerant
Water Weight
Cooler Condenser
Cooler Condenser
Weight (lb)
(lb)
Only
Only
Only
Only
Cooler Condenser Cooler Condenser
20
3407
3373
416
252
402
398
1547
1531
21
3555
3540
459
252
456
462
1614
1607
22
3711
3704
505
252
514
526
1685
1682
30
4071
3694
510
308
464
464
1848
1677
31
4253
3899
565
308
531
543
1931
1770
32
4445
4100
626
308
601
621
2018
1861
35
4343
4606
577
349
511
513
1972
2091
36
4551
4840
639
349
587
603
2066
2197
37
4769
5069
709
349
667
692
2165
2301
40
4908
5039
726
338
863
915
2228
2288
41
5078
5232
783
338
930
995
2305
2375
42
5226
5424
840
338
990
1074
2373
2462
45
5363
5602
821
383
938
998
2435
2543
46
5559
5824
874
383
1014
1088
2524
2644
47
5730
6044
949
383
1083
1179
2601
2744
50
5713
6090
897
446
1101
1225
2594
2765
51
5940
6283
974
446
1192
1304
2697
2852
52
6083
6464
1021
446
1248
1379
2762
2935
53
6141
6529
1010
446
1277
1409
2788
2964
54
6192
6591
987
446
1302
1439
2811
2992
55
6257
6785
1014
504
1201
1339
2841
3080
56
6517
7007
1101
504
1304
1429
2959
3181
57
6682
7215
1154
504
1369
1514
3034
3276
58
6751
7291
1143
504
1401
1550
3065
3310
59
6811
7363
1116
504
1430
1583
3092
3343
5A
5124
—
491
—
1023
—
2326
—
5B
5177
—
510
—
1050
—
2350
—
5C
5243
—
532
—
1079
—
2380
—
5F
5577
—
553
—
1113
—
2532
—
5G
5640
—
575
—
1143
—
2561
—
5H
5716
—
600
—
1176
—
2595
—
5K
4993
—
673
—
1067
—
2267
—
5L
5090
—
706
—
1118
—
2311
—
5M
5165
—
742
—
1162
—
2345
—
5P
5041
—
641
—
1111
—
2289
—
5Q
5131
—
678
—
1155
—
2329
—
5R
5214
—
709
—
1206
—
2367
—
5T
5425
—
768
—
1162
—
2463
—
5U
5534
—
801
—
1220
—
2512
—
5V
5620
—
843
—
1270
—
2551
—
5X
5484
—
730
—
1212
—
2490
—
5Y
5584
—
769
—
1262
—
2535
—
5Z
5678
—
805
—
1320
—
2578
—
60
6719
6764
1091
479
1400
1521
3050
3071
61
6895
6949
1150
479
1470
1597
3130
3155
62
7038
7130
1202
479
1527
1671
3195
3237
63
7103
7199
1202
479
1559
1704
3225
3268
64
7161
7264
1178
479
1587
1735
3251
3298
65
7392
6782
1241
542
1530
1667
3356
3079
66
7594
7894
1309
542
1610
1753
3448
3584
67
7759
8102
1369
542
1674
1838
3523
3678
68
7836
8182
1359
542
1711
1875
3558
3715
69
7905
8258
1332
542
1743
1911
3589
3749
*Rigging weights are for standard tubes of standard wall thickness (0.025-in. [0.635 mm] wall).
NOTES:
1. Cooler includes the control panel (ICVC), suction elbow, and 1/2 the distribution piping weight.
2. Condenser includes float valve and sump, discharge elbow, and 1/2 the distribution piping weight.
3. For special tubes refer to the 19XRV Computer Selection Program.
4. All weights for standard 2-pass NIH (nozzle-in-head) design.
111
Machine Charge
Refrigerant
Weight (kg)
Cooler Condenser
189
114
208
114
229
114
232
140
257
140
284
140
262
158
290
158
322
158
330
153
355
153
381
153
373
174
397
174
431
174
407
202
442
202
464
202
459
202
448
202
460
229
500
229
524
229
519
229
507
229
223
—
232
—
242
—
251
—
261
—
272
—
306
—
321
—
337
—
291
—
308
—
322
—
349
—
364
—
383
—
331
—
349
—
365
—
495
217
522
217
546
217
546
217
535
217
563
246
594
246
622
246
617
246
605
246
Water Weight
(kg)
Cooler Condenser
183
181
207
210
233
239
211
211
241
247
273
282
232
233
266
274
303
314
392
415
422
452
449
488
426
453
460
494
492
535
500
556
541
592
567
626
580
640
591
653
545
608
592
649
622
687
636
704
649
719
464
—
477
—
490
—
505
—
519
—
534
—
484
—
508
—
528
—
504
—
524
—
548
—
528
—
554
—
577
—
550
—
573
—
599
—
636
691
667
725
693
759
708
774
720
788
695
757
731
796
760
834
777
851
791
868
Table 23A — 19XR Heat Exchanger Data — Drive End Entering Cooler Water (cont)
ENGLISH
CODE
6K
6L
6M
6P
6Q
6R
6T
6U
6V
6X
6Y
6Z
70
71
72
73
74
75
76
77
78
79
7K
7L
7M
7P
7Q
7R
7T
7U
7V
7X
7Y
7Z
80
81
82
83
84
85
86
87
88
89
8K
8L
8M
8P
8Q
8R
8T
8U
8V
8X
8Y
8Z
Dry Rigging Weight
(lb)*
Cooler
Only
Condenser
Only
5716
5804
5894
5768
5852
5938
6230
6330
6433
6293
6388
6487
9942
10330
10632
10715
10790
10840
11289
11638
11738
11828
8728
8959
9161
8792
9023
9229
9431
9698
9932
9510
9777
10016
12664
12998
13347
13437
13523
13804
14191
14597
14705
14808
11153
11400
11650
11219
11470
11719
12069
12357
12645
12152
12444
12733
—
—
—
—
—
—
—
—
—
—
—
—
10786
11211
11622
11737
11775
11859
12345
12814
12949
12994
—
—
—
—
—
—
—
—
—
—
—
—
12753
13149
13545
13872
14217
14008
14465
14923
15311
15721
—
—
—
—
—
—
—
—
—
—
—
—
METRIC (SI)
Dry Rigging Weight
(kg)*
Machine Charge
Refrigerant
Weight (lb)
Cooler Condenser
760
—
797
—
828
—
725
—
764
—
798
—
863
—
905
—
941
—
823
—
868
—
906
—
1409
840
1539
840
1646
840
1622
840
1584
840
1599
950
1747
950
1869
950
1849
950
1806
950
1047
—
1132
—
1214
—
1002
—
1087
—
1167
—
1194
—
1292
—
1403
—
1142
—
1240
—
1347
—
1700
836
1812
836
1928
836
1877
836
1840
836
1927
945
2054
945
2186
945
2142
945
2099
945
1385
—
1484
—
1589
—
1334
—
1430
—
1535
—
1580
—
1694
—
1814
—
1522
—
1632
—
1752
—
Water Weight
(lb)
Cooler Condenser
1291
—
1341
—
1399
—
1338
—
1385
—
1439
—
1405
—
1462
—
1528
—
1459
—
1512
—
1574
—
2008
2225
2164
2389
2286
2548
2328
2604
2366
2622
2183
2431
2361
2619
2501
2801
2548
2864
2592
2885
1948
—
2094
—
2229
—
2010
—
2156
—
2295
—
2115
—
2282
—
2436
—
2185
—
2352
—
2511
—
2726
2977
2863
3143
3005
3309
3053
3476
3099
3651
2951
3238
3108
3428
3271
3618
3325
3608
3378
4009
2760
—
2926
—
3088
—
2830
—
2999
—
3161
—
2991
—
3180
—
3365
—
3070
—
3264
—
3448
—
Cooler
Only
Condenser
Only
2595
2635
2676
2619
2657
2696
2828
2874
2921
2857
2900
2945
4514
4690
4827
4865
4899
4921
5125
5284
5329
5370
3963
4067
4159
3992
4096
4190
4282
4403
4509
4318
4439
4547
5749
5901
6060
6100
6139
6267
6443
6627
6676
6723
5063
5176
5289
5093
5207
5320
5479
5610
5741
5517
5650
5781
—
—
—
—
—
—
—
—
—
—
—
—
4897
5090
5276
5329
5346
5384
5605
5818
5879
5899
—
—
—
—
—
—
—
—
—
—
—
—
5790
5970
6149
6298
6455
6360
6567
6775
6951
7137
—
—
—
—
—
—
—
—
—
—
—
—
*Rigging weights are for standard tubes of standard wall thickness (0.025-in. [0.635 mm] wall).
NOTES:
1. Cooler includes the control panel (ICVC), suction elbow, and 1/2 the distribution piping weight.
2. Condenser includes float valve and sump, discharge elbow, and 1/2 the distribution piping weight.
3. For special tubes refer to the 19XRV Computer Selection Program.
4. All weights for standard 2-pass NIH (nozzle-in-head) design.
112
Machine Charge
Refrigerant
Weight (kg)
Cooler Condenser
345
—
362
—
376
—
329
—
347
—
362
—
392
—
411
—
427
—
374
—
394
—
411
—
640
381
699
381
747
381
736
381
719
381
726
431
793
431
849
431
839
431
820
431
475
—
514
—
551
—
455
—
493
—
530
—
542
—
587
—
637
—
518
—
563
—
612
—
772
380
823
380
875
380
852
380
835
380
875
429
933
429
992
429
972
429
953
429
629
—
674
—
721
—
606
—
649
—
697
—
717
—
769
—
824
—
691
—
741
—
795
—
Water Weight
(kg)
Cooler Condenser
586
—
609
—
635
—
607
—
629
—
653
—
638
—
664
—
694
—
662
—
686
—
715
—
912
1010
982
1085
1038
1157
1057
1182
1074
1190
991
1104
1072
1189
1135
1272
1157
1300
1177
1310
884
—
951
—
1012
—
913
—
979
—
1042
—
960
—
1036
—
1106
—
992
—
1068
—
1140
—
1238
1352
1300
1427
1364
1502
1386
1578
1407
1658
1340
1470
1411
1556
1485
1643
1510
1638
1534
1820
1253
—
1328
—
1402
—
1285
—
1362
—
1435
—
1358
—
1444
—
1528
—
1394
—
1482
—
1565
—
Table 23B — 19XR Heat Exchanger Data — Compressor End Entering Cooler Water
ENGLISH
CODE
20
21
22
30
31
32
35
36
37
40
41
42
45
46
47
50
51
52
53
54
55
56
57
58
59
5A
5B
5C
5F
5G
5H
5K
5L
5M
5P
5Q
5R
5T
5U
5V
5X
5Y
5Z
60
61
62
63
64
65
66
67
68
69
Dry Rigging Weight
(lb)*
Cooler
Only
Condenser
Only
3407
3555
3711
4071
4253
4445
4343
4551
4769
4908
5078
5226
5363
5559
5730
5713
5940
6083
6141
6192
6257
6517
6682
6751
6811
5124
5177
5243
5577
5640
5716
4993
5090
5165
5041
5131
5214
5425
5534
5620
5484
5584
5678
6719
6895
7038
7103
7161
7392
7594
7759
7836
7905
3373
3540
3704
3694
3899
4100
4606
4840
5069
5039
5232
5424
5602
5824
6044
6090
6283
6464
6529
6591
6785
7007
7215
7291
7363
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
6764
6949
7130
7199
7264
7682
7894
8102
8182
8258
METRIC (SI)
Dry Rigging Weight
(kg)*
Machine Charge
Refrigerant
Weight (lb)
Cooler Condenser
345
225
385
225
435
225
350
260
420
260
490
260
400
310
480
310
550
310
560
280
630
280
690
280
640
330
720
330
790
330
750
400
840
400
900
400
900
400
900
400
870
490
940
490
980
490
980
490
980
490
500
—
520
—
550
—
550
—
570
—
600
—
673
—
706
—
742
—
641
—
678
—
709
—
768
—
801
—
843
—
730
—
769
—
805
—
940
420
980
420
1020
420
1020
420
1020
420
1020
510
1060
510
1090
510
1090
510
1090
510
Water Weight
(lb)
Cooler Condenser
402
398
456
462
514
526
464
464
531
543
601
621
511
513
587
603
667
692
863
915
930
995
990
1074
938
998
1014
1088
1083
1179
1101
1225
1192
1304
1248
1379
1277
1409
1302
1439
1201
1339
1304
1429
1369
1514
1401
1550
1430
1583
1023
—
1050
—
1079
—
1113
—
1143
—
1176
—
1067
—
1118
—
1162
—
1111
—
1155
—
1206
—
1162
—
1220
—
1270
—
1212
—
1262
—
1320
—
1400
1521
1470
1597
1527
1671
1559
1714
1587
1735
1530
1667
1610
1753
1674
1838
1711
1875
1743
1911
Cooler
Only
Condenser
Only
1545
1613
1683
1847
1929
2016
1970
2064
2163
2226
2303
2370
2433
2522
2599
2591
2694
2759
2788
2811
2838
2956
3031
3065
3092
2324
2348
2378
2530
2558
2593
2267
2311
2345
2289
2329
2367
2463
2512
2551
2490
2535
2578
3048
3128
3192
3225
3251
3353
3445
3519
3558
3589
1530
1606
1680
1676
1769
1860
2089
2195
2299
2286
2373
2460
2541
2642
2742
2762
2850
2932
2964
2992
3078
3178
3273
3310
3343
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
3068
3152
3234
3268
3298
3484
3581
3675
3715
3749
*Rigging weights are for standard tubes of standard wall thickness (0.025-in. [0.635 mm] wall).
NOTES:
1. Cooler includes the control panel (ICVC), suction elbow, and 1/2 the distribution piping weight.
2. Condenser includes float valve and sump, discharge elbow, and 1/2 the distribution piping weight.
3. For special tubes refer to the 19XRV Computer Selection Program.
4. All weights for standard 2-pass NIH (nozzle-in-head) design.
113
Machine Charge
Refrigerant
Weight (kg)
Cooler Condenser
156
102
175
102
197
102
159
118
191
118
222
118
181
141
218
141
249
141
254
127
286
127
313
127
290
150
327
150
358
150
340
181
381
181
408
181
409
182
409
182
395
222
426
222
445
222
445
222
445
222
227
—
236
—
249
—
249
—
259
—
272
—
306
—
321
—
337
—
291
—
308
—
322
—
349
—
364
—
383
—
331
—
349
—
365
—
426
191
445
191
463
191
463
191
463
191
463
231
481
231
494
231
495
232
495
232
Water Weight
(kg)
Cooler Condenser
182
181
207
210
233
239
210
210
241
246
273
282
232
233
266
274
303
314
391
415
422
451
449
487
425
453
460
494
491
535
499
556
541
591
566
626
580
640
591
653
545
607
591
648
621
687
636
704
649
719
464
—
476
—
489
—
505
—
518
—
533
—
484
—
508
—
528
—
504
—
524
—
548
—
528
—
554
—
577
—
550
—
573
—
599
—
635
690
667
724
693
758
708
778
720
788
694
756
730
795
759
834
777
851
791
868
Table 23B — 19XR Heat Exchanger Data — Compressor End Entering Cooler Water (cont)
ENGLISH
CODE
6K
6L
6M
6P
6Q
6R
6T
6U
6V
6X
6Y
6Z
70
71
72
73
74
75
76
77
78
79
7K
7L
7M
7P
7Q
7R
7T
7U
7V
7X
7Y
7Z
80
81
82
83
84
85
86
87
88
89
8K
8L
8M
8P
8Q
8R
8T
8U
8V
8X
8Y
8Z
Dry Rigging Weight
(lb)*
Cooler
Only
Condenser
Only
5716
5804
5894
5768
5852
5938
6230
6330
6433
6293
6388
6487
9942
10330
10632
10715
10790
10840
11289
11638
11738
11828
8728
8959
9161
8792
9023
9229
9431
9698
9932
9510
9777
10016
12664
12998
13347
13437
13523
13804
14191
14597
14705
14808
11153
11400
11650
11219
11470
11719
12069
12357
12645
12152
12444
12733
—
—
—
—
—
—
—
—
—
—
—
—
10782
11211
11612
11737
11775
11854
12345
12803
12949
12994
—
—
—
—
—
—
—
—
—
—
—
—
12753
13149
13545
13872
14217
14008
14465
14923
15311
15721
—
—
—
—
—
—
—
—
—
—
—
—
METRIC (SI)
Dry Rigging Weight
(kg)*
Machine Charge
Refrigerant
Weight (lb)
Cooler
Condenser
760
797
828
725
764
798
863
905
941
823
868
906
1220
1340
1440
1440
1440
1365
1505
1625
1625
1625
1047
1132
1214
1002
1087
1167
1194
1292
1403
1142
1240
1347
1500
1620
1730
1730
1730
1690
1820
1940
1940
1940
1385
1484
1589
1334
1430
1535
1580
1694
1814
1522
1632
1752
—
—
—
—
—
—
—
—
—
—
—
—
780
780
780
780
780
925
925
925
925
925
—
—
—
—
—
—
—
—
—
—
—
—
720
720
720
720
720
860
860
860
860
860
—
—
—
—
—
—
—
—
—
—
—
—
Water Weight
(lb)
Cooler
Condenser
1291
1341
1399
1338
1385
1439
1405
1462
1528
1459
1512
1574
2008
2164
2286
2328
2366
2183
2361
2501
2548
2592
1948
2094
2229
2010
2156
2295
2115
2282
2436
2185
2352
2511
2726
2863
3005
3053
3099
2951
3108
3271
3325
3378
2760
2926
3088
2830
2999
3161
2991
3180
3365
3070
3264
3448
—
—
—
—
—
—
—
—
—
—
—
—
2223
2389
2544
2604
2622
2429
2619
2796
2864
2885
—
—
—
—
—
—
—
—
—
—
—
—
2977
3143
3309
3476
3651
3238
3428
3618
3808
4009
—
—
—
—
—
—
—
—
—
—
—
—
Cooler
Only
Condenser
Only
2595
2635
2676
2619
2657
2696
2828
2874
2921
2857
2900
2945
4510
4686
4823
4865
4899
4917
5121
5279
5329
5370
3963
4067
4159
3992
4096
4190
4282
4403
4509
4318
4439
4547
5744
5896
6054
6100
6139
6261
6437
6621
6676
6723
5063
5176
5289
5093
5207
5320
5479
5610
5741
5517
5650
5781
—
—
—
—
—
—
—
—
—
—
—
—
4891
5085
5267
5329
5346
5377
5600
5807
5879
5899
—
—
—
—
—
—
—
—
—
—
—
—
5785
5964
6144
6298
6455
6354
6561
6769
6951
7137
—
—
—
—
—
—
—
—
—
—
—
—
*Rigging weights are for standard tubes of standard wall thickness (0.025-in. [0.635 mm] wall).
NOTES:
1. Cooler includes the control panel (ICVC), suction elbow, and 1/2 the distribution piping weight.
2. Condenser includes float valve and sump, discharge elbow, and 1/2 the distribution piping weight.
3. For special tubes refer to the 19XRV Computer Selection Program.
4. All weights for standard 2-pass NIH (nozzle-in-head) design.
114
Machine Charge
Refrigerant
Weight (kg)
Cooler
Condenser
345
362
376
329
347
362
392
411
427
374
394
411
553
608
653
654
654
619
683
737
738
738
475
514
551
455
493
530
542
587
637
518
563
612
680
735
785
785
785
767
826
880
881
881
629
674
721
606
649
697
717
769
824
691
741
795
—
—
—
—
—
—
—
—
—
—
—
—
354
354
354
354
354
420
420
420
420
420
—
—
—
—
—
—
—
—
—
—
—
—
327
327
327
327
327
390
390
390
390
390
—
—
—
—
—
—
—
—
—
—
—
—
Water Weight
(kg)
Cooler
Condenser
586
609
635
607
629
653
638
664
694
662
686
715
911
982
1037
1057
1074
990
1071
1134
1157
1177
884
951
1012
913
979
1042
960
1036
1106
992
1068
1140
1236
1299
1363
1386
1407
1339
1410
1484
1510
1534
1253
1328
1402
1285
1362
1435
1358
1444
1528
1394
1482
1565
—
—
—
—
—
—
—
—
—
—
—
—
1008
1084
1154
1182
1190
1102
1188
1268
1300
1310
—
—
—
—
—
—
—
—
—
—
—
—
1350
1426
1501
1578
1658
1469
1555
1641
1729
1820
—
—
—
—
—
—
—
—
—
—
—
—
Table 24 — 19XRV Additional Data for Marine Waterboxes*
HEAT EXCHANGER
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)
Water Volume (gal)
Cooler
Condenser
Cooler
Condenser
730
—
84
—
365
365
42
42
730
—
84
—
365
365
42
42
1888
—
109
—
944
989
54
54
2445
—
122
—
1223
1195
61
60
2860
—
139
—
1430
1443
69
69
3970
—
309
—
1720
1561
155
123
5048
—
364
—
2182
1751
182
141
860
—
84
—
430
430
42
42
860
—
84
—
430
430
42
42
2162
—
109
—
1552
1641
47
47
2655
—
122
—
1965
1909
53
50
3330
—
139
—
2425
2451
58
58
5294
—
309
—
4140
4652
146
94
6222
—
364
—
4952
4559
161
94
kPa
1034
2068
SI
Rigging Weight (kg)
Cooler
Condenser
331
—
166
166
331
—
166
166
856
—
428
449
1109
—
555
542
1297
—
649
655
1801
—
780
708
2290
—
990
794
390
—
195
195
390
—
195
195
981
—
704
744
1204
—
891
866
1510
—
1100
1112
2401
—
1878
2110
2822
—
2246
2068
Water Volume (L)
Cooler
Condenser
318
—
159
159
318
—
159
159
412
—
205
205
462
—
231
226
524
—
262
262
1170
—
585
465
1376
—
688
532
318
—
159
159
318
—
159
159
412
—
178
178
462
—
199
190
524
—
218
218
1170
—
553
356
1376
—
609
355
*Add to heat exchanger data for total weights or volumes.
NOTE: For the total weight of a vessel with a marine waterbox, add these values to the heat exchanger weights (or volumes).
Table 25 — 19XRV Compressor Component Weights
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
(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 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 2
COMPRESSOR
WEIGHT
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
*Transmission weight does not include rotor, shaft, and gear.
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-26D.
115
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
Table 26A — 19XRV Compressor and Motor Weights* — Compressor Frame Size 2†
ENGLISH
SI
60 Hz
50 Hz
60 Hz
50 Hz
End Bell
End Bell
MOTOR Compressor
Compressor
Cover
Cover
CODE
Stator
Rotor
Stator
Rotor
Stator
Rotor
Stator
Rotor
Weight**
Weight**
Weight†† Weight Weight†† Weight Weight
Weight†† Weight Weight†† Weight Weight
(lb)
(kg)
(lb)
(kg)
(lb)
(lb)
(lb)
(lb)
(kg)
(kg)
(kg)
(kg)
STANDARD-EFFICIENCY MOTORS / LOW VOLTAGE (200-575v)
BDS
2300
900
190
915
205
185
1043
408
86
415
93
84
BES
2300
915
BFS
2300
975
200
965
220
185
1043
415
91
438
100
84
215
1000
230
185
1043
442
98
454
104
BGS
2300
84
1000
230
1060
250
185
1043
454
104
481
113
BHS
84
2300
1030
240
1105
265
185
1043
467
109
501
120
BJS
84
2300
1105
265
—
—
185
1043
501
120
—
—
84
HIGH-EFFICIENCY MOTORS / LOW VOLTAGE (200-575v)
BDH
2300
1030
240
1030
240
185
1043
467
109
467
109
84
BEH
2300
1070
250
1070
250
185
1043
485
113
485
113
84
BFH
2300
1120
265
1120
265
185
1043
508
120
508
120
84
BGH
2300
1175
290
1175
290
185
1043
533
132
533
132
84
BHH
2300
1175
290
1175
290
185
1043
533
132
533
132
84
BJH
2300
1175
290
—
—
185
1043
533
132
—
—
84
JBH
2300
1003
226
1063
248
185
1043
455
103
482
112
84
JCH
2300
1063
248
1113
263
185
1043
482
112
505
119
84
JDH
2300
1113
263
1149
278
185
1043
505
119
521
126
84
JEH
2300
1149
278
1196
295
185
1043
521
126
542
134
84
JFH
2300
1196
295
—
—
185
1043
542
134
—
—
84
*Total compressor weight is the sum of the compressor aerodynamic components (compressor weight
column), stator, rotor, and end bell cover weights.
†Compressor size number is the first digit of the compressor code. See Model Number Nomenclature
in Fig. 1.
**Compressor aerodynamic component weight only, motor weight not included. Applicable to standard
compressors only. For high lift compressors, contact Carrier Chiller Marketing for weights.
††Stator weight includes the stator and shell.
116
Table 26B — 19XRV Compressor and Motor Weights* — Compressor Frame Size 3† (cont)
ENGLISH
SI
60 Hz
50 Hz
60 Hz
50 Hz
End Bell
End Bell
MOTOR Compressor
Compressor
Cover
Cover
CODE
Stator
Rotor
Stator
Rotor
Stator
Rotor
Stator
Rotor
Weight**
Weight**
Weight†† Weight Weight†† Weight Weight
Weight†† Weight Weight†† Weight Weight
(lb)
(kg)
(lb)
(kg)
(lb)
(lb)
(lb)
(lb)
(kg)
(kg)
(kg)
(kg)
STANDARD-EFFICIENCY MOTORS / LOW VOLTAGE (200-575v)
CBS
2816
1146
219
1188
236
274
1277
520
99
539
107
124
CCS
2816
1171
227
1196
242
274
1277
531
103
542
110
124
CDS
2816
1198
237
1258
255
274
1277
543
108
571
116
124
CES
2816
1207
240
1272
258
274
1277
547
109
577
117
124
CLS
2816
1247
249
1328
273
274
1277
566
113
602
124
124
CMS
2816
1270
257
1353
278
274
1277
576
117
614
126
124
CNS
2816
1321
266
1386
282
274
1277
599
121
629
128
124
CPS
2816
1334
269
1401
287
274
1277
605
122
635
130
124
CQS
2816
1353
276
1408
290
274
1277
614
125
639
132
124
CRS
2816
1259
321
—
—
274
CRS
2816
1328
346
—
—
274
(380v)
STANDARD-EFFICIENCY MOTORS / MEDIUM VOLTAGE (2400-4160v)
1277
571
146
—
—
124
1277
602
157
—
—
124
CBS
2816
1154
236
1160
255
274
1277
523
107
526
116
124
CCS
2816
1182
243
1177
260
274
1277
536
110
534
118
124
CDS
2816
1220
252
1212
270
274
1277
553
114
550
122
124
CES
2816
1253
261
1259
281
274
1277
568
118
571
127
124
CLS
2816
1261
265
1271
284
274
1277
572
120
577
129
124
CMS
2816
1294
273
1318
293
274
1277
587
124
598
133
124
CNS
2816
1314
280
1357
303
274
1277
596
127
616
137
124
CPS
2816
1343
282
1413
308
274
1277
609
128
641
140
124
CQS
2816
1419
300
1522
336
274
1277
644
136
690
152
124
HIGH-EFFICIENCY MOTORS / LOW VOLTAGE (200-575v)
CBH
2816
1235
239
1290
254
274
1277
560
108
585
115
124
CCH
2816
1260
249
1295
259
274
1277
572
113
587
117
124
CDH
2816
1286
258
1358
273
274
1277
583
117
616
124
124
CEH
2816
1305
265
1377
279
274
1277
592
120
625
127
124
CLH
2816
1324
271
1435
292
274
1277
601
123
651
132
124
CMH
2816
1347
275
1455
298
274
1277
611
125
660
135
124
CNH
2816
1358
278
1467
301
274
1277
616
126
665
137
124
CPH
2816
1401
290
1479
304
274
1277
635
132
671
138
124
CQH
2816
1455
304
1479
304
274
1277
670
138
671
138
124
KBH
2816
1313
276
1353
285
274
1277
596
125
614
129
124
KCH
2816
1353
285
1381
291
274
1277
614
129
626
132
124
KDH
2816
1381
291
1417
307
274
1277
626
132
643
139
124
KEH
2816
1417
307
1441
313
274
1277
643
139
654
142
124
KFH
2816
1441
313
1470
320
274
1277
654
142
667
145
124
KGH
2816
1470
320
1505
333
274
1277
667
145
683
151
124
KHH
2816
1505
333
—
—
274
1277
683
151
—
—
124
*Total compressor weight is the sum of the compressor aerodynamic components (compressor weight
column), stator, rotor, and end bell cover weights.
†Compressor size number is the first digit of the compressor code. See Model Number Nomenclature
in Fig. 1.
**Compressor aerodynamic component weight only, motor weight not included. Applicable to standard
compressors only. For high lift compressors, contact Carrier Chiller Marketing for weights.
††Stator weight includes the stator and shell.
117
Table 26B — 19XRV Compressor and Motor Weights* — Compressor Frame Size 3† (cont)
ENGLISH
60 Hz
SI
50 Hz
60 Hz
50 Hz
End Bell
End Bell
MOTOR Compressor
Compressor
Cover
Cover
CODE
Stator
Rotor
Stator
Rotor
Stator
Rotor
Stator
Rotor
Weight**
Weight**
Weight†† Weight Weight†† Weight Weight
Weight†† Weight Weight†† Weight Weight
(lb)
(kg)
(lb)
(kg)
(lb)
(lb)
(lb)
(lb)
(kg)
(kg)
(kg)
(kg)
HIGH-EFFICIENCY MOTORS / MEDIUM VOLTAGE (2400-4160v)
CBH
2816
1114
242
1156
255
274
1277
505
110
524
116
124
CCH
2816
1129
247
1163
257
274
1277
512
112
528
117
124
CDH
2816
1155
253
1190
263
274
1277
524
115
540
119
124
CEH
2816
1175
263
1236
276
274
1277
533
119
561
125
124
CLH
2816
1242
280
1305
296
274
1277
563
127
592
134
124
CMH
2816
1321
303
1305
296
274
1277
599
137
592
134
124
CNH
2816
1369
316
1386
316
274
1277
621
143
629
143
124
CPH
2816
1411
329
1386
316
274
1277
640
149
629
143
124
CQH
2816
1411
329
1428
329
274
1277
640
149
648
149
124
*Total compressor weight is the sum of the compressor aerodynamic components (compressor weight
column), stator, rotor, and end bell cover weights.
†Compressor size number is the first digit of the compressor code. See Model Number Nomenclature
in Fig. 1.
**Compressor aerodynamic component weight only, motor weight not included. Applicable to standard
compressors only. For high lift compressors, contact Carrier Chiller Marketing for weights.
††Stator weight includes the stator and shell.
118
Table 26C — 19XRV Compressor and Motor Weights* — Compressor Frame Size 4†
ENGLISH
SI
60 Hz
50 Hz
60 Hz
MOTOR Compressor
CODE
Stator
Rotor
Stator
Rotor
Weight**
Weight†† Weight Weight†† Weight
(lb)
(lb)
(lb)
(lb)
(lb)
50 Hz
End Bell
Compressor
Cover
Stator
Rotor
Stator
Rotor
Weight**
Weight
Weight†† Weight Weight†† Weight
(kg)
(lb)
(kg)
(kg)
(kg)
(kg)
End Bell
Cover
Weight
(kg)
STANDARD-EFFICIENCY MOTORS / LOW VOLTAGE (200-575v)
DBS
3425 / 4211
1570
324
1725
347
236
1554 / 1910
712
147
782
157
107
DCS
3425 / 4211
1580
326
1737
352
236
1554 / 1910
717
148
788
160
107
DDS
3425 / 4211
1595
329
1749
357
236
1554 / 1910
723
149
793
162
107
DES
3425 / 4211
1685
345
1762
365
236
1554 / 1910
764
156
799
166
107
DFS
3425 / 4211
1690
348
1801
372
236
1554 / 1910
767
158
817
169
107
DGS
3425 / 4211
1692
352
1858
386
236
1554 / 1910
767
160
843
175
107
DHS
3425 / 4211
1774
366
1904
398
236
1554 / 1910
805
166
864
181
107
DJS
3425 / 4211
—
—
2020
401
318
1554 / 1910
—
—
916
182
142
STANDARD-EFFICIENCY MOTORS / MEDIUM VOLTAGE (2400-4160v)
DBS
3425 / 4211
1524
296
1637
327
236
1554 / 1910
691
134
743
148
107
DCS
3425 / 4211
1569
307
1685
354
236
1554 / 1910
712
139
764
161
107
DDS
3425 / 4211
1588
313
1713
357
236
1554 / 1910
720
142
777
162
107
DES
3425 / 4211
1613
324
1746
360
236
DFS
3425 / 4211
1675
347
1811
381
1554 / 1910
732
147
792
163
107
236
236 (60 Hz)
DGS
3425 / 4211
1704
355
1998
422
318 (50 Hz)
DHS
3425 / 4211
1737
361
2056
443 236 (60 Hz)
318 (50 Hz)
DJS
3425 / 4211
1769
365
2101
464 236 (60 Hz)
318 (50 Hz)
STANDARD-EFFICIENCY MOTORS / MEDIUM VOLTAGE (6300-6900v)
1554 / 1910
760
157
821
173
1554 / 1910
773
161
906
191
1554 / 1910
788
164
933
201
1554 / 1910
802
166
953
210
107
107 (60 Hz)
142 (50 Hz)
107 (60 Hz)
142 (50 Hz)
107 (60 Hz)
142 (50 Hz)
DDS
3425 / 4211
1919
423
2069
458
318
1554 / 1910
870
192
938
208
142
DES
3425 / 4211
1939
428
2089
463
318
1554 / 1910
880
194
947
210
142
DFS
3425 / 4211
1989
448
2139
478
318
1554 / 1910
902
203
970
217
142
DGS
3425 / 4211
2054
473
—
—
318
1554 / 1910
932
215
—
—
142
DHS
3425 / 4211
2099
488
—
—
318
1554 / 1910
952
221
—
—
142
DJS
3425 / 4211
2159
508
—
—
318
1554 / 1910
979
230
—
—
142
HIGH-EFFICIENCY MOTORS / LOW VOLTAGE (200-575v)
DBH
3425 / 4211
1773
406
1827
406
318
1554 / 1910
804
184
829
184
142
DCH
3425 / 4211
1827
406
1827
414
318
1554 / 1910
829
184
829
188
142
DDH
3425 / 4211
1827
414
1881
422
318
1554 / 1910
829
188
853
191
142
DEH
3425 / 4211
1881
422
1881
422
318
1554 / 1910
853
191
853
191
142
DFH
3425 / 4211
1881
439
1963
439
318
1554 / 1910
853
199
890
199
142
DGH
3425 / 4211
1963
455
1963
455
318
1554 / 1910
890
206
890
206
142
DHH
3425 / 4211
1963
455
2050
463
318
1554 / 1910
890
206
930
210
142
DJH
3425 / 4211
—
—
2050
471
318
1554 / 1910
—
—
930
213
142
DKH
3425 / 4211
2050
471
—
—
318
1554 / 1910
930
214
—
—
142
*Total compressor weight is the sum of the compressor aerodynamic components (compressor weight
column), stator, rotor, and end bell cover weights.
†Compressor size number is the first digit of the compressor code. See Model Number Nomenclature
in Fig. 1.
**Compressor aerodynamic component weight only, motor weight not included. Applicable to standard
compressors only. For high lift compressors, contact Carrier Chiller Marketing for weights. For compressor frame size 4, two compressor weights are shown. The second value, 4211 lb (1910 kg), represents the weight when the compressor is equipped with a Split Ring Diffuser (SRD).
††Stator weight includes the stator and shell.
119
Table 26C — 19XRV Compressor and Motor Weights* — Compressor Frame Size 4† (cont)
ENGLISH
SI
60 Hz
50 Hz
60 Hz
50 Hz
End Bell
End Bell
MOTOR Compressor
Compressor
Cover
Cover
CODE
Stator
Rotor
Stator
Rotor
Stator
Rotor
Stator
Rotor
Weight**
Weight**
Weight†† Weight Weight†† Weight Weight
Weight†† Weight Weight†† Weight Weight
(lb)
(kg)
(lb)
(kg)
(lb)
(lb)
(lb)
(lb)
(kg)
(kg)
(kg)
(kg)
HIGH-EFFICIENCY MOTORS / LOW VOLTAGE (200-575v)
LBH
3425 / 4211
1873
364
1939
389
318
1554 / 1910
850
165
880
176
144
LCH
3425 / 4211
1939
389
2023
406
318
1554 / 1910
880
176
918
184
144
LDH
3425 / 4211
2023
406
2043
417
318
1554 / 1910
918
184
927
189
144
LEH
3425 / 4211
2043
417
2096
434
318
1554 / 1910
927
189
951
197
144
LFH
3425 / 4211
2096
434
2133
444
318
1554 / 1910
951
197
968
201
144
LGH
3425 / 4211
2133
444
2199
458
318
1554 / 1910
968
201
997
208
144
LHH
3425 / 4211
2199
458
2066
437
318
1554 / 1910
997
208
937
198
144
HIGH-EFFICIENCY MOTORS / MEDIUM VOLTAGE (2400-4160v)
DBH
3425 / 4211
1950
405
1950
405
318
1554 / 1910
885
184
885
184
144
DCH
3425 / 4211
1950
405
2025
429
318
1554 / 1910
885
184
919
195
144
DDH
3425 / 4211
1950
405
2025
429
318
1554 / 1910
885
184
919
195
144
DEH
3425 / 4211
2025
429
2100
452
318
1554 / 1910
919
195
953
205
144
DFH
3425 / 4211
2025
429
2100
452
318
1554 / 1910
919
195
953
205
144
DGH
3425 / 4211
2100
452
2200
480
318
1554 / 1910
953
205
998
218
144
DHH
3425 / 4211
2100
452
2320
575
318
1554 / 1910
953
205
1052
261
144
DJH
3425 / 4211
2100
452
2320
587
318
1554 / 1910
953
205
1052
266
144
DKH
3425 / 4211
2320
587
—
—
318
1554 / 1910
1052
266
—
—
144
HIGH-EFFICIENCY MOTORS / MEDIUM VOLTAGE (6300-6900v)
DDH
3425 / 4211
2150
536
2250
546
318
1554 / 1910
975
243
1021
248
144
DEH
3425 / 4211
2150
550
2250
550
318
1554 / 1910
975
249
1021
249
144
DFH
3425 / 4211
2250
575
2380
567
318
1554 / 1910
1021
261
1080
261
144
DGH
3425 / 4211
2250
599
2380
599
318
1554 / 1910
1021
272
1080
272
144
DHH
3425 / 4211
2380
604
2380
604
318
1554 / 1910
1080
274
1080
274
144
DJH
3425 / 4211
2380
614
2380
614
318
1554 / 1910
1080
279
1080
279
144
DKH
3425 / 4211
2380
614
—
—
318
1554 / 1910
1080
279
—
—
144
*Total compressor weight is the sum of the compressor aerodynamic components (compressor weight
column), stator, rotor, and end bell cover weights.
†Compressor size number is the first digit of the compressor code. See Model Number Nomenclature
in Fig. 1.
**Compressor aerodynamic component weight only, motor weight not included. Applicable to standard
compressors only. For high lift compressors, contact Carrier Chiller Marketing for weights. For compressor frame size 4, two compressor weights are shown. The second value, 4211 lb (1910 kg), represents the weight when the compressor is equipped with a Split Ring Diffuser (SRD).
††Stator weight includes the stator and shell.
120
Table 26D — 19XRV Compressor and Motor Weights* — Compressor Frame Size 5† (cont)
ENGLISH
SI
60 Hz
50 Hz
60 Hz
50 Hz
End Bell
End Bell
MOTOR Compressor
Compressor
Cover
Cover
CODE
Stator
Rotor
Stator
Rotor
Stator
Rotor
Stator
Rotor
Weight**
Weight**
Weight†† Weight Weight†† Weight Weight
Weight†† Weight Weight†† Weight Weight
(lb)
(kg)
(lb)
(kg)
(lb)
(lb)
(lb)
(lb)
(kg)
(kg)
(kg)
(kg)
STANDARD-EFFICIENCY MOTORS / LOW VOLTAGE (200-575v)
EHS
7285
2843
741
2943
775
414
3304
1290
336
1335
352
188
EJS
7285
2826
741
2943
775
414
3304
1281
336
1335
352
188
EKS
7285
2943
775
2997
810
414
3304
1335
352
1359
367
188
ELS
7285
2932
775
2997
810
414
3304
1330
352
1359
367
188
EMS
7285
2986
810
3096
862
414
3304
1354
367
1404
391
188
ENS
7285
2986
810
3203
914
414
3304
1354
367
1453
415
188
EPS
7285
2986
810
3203
914
414
3304
1354
367
1453
415
188
EQS
7285
3013
621
—
—
414
3304
1367
282
—
—
188
STANDARD-EFFICIENCY MOTORS / MEDIUM VOLTAGE (2400-4160v)
EHS
7285
2744
706
2818
741
414
3304
1245
320
1278
336
188
EJS
7285
2816
741
2892
775
414
3304
1277
336
1312
352
188
EKS
7285
2816
741
2930
775
414
3304
1277
336
1329
352
188
ELS
7285
2808
741
3005
810
414
3304
1274
336
1363
367
188
EMS
7285
2892
775
3005
810
414
3304
1322
352
1363
367
188
ENS
7285
2997
775
3143
879
414
3304
1359
352
1426
399
188
EPS
7285
2967
810
3144
879
414
3304
1346
367
1426
399
188
STANDARD-EFFICIENCY MOTORS / MEDIUM VOLTAGE (6300-6900v)
EHS
7285
2773
735
2845
769
414
3304
1258
333
1290
349
188
EJS
7285
2855
769
2855
769
414
3304
1295
349
1295
349
188
EKS
7285
2919
803
2919
803
414
3304
1324
364
1324
364
188
ELS
7285
2908
803
3058
871
414
3304
1319
364
1387
395
188
EMS
7285
3029
854
3068
871
414
3304
1374
387
1392
395
188
ENS
7285
3023
854
3281
974
414
3304
1371
387
1488
442
188
EPS
7285
3068
871
3288
974
414
3304
1392
395
1491
442
188
HIGH-EFFICIENCY MOTORS / LOW VOLTAGE (200-575v)
EHH
7285
2939
776
2995
810
414
3304
1333
352
1359
367
188
EJH
7285
2944
776
3002
810
414
3304
1335
352
1362
367
188
EKH
7285
2992
810
3110
862
414
3304
1357
367
1411
391
188
ELH
7285
2299
810
3099
862
414
3304
1043
367
1406
391
188
EMH
7285
2965
810
3210
914
414
3304
1345
367
1456
415
188
ENH
7285
3015
855
3293
974
414
3304
1368
388
1494
442
188
EPH
7285
3029
855
3289
974
414
3304
1374
388
1492
442
188
EQH
7285
3162
664
—
—
414
3304
1434
301
—
—
188
*Total compressor weight is the sum of the compressor aerodynamic components (compressor weight
column), stator, rotor, and end bell cover weights.
†Compressor size number is the first digit of the compressor code. See Model Number Nomenclature
in Fig. 1.
**Compressor aerodynamic component weight only, motor weight not included. Applicable to standard
compressors only. For high lift compressors, contact Carrier Chiller Marketing for weights.
††Stator weight includes the stator and shell.
121
Table 26D — 19XRV Compressor and Motor Weights* — Compressor Frame Size 5† (cont)
ENGLISH
SI
60 Hz
50 Hz
60 Hz
50 Hz
End Bell
End Bell
MOTOR Compressor
Compressor
Cover
Cover
CODE
Stator
Rotor
Stator
Rotor
Stator
Rotor
Stator
Rotor
Weight**
Weight**
Weight†† Weight Weight†† Weight Weight
Weight†† Weight Weight†† Weight Weight
(lb)
(kg)
(lb)
(kg)
(lb)
(lb)
(lb)
(lb)
(kg)
(kg)
(kg)
(kg)
HIGH-EFFICIENCY MOTORS / LOW VOLTAGE (200-575v)
MBH
7285
2795
645
2856
665
414
3304
1268
293
1295
302
188
MCH
7285
2873
672
2925
693
414
3304
1303
305
1327
314
188
MDH
7285
2906
684
3013
724
414
3304
1318
310
1367
328
188
MEH
7285
2956
704
3071
737
414
3304
1341
319
1392
334
188
MFH
7285
3034
724
3153
791
414
3304
1376
328
1430
359
188
MGH
7285
3071
737
—
—
414
3304
1393
334
—
—
188
HIGH-EFFICIENCY MOTORS / MEDIUM VOLTAGE (2400-4160v)
EHH
7285
2939
776
2997
810
414
3304
1333
352
1359
367
188
EJH
7285
2999
810
3108
862
414
3304
1360
367
1410
391
188
EKH
7285
2988
810
3102
862
414
3304
1355
367
1407
391
188
ELH
7285
2981
810
3065
872
414
3304
1352
367
1390
396
188
EMH
7285
3031
855
3077
872
414
3304
1375
388
1396
396
188
ENH
7285
3075
872
3260
974
414
3304
1395
396
1479
442
188
EPH
7285
3081
872
3298
974
414
3304
1398
396
1496
442
188
EQH
7285
3195
657
—
—
414
3304
1449
298
—
—
188
HIGH-EFFICIENCY MOTORS / MEDIUM VOLTAGE (6300-6900v)
EHH
7285
2998
810
3097
862
414
3304
1360
367
1405
391
188
EJH
7285
3029
855
3100
862
414
3304
1374
388
1406
391
188
EKH
7285
3049
855
3064
872
414
3304
1383
388
1390
396
188
ELH
7285
3068
872
3060
872
414
3304
1390
396
1388
396
188
EMH
7285
—
—
3072
872
414
3304
—
—
1393
396
188
ENH
7285
3075
872
3260
974
414
3304
1395
396
1479
442
188
EPH
7285
3081
872
3288
974
414
3304
1398
396
1491
442
188
EQH
7285
3195
657
—
—
414
3304
1449
298
—
—
188
HIGH-EFFICIENCY MOTORS / HIGH VOLTAGE (10000-11000v)
MCH
7285
—
—
3956
678
414
3304
—
—
1794
308
188
MDH
7285
—
—
3956
678
414
3304
—
—
1794
308
188
MFH
7285
—
—
4062
719
414
3304
—
—
1842
326
188
MGH
7285
3820
657
—
—
414
3304
1733
298
—
—
188
MHH
7285
3820
657
—
—
414
3304
1733
298
—
—
188
*Total compressor weight is the sum of the compressor aerodynamic components (compressor weight
column), stator, rotor, and end bell cover weights.
†Compressor size number is the first digit of the compressor code. See Model Number Nomenclature
in Fig. 1.
**Compressor aerodynamic component weight only, motor weight not included. Applicable to standard
compressors only. For high lift compressors, contact Carrier Chiller Marketing for weights.
††Stator weight includes the stator and shell.
122
Table 27A — 19XRV Waterbox Cover Weights — English (lb)
FRAMES 2 and 3 — COOLER
Frame 2
WATERBOX DESCRIPTION
Frame 3
Standard Nozzles
Flanged
Standard Nozzles
Flanged
NIH, 1 Pass Cover, 150 psig
320
350
320
350
NIH, 2 Pass Cover, 150 psig
320
350
320
350
NIH, 3 Pass Cover, 150 psig
310
340
310
340
NIH Plain End Cover, 150 psig
300
300
300
300
MWB End Cover, 150 psig
300
300
300
300
MWB Return Cover, 150 psig
243
243
243
243
NIH, 1 Pass Cover, 300 psig
411
486
411
486
NIH, 2 Pass Cover, 300 psig
411
518
411
518
NIH, 3 Pass Cover, 300 psig
433
468
433
468
NIH Plain End Cover, 300 psig
400
400
400
400
MWB End Cover, 300 psig
400
400
400
400
MWB Return Cover, 300 psig
445
445
445
445
FRAMES 2 and 3 — CONDENSER
Frame 2
WATERBOX DESCRIPTION
Frame 3
Standard Nozzles
Flanged
Standard Nozzles
Flanged
NIH, 1 Pass Cover, 150 psig
320
350
320
350
NIH, 2 Pass Cover, 150 psig
320
350
320
350
NIH, 3 Pass Cover, 150 psig
310
310
310
340
NIH Plain End Cover, 150 psig
300
300
300
300
MWB End Cover, 150 psig
300
300
300
300
MWB Return Cover, 150 psig
225
225
225
225
NIH, 1 Pass Cover, 300 psig
411
486
411
486
NIH, 2 Pass Cover, 300 psig
411
518
411
518
NIH, 3 Pass Cover, 300 psig
433
468
433
468
NIH Plain End Cover, 300 psig
400
400
400
400
MWB End Cover, 300 psig
400
400
400
400
MWB Return Cover, 300 psig
359
359
359
359
LEGEND
NIH — Nozzle-in-Head
MWB — Marine Waterbox
NOTE: Weight for NIH 2-pass cover, 150 psig, is included in the heat exchanger weights shown in Tables 23A and 23B.
123
Table 27A — 19XRV Waterbox Cover Weights — English (lb) (cont)
FRAMES 4, 5, and 6 — COOLER
Frame 4
WATERBOX DESCRIPTION
Standard
Nozzles
NIH, 1 Pass Cover, 150 psig
NIH, 2 Pass Cover, 150 psig
Frame 5
Flanged
Standard
Nozzles
148
185
202
256
NIH, 3 Pass Cover, 150 psig
473
NIH Plain End Cover, 150 psig
Frame 6
Flanged
Standard
Nozzles
Flanged
168
229
187
223
224
298
257
330
489
629
655
817
843
138
138
154
154
172
172
MWB End Cover, 150 psig
317
317
393
393
503
MWB Return Cover, 150 psig
138
138
154
154
172
172
NIH, 1 Pass Cover, 300 psig
593
668
764
839
959
1035
NIH, 2 Pass Cover, 300 psig
594
700
761
878
923
1074
NIH, 3 Pass Cover, 300 psig
621
656
795
838
980
1031
NIH/MWB End Cover, 300 psig
569
569
713
713
913
913
Flanged
Standard
Nozzles
Flanged
503
FRAMES 4, 5, and 6 — CONDENSER
Frame 4
WATERBOX DESCRIPTION
Frame 5
Frame 6
Standard
Nozzles
Flanged
Standard
Nozzles
NIH, 1 Pass Cover, 150 psig
148
185
168
229
187
223
NIH, 2 Pass Cover, 150 psig
202
256
224
298
257
330
NIH, 3 Pass Cover, 150 psig
473
489
629
655
817
843
NIH Plain End Cover, 150 psig
138
138
154
154
172
172
MWB End Cover, 150 psig
317
317
393
393
503
503
MWB Return Cover, 150 psig
138
138
154
154
172
172
NIH, 1 Pass Cover, 300 psig
593
668
764
839
959
1035
NIH, 2 Pass Cover, 300 psig
594
700
761
878
923
1074
NIH, 3 Pass Cover, 300 psig
621
656
795
838
980
1031
NIH/MWB End Cover, 300 psig
569
569
713
713
913
913
LEGEND
NIH — Nozzle-in-Head
MWB — Marine Waterbox
NOTE: Weight for NIH 2-pass cover, 150 psig, is included in the heat exchanger weights shown in Tables 23A and 23B.
124
Table 27A — 19XRV Waterbox Cover Weights — English (lb) (cont)
FRAMES 7 and 8 — COOLER
FRAME 7
WATERBOX DESCRIPTION
FRAME 8
Standard Nozzles
Flanged
Standard Nozzles
Flanged
NIH, 1 Pass Cover, 150 psig
329
441
417
494
NIH, 2 Pass Cover, 150 psig
426
541
531
685
NIH, 3 Pass Cover, 150 psig
1625
1202
1239
1568
NIH Plain End Cover, 150 psig
315
315
404
404
MWB End Cover, 150 psig
789
789
1339
1339
MWB Return Cover, 150 psig
315
315
404
404
NIH, 1 Pass Cover, 300 psig
1636
1801
2265
2529
NIH, 2 Pass Cover, 300 psig
1585
1825
2170
2499
NIH, 3 Pass Cover, 300 psig
1660
1741
2273
2436
NIH/MWB End Cover, 300 psig
1451
1451
1923
1923
FRAMES 7 and 8 — CONDENSER
Frame 7
WATERBOX DESCRIPTION
Frame 8
Standard
Nozzles
Flanged
Standard
Nozzles
Flanged
NIH, 1 Pass Cover, 150 psig
329
441
417
494
NIH, 2 Pass Cover, 150 psig
426
541
531
685
NIH, 3 Pass Cover, 150 psig
1113
1171
1438
1497
NIH Plain End Cover, 150 psig
315
315
404
404
MWB End Cover, 150 psig
703
703
898
898
Bolt On MWB End Cover, 150 psig
700
700
1307
1307
MWB Return Cover, 150 psig
315
315
404
404
NIH, 1 Pass Cover, 300 psig
1472
1633
1860
2015
NIH, 2 Pass Cover, 300 psig
1410
1644
1735
2044
NIH, 3 Pass Cover, 300 psig
1495
1613
1883
1995
NIH/MWB End Cover, 300 psig
1440
1440
1635
1635
LEGEND
NIH — Nozzle-in-Head
MWB — Marine Waterbox
NOTE: Weight for NIH 2-pass cover, 150 psig, is included in the heat exchanger weights shown in Tables 23A and 23B.
125
Table 27B — 19XRV Waterbox Cover Weights — SI (kg)
FRAMES 2 and 3 — COOLER
FRAME 2
WATERBOX DESCRIPTION
FRAME 3
Standard Nozzles
Flanged
Standard Nozzles
Flanged
NIH, 1 Pass Cover, 1034 kPa
145
159
145
159
NIH, 2 Pass Cover, 1034 kPa
145
159
145
159
NIH, 3 Pass Cover, 1034 kPa
141
154
141
154
NIH Plain End Cover, 1034 kPa
136
136
136
136
MWB End Cover, 1034 kPa
136
136
136
136
MWB Return Cover, 1034 kPa
110
110
110
110
NIH, 1 Pass Cover, 2068 kPa
186
220
186
220
NIH, 2 Pass Cover, 2068 kPa
186
235
186
235
NIH, 3 Pass Cover, 2068 kPa
196
212
196
212
NIH Plain End Cover, 2068 kPa
181
181
181
181
MWB End Cover, 2068 kPa
181
181
181
181
MWB Return Cover, 2068 kPa
202
202
202
202
FRAMES 2 and 3 — CONDENSER
Frame 2
WATERBOX DESCRIPTION
Frame 3
Standard Nozzles
Flanged
Standard Nozzles
Flanged
NIH, 1 Pass Cover, 1034 kPa
145
159
145
159
NIH, 2 Pass Cover, 1034 kPa
145
159
145
159
NIH, 3 Pass Cover, 1034 kPa
141
154
141
154
NIH Plain End Cover, 1034 kPa
136
136
136
136
MWB End Cover, 1034 kPa
136
136
136
136
MWB Return Cover, 1034 kPa
102
102
102
102
NIH, 1 Pass Cover, 2068 kPa
186
220
186
220
NIH, 2 Pass Cover, 2068 kPa
186
235
186
235
NIH, 3 Pass Cover, 2068 kPa
196
212
196
212
NIH Plain End Cover, 2068 kPa
181
181
181
181
MWB End Cover, 2068 kPa
181
181
181
181
MWB Return Cover, 2068 kPa
163
163
163
163
LEGEND
NIH — Nozzle-in-Head
MWB — Marine Waterbox
NOTE: Weight for NIH 2-pass cover, 1034 kPa, is included in the heat exchanger weights shown in Tables 23A and 23B.
126
Table 27B — 19XR Waterbox Cover Weights — SI (kg) (cont)
FRAMES 4, 5, and 6 — COOLER
Frame 4
WATERBOX DESCRIPTION
Standard
Nozzles
Frame 5
Flanged
Standard
Nozzles
Frame 6
Flanged
Standard
Nozzles
Flanged
NIH, 1 Pass Cover, 1034 kPa
67
84
76
104
85
101
NIH, 2 Pass Cover, 1034 kPa
92
116
102
135
117
150
NIH, 3 Pass Cover, 1034 kPa
215
222
285
297
371
382
63
63
70
70
78
78
144
144
178
178
228
228
NIH Plain End Cover, 1034 kPa
MWB End Cover, 1034 kPa
MWB Return Cover, 1034 kPa
63
63
70
70
78
78
NIH, 1 Pass Cover, 2068 kPa
269
303
347
381
435
479
NIH, 2 Pass Cover, 2068 kPa
269
318
345
393
419
487
NIH, 3 Pass Cover, 2068 kPa
282
298
361
376
495
468
NIH/MWB End Cover, 2068 kPa
258
258
323
298
414
414
FRAMES 4, 5, and 6 — CONDENSER
Frame 4
WATERBOX DESCRIPTION
Standard
Nozzles
Frame 5
Flanged
Frame 6
Standard
Nozzles
Flanged
Standard
Nozzles
Flanged
NIH, 1 Pass Cover, 1034 kPa
67
84
76
104
85
101
NIH, 2 Pass Cover, 1034 kPa
92
116
102
135
117
150
NIH, 3 Pass Cover, 1034 kPa
215
222
285
297
371
382
NIH Plain End Cover, 1034 kPa
MWB End Cover, 1034 kPa
63
63
70
70
78
78
144
144
178
178
228
228
MWB Return Cover, 1034 kPa
63
63
70
70
78
78
NIH, 1 Pass Cover, 2068 kPa
269
303
347
381
435
469
NIH, 2 Pass Cover, 2068 kPa
269
318
345
393
419
487
NIH, 3 Pass Cover, 2068 kPa
282
298
361
376
445
468
NIH/MWB End Cover, 2068 kPa
258
258
323
298
414
414
LEGEND
NIH — Nozzle-in-Head
MWB — Marine Waterbox
NOTE: Weight for NIH 2-pass cover, 1034 kPa, is included in the heat exchanger weights shown in Tables 23A and 23B.
127
Table 27B — 19XR Waterbox Cover Weights — SI (kg) (cont)
FRAMES 7 and 8 — COOLER
Frame 7
WATERBOX DESCRIPTION
Frame 8
Standard
Nozzles
Flanged
Standard
Nozzles
Flanged
NIH, 1 Pass Cover, 1034 kPa
149
200
189
224
NIH, 2 Pass Cover, 1034 kPa
193
245
241
311
NIH, 3 Pass Cover, 1034 kPa
545
562
711
737
NIH Plain End Cover, 1034 kPa
143
143
183
183
MWB End Cover, 1034 kPa
358
358
607
607
MWB Return Cover, 1034 kPa
143
143
183
183
NIH, 1 Pass Cover, 2068 kPa
742
817
1027
1147
NIH, 2 Pass Cover, 2068 kPa
719
828
984
1134
NIH, 3 Pass Cover, 2068 kPa
753
790
1031
1105
NIH/MWB End Cover, 2068 kPa
658
658
872
872
FRAMES 7 and 8 — CONDENSER
FRAME 7
WATERBOX DESCRIPTION
Standard
Nozzles
NIH, 1 Pass Cover, 1034 kPa
FRAME 8
Flanged
Standard
Nozzles
Flanged
149
200
189
224
NIH, 2 Pass Cover, 1034 kPa
193
245
241
311
NIH, 3 Pass Cover, 1034 kPa
505
531
652
679
NIH Plain End Cover, 1034 kPa
143
143
183
183
MWB End Cover, 1034 kPa
319
319
407
407
Bolt On MWB End Cover, 1034 kPa
318
318
593
593
MWB Return Cover, 1034 kPa
143
143
183
183
NIH, 1 Pass Cover, 2068 kPa
668
741
844
914
NIH, 2 Pass Cover, 2068 kPa
640
746
787
927
NIH, 3 Pass Cover, 2068 kPa
678
732
859
905
NIH/MWB End Cover, 2068 kPa
653
653
742
742
LEGEND
NIH — Nozzle-in-Head
MWB — Marine Waterbox
NOTE: Weight for NIH 2-pass cover, 1034 kPa, is included in the heat exchanger weights shown in Tables 23A and 23B.
128
Table 28 — 19XRV Component Weights
FRAME 2
FRAME 3
FRAME 4
FRAME 5
COMPRESSOR* COMPRESSOR* COMPRESSOR* COMPRESSOR*
COMPONENT
lb
kg
lb
kg
Suction Elbow
116
lb
53
185
84
239
108
407
185
Discharge Elbow
100
45
125
57
157
71
325
147
34
15
34
15
34
15
34
15
11
Control Panel†
Optional Cooler Inlet Isolation Valve
kg
lb
kg
8
4
13
6
20
9
24
26
12
46
21
74
34
108
Std Tier VFD — 380, 400, and 460-v (335, 445 A)
650
295
650
295
—
—
—
—
Std Tier VFD — 380, 400, and 460-v (485, 550 A)
—
—
1035
469
1035
469
—
—
Std Tier VFD — 380, 400, and 460-v (605, 680, 765, 855, 960, 1070 A)
—
—
1600
726
1600
726
—
—
—
—
2800
1270
2800
1270
Optional Discharge Isolation Valve
Std Tier VFD — 380, 400, and 460-v (1275, 1530 A)
LiquiFlo™ 2 VFD — 380, 400, and 460-v (405 A / 608 A)
LiquiFlo 2 VFD — 380, 400, and 460-v (900 A)
LiquiFlo 2 VFD — 380, 400, and 460-v (1200 A)
LiquiFlo 2 VFD — 575-v (390 A)
VFD Shelf
49
1600
726
1600
726
1600
726
—
—
—
—
—
—
2800
1270
2800
1270
1293
—
—
—
—
2850
1293
2850
2400
1089
2400
1089
—
—
—
—
—
—
—
—
1049
476
1049
476
*To determine compressor frame size, refer to 19XR,XRV Computer Selection Program.
†Included in total cooler weight.
Table 30 — Motor Voltage Code
Table 29 — Optional Pumpout Electrical Data
PUMPOUT UNIT
19XR04026501
19XR04026501
19XR04026502
19XR04026503
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
Code
60
61
62
63
64
65
66
67
68
69
6A
6B
50
51
52
53
54
55
5A
5B
LRA
105
105
52
52
LEGEND
LRA — Locked Rotor Amps
RLA — Rated Load Amps
129
MOTOR VOLTAGE CODE
Volts
200
230
380
416
460
575
2400
3300
4160
6900
11000
10000
230
346
400
3000
3300
6300
10000
11000
Frequency
60
60
60
60
60
60
60
60
60
60
60
60
50
50
50
50
50
50
50
50
19XRV COMPRESSOR FITS AND CLEARANCES (in.)
COMPRESSOR
Code
ITEM
A
B
C1
C2
D
E
F1
F2
G
H
I
J
K
L
M
N
O
P
FRAME 2
201-299, 2ZZ
FRAME 3
FRAME 4
FRAME 5
321-389, 3ZZ
421-487, 4B1-4W7
501-599
Rolling
Rolling
Rolling
Oil Film
Oil Film
Oil Film
Element
Element
Element
DESCRIPTION
Bearings
Bearings
Bearings
Bearings
Bearings
Bearings
Low Speed Journal-Gear End
.0050/.0040
.0050/.0040
.0055/.0043
.0055/.0043
.0069/.0059
.0069/.0059
Low Speed Journal-Motor End
.0050/.0040
.0050/.0040
.0053/.0043
.0053/.0043
.0065/.0055
.0065/.0055
Low Speed Labyrinth to Thrust Disk .0115/.0055
N/A
.010/.005
N/A
N/A
N/A
Labyrinth to Low Speed Shaft
N/A
.010/.005
.0095/.0055
.0095/.0055
.013/.009
.013/.009
Low Speed Shaft Thrust Float
.020/.008
.020/.008
.023/.008
.023/.008
.020/.008
.020/.008
Impeller Eye to Shroud
*
*
*
*
*
*
Impeller Bore to Shaft-Rear
–.0020/–.0005 –.0025/–.0010 –.0014/–.0029 –.0014/–.0029 –.0019/–.0005 –.0019/–.0005
Impeller Bore to Shaft-Front
N/A
N/A
–.0005/–.0025 –.0005/–.0025 –.0014/.0000
N/A
Impeller Discharge to Shroud
*
*
*
*
*
*
Impeller Spacer to Shaft
.0025/.0010
.0025/.0010
.0025/.0010
.0025/.0010
.0024/.0010
.0024/.0010
Slinger to Shaft
.0013/.0005
.0012/.0004
.0012/.0004
.0012/.0004
.0012/.0004
.0012/.0004
Labyrinth to Slinger
.013/.009
.010/.006
.010/.006
.010/.006
.010/.006
.010/.006
Labyrinth to Impeller
.012/.008
.012/.008
.012/.008
.012/.008
.012/.008
.012/.008
High Speed Journal-Impeller End
.0047/.0037
N/A
.0040/.0028
N/A
.0048/.0038
N/A
Thrust Assembly Seal Ring Axial
.006/.002
N/A
.006/.002
N/A
.006/.002
N/A
Clearance
Thrust Assembly Seal Ring to Shaft
.0045/.0015
N/A
.0045/.0015
N/A
.0045/.0015
N/A
High Speed Shaft Thrust Float
.014/.008
0 Float
.014/.008
Float
.014/.008
0 Float
High Speed Journal-Gear End
.0050/.0040
N/A
.0048/.0038
N/A
.0062/.0052
N/A
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 a 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
SEE VIEW A1 OR A2
A
2
3
SEE VIEW B
D
4
1
COMPRESSOR, TRANSMISSION AREA (FRAME 5 COMPRESSOR SHOWN)
1) OIL HEATER RETAINING NUT (NOT SHOWN)
2) BULL GEAR RETAINING BOLT
3) DEMISTER BOLTS (NOT SHOWN)
4) IMPELLER BOLT
COMPRESSOR, TRANSMISSION AREA
Fig. 52 — Compressor Fits and Clearances
130
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
G
SEE
NOTE 5
E
H
O
F1
F2
THRUST
P
I
J
IMPELLER SHIMMING
TO BE DETERMINED
AT ASSEMBLY
L
K
SEE VIEW C
a19-1639
VIEW B — HIGH SPEED SHAFT (FRAME 2, 4, OR 5)
Fig. 52 — Compressor Fits and Clearances (cont)
131
+0.0007
-0.0007
0.0050
0.0020
0.025
0.005
+0.0007
-0.0007
THRUST
0.0011
0.0013
INTERFERENCE
0.0011
0.0013
INTERFERENCE
a19-1640
0.0012
0.0004
VIEW B — HIGH SPEED SHAFT (FRAME 3)
N
M
VIEW C — HIGH SPEED SHAFT RING SEAL
Fig. 52 — Compressor Fits and Clearances (cont)
132
a19-1642
a19-1643
MOTOR LEAD INSTALLATION LABELS
19XRV COMPRESSOR ASSEMBLY TORQUES
COMPRESSOR
Code
FRAME 2
201-299, 2ZZ
DESCRIPTION
Fixed Diffuser
ITEM
1
2
3
4
Oil Heater Retaining Nut — ft-lb (N·m)
Bull Gear Retaining Bolt — ft-lb (N·m)
Demister Bolts — ft-lb (N·m)
Impeller bolt Torque — ft-lb (N·m)
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)
Fig. 52 — Compressor Fits and Clearances (cont)
LEGEND FOR FIG. 53-58
AUX
CB
CCM
CCN
COM
COMM
DL/DP
GND
GV
GVA
HGBP
HPS
ICVC
J
NTC
RHS
T
TB
UPC
VFD
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
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
Universal Protocol Converter
Variable Frequency Drive
1C
2C
3C
— Compressor Oil Heater Contactor
— Oil Pump Contactor
— Hot Gas Bypass Relay
Field Control Wiring
Field Power Wiring
Factory Wiring
Compr Oil Pump Terminal
Cartridge Fuse
Resistor
Male/Female Connector
Chassis Ground
Terminal Block Connection
Temperature Switch
Component Terminal
Thermistor
+
Pressure Switch
Shielded Cable
Wire Splice or Junction
-
Potentiometer
Transducer
133
Common Potential
VFD Terminal
Transformer
Capacitor
(SHIELD)
AUTO DEMAND LIMIT
(OPTIONAL)
EXT
4-20mA
(1-5vdc)
AUTO CHILLED WATER
RESET (OPTIONAL)
EXT
4-20mA
(1-5vdc)
(RED)
(BLK)
(CLR)
(CLR)
(BLK)
(SHIELD)
4-20mAkw
OUTPUT
6
+
-
+
+
-
+
-
2
3
5
4
3
2
J5
1
(BLK)
2
EVAP LVG
WATER TEMP
(RED)
3
(BLK)
4
COND ENT
WATER TEMP
(RED)
5
(BLK)
6
COND LVG
WATER TEMP
(RED)
7
(BLK)
8
(CLR)
9
(BLK)
10
4
7
10K
J7
1
J8
SWITCH POSITION
O
N
1 2 3
SEE NOTE
SW "ON" = EXT 4-20mA
SW "OFF" = EXT 1-5Vdc
SW2
(WHT)
1 "OFF"
2 "ON"
(BLU)
COMP'R
DISCH TEMP
1
2
3
COMP'R OIL
SUMP TEMP
1
2
3
NOISE
SUPPRESSOR
(RED)
11
(BLK)
12
(WHT)
13
(BLK)
14
L2
DIFFUSER ACTUATOR
(BLK)
(SHIELD)
3
(CLR)
2
(RED)
1
(BLK)
(WHT)
COMMON
X
G.V. INCREASE
L1
L2
(RED)
17
(BLK)
18
(CLR)
19
(BLK)
20
GUIDE VANE ACTUATOR
(RED)
(BLK)
(YEL)
(CLR)
CB2
(SPARE)
(RED)
21
(BLK)
22
(CLR)
23
(BLK)
24
6
(BLK)
5
(BRN)
(BLU)
3
(BLK)
2
(WHT)
(BRN)
3C
(WHT)
HGBP (OPTIONAL)
(BRN)
(BRN)
27
(BLK)
28
(BLK)
1
(CLR)
2
+
(RED)
3
(BLK)
4
(CLR)
5
(RED)
(BLK)
6
+
7
LOAD RESISTOR
8
4.3K
S
1C
(ORN)
9
(RED)
(WHT)
COMP'R OIL PUMP
(RED)
(BRN)
COMP'R OIL HEATER
(GRY)
(BRN)
(WHT)
CCM
+
100»f
+
NOTE: GND SHIELDS AT THIS END ONLY
100»f
(SHIELD)
J3 (UPPER)
26
(WHT)
C1
2C
C1
25
(BLK)
+
*
1
C2
SPARE TEMP #2
(OPTIONAL)
-
VFD COOLANT
SOLENOID
(CLR)
(BLK)
3
4
(BLK)
(BLK)
(SPARE)
SPARE TEMP #1
(OPTIONAL)
RMS
2
16
1
RELATIVE
HUMIDITY
3
G.V. DECREASE
15
(WHT)
OIL PUMP
DISCH PRESS
(YEL)
L1
C2
OIL SUMP
PRESS
(BLK)
(ORN)
3 "ON"
J11
REMOTE TEMP
RESET
(OPTIONAL)
COMP'R
MOTOR TEMP
J6
(SHIELD)
EVAP REFRIG
LIQUID TEMP
COMP'R THRUST
BRG TEMP
2
1
J12
8
3
+
J4 (LOWER)
G.V. POSITION
FEEDBACK
4
-
J10
(RED)
J4 (UPPER)
EVAP ENT
WATER TEMP
1
+
J9
6
-
(SHIELD)
(RED)
+
(RED)
(CLR)
G
(WHT)
(BLK)
-
(BLK)
CCN
(WHT)
10
SEE NOTE
SP
11
ALL SWITCHES SET
TO "OFF" POSITION
LOAD RESISTOR
12
(RED)
1
(GRY)
2
10K
14
LOAD RESISTOR
17
18
19
20
J3 (LOWER)
16
JUMPER
0
N
SW1
15
4.3K
1 2 3 4 5 6 7 8
13
R
2
(RED)
J1
21
22
CB1
1
(GRY)
(GRY)
23
JUMPER
(RED)
5
ICVC
24VAC
(GRY)
4
(BLK)
3
-
(CLR)
2
G
1
+
(RED)
(GRY)
24
ALARM
J1
LOAD RESISTOR
4.3K
J7
6
STOP
J8
(BLK)
1
(CLR)
2
(RED)
3
(BLK)
4
-
EVAP PRESS
SERVICE
-
COND PRESS
(CLR)
5
(RED)
6
+
a19-2000
J2
+
NOTE:
On all units with Frame 5 compressors and Frame 4 compressors with the
variable (split ring) diffuser option, a diffuser acutator is added and the resistor
on J3 (upper) board, terminals 11 and 12, are replaced with a transducer connected to terminals 10, 11, and 12.
Fig. 53 — Typical Electronic PIC III Control Panel Wiring Schematic
134
(GRN)
1
TO TB-G **
21
COMP'R OIL HEATER
11
11
230V
1C
22
(BLK)
23
(WHT)
6
(WHT)
13
(WHT)
(RED)
(BLK)
(WHT)
(WHT)
1C
OPEN
HGBP
ACTUATOR
1C
13
COM
(WHT)
12
(BLK)
1C
COM
3
5
1C
(BLK)
12
115V
2
4 CLOSE
(BLK)
(BLK)
3C
6
(WHT)
1C
5
230V WIRING MODIFICATION
COMP'R OIL HEATER
(BLU)
(BLK)
3C
(BLK)
(BLU)
4
2
(WHT)
(WHT)
HOT GAS BYPASS
(BLK)
(BLK)
(FR #7 & 8 HT EXCH)
115V CONTROL ONLY
(BLK)
(RED)
(RED)
51
(ORN)
50
(BRN)
43
(BLK)
(BLK)
17
(BLK)
(CLR)
C
(BLK)
B
(RED)
A
(RED)
(WHT)
(BLK)
(BLK)
(BLK)
(WHT)
(YEL)
(WHT)
T1
24VAC
(RED)
(WHT)
(WHT)
(RED)
T3
24VAC
T2
24VAC
(GRN)
TO VFD
(BRN)
(BRN)
(BRN)
(BRN)
(BRN)
(BRN)
(BLU)
COMP'R DISCH
HIGH PRESS
(RED)
(BLU)
(RED)
HGBP
SOLENOID
(YEL)
(BLK)
(SHIELD)
(RED)
(BLK)
(GRY)
(RED)
(BLK)
(BLK)
(GRY)
(YEL)
4
2
(RED)
3C
(BLK)
SHOWN WIRED FOR 115V
(CLR)
(BLK)
(BRN)
23
2
1
21
(GRN)
WHT
WHT
UPC
(WHT)
(WHT)
(BLU)
(RED)
COMP'R OIL PUMP MOTOR
WINDING HIGH TEMPERATURE
(BLU)
(RED)
(WHT)
(YEL)
(RED)
(BLK)
HGBP
SOLENOID
(BLK)
(GRY)
(BLK)
(YEL)
4
2
3C
230V WIRING MODIFICATION
HOT GAS BYPASS
a19-1947
(FR #1 - 6 HT EXCH)
YEL
11
21
(YEL)
VOLTAGE
2C
22
PER JOB
REQM'T
BLK
12
(RED)
2C
* Standard on LF2 drive; optional on machines equipped with other VFDs.
Fig. 53 — Typical Electronic PIC III Control Panel Wiring Schematic (cont)
135
COMP'R OIL
PUMP MOTOR
RED
13
23
(1-1/2 HP)
M
(BLK)
2C
136
A
(RED)
(RED)
(BLK)
(CLR)
TO CCM J7-2*
TO CCM J7-1*
(SHIELD)
B
(BLK)
C
17
(BLK)
(CLR)
(BLK)
43
(BRN)
TO CCM J7-3*
TO VFD
(BLK)
50
(ORN)
(BLK)
COMPR OIL
PUMP MOTOR
(1-1/2 HP)
M
COMM
115V
230V
COMPR DISCH
HIGH PRESS
(WHT)
RED
BLK
51
(YEL)
TO CB2*
(RED)
(BLK)
(YEL)
YEL
(RED)
(WHT)
13
12
11
TO CCM J12-2*
(BLK)
TO GVA L1
2C
2C
2C
(WHT)
23
22
21
TO GVA L2
VOLTAGE
PER JOB
REQMT
a19-2009
(BLK)
TO CB2*
(BLK)
(WHT)
(BRN)
(RED)
TO CCM
J12-5*
13
12
11
(BLK)
TO CB3*
(RED)
(BRN)
VFD COOLANT
SOLENOID
TO UPC*
(GRY)
(BRN)
T3
24VAC
(RED)
(BLK)
(WHT)
(WHT)
(BLK)
(CLR)
1C
1C
1C
C1
1C
C2
COMPR OIL HEATER
2C
1
3C
HGBP
C2
3
(WHT)
WHT
(ORN)
TO CCM
J12-1*
TO CCM
J12-4*
(BLU)
(OPTIONAL)
(BRN)
C1
COMPR OIL PUMP
WHT
(WHT)
(BLK)
(BLU)
(BLK)
(YEL)
(RED)
(BLU)
115V WIRING
(BLK)
(YEL)
(RED)
(GRN)
(GRN)
3C
4
3C
HGBP
SOLENOID
4
HGBP
SOLENOID
(WHT)
(WHT)
HOT GAS BYPASS OPTION FOR
FR. 1,2,3,4,5 & 6 HT. EXCH.
230V WIRING MODIFICATION
(BLK)
(YEL)
(RED)
(BLU)
23
(BLK)
(YEL)
(RED)
(BLU)
(BLK)
(BLK)
230V WIRING MODIFICATION
13
12
11
COMPR OIL PUMP MOTOR
WINDING HIGH TEMPERATURE
(BRN)
(BRN)
(RED)
(BLU)
(BLK)
(WHT)
(WHT)
(BLK)
(BLK)
COMPR OIL HEATER
Fig. 54 — Power Panel Wiring Schematic
(BRN)
TO CB1*
(GRY)
(BRN)
(BRN)
T2
24VAC
(RED)
(BLK)
1C
1C
1C
TO CCM J1-2*
(BRN)
T1
24VAC
(BRN)
(WHT)
23
22
21
(WHT)
(BLK)
(RED)
(RED)
TO TB-G**
2
2
A
B
C
17
43
50
51
(BLK)
21
21
11
12
22
1C
T2
23
13
(BLK)
115V
5
22
COM
1
ESSEX
L1
3C
L2
(WHT)
32
35
36
3
6
4
HGBP
ACTUATOR
(GRN)
(BLU)
4
2
5
GROUND
SCREW
(WHT)
23
13
HGBP
OPTION
HOT GAS BYPASS
(FR #7 & 8 HT EXCH)
115V CONTROL ONLY
2
12
2C
6(RED)
21
11
T3
(BLK)
23
22
GROUND LUG
(BLK)
T1
COMPONENT LAYOUT
a19-1733
137
Fig. 55 — 19XRV 442A and 608A Chiller Control Schematic
a19-1997
138
UPC
Fig. 55 — 19XRV 442A and 608A Chiller Control Schematic (cont)
1
2
a19-2015
139
312

Fig. 55 — 19XRV 442A and 608A Chiller Control Schematic (cont)
a19-1736
140
Fig. 56 — 19XRV 900A and 1200A Chiller Control Schematic
a19-1999
141
UPC
2
Fig. 56 — 19XRV 900A and 1200A Chiller Control Schematic (cont)
1
a19-2016
312
142

Fig. 56 — 19XRV 900A and 1200A Chiller Control Schematic (cont)
120A
118
116
114
143
K1A
20A
600V
TS1
T1
T2
T3
A2
L1
L2
L3
A1
153
14
13
154
PRECHARGE
CONTACTORS
132
PRECHARGE
RESISTORS
10 , 600W
137A,B
2
139
R4
128
FU7
127
136
4x 140J
2V
FU4
FU5
FU6
150A
600V
138
119A
117
115
IND1
INPUT INDUCTOR
MAIN
CIRCUIT BREAKER
CB1
GND
129
20A
600V
1uF
113
46uF ea
100k , 50W
FILTER CAP ASSY
a19-2017
312
1
4
R
R5
131
FU8
130A
7
1
L1
155
A1
A2
T3
T2
L3
L2
14
T1
8
2
S
L1
13
5
L2
9
3
T
K1B
156
6
L3
140
135
20A
600V
1
M3
M2
R6
134
FU9
2
1
2
1
157
A1
L3
L2
L1
13
124
123
126
125
FU3
FU2
FU1
152
151
1A/600V
CLASS 'CC'
133
112
110
108
2
T2
L2
106
ST
T1
L1
104
CONTROL BREAKER
(2 POLE, 15A)
CB2
AC INPUT
FIELD WIRING
H*
H1
K1C
M4
2
1
TB3
4
3
2
1
122
121
145
MECHANICAL
JUMPER
)
X2
X1
CLASS 'CC'
15A
5A
120V
SWITCHED
120V_N
142
150F
102C
CLASS 'CC'
102B 15A
102A
FU10
FU11A
FU11B
0.5A
P1-10
F1
PILOT
RELAY
P1-9
P1-12
+
(OPTIONAL)
METERS W/SWITCH
VM1
VOLTMETER
A2 LINE SYNC PCB
P1-14
P1-8
P1-7
P1-13
SW1
P2-3
L2
L3
B2 B1 A2 A1
L1
P2-18
P2-17
P2-14
+
AMMETER
COIL_RETURN
+24V_COIL
AM1
OVER_TEMP_2
OVER_TEMP_1
14
13
12
11
9
10
I/O_AGND
RECT_AC_LINE
P2-9
P2-10
P2-13
8
7
6
5
4
3
2
1
P1
+12VDC_I/O
I/O_AGND
-12VDC_I/O
I/O_ DGND
+5V_I/O
/CA>AB
/BC>CA
/AB>BC
150C
190
P2-8
P2-7
P2-6
P2-5
P2-4
P2-1
P2-2
P1-1
101C
P1-5
SIGNAL
CONDITIONING
AND ISOLATION
P1-11
150D
101D
P1-3
101A
L3
187
TB1
A12
AC LINE I/O
LOGIC COM
LOGIC IN 1
LOGIC IN 2
LOGIC IN 3
LOGIC IN 4
DO NC5
DO COM5
DO NO5
DO NC6
DO COM6
DO NO6
AO I1AO I1+
EXV C2EXV C2+
DO NC1
DO COM1
DO NO1
DO NC2
DO COM2
DO NO2
DO NC3
DO COM3
DO NO3
DO NC4
DO COM4
DO NO4
AO V1AO V1+
EXT NTC
EXT COM
TB1
+24V
LOGIC COM
24V COM
DI1
DI2
DI3
DI4
DI5
DI6
DO NC1
DO COM1
DO NO1
DO NC2
DO COM2
DO NO2
AI I1AI I1+
AI I2AI I2+
-10V
+10V
AI V1AI V1+
AI V2AI V2+
Vref COM
AO V1AO V1+
AO I1AO I1+
A1 VFD POWER MODULE
L1
L2
188
186
185
184
183
STANDARD I/O
A22
150A
101B
150B
Fig. 57 — 19XRV 442A and 608A Chiller VFD Schematic
141
(
H1-H4: 380-415VAC
H1-H5: 440-480VAC
*T1 INPUT (50/60Hz)
158

A2
T3
T2
T1
14
111
109
107
105
103
(3.0kVA, 120V, 25A)
CONTROL POWER
TRANSFORMER
T1
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
A34
NTC
A32
RS485
2
1
TB1
GATE-KILL
A33
179
180
171
172
U
V
W
T3
6
GND
M1
MOTOR
155
156
154
EXTERNAL- REF. ONLY
T1
T2
COM
4
SHIELD
B
5
A
2
TERM
174
173
175
177
3
1
170
169
1
2
3
4
5
6
7
8
9
10
TB1
TB2
3
2
1
GND
POS
COM
NEG
CN3
EVAP PUMP
EVAP PUMP
COND PUMP
COND PUMP
TOWER FAN LOW
TOWER FAN LOW
TOWER FAN HIGH
TOWER FAN HIGH
TRIP ALARM
TRIP ALARM
RED
BLK
WHT
HIGH PRESS SW
HIGH PRESS SW
4-20mA PRESS REF4-20mA PRESS REF+
SPARE SAFETY
SPARE SAFETY
ICE BUILD
ICE BUILD
REMOTE START
REMOTE START
OIL INT/LOCK
NOTE: MOTOR OVERLOAD IS
FACTORY PRE-SET.
DO NOT ADJUST.
159
160
161
162
163
164
165
166
167
168
15
16
17
18
19
20
21
22
23
24
CN2
PE
LL2
LL1
CN1A
SH2
SH1
CN1B
OIL INT/LOCK
2
1
2
1
312
1 uF
R1
R2
R3
144
T1
T2
T3
A2
L1
L2
L3
A1
231F
14
13
K1A
225E
PRECHARGE
CONTACTORS
227D
PRECHARGE
RESISTORS
20
2
1
TS1
20A
600V
2
227A
R4
203
200
229
228
1
207
2
FU7
2V
4x 140J
FU4
FU5
FU6
300A
2 500V
INPUT INDUCTOR
IND1
CB1
MAIN CIRCUIT
BREAKER
GND
INPUT FIELD WIRING REF.
206
20A
600V
1
46 uF ea
50k , 100W
FILTER CAP ASSY
a19-2019
1
4
R
201
7
1
R5
204
FU8
L1
231G
A1
L3
A2
T3
T2
L2
14
T1
8
2
S
L1
13
5
L2
9
3
T
K1B
225F
6
L3
1
231C
227E
208
20A
600V
2
1
R6
205
FU9
202
214
213
2
1
2
1
2
1
2
225C
K1C
232
FU3
FU2
2
FU1
233
*T1 INPUT (50/60Hz)
217
216
215
H1-H2: 346VAC
H1-H3: 380VAC
H1-H4: 400-415VAC
H1-H5: 460VAC
H1-H6: 480VAC
X2
X1
L2
L3
B2 B1 A2 A1
L1
231A
225B
225A,B,C,D
224B
224A
(OPTIONAL)
METERS W/SWITCH
+
SW1
X1
4
3
2
1
VOLTMETER
VM1
225C
231H
231E,J
231C,D
230E,J
230C,D
( MECHANICAL JUMPER)
H*
H1
T1 CONTROL TRANSFORMER
(3kVA, 120V, 25A)
+
226B
262
263B
261
259
260
257
258
263A
AM1
FU10
FU11
AMMETER
10A
20A
263A,B
232
229
227A
233
231A,H
L1
L2
L3
L3
L2
L1
TB7
TEMPSW INV
5
TB3
TB4
TB9
DO 4 NO
DO 4 COM
DO 4 NC
DO 3 NO
DO 3 COM
DO 3 NC
DO 2 NO
DO 2 COM
DO 2 NC
DO 7 NO
DO 7 COM
DO 7 NC
DO 6 NO
DO 6 COM
DO 6 NC
DO 5 NO
DO 5 COM
DO 5 NC
VFD POWER MODULE
TB1
TB2
D1 24VDI COM 1
DI 4
DI 3
DI 2
DI 1
DI 24V+
GATEKILL GATEKILL +
DI 5
AO 1+
AO 1AO 2+
AO 2AO 4+
AO 4-
COMBINED I/O
PRECHARGE FB
A12
A1
7
TEMPSW RCT
SW 24V
6
SHUNT TRIP
4
PRECHARGE OUT
CNTRL PWR
3
2
1
LINE
SYNC
5
3
1
TB5
225D
Fig. 58 — 19XRV 900A and 1200A Chiller VFD Schematic
A2
T3
T2
T1
14
230J
231J
230E
231E
230D
231D
231H
A1
L3
L2
L1
13

M5
M4
M3
M2
1
230C
T3
L3
220
1A/600V
CLASS 'CC'
1
T2
L2
219
2
T1
L1
212
225A
223
CONTROL BREAKER
(3 POLE, 15A)
218
ST
222B
221B
CB2
1
2
3
4
5
6
7
8
9
4
5
6
7
8
9
10
11
12
1
2
3
4
5
6
7
8
9
6
1
2
3
4
7
8
A32
RS485
W
V
U
B
COM
3
4
6
GND
SHIELD
A
2
5
TERM
1
(OS1) PP/2C-21
WHITE
M1
RED
BLACK
RED
ORANGE
253
252
251
250
249
248
247
246
245
244
BROWN
BLACK
239
238
236
237
235
234
PP50
GND
NOTE: MOTOR OVERLOAD IS
FACTORY PRE-SET.
DO NOT ADJUST.
(POS) PPA
COMM
OIL
INT/LOCK
(COM) PPB
(NEG) PPC
PP51
TB2
HIGH
PRESSURE
SW
EVAP PUMP
EVAP PUMP
COND PUMP
COND PUMP
TOWER FAN LOW
TOWER FAN LOW
TOWER FAN HIGH
TOWER FAN HIGH
TRIP ALARM
TRIP ALARM
PP43
1
2
3
4
5
6
7
8
9
10
TB1
OIL HEATER
CONTACTOR
OIL PUMP
CONTACTOR
NOT USED
NOT USED
4-20mA PRESS REF4-20mA PRESS REF+
SPARE SAFETY
SPARE SAFETY
ICE BUILD
ICE BUILD
REMOTE START
REMOTE START
PP17
15
16
17
18
19
20
21
22
23
24
(PE) PP/CHASIS
(LL2) PP/1C-23
(LL1) PP/1C-22
(OS3) PP/2C-23
(OS2) PP/2C-22
MOTOR
EXTERNAL- REF. ONLY
T3/T5
T2/T4
T1/T6
256
255
254
240
241
243
242
GREEN
WHITE
BLACK
RED
BLACK
YELLOW
a19-2001
145
Fig. 59 — 19XRV Chiller Control Panel Component Layout
TB2
TB3 − LF2
VFD FRAME 4
TB1 − LF2
VFD FRAME 3
GATE KILL
†
*
OIL PUMP
INTERLOCK
OIL PUMP
INTERLOCK
TB1 − LF2
VFD FRAME 4
**
POWER
PANEL
*
a19-2010
* Located on A12 card, other terminals on field terminal strip.
† Located on A33 card, other terminals on field terminal strip.
** Located on A22 card, other terminals on field terminal strip.
Fig. 60 — 19XRV Field Wiring — LiquiFlowTM VFD
146
a19-1714
Fig. 60 — 19XRV Field Wiring — LiquiFlowTM VFD (cont)
147
LEGEND FOR FIG. 60
REFERENCE
NUMBER
1
2
A
B
C
D
E
F
G
H
J
K
L
M
N
P
DESCRIPTION
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
148
NOTES FOR FIG. 60
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.
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.
III Control Wiring
3.0 Field-supplied control conductors to be at least 18 AWG
(American Wire Gage) or larger.
3.1 Ice build start/terminate device contacts, remote start/stop
device contacts and spare safety device contacts (devices
not supplied by Carrier) must have 24 vac rating. Max current
is 60 mA, nominal current is 10 mA. Switches with goldplated bifurcated contacts are recommended.
3.2 Remove jumper wire between TB1-19 and TB1-20 before
connecting auxiliary safeties between these terminals.
3.3 Each integrated contact output can control loads (VA) for
evaporator pump, condenser pump, tower fan low, tower fan
high and alarm annunciator devices rated 5 amps at 115 vac
and up to 3 amps at 250 vac.
II Power Wiring To VFD
2.0 Provide a means of disconnecting branch feeder power to
VFD. Provide short circuit protection and interrupt capacity for
branch feeder in compliance with all applicable codes.
2.1 Metal conduit must be used for the power wires, from VFD to
branch feeder.
2.2 Line side power conductor rating must meet VFD nameplate
voltage and chiller full load amps (minimum circuit ampacity).
2.3 Lug adapters may be required if installation conditions dictate
that conductors be sized beyond the minimum ampacity
required. Circuit breaker lugs will accommodate the quantity
(#) and size cables (per phase) as follows.
VFD
MAX INPUT
AMPS
442A
608A
900A
1200A
WARNING
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
(PER PHASE)
(PER PHASE)
No. of
Conductor
No. of
Conductor
Conductors
Range
Conductors
Range
3
3/0 — 500MCM
2
400 — 500MCM
3
3/0 — 500MCM
3
3/0 — 400MCM
4
500 — 1000MCM
4
500 — 1000MCM
4
500 — 1000MCM
4
500 — 1000MCM
149
POWER
PANEL
OIL PUMP
INTERLOCK
OIL PUMP
INTERLOCK
TB4-1
SEE
NOTE 3.6
a19-1950
Fig. 61 — 19XRV Field Wiring — Standard Tier VFD
150
a19-1951
Fig. 61 — 19XRV Field Wiring — Standard Tier VFD (cont)
151
LEGEND FOR FIG. 61
REFERENCE
NUMBER
1
2
A
B
C
D
E
F
G
H
J
K
L
M
N
P
EXPLANATION
3 Phase Under/Over Voltage (Line Side)
Phase Loss/Imbalance/Reversal (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 (3KVA)
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
152
NOTES FOR FIG. 61
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.
1.7 All field-installed wiring is field-supplied.
2.4 Compressor motor and controls must be grounded by using
equipment grounding lug provided inside unit-mounted VFD
enclosure.
III Control Wiring
3.0 Field-supplied control conductors to be at least 18 AWG
(American Wire Gage) or larger.
3.1 Ice build start/terminate device contacts, remote start/stop
device contacts and spare safety device contacts (devices
not supplied by Carrier) must have 24 vac rating. Max current
is 60 mA, nominal current is 10 mA. Switches with goldplated bifurcated contacts are recommended.
3.2 Remove jumper wire between TB1-19 and TB1-20 before
connecting auxiliary safeties between these terminals.
3.3 Each integrated contact output can control loads (VA) for
evaporator pump, condenser pump, tower fan low, tower fan
high and alarm annunciator devices rated 5 amps at 115 vac
and up to 3 amps at 250 vac.
CAUTION
II Power Wiring To VFD
2.0 Provide a means of disconnecting branch feeder power to
VFD. Provide short circuit protection and interrupt capacity for
branch feeder in compliance with all applicable codes.
2.1 Metal conduit must be used for the power wires, from VFD to
branch feeder.
2.2 Line side power conductor rating must meet VFD nameplate
voltage and chiller full load amps (minimum circuit ampacity).
2.3 Lug adapters may be required if installation conditions dictate
that conductors be sized beyond the minimum ampacity
required. Circuit breaker lugs will accommodate the quantity
(#) and size cables (per phase) as follows.
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 4-20 mA output signal is designed for controllers with a
non-grounded 4-20 mA input signal and a maximum input
impedance of 500 ohms.
STANDARD 65K AIC
OPTIONAL 100K AIC
LUG CAPACITY
LUG CAPACITY
VFD
(PER PHASE)
(PER PHASE)
MAX INPUT
AMPS
No. of
Conductor
No. of
Conductor
Conductors
Range
Conductors
Range
445A
3
3/0 — 500MCM
2
400 — 500MCM
685A
3
3/0 — 500MCM
3
3/0 — 400MCM
1500A
4
500 — 1000MCM
4
500 — 1000MCM
If larger lugs are required, they can be purchased from the
manufacturer of the circuit breaker. For larger lugs, refer to
PPS HH83RZ015 and PPS HH87LZ500.
153
154
—
—
—
—
—
4
LEGEND
Carrier Comfort Network® (CCN) Interface
Circuit Breakers
Control Panel Internal View
Chiller Control Module (CCM)
CCN Conduit Knockout
Factory Wiring
Field Wiring
5
5
3
1
WHT
2
1
RED
BLK
RED
BLK
WHT
19XRV CHILLERS
4
3
2
5
1
Fig. 62 — CCN Communication Wiring for Multiple Chillers (Typical)
NOTE: Field supplied terminal strip must be located in control panel.
1
2
3
4
5
a19-1744
RED
BLK
WHT
4
3
2
APPENDIX A — 19XRV LIQUIFLO™ 2 ICVC PARAMETER INDEX
PARAMETER
0% Actual Guide Vane Position
100% Actual Guide Vane Position
1st Current Alarm State
20mA Demand Limit Opt
2nd Current Alarm State
3rd Current Alarm State
4th Current Alarm State
5th Current Alarm State
Active Delta P
Active Delta T
Active Delta Tsat
Active Delta Tsat
Active Demand Limit
Active Region
Actual Guide Vane Pos
Actual Guide Vane Pos
Actual Guide Vane Pos
Actual Guide Vane Pos
Actual Guide Vane Position
Actual Guide Vane Position
Actual Superheat
Actual VFD Speed
Actual VFD Speed
Actual VFD Speed
Actual VFD Speed
Address
Alarm Configuration
ALARM HISTORY
Alarm Relay
Alarm Relay Test
Alarm Routing
ALERT HISTORY
Amps or kW Ramp %/Min.
Amps/kW Ramp
ATTACH TO NETWORK DEVICE
Auto Chilled Water Reset
Auto Demand Limit Input
Auto Restart Option
Average Line Current
Average Line Voltage
Average Load Current
Base Demand Limit
Baud Rate
Broadcast Option
Bus Number
Calc Evap Sat Temp
Calc Evap Sat Temp
Capacity Control
Capacity Control
CCM Pressure Transducers
CCM Temperature Thermistors
CCN
CCN Mode?
CCN Occupancy Config:
CCN Time Schedule
CCN Time Schedule (OCCPC03S)
Chill Water Pulldown/Min
Chilled Medium
Chilled Water Deadband
Chilled Water Delta P
Chilled Water Delta P
Chilled Water Delta P
MENU
SOFTKEY
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
STATUS
STATUS
SERVICE
STATUS
STATUS
SERVICE
SERVICE
SERVICE
STATUS
STATUS
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
STATUS
STATUS
SERVICE
SERVICE
SERVICE
STATUS
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
STATUS
STATUS
SERVICE
STATUS
STATUS
STATUS
SETPOINT
SERVICE
SERVICE
SERVICE
STATUS
STATUS
SERVICE
SERVICE
SERVICE
SERVICE
STATUS
SERVICE
SCHEDULE
SERVICE
STATUS
SERVICE
SERVICE
SERVICE
SERVICE
STATUS
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
GUIDE VANE CALIBRATION
GUIDE VANE CALIBRATION
CUR_ALARM
RAMP_DEM
CUR_ALARM
CUR_ALARM
CUR_ALARM
CUR_ALARM
HEAT_EX
HEAT_EX
SURGPREV
VPF_STAT
MAINSTAT
SURGPREV
CAPACITY
SURGPREV
STARTUP
COMPRESS
GUIDE VANE CALIBRATION
IGV & SRD ACTUATOR
OVERRIDE
CAPACITY
VFD_HIST
COMPRESS
POWER
ICVC CONFIGURATION
NET_OPT
CONTROL TEST
EQUIPMENT CONFIGURATION
MAINSTAT
DISCRETE OUTPUTS
NET_OPT
EQUIPMENT SERVICE
CONTROL ALGORITHM STATUS
RAMP_DEM
CAPACITY
CONTROL ALGORITHM STATUS
CONTROL ALGORITHM STATUS
CONTROL ALGORITHM STATUS
CONTROL ALGORITHM STATUS
CONTROL TEST
CONTROL TEST
CONTROL ALGORITHM STATUS
CONTROL ALGORITHM STATUS
CONTROL ALGORITHM STATUS
EQUIPMENT SERVICE
EQUIPMENT CONFIGURATION
CONTROL ALGORITHM STATUS
EQUIPMENT SERVICE
EQUIPMENT CONFIGURATION
EQUIPMENT CONFIGURATION
EQUIPMENT SERVICE
EQUIPMENT SERVICE
CONTROL TEST
CONTROL TEST
155
MAINSTAT
MAINSTAT
OPTIONS
POWER
POWER
POWER
SETPOINT
ICVC CONFIGURATION
NET_OPT
ICVC CONFIGURATION
HEAT_EX
VPF_STAT
CAPACITY
SETUP2
CONTROL TEST
CONTROL TEST
DEFAULT SCREEN
ICVC_PWD
NET_OPT
OCCP03S
OCCDEFCS
HEAT_EX
SETUP1
SETUP1
PRESSURE TRANSDUCERS
PUMPS
HEAT_EX
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
APPENDIX A — 19XRV LIQUIFLO™ 2 ICVC PARAMETER INDEX (cont)
PARAMETER







Chilled Water Delta T
Chilled Water Delta T
Chilled Water Flow
Chilled Water Flow
Chilled Water Pump
Chilled Water Pump
Chilled Water Temp
Chilled Water Temp
Chiller Fault State
Chiller Start/Stop
CHW Delta T->Full Reset
CHW Delta T->No Reset
CHW Setpt Reset Value
Commanded State
Common Sensor Option
Comp Discharge Alert
Comp Discharge Alert
Comp Discharge Temp
Comp Discharge Temp
Comp Discharge Temp
Comp Motor Frequency
Comp Motor Frequency
Comp Motor Frequency
Comp Motor Frequency
Comp Motor RPM
Comp Motor RPM
Comp Motor RPM
Comp Motor RPM
Comp Motor Temp Override
Comp Motor Temp Override
Comp Motor Winding Temp
Comp Motor Winding Temp
Comp Motor Winding Temp
Comp Thrust Brg Alert
Comp Thrust Brg Alert
Comp Thrust Brg Reset
Comp Thrust Brg Reset
Comp Thrust Brg Temp
Comp Thrust Brg Temp
Comp Thrust Brg Temp
Comp Thrust Brg Trip
Comp Thrust Brg Trip
Comp Thrust Lvg Oil Temp
Comp Thrust Lvg Oil Temp
Compressor 100% Speed
Compressor Ontime
Compressor Ontime
Cond Approach Alert
Cond Flow Delta P Cutout
Cond Hi Flow Alarm Option
Cond Hi Flow Delta P Limit
Cond Press Override
Cond Press Override
Condenser Approach
Condenser Freeze Point
Condenser High Pressure
Condenser Pressure
Condenser Pressure
Condenser Pressure
Condenser Refrig Temp
Condenser Refrig Temp
Condenser Refrigerant Temperature
312
MENU
SOFTKEY
STATUS
STATUS
SERVICE
STATUS
SERVICE
STATUS
SERVICE
STATUS
SERVICE
STATUS
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
STATUS
SERVICE
SERVICE
STATUS
STATUS
SERVICE
SERVICE
STATUS
STATUS
SERVICE
SERVICE
SERVICE
SERVICE
STATUS
SERVICE
SERVICE
SERVICE
STATUS
SERVICE
SERVICE
STATUS
SERVICE
SERVICE
SERVICE
STATUS
SERVICE
STATUS
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
STATUS
SERVICE
STATUS
SERVICE
SERVICE
STATUS
SERVICE
STATUS
TABLE
CONTROL TEST
CONTROL TEST
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
CONTROL ALGORITHM STATUS
CONTROL ALGORITHM STATUS
CONTROL ALGORITHM STATUS
CONTROL ALGORITHM STATUS
EQUIPMENT SERVICE
CONTROL ALGORITHM STATUS
CONTROL TEST
CONTROL ALGORITHM STATUS
EQUIPMENT SERVICE
CONTROL ALGORITHM STATUS
CONTROL ALGORITHM STATUS
CONTROL TEST
CONTROL ALGORITHM STATUS
EQUIPMENT SERVICE
CONTROL ALGORITHM STATUS
VFD CONFIG DATA
EQUIPMENT SERVICE
EQUIPMENT SERVICE
EQUIPMENT SERVICE
EQUIPMENT SERVICE
CONTROL ALGORITHM STATUS
EQUIPMENT SERVICE
EQUIPMENT SERVICE
CONTROL ALGORITHM STATUS
CONTROL TEST
CONTROL ALGORITHM STATUS
156
SCREEN NAME
HEAT_EX
VPF_STAT
PUMPS
STARTUP
PUMPS
STARTUP
WSMDEFME
MAINSTAT
VFD_HIST
MAINSTAT
TEMP_CTL
TEMP_CTL
WSMDEFME
WSMDEFME
LEADLAG
OVERRIDE
SETUP1
OVERRIDE
THERMISTORS
COMPRESS
CAPACITY
VFD_HIST
HEAT_EX
STARTUP
CAPACITY
VFD_HIST
POWER
STARTUP
OVERRIDE
SETUP1
OVERRIDE
THERMISTORS
COMPRESS
OVERRIDE
SETUP1
OVERRIDE
COMPRESS
OVERRIDE
THERMISTORS
COMPRESS
OVERRIDE
SETUP1
OVERRIDE
COMPRESS
VFD_CONF
DEFAULT SCREEN
MAINSTAT
SETUP1
SETUP1
SETUP1
SETUP1
OVERRIDE
SETUP1
HEAT_EX
SETUP1
VFD_STAT
OVERRIDE
PRESSURE TRANSDUCERS
HEAT_EX
OVERRIDE
HEAT_EX
DEFAULT SCREEN
CONFIGURABLE
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
APPENDIX A — 19XRV LIQUIFLO™ 2 ICVC PARAMETER INDEX (cont)
PARAMETER
Condenser Water Delta P
Condenser Water Delta P
Condenser Water Delta P
Condenser Water Flow
Condenser Water Flow
Condenser Water Pump
Condenser Water Pump
CONSUME
Control Mode
Control Point
Control Point
Control Point
Control Point
Control Point Error
CONTROL TEST
Current CHW Setpoint
Current Date
Current Mode
Current Time
Date
Day of Week
Daylight Savings
DC Bus Voltage
DC Bus Voltage
DC Bus Voltage Reference
DC Bus Voltage Reference
Decrease Ramp Time
Degrees Reset
Degrees Reset At 20 mA
Delta P at 0% (4 mA)
Delta P at 100% (20 mA)
Demand Kilowatts
Demand Limit and kW Ramp
Demand Limit At 20 mA
Demand Limit Decrease
Demand Limit Inhibit
Demand Limit Prop Band
Demand Limit Source
Demand Watts Interval
Description
Device Name
Diffuser 25% Load Point
Diffuser 50% Load Point
Diffuser 75% Load Point
Diffuser Actuator
Diffuser Actuator
Diffuser Actuator
Diffuser Actuator
Diffuser Control
Diffuser Full Span mA
Diffuser Option
Disable Service Password
Discharge Pressure
Discrete Outputs Control Test
ECW Control Option
ECW Delta T
ECW Reset
ECW Setpoint
Emergency Stop
Enable Reset Type
Entering Chilled Water
Entering Chilled Water
MENU
SOFTKEY
SERVICE
SERVICE
STATUS
STATUS
SERVICE
STATUS
SERVICE
SERVICE
STATUS
SERVICE
SERVICE
SETPOINT
STATUS
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
STATUS
SERVICE
STATUS
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
STATUS
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
STATUS
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
SETPOINT
STATUS
SERVICE
SERVICE
TABLE
SCREEN NAME
CONTROL TEST
CONTROL TEST
PRESSURE TRANSDUCERS
PUMPS
HEAT_EX
STARTUP
PUMPS
STARTUP
PUMPS
CONSUME
MAINSTAT
CAPACITY
TEMP_CTL
SETPOINT
MAINSTAT
CAPACITY
CONTROL TEST
CONTROL TEST
EQUIPMENT CONFIGURATION
CONTROL ALGORITHM STATUS
EQUIPMENT SERVICE
CONTROL ALGORITHM STATUS
CONTROL ALGORITHM STATUS
CONTROL ALGORITHM STATUS
EQUIPMENT CONFIGURATION
CONTROL ALGORITHM STATUS
CONTROL ALGORITHM STATUS
VFD CONFIG DATA
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
157
WSMDEFME
TIME AND DATE
LL_MAINT
TIME AND DATE
TIME AND DATE
TIME AND DATE
BRODEF
VFD_HIST
POWER
VFD_HIST
POWER
VFD_CONF
TEMP_CTL
TEMP_CTL
OPTIONS
OPTIONS
POWER
RAMP_DEM
RAMP_DEM
NET_OPT
CAPACITY
RAMP_DEM
RAMP_DEM
RAMP_DEM
ICVC CONFIGURATION
ICVC CONFIGURATION
SETUP2
SETUP2
SETUP2
CONTROL TEST
DIFFUSER ACTUATOR
IGV & SRD ACTUATOR
COMPRESS
SETUP2
SETUP2
SETUP2
ICVC_PWD
PRESSURE TRANSDUCERS
CONTROL TEST
TEMP_CTL
CAPACITY
CAPACITY
SETPOINT
MAINSTAT
TEMP_CTL
DEFAULT SCREEN
CAPACITY
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
X
X
APPENDIX A — 19XRV LIQUIFLO™ 2 ICVC PARAMETER INDEX (cont)
PARAMETER
MENU
SOFTKEY
SERVICE
STATUS
SERVICE
Entering Chilled Water
Entering Chilled Water
Entering Cond Water
Entering Condenser Water
Entering Condenser Water
STATUS
Equipment Status
SERVICE
Evap Approach Alert
SERVICE
Evap Flow Delta P Cutout
SERVICE
Evap Ref Override Temp
SERVICE
Evap Refrig Liquid Temp
STATUS
Evap Refrig Trippoint
SERVICE
Evap Saturation Temp
SERVICE
Evap Saturation Temp
STATUS
Evaporator Approach
STATUS
Evaporator Pressure
SERVICE
Evaporator Pressure
STATUS
Evaporator Refrig Temp
SERVICE
Evaporator Refrigerant Temperature
Flow Delta P Display
SERVICE
Flux Current
SERVICE
Flux Current
STATUS
Frequency Fault
STATUS
Ground Fault
STATUS
Ground Fault Current
SERVICE
Ground Fault Current
STATUS
Group Number
SERVICE
Guide Vane 25% Load Pt
SERVICE
Guide Vane 50% Load Pt
SERVICE
Guide Vane 75% Load Pt
SERVICE
Guide Vane Calibration
SERVICE
Guide Vane Control
SERVICE
Guide Vane Delta
SERVICE
Guide Vane Delta
SERVICE
Guide Vane Delta
STATUS
Guide Vane Travel Limit
SERVICE
Head Pressure Output Control Test
SERVICE
Head Pressure Reference
SERVICE
Head Pressure Reference
SERVICE
Head Pressure Reference
STATUS
HGBP Off Delta T
SERVICE
HGBP Off Delta T
SERVICE
HGBP On Delta T
SERVICE
HGBP On Delta T
SERVICE
HGBP/VFD Active
SERVICE
High DC Bus Voltage
STATUS
High Line Voltage
STATUS
Holiday
SERVICE
HOLIDAYS
SERVICE
Hot Gas Bypass Relay
SERVICE
Hot Gas Bypass Relay
STATUS
Hot Gas Bypass Relay
STATUS
Hot Gas Bypass Relay Test
SERVICE
Humidity Sensor Input
STATUS
Humidity Sensor Input
SERVICE
Ice Build Contact
STATUS
Ice Build Control
SERVICE
Ice Build Option
SERVICE
Ice Build Recycle
SERVICE
Ice Build Setpoint
SETPOINT
Ice Build Termination
SERVICE
Ice Build Time Schedule
SCHEDULE
Ice Build Time Schedule (OCCPC02S) SERVICE
TABLE
SCREEN NAME
CONTROL TEST
THERMISTORS
HEAT_EX
THERMISTORS
DEFAULT SCREEN
HEAT_EX
WSMDEFME
SETUP1
SETUP1
OVERRIDE
HEAT_EX
SETUP1
THERMISTORS
HEAT_EX
HEAT_EX
PRESSURE TRANSDUCERS
HEAT_EX
OVERRIDE
DEFAULT SCREEN
SETUP1
VFD_HIST
POWER
VFD_STAT
VFD_STAT
VFD_HIST
POWER
NET_OPT
SETUP2
SETUP2
SETUP2
CONTROL TEST
IGV & SRD ACTUATOR
CAPACITY
SURGPREV
COMPRESS
SETUP2
CONTROL TEST
OPTIONS
HEAD PRESSURE OUTPUT
HEAT_EX
SURGPREV
OPTIONS
SURGPREV
OPTIONS
SURGPREV
VFD_STAT
VFD_STAT
TIME AND DATE
HOLIDAYS
SURGPREV
HEAT_EX
VFP_STAT
DISCRETE OUTPUTS
POWER
PRESSURE TRANSDUCERS
MAINSTAT
OPTIONS
OPTIONS
OPTIONS
SETPOINT
OPTIONS
OCCP02S
OCCDEFCS
CONTROL TEST
CONTROL ALGORITHM STATUS
EQUIPMENT SERVICE
EQUIPMENT SERVICE
CONTROL ALGORITHM STATUS
EQUIPMENT SERVICE
CONTROL TEST
CONTROL TEST
CONTROL ALGORITHM STATUS
EQUIPMENT SERVICE
CONTROL ALGORITHM STATUS
CONTROL ALGORITHM STATUS
EQUIPMENT CONFIGURATION
EQUIPMENT SERVICE
EQUIPMENT SERVICE
EQUIPMENT SERVICE
CONTROL TEST
CONTROL ALGORITHM STATUS
CONTROL ALGORITHM STATUS
EQUIPMENT SERVICE
EQUIPMENT SERVICE
CONTROL TEST
CONTROL ALGORITHM STATUS
EQUIPMENT SERVICE
CONTROL ALGORITHM STATUS
EQUIPMENT SERVICE
CONTROL ALGORITHM STATUS
EQUIPMENT CONFIGURATION
CONTROL ALGORITHM STATUS
CONTROL TEST
CONTROL TEST
EQUIPMENT SERVICE
EQUIPMENT SERVICE
EQUIPMENT SERVICE
EQUIPMENT SERVICE
EQUIPMENT CONFIGURATION
158
CONFIGURABLE
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
APPENDIX A — 19XRV LIQUIFLO™ 2 ICVC PARAMETER INDEX (cont)
PARAMETER
ICVC CONFIGURATION
IGV & SRD Actuator
Incompatibility Fault
Increase Ramp Time
Inverter Overcurrent
Inverter Overload
Inverter Overtemp
Inverter Power Fault
Inverter PWM Frequency
Inverter Temp Override
Inverter Temp Override
Inverter Temperature
Inverter Temperature
Inverter Temperature
LAG % Capacity
LAG Address
LAG CHILLER: Mode
LAG Start Time
LAG START Timer
LAG Stop Time
LAG STOP Timer
LCW Reset
LCW Setpoint
LEAD CHILLER in Control
Lead Lag Control
Lead Lag Control
LEAD/LAG: Configuration
LEAD/LAG: Configuration
Leaving Chilled Water
Leaving Chilled Water
Leaving Chilled Water
Leaving Chilled Water
Leaving Cond Water
Leaving Condenser Water
Leaving Condenser Water
LID Language
Line Active Current
Line Active Current
Line Active Voltage
Line Active Voltage
Line Current % Imbalance
Line Current Imbal Time
Line Current Imbalance
Line Current Imbalance
Line Current Imbalance
Line Current Ph1 (R)
Line Current Ph1 (R)
Line Current Ph2 (S)
Line Current Ph2 (S)
Line Current Ph3 (T)
Line Current Ph3 (T)
Line Freq=60 Hz? (No=50)
Line Frequency
Line Frequency
Line Kilowatts
Line Phase Reversal
Line Power Factor
Line Power Factor
Line Reactive Current
Line Reactive Current
Line Reactive Voltage
Line Reactive Voltage
MENU
SOFTKEY
SERVICE
SERVICE
STATUS
SERVICE
STATUS
STATUS
STATUS
STATUS
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
STATUS
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
SETPOINT
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
STATUS
SERVICE
STATUS
SERVICE
SERVICE
STATUS
SERVICE
STATUS
SERVICE
SERVICE
SERVICE
STATUS
STATUS
SERVICE
STATUS
SERVICE
STATUS
SERVICE
STATUS
SERVICE
SERVICE
STATUS
STATUS
STATUS
SERVICE
STATUS
SERVICE
STATUS
SERVICE
STATUS
TABLE
VFD CONFIG DATA
VFD CONFIG DATA
CONTROL ALGORITHM STATUS
EQUIPMENT SERVICE
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 ALGORITHM STATUS
CONTROL ALGORITHM STATUS
EQUIPMENT SERVICE
CONTROL ALGORITHM STATUS
EQUIPMENT SERVICE
CONTROL ALGORITHM STATUS
CONTROL TEST
CONTROL TEST
CONTROL ALGORITHM STATUS
CONTROL ALGORITHM STATUS
VFD CONFIG DATA
VFD CONFIG DATA
CONTROL ALGORITHM STATUS
CONTROL ALGORITHM STATUS
CONTROL ALGORITHM STATUS
CONTROL ALGORITHM STATUS
VFD CONFIG DATA
CONTROL ALGORITHM STATUS
CONTROL ALGORITHM STATUS
CONTROL ALGORITHM STATUS
CONTROL ALGORITHM STATUS
159
SCREEN NAME
CONTROL TEST
VFD_STAT
VFD_CONF
VFD_STAT
POWER
VFD_STAT
VFD_STAT
VFD_CONF
OVERRIDE
SETUP1
OVERRIDE
VFD_HIST
POWER
LEADLAG
LEADLAG
LL_MAINT
LL_MAINT
LEADLAG
LL_MAINT
LEADLAG
CAPACITY
SETPOINT
LL_MAINT
LL_MAINT
LEADLAG
LL_MAINT
LEADLAG
DEFAULT SCREEN
CAPACITY
THERMISTORS
HEAT_EX
THERMISTORS
DEFAULT SCREEN
HEAT_EX
ICVC CONFIGURATION
VFD_HIST
POWER
VFD_HIST
POWER
VFD_CONF
VFD_CONF
VFD_HIST
POWER
VFD_STAT
VFD_HIST
POWER
VFD_HIST
POWER
VFD_HIST
POWER
VFD_CONF
VFD_HIST
POWER
POWER
VFD_STAT
VFD_HIST
POWER
VFD_HIST
POWER
VFD_HIST
POWER
CONFIGURABLE
X
X
X
X
X
X
X
X
X
X
X
X
X
APPENDIX A — 19XRV LIQUIFLO™ 2 ICVC PARAMETER INDEX (cont)
PARAMETER
Line Volt Imbalance Time
Line Voltage Imbalance
Line Voltage Imbalance
Line Voltage Imbalance
Line Voltage % Imbalance
Line Voltage Ph1 (RS)
Line Voltage Ph1 (RS)
Line Voltage Ph2 (ST)
Line Voltage Ph2 (ST)
Line Voltage Ph3 (TR)
Line Voltage Ph3 (TR)
Load Balance Option
Load Balance Option
Load Current Ph1 (U)
Load Current Ph1 (U)
Load Current Ph2 (V)
Load Current Ph2 (V)
Load Current Ph3 (W)
Load Current Ph3 (W)
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
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
MENU
SOFTKEY
SERVICE
SERVICE
STATUS
STATUS
SERVICE
SERVICE
STATUS
SERVICE
STATUS
SERVICE
STATUS
SERVICE
SERVICE
SERVICE
STATUS
SERVICE
STATUS
SERVICE
STATUS
SERVICE
SERVICE
SERVICE
SERVICE
TABLE
SCREEN NAME
CONFIGURABLE
VFD CONFIG DATA
CONTROL ALGORITHM STATUS
VFD_CONF
VFD_HIST
POWER
VFD_STAT
VFD_CONF
VFD_HIST
POWER
VFD_HIST
POWER
VFD_HIST
POWER
LL_MAINT
LEADLAG
VFD_HIST
POWER
VFD_HIST
POWER
VFD_HIST
POWER
LOADSHED
NET_OPT
LOADSHED
LOADSHED
DEFAULT SCREEN
ATTACH TO NETWORK DEVICE
OCCP01S
OCCDEFCS
X
VFD CONFIG DATA
CONTROL ALGORITHM STATUS
CONTROL ALGORITHM STATUS
CONTROL ALGORITHM STATUS
CONTROL ALGORITHM STATUS
EQUIPMENT SERVICE
CONTROL ALGORITHM STATUS
CONTROL ALGORITHM STATUS
CONTROL ALGORITHM STATUS
CONTROL ALGORITHM STATUS
EQUIPMENT CONFIGURATION
CONTROL ALGORITHM STATUS
CONTROL ALGORITHM STATUS
SERVICE
SCHEDULE
SERVICE
EQUIPMENT CONFIGURATION
SERVICE
STATUS
STATUS
SERVICE
EQUIPMENT CONFIGURATION
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
SERVICE CONTROL ALGORITHM STATUS
STATUS
STATUS
SERVICE CONTROL ALGORITHM STATUS
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
160
VFD_STAT
VFD_STAT
NET_OPT
OPTIONS
ICVC CONFIGURATION
VFD_STAT
VFD_CONF
VFD_CONF
POWER
VFD_STAT
VFD_HIST
POWER
POWER
VFD_CONF
VFD_CONF
VFD_CONF
VFD_CONF
VFD_HIST
POWER
VFD_STAT
VFD_HIST
POWER
VFD_CONF
VFD_CONF
OCCP01S
OCCP02S
OCCP03S
OCCDEFCS
OCCDEFCS
OCCDEFCS
MAINSTAT
COMPRESS
DISCRETE OUTPUTS
SETUP1
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
APPENDIX A — 19XRV LIQUIFLO™ 2 ICVC PARAMETER INDEX (cont)
PARAMETER
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
Override Decrease Active
Override Inhibit Active
Password (VFD CONFIG DATA)
Password (SERVICE)
Percent Line Current
Percent Line Current
Percent Line Current
Percent Line Kilowatts
Percent Line Kilowatts
Percent Line Voltage
Percent Load Current
Percent Motor Kilowatts
Pressure Transducers Control Test
PRESTART FAULT Time
PRESTART FAULT Timer
PRIMARY MESSAGE
Proportional Dec Band
Proportional ECW Gain
Proportional Inc Band
Pulldown Ramp Type:
Pulldown: Delta T / Min
Pulldown Time
Pulldown Timer
Pumpdown/Lockout Control Test
Pumpdown/Lockout Control Test
Pumps Control Test
Ramp Loading Active
Rated Line Amps
Rated Line Kilowatts
Rated Line Voltage
Re-alarm Time
Recovery Start Request
Rectifier Overcurrent
Rectifier Overload
Rectifier Overtemp
Rectifier Power Fault
Rectifier Temp Override
Rectifier Temp Override
Rectifier Temperature
Rectifier Temperature
Rectifier Temperature
Recycle Control
Redline
Reference Number
Refrig Override Delta T
Refrigerant Leak Alarm mA
Refrigerant Leak Option
Relative Humidity
Relative Humidity
Remote Contacts Option
MENU
SOFTKEY
TABLE
SERVICE
SERVICE
SERVICE
STATUS
STATUS
SERVICE
STATUS
CONTROL TEST
CONTROL TEST
CONTROL TEST
SERVICE
STATUS
STATUS
SERVICE
SERVICE
SERVICE
SERVICE
CONTROL TEST
STATUS
STATUS
STATUS
STATUS
STATUS
STATUS
STATUS
SERVICE
SERVICE
SERVICE
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
SERVICE
SERVICE
STATUS
SERVICE
CONTROL TEST
CONTROL ALGORITHM STATUS
CONTROL ALGORITHM STATUS
CONTROL ALGORITHM STATUS
EQUIPMENT SERVICE
EQUIPMENT SERVICE
EQUIPMENT SERVICE
EQUIPMENT SERVICE
EQUIPMENT SERVICE
CONTROL ALGORITHM STATUS
CONTROL ALGORITHM STATUS
EQUIPMENT CONFIGURATION
CONTROL TEST
CONTROL ALGORITHM STATUS
VFD CONFIG DATA
VFD CONFIG DATA
VFD CONFIG DATA
EQUIPMENT CONFIGURATION
CONTROL ALGORITHM STATUS
CONTROL ALGORITHM STATUS
EQUIPMENT SERVICE
CONTROL ALGORITHM STATUS
CONTROL ALGORITHM STATUS
EQUIPMENT SERVICE
CONTROL ALGORITHM STATUS
EQUIPMENT SERVICE
EQUIPMENT SERVICE
EQUIPMENT SERVICE
CONTROL TEST
EQUIPMENT SERVICE
161
SCREEN NAME
DEFAULT SCREEN
PUMPS
PRESSURE TRANSDUCERS
PUMPS
COMPRESS
STARTUP
PUMPS
STARTUP
DEFAULT SCREEN
THERMISTORS
COMPRESS
STARTUP
SURGPREV
SURGPREV
VFD CONFIG DATA
ICVC CONFIGURATION
DEFAULT SCREEN
MAINSTAT
POWER
MAINSTAT
POWER
POWER
POWER
POWER
CONTROL TEST
LL_MAINT
LEADLAG
DEFAULT SCREEN
SETUP2
SETUP2
SETUP2
RAMP_DEM
LL_MAINT
LL_MAINT
LEADLAG
CONTROL TEST
CONTROL TEST
CONTROL TEST
SURGPREV
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
OPTIONS
OPTIONS
PRESSURE TRANSDUCERS
POWER
OPTIONS
CONFIGURABLE
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
APPENDIX A — 19XRV LIQUIFLO™ 2 ICVC PARAMETER INDEX (cont)
PARAMETER
Remote Reset Option
Remote Reset Sensor
Remote Reset Sensor
Remote Start Contact
Remote Temp->Full Reset
Remote Temp->No Reset
RESET
Reset Alarm?
RESET TYPE 1
RESET TYPE 2
RESET TYPE 3
Restart Delta T
Run Status
Run Status
RUNTIME
Schedule Number
SECONDARY MESSAGE
Serial Number
Service Ontime
Shunt Trip Relay
Shunt Trip Relay Test
Shutdown Delta T
Single Cycle Dropout
Single Cycle Dropout
Skip Frequency 1
Skip Frequency 2
Skip Frequency 3
Skip Frequency Band
Soft Stop Amps Threshold
Software Part Number
Spare Alert/Alarm Enable
Spare Safety Input
Spare Temp #1 Enable
Spare Temp #1 Limit
Spare Temp #2 Enable
Spare Temp #2 Limit
Spare Temperature 1
Spare Temperature 1
Spare Temperature 1
Spare Temperature 2
Spare Temperature 2
Spare Temperature 2
Speed Change In Effect
STANDBY % Capacity
STANDBY Address
STANDBY Chiller Option
STANDBY CHILLER: Mode
Start Acceleration Fault
Start Advance
Start Complete
Start Complete
Start Day of Week
Start Inhibit Timer
Start Month
Start Time
Start Week
Start/Stop
Starts In 12 Hours
Stop Back
Stop Complete
Stop Complete
Stop Day of Week
MENU
SOFTKEY
STATUS
SERVICE
STATUS
STATUS
SERVICE
SERVICE
STATUS
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
STATUS
SERVICE
SERVICE
SERVICE
STATUS
STATUS
SERVICE
SERVICE
STATUS
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
STATUS
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
STATUS
SERVICE
SERVICE
STATUS
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
STATUS
SERVICE
STATUS
STATUS
SERVICE
STATUS
SERVICE
SERVICE
SERVICE
SERVICE
STATUS
SERVICE
STATUS
STATUS
SERVICE
TABLE
CONTROL TEST
EQUIPMENT SERVICE
EQUIPMENT SERVICE
EQUIPMENT SERVICE
EQUIPMENT SERVICE
EQUIPMENT SERVICE
EQUIPMENT SERVICE
CONTROL ALGORITHM STATUS
EQUIPMENT CONFIGURATION
EQUIPMENT CONFIGURATION
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
CONTROL ALGORITHM STATUS
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
162
SCREEN NAME
CONFIGURABLE
ICVC_PWD
THERMISTORS
MAINSTAT
MAINSTAT
TEMP_CTL
TEMP_CTL
DEFAULT SCREEN
ICVC_PWD
TEMP_CTL
TEMP_CTL
TEMP_CTL
SETUP1
LL_MAINT
MAINSTAT
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
LL_MAINT
THERMISTORS
COMPRESS
LL_MAINT
THERMISTORS
COMPRESS
SURGPREV
LEADLAG
LEADLAG
LEADLAG
LL_MAINT
VFD_STAT
BRODEF
STARTUP
VFD_STAT
BRODEF
MAINSTAT
BRODEF
BRODEF
BRODEF
LL_MAINT
MAINSTAT
BRODEF
STARTUP
VFD_STAT
BRODEF
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
X
X
X
X
APPENDIX A — 19XRV LIQUIFLO™ 2 ICVC PARAMETER INDEX (cont)
PARAMETER







Stop Fault
Stop Month
Stop Time
Stop Week
Superheat Required
Surge Counts
Surge Delta % Amps
Surge / HGBP Deadband
Surge / HGBP Delta Ts max
Surge / HGBP Delta Ts max
Surge / HGBP Delta Ts min
Surge / HGBP Delta Ts min
Surge / HGBP IGV max
Surge / HGBP IGV max
Surge / HGBP IGV min
Surge / HGBP IGV min
Surge / Hot Gas Bypass
Surge Limit/HGBP Option
Surge Limit/HGBP Option
Surge Line Delta Tsat
Surge Line High Offset
Surge Line High Offset
Surge Line % Amps
Surge Line Shape Factor
Surge Line Shape Factor
Surge Line Speed Factor
Surge Prevention Active
Surge Prevention Active
Surge Prevention Active?
Surge Protection
Surge Protection Counts
Surge Protection Counts
Surge Time Period
Surge Time Period
System Alert/Alarm
Target Guide Vane Pos
Target Guide Vane Pos
Target Guide Vane Pos
Target VFD Speed
Target VFD Speed
Target VFD Speed
Target VFD Speed
Temp Pulldown Deg/Min.
Temperature Reset
Temperature Reset
Terminate Lockout
Thermistors Control Test
Thrust Brg Alert
Thrust Brg Reset
Thrust Brg Reset Factor
Thrust Brg Temp
Thrust Brg Trip
Thrust Lvg Oil Temp
Thrust Lvg Oil Temp
TIME AND DATE
Time Broadcast Enable
Torque Current
Torque Current
Total Compressor Starts
Total Error + Resets
Tower Fan High Setpoint
Tower Fan Relay High
MENU
SOFTKEY
STATUS
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
STATUS
SERVICE
STATUS
SERVICE
STATUS
SERVICE
STATUS
SERVICE
SERVICE
SERVICE
SERVICE
STATUS
STATUS
STATUS
SERVICE
STATUS
SERVICE
STATUS
STATUS
SERVICE
SERVICE
STATUS
SERVICE
SERVICE
STATUS
STATUS
SERVICE
SERVICE
STATUS
SERVICE
SERVICE
STATUS
STATUS
SERVICE
SERVICE
STATUS
SERVICE
SERVICE
SERVICE
STATUS
SERVICE
STATUS
SERVICE
SERVICE
STATUS
SERVICE
SERVICE
SERVICE
STATUS
STATUS
SERVICE
SETPOINT
STATUS
TABLE
EQUIPMENT CONFIGURATION
EQUIPMENT CONFIGURATION
EQUIPMENT CONFIGURATION
CONTROL ALGORITHM STATUS
CONTROL ALGORITHM STATUS
EQUIPMENT SERVICE
EQUIPMENT SERVICE
EQUIPMENT SERVICE
EQUIPMENT SERVICE
EQUIPMENT SERVICE
EQUIPMENT SERVICE
EQUIPMENT SERVICE
CONTROL ALGORITHM STATUS
EQUIPMENT SERVICE
CONTROL ALGORITHM STATUS
EQUIPMENT SERVICE
EQUIPMENT SERVICE
EQUIPMENT SERVICE
CONTROL ALGORITHM STATUS
EQUIPMENT SERVICE
CONTROL ALGORITHM STATUS
EQUIPMENT SERVICE
CONTROL ALGORITHM STATUS
CONTROL ALGORITHM STATUS
CONTROL ALGORITHM STATUS
CONTROL ALGORITHM STATUS
EQUIPMENT SERVICE
EQUIPMENT SERVICE
EQUIPMENT SERVICE
EQUIPMENT SERVICE
EQUIPMENT SERVICE
EQUIPMENT SERVICE
CONTROL ALGORITHM STATUS
EQUIPMENT CONFIGURATION
CONTROL ALGORITHM STATUS
CONTROL ALGORITHM STATUS
163
SCREEN NAME
VFD_STAT
BRODEF
BRODEF
BRODEF
OVERRIDE
SURGPREV
OPTIONS
OPTIONS
OPTIONS
VPF_STAT
OPTIONS
VPF_STAT
OPTIONS
VPF_STAT
OPTIONS
VPF_STAT
OPTIONS
SURGPREV
OPTIONS
SURGPREV
VPF_STAT
OPTIONS
VPF_STAT
OPTIONS
VPF_STAT
OPTIONS
HEAT_EX
VPF_STAT
SURGPREV
OPTIONS
COMPRESS
SURGPREV
OPTIONS
VPF_STAT
MAINSTAT
CAPACITY
SURGPREV
COMPRESS
CAPACITY
SURGPREV
COMPRESS
STARTUP
TEMP_CTL
TEMP_CTL
MAINSTAT
CONTROL TEST
CONTROL TEST
SETUP1
COMPRESS
SETUP1
COMPRESS
SETUP1
OVERRIDE
COMPRESS
TIME AND DATE
BRODEF
VFD_HIST
POWER
MAINSTAT
CAPACITY
SETPOINT
STARTUP
CONFIGURABLE
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
312
APPENDIX A — 19XRV LIQUIFLO™ 2 ICVC PARAMETER INDEX (cont)
PARAMETER
Tower Fan Relay High Test
Tower Fan Relay Low
Tower Fan Relay Low Test
Transducer Voltage Ref
US Imp / Metric
Values at Last Fault:
VFD Checksum Error
VFD Cold Plate Temp
VFD Cold Plate Temp
VFD Comm Fault
VFD CONFIG PASSWORD
VFD Coolant Flow
VFD Coolant Flow
VFD Coolant Solenoid Test
VFD Dewpoint
VFD ENCL Temp Correction
VFD Enclosure Temp
VFD Enclosure Temp
VFD Fault
VFD Fault Code
VFD Fault Code
VFD FAULT HISTORY
VFD Gain
VFD Gateway Version #
VFD Increase Step
VFD Inverter Version #
VFD Load Factor
VFD Maximum Speed
VFD Minimum Speed
VFD Overload Decrease
VFD Overload Delta
VFD Power On Reset
VFD Rampdown Active
VFD Rectifier Version #
VFD Speed Control
VFD Speed Factor
VFD Start
VFD Start Speed
VFD Start Inhibit
VFD Surge Line Gain
Water Flow Verify Time
WSM Active?
MENU
SOFTKEY
SERVICE
STATUS
SERVICE
SERVICE
SERVICE
SERVICE
STATUS
SERVICE
STATUS
STATUS
SERVICE
STATUS
STATUS
SERVICE
STATUS
SERVICE
SERVICE
STATUS
STATUS
SERVICE
STATUS
SERVICE
SERVICE
STATUS
SERVICE
STATUS
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
STATUS
SERVICE
STATUS
SERVICE
SERVICE
STATUS
SERVICE
STATUS
SERVICE
SERVICE
SERVICE
TABLE
SCREEN NAME
CONFIGURABLE
CONTROL TEST
DISCRETE OUTPUTS
STARTUP
DISCRETE OUTPUTS
PRESSURE TRANSDUCERS
ICVC CONFIGURATION
VFD_HIST
VFD_STAT
VFD_HIST
POWER
VFD_STAT
VFD CONFIG DATA
HEAT_EX
POWER
DISCRETE OUTPUTS
POWER
SETUP2
VFD_HIST
POWER
VFD_STAT
VFD_HIST
VFD_STAT
VFD_HIST
SETUP2
VFD_STAT
SETUP2
VFD_STAT
SURGPREV
SETUP2
SETUP2
RAMP_DEM
RAMP_DEM
VFD_STAT
SURGPREV
VFD_STAT
SETUP2
SURGPREV
STARTUP
SETUP2
VFD_STAT
SETUP2
SETUP1
WSMDEFME
X
CONTROL TEST
CONTROL TEST
CONTROL ALGORITHM STATUS
CONTROL ALGORITHM STATUS
CONTROL TEST
EQUIPMENT SERVICE
CONTROL ALGORITHM STATUS
CONTROL ALGORITHM STATUS
CONTROL ALGORITHM STATUS
EQUIPMENT SERVICE
EQUIPMENT SERVICE
CONTROL ALGORITHM STATUS
EQUIPMENT SERVICE
EQUIPMENT SERVICE
EQUIPMENT SERVICE
EQUIPMENT SERVICE
CONTROL ALGORITHM STATUS
EQUIPMENT SERVICE
CONTROL ALGORITHM STATUS
EQUIPMENT SERVICE
EQUIPMENT SERVICE
EQUIPMENT SERVICE
CONTROL ALGORITHM STATUS
164
X
X
X
X
X
X
X
X
X
X
X
X
X
X
19XR Lead Lag Schematic Series Cooler Flow
APPENDIX B — LEAD/LAG WIRING
a19-1655
165
19XR Lead Lag Schematic Parallel Cooler Flow
APPENDIX B — LEAD/LAG WIRING (cont)
a19-1717
166
APPENDIX C — MAINTENANCE SUMMARY AND LOG SHEETS
19XRV Maintenance Interval Requirements
WEEKLY
Compressor
Check Oil Level.
Controls
Review ICVC Alarm/Alert History.
Cooler
None.
Starter
None.
Condenser
None.
Oil Reclaim
None.
MONTHLY
Compressor
None.
Controls
Cooler
None.
Starter
Perform an Automated Controls test.
None.
Condenser
None.
Oil Reclaim
None.
FIRST YEAR

Compressor
Cooler
Condenser
Change oil filter. Send oil sample out for analysis. Change oil if required by analysis. Leak
test.
Inspect and clean cooler tubes. Inspect relief
valves. Leak test. Verify water pressure differential. Inspect water pumps and cooling
tower.
Replace refrigerant filter/drier. Inspect and
clean condenser tubes. Inspect relief valves.
Leak test. Verify water pressure differential.
Inspect water pumps and cooling tower.
Controls
Perform general cleaning. Tighten connections. Check
pressure transducers. Confirm accuracy of thermistors.
Starter
Perform general cleaning. Tighten connections. Change
VFD refrigerant strainer.
Oil Reclaim
Inspect oil sump strainer.
ANNUALLY

Compressor
Cooler
Condenser
Change oil filter. Send oil sample out for analysis. Change oil if required by analysis. Leak
test.
Inspect and clean cooler tubes. Inspect relief
valves. Leak test. Verify water pressure differential. Inspect water pumps and cooling
tower.
Replace refrigerant filter/drier. Inspect and
clean condenser tubes. Inspect relief valves.
Leak test. Verify water pressure differential.
Inspect water pumps and cooling tower.
Controls
Perform general cleaning. Tighten connections. Check
pressure transducers. Confirm accuracy of thermistors.
Starter
Perform general cleaning. Tighten connections. Change
VFD refrigerant strainer.
Oil Reclaim
None.
EVERY 3-5 YEARS
Compressor
Cooler
Condenser
None.
Perform eddy current test.
Inspect float valve and strainer. Perform eddy
current test.
Controls
None.
Starter
None.
Oil Reclaim
None.
EVERY 5 YEARS

Compressor
Cooler
Change oil charge (if required based on oil
analysis or if oil analysis has not been performed). Inspect compressor shafts and
bearings (every 5-10 years).
None.
Condenser
None.
Compressor
None.
Controls
None.
Starter
None.
Oil Reclaim
Inspect oil sump strainer. Inspect oil sump heater.
SEASONAL SHUTDOWN
Cooler
Condenser
Isolate and drain waterbox. Remove waterbox cover from one end. Use compressed air
to clear tubes.
Isolate and drain waterbox. Remove waterbox cover from one end. Use compressed air
to clear tubes.
Controls
Do not disconnect control power.
Starter
None.
Oil Reclaim
None.
NOTE: Equipment failures caused by lack of adherence to the Maintenance Interval Requirements are not covered under warranty.
167
312
APPENDIX C — MAINTENANCE SUMMARY AND LOG SHEETS
19XRV Weekly Maintenance Log
Plant ___________________________Machine Serial No. ________________________________
Machine Model No. ________________Refrigerant Type __________________________________
DATE
OIL LEVEL
CHECK ALARMS
/ FAULTS
OPERATOR
INITIALS
REMARKS
NOTE: Equipment failures caused by lack of adherence to the Maintenance Interval Requirements are not covered under warranty.
168
APPENDIX C — MAINTENANCE SUMMARY AND LOG SHEETS
19XRV Maintenance Log
Month
Date
Operator
UNIT SECTION
Compressor
Cooler
169
Condenser
Controls
Starter
Oil Reclaim
1
/
ACTION
Change Oil Charge
Change Oil Filter
Send Oil Sample Out for Analysis
Leak Test
Inspect Compressor Rotors
Bearing Inspection
Inspect Inlet Bearing Oil Orifice
Inspect & Clean Cooler Tubes
Inspect Relief Valves
Leak Test
Record Water Pressure Differential (PSI)
Inspect Water Pumps
Eddy Current Test
Leak Test
Inspect and Clean Condenser Tubes
Record Water Pressure Differential (PSI)
Inspect Water Pumps and Cooling Tower
Inspect Relief Valves
Replace Refrigerant Filter Drier
Inspect Float Valve and Strainer
Eddy Current Test
General Cleaning and Tightening Connections
Check Pressure Transducers
Confirm Accuracy of Thermistors
Perform Automated Controls Test
General Tightening and Cleaning Connections
Change VFD Refriferant Strainer
Inspect Oil Sump Strainer
Inspect Oil Sump Heater
2
/
UNIT
yes/no
yes/no
yes/no
ppm
yes/no
yes/no
yes/no
yes/no
yes/no
PPM
PSI
yes/no
yes/no
PPM
yes/no
PSI
yes/no
yes/no
yes/no
yes/no
yes/no
yes/no
yes/no
yes/no
yes/no
yes/no
yes/no
yes/no
yes/no
NOTE: Equipment failures caused by lack of adherence to the Maintenance Interval Requirements
are not covered under warranty.
/
3
/
/
4
/
/
5
/
/
6
/
/
7
/
/
ENTRY
8
/
/
9
/
/
/
10
/ /
11
/ /
12
/ /
APPENDIX C — MAINTENANCE SUMMARY AND LOG SHEETS
19XRV Seasonal Shutdown Log
Month
Date
Operator
UNIT SECTION
Cooler
Condenser
Controls
1
/
2
/
/
3
/
ACTION
Isolate and Drain Waterbox
Remove Waterbox Cover from One End
Use Compressed Air to Clean Tubes
Isolate and Drain Waterbox
Remove Waterbox Cover from One End
Use Compressed Air to Clean Tubes
Do Not Disconnect Control Power
NOTE: Equipment failures caused by lack of adherence to the Maintenance Interval Requirements
are not covered under warranty.
/
4
/
/
5
/
/
6
/
/
7
/
ENTRY
/
8
/
/
9
/
/
/
10
/ /
11
/ /
12
/ /
170
APPENDIX D — OPTIONAL BACNET COMMUNICATIONS WIRING
Optional BACnet* Communications Wiring —
6
5
7 8
2 34
5
6
10's
1
9 0
A48-8579
2 34
7 8
9 0
1
The following section is used to configure the UPC Open controller which is used when the BACnet communications option
is selected. The UPC Open controller is mounted in a separate
enclosure below the main control box.
TO ADDRESS THE UPC OPEN CONTROLLER — The
user must give the UPC Open controller an address that is
unique on the BACnet network. Perform the following procedure to assign an address:
1. If the UPC Open controller is powered, pull the screw terminal connector from the controller's power terminals labeled Gnd and HOT. The controller reads the address
each time power is applied to it.
2. Using the rotary switches (see Fig. A and B), set the controller's address. Set the Tens (10's) switch to the tens digit of the address, and set the Ones (1's) switch to the ones
digit.
As an example in Fig. B, if the controller’s address is 25,
point the arrow on the Tens (10's) switch to 2 and the arrow on
the Ones (1's) switch to 5.
1's
Fig. B — Address Rotary Switches
BACNET DEVICE INSTANCE ADDRESS — The UPC
Open controller also has a BACnet Device Instance address.
This Device Instance MUST be unique for the complete BACnet system in which the UPC Open controller is installed. The
Device Instance is auto generated by default and is derived by
adding the MAC address to the end of the Network Number.
The Network Number of a new UPC Open controller is 16101,
but it can be changed using i-Vu® Tools or BACView device.
By default, a MAC address of 20 will result in a Device Instance of 16101 + 20 which would be a Device Instance of
1610120.
BT485
TERMINATOR
BACNET
CONNECTION
(BAS PORT)
POWER LED
Tx1 LED
Rx1 LED
Tx2 LED
Rx2 LED
23
45
01
8
67 9
EIA-485
JUMPERS
01
8
67 9
23
45
BACNET
BAUD RATE
DIP SWITCHES
ADDRESS
ROTARY
SWITCHES
RUN LED
ERROR LED
Fig. A — UPC Open Controller
A48-8578
* Sponsored by ASHRAE (American Society of Heating, Refrigerating and Air Conditioning Engineers).
171
APPENDIX D — OPTIONAL BACNET COMMUNICATIONS WIRING (cont)
CONFIGURING THE BAS PORT FOR BACNET MS/
TP — Use the same baud rate and communication settings for
all controllers on the network segment. The UPC Open controller is fixed at 8 data bits, No Parity, and 1 Stop bit for this
protocol's communications.
If the UPC Open controller has been wired for power, pull
the screw terminal connector from the controller's power termiA48nals labeled Gnd and HOT. The controller reads the DIP
8580
Switches and jumpers each time power is applied to it.
Set the BAS Port DIP switch DS3 to “enable.” Set the BAS
Port DIP switch DS4 to “E1-485.” Set the BMS Protocol DIP
switches DS8 through DS5 to “MSTP.” See Table A.
Fig. C — DIP Switches
Table A — SW3 Protocol Switch Settings
for MS/TP
Wire the controllers on an MS/TP network segment in a daisy-chain configuration. Wire specifications for the cable are 22
DS8
DS7
DS6
DS5
DS4
DS3
AWG (American Wire Gage) or 24 AWG, low-capacitance,
Off
Off
Off
Off
On
Off
twisted, stranded, shielded copper wire. The maximum length
Verify that the EIA-485 jumpers below the CCN Port are set
is 2000 ft.
to EIA-485 and 2W.
Install a BT485 terminator on the first and last controller on
The example in Fig. C shows the BAS Port DIP Switches
a network segment to add bias and prevent signal distortions
set for 76.8k (Carrier default) and MS/TP.
due to echoing. See Fig. A, D, and E.
Set the BAS Port DIP Switches DS2 and DS1 for the approTo wire the UPC Open controller to the BAS network:
priate communications speed of the MS/TP network (9600,
1. Pull the screw terminal connector from the controller's
19.2k, 38.4k, or 76.8k bps). See Fig. C and Table B.
BAS Port.
Table B — Baud Selection Table
2. Check the communications wiring for shorts and
grounds.
BAUD RATE
DS2
DS1
3. Connect the communications wiring to the BAS port’s
9,600
Off
Off
screw terminals labeled Net +, Net -, and Shield.
19,200
On
Off
NOTE:
Use the same polarity throughout the network
38,400
Off
On
segment.
76,800
On
On
4. Insert the power screw terminal connector into the UPC
WIRING THE UPC OPEN CONTROLLER TO THE MS/
Open controller's power terminals if they are not currentTP NETWORK — The UPC Open controller communicates
ly connected.
using BACnet on an MS/TP network segment communications
5.
Verify
communication with the network by viewing a
at 9600 bps, 19.2 kbps, 38.4 kbps, or 76.8 kbps.
module status report. To perform a module status report
using the BACview keypad/display unit, press and hold
the “FN” key then press the “.” Key.
A48-8581
Fig. D — Network Wiring
172
APPENDIX D — OPTIONAL BACNET COMMUNICATIONS WIRING (cont)
A48-8582
Fig. E — BT485 Terminator Installation
To install a BT485 terminator, push the BT485 terminator
on to the BT485 connector located near the BACnet connector.
NOTE: The BT485 terminator has no polarity associated with
it.
To order a BT485 terminator, consult Commercial Products
i-Vu® Open Control System Master Prices.
MS/TP WIRING RECOMMENDATIONS — Recommendations are shown in Tables C and D. The wire jacket and UL
temperature rating specifications list two acceptable alternatives. The Halar specification has a higher temperature rating
and a tougher outer jacket than the SmokeGard specification,
and it is appropriate for use in applications where the user is
concerned about abrasion. The Halar jacket is also less likely to
crack in extremely low temperatures.
NOTE: Use the specified type of wire and cable for maximum
signal integrity.
Table C — MS/TP Wiring Recommendations
SPECIFICATION
Cable
Conductor
Insulation
Color Code
Twist Lay
Shielding
Jacket
DC Resistance
Capacitance
Characteristic Impedance
Weight
UL Temperature Rating
Voltage
Listing
AWG
CL2P
DC
FEP
NEC
O.D.
TC
UL
RECOMMMENDATION
Single twisted pair, low capacitance, CL2P, 22 AWG (7x30), TC foam FEP, plenum rated cable
22 or 24 AWG stranded copper (tin plated)
Foamed FEP 0.015 in. (0.381 mm) wall 0.060 in. (1.524 mm) O.D.
Black/White
2 in. (50.8 mm) lay on pair 6 twists/foot (20 twists/meter) nominal
Aluminum/Mylar shield with 24 AWG TC drain wire
SmokeGard Jacket (SmokeGard PVC) 0.021 in. (0.5334 mm) wall 0.175 in. (4.445 mm) O.D.
Halar Jacket (E-CTFE) 0.010 in. (0.254 mm) wall 0.144 in. (3.6576 mm) O.D.
15.2 Ohms/1000 feet (50 Ohms/km) nominal
12.5 pF/ft (41 pF/meter) nominal conductor to conductor
100 Ohms nominal
12 lb/1000 feet (17.9 kg/km)
SmokeGard 167°F (75°C)
Halar -40 to 302°F (-40 to 150°C)
300 Vac, power limited
UL: NEC CL2P, or better
LEGEND
— American Wire Gage
— Class 2 Plenum Cable
— Direct Current
— Fluorinated Ethylene Polymer
— National Electrical Code
— Outside Diameter
— Tinned Copper
— Underwriters Laboratories
173
APPENDIX D — OPTIONAL BACNET COMMUNICATIONS WIRING (cont)
Table D — Open System Wiring Specifications and Recommended Vendors
WIRING SPECIFICATIONS
Wire Type
RECOMMENDED VENDORS AND PART NUMBERS
Connect Air
Contractors
Belden RMCORP
International
Wire and Cable
Description
22 AWG, single twisted shielded pair, low capacitance, CL2P,
TC foam FEP, plenum rated. See MS/TP Installation Guide for
specifications.
MS/TP
Network (RS-485) 24 AWG, single twisted shielded pair, low capacitance, CL2P,
TC foam FEP, plenum rated. See MS/TP Installation Guide
for specifications.
Rnet
4 conductor, unshielded, CMP, 18 AWG, plenum rated.
AWG
CL2P
CMP
FEP
TC
W221P-22227
—
25160PV
CLP0520LC
W241P-2000F
82841
25120-OR
—
W184C-2099BLB
6302UE
21450
CLP0442
LEGEND
— American Wire Gage
— Class 2 Plenum Cable
— Communications Plenum Rated
— Fluorinated Ethylene Polymer
— Tinned Copper
LOCAL ACCESS TO THE UPC OPEN CONTROLLER — The user can use a BACview6 handheld keypad display unit or the Virtual BACview software as a local user interface to an Open controller. These items let the user access the
controller network information. These are accessory items and
do not come with the UPC Open controller.
The BACview6 unit connects to the local access port on the
UPC Open controller. See Fig. F. The BACview software must
be running on a laptop computer that is connected to the local
access port on the UPC Open controller. The laptop will require an additional USB link cable for connection.
See the BACview Installation and User Guide for instructions on connecting and using the BACview6 device.
To order a BACview6 Handheld (BV6H), consult Commercial Products i-Vu® Open Control System Master Prices.
CONFIGURING THE UPC OPEN CONTROLLER'S
PROPERTIES — The UPC Open device and ComfortLink
control must be set to the same CCN Address (Element) number and CCN Bus number. The factory default settings for
CCN Element and CCN Bus number are 1 and 0 respectively.
If modifications to the default Element and Bus number are
required, both the ComfortLink™ and UPC Open configurations must be changed.
The following configurations are used to set the CCN Address and Bus number in the ComfortLink control. These configurations can be changed using the scrolling marquee display
or accessory Navigator™ handheld device.
Configuration→CCN→CCN.A (CCN Address)
Configuration→CCN→CCN.B (CCN Bus Number)
The following configurations are used to set the CCN Address and Bus Number in the UPC Open controller. These configurations can be changed using the accessory BACview6
display.

Navigation: BACview→CCN
Home: Element Comm Stat
Element: 1
Bus: 0
TROUBLESHOOTING — If there are problems wiring or
addressing the UPC Open controller, contact Carrier Technical
Support.
A48-8583
Fig. F — BACview6 Device Connection
174
APPENDIX D — OPTIONAL BACNET COMMUNICATIONS WIRING (cont)
COMMUNICATION LEDS — The LEDs indicate if the
controller is communicating with the devices on the network.
IMPORTANT: Power must be ON to the UPC Open when
See Tables E and F. The LEDs should reflect communication
replacing the battery, or the date, time, and trend data will
traffic based on the baud rate set. The higher the baud rate the
be lost.
more solid the LEDs become. See Fig. 67 for location of LEDs
Remove the battery from the controller, making note of the
on UPC Open module.
battery's polarity. Insert the new battery, matching the battery's
REPLACING THE UPC OPEN BATTERY — The UPC
polarity with the polarity indicated on the UPC Open
Open controller's 10-year lithium CR2032 battery provides a
controller.
minimum of 10,000 hours of data retention during power
NETWORK POINTS LIST — The points list for the controloutages.
ler is shown in Table G.
Table E — LED Status Indicators
LED
Power
Rx
Tx
Run
Error
STATUS
Lights when power is being supplied to the controller. The UPC Open controller is protected by internal solid-state polyswitches on
the incoming power and network connections. These polyswitches are not replaceable and will reset themselves if the condition
that caused the fault returns to normal.
Lights when the controller receives data from the network segment; there is an Rx LED for Ports 1 and 2.
Lights when the controller transmits data to the network segment; there is an Tx LED for Ports 1 and 2.
Lights based on controller status. See Table F.
Lights based on controller status. See Table F.
Table F — Run and Error LEDs Controller and Network Status Indication
RUN LED
2 flashes per second
2 flashes per second
2 flashes per second
2 flashes per second
2 flashes per second
5 flashes per second
5 flashes per second
7 flashes per second
14 flashes per second
ERROR LED
Off
2 flashes, alternating with Run LED
3 flashes, then off
1 flash per second
On
On
Off
7 flashes per second, alternating with Run LED
14 flashes per second, alternating with Run LED
175
STATUS
Normal
Five minute auto-restart delay after system error
Controller has just been formatted
Controller is alone on the network
Exec halted after frequent system errors or control programs halted
Exec start-up aborted, Boot is running
Firmware transfer in progress, Boot is running
Ten second recovery period after brownout
Brownout
APPENDIX D — OPTIONAL BACNET COMMUNICATIONS WIRING (cont)
Table G — Network Points List
%
%
%
°F
^F
^F
^F
N/A
°F
N/A
°F
°F
°F
N/A
N/A
PSI
°F
PSI
°F
°F
%
%
%
N/A
DEFAULT
VALUE
N/A
N/A
N/A
N/A
N/A
1.0
N/A
N/A
OFF
N/A
STOP
N/A
N/A
N/A
NO
OFF
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
R
N/A
N/A
EMSTOP
R
N/A
ENABLE
ECW
ECDW
R
R
°F
°F
N/A
N/A
Equipment Alarm
N/A
R
N/A
N/A
Evaporator Pressure
Evaporator Refrigerant Temp
Leaving Chilled Water Prime Variable
Leaving Condenser Water
Line Active Current
Line Active Voltage
Line Frequency
Line Power Factor
Local Schedule
Occupied?
Oil Sump Temperature
Remote Start Contact
ERP
ERT
R
R
PSI
°F
N/A
N/A
ENABLE/
EMSTOP
-40 to 245
-40 to 245
Comm Normal
Comm Lost
-6.7 to 420
-40 to 245
LCW
R
°F
N/A
LCDW
AMPS_ACT
VOLT_ACT
LINEFREQ
LINE_PF
N/A
OCC
OILT
REM_CON
R
R
R
R
R
R
R
R
R/W
°F
A
V
Hz
N/A
N/A
°F
N/A
N/A
N/A
N/A
N/A
N/A
N/A
NO
N/A
OPEN
STATUS
R
N/A
N/A
POINT DESCRIPTION
1st Current Alarm State
Active Demand Limit
Actual Guide Vane Position
Actual VFD Speed
Calc Evap Sat Temp
Chilled Water Deadband
Chilled Water Delta P
Chilled Water Delta T
Chilled Water Pump
Chilled Water Temp
Chiller Start/Stop
Comp Discharge Temp
Comp Motor Winding Temp
Comp Thrust Brg Temp
Cond Water Flow
Cond Water Pump
Condenser Pressure
Condenser Refrig Temp
Condenser Water Delta P
Control Point
Current CHW Setpoint
Demand Level 1
Demand Level 2
Demand Level 3
Element Comm Status
Element Communications
Alarm
Emergency Stop
Entering Chilled Water
Entering Condenser Water
Run Status
CHW
R
VFD
W
CCN
POINT NAME
ALARM_01
DEM_LIM
GV_POS
VFD_ACT
EAT
CWDB
CHWPD
CHW_DT
CHLP
CHW_TMP
CHIL_S_S
CMPD
MTRW
MTRB
CDW_FLOW
CDP
CRP
CRT
CDWPD
LCW_STPT
CHWSTPT
N/A
N/A
N/A
N/A
READ/
WRITE
R
R/W
R
R
R
R
R
R
R
R
R/W
R
R
R
R
R
R
R
R
R/W
R
R
R
R
R
N/A
UNITS
LEGEND
— Chilled Water
— Read
— Variable Frequency Drive
— Write
176
0-270
40 to 100
0 to 100
0 to 110
-40 to 245
0.5 to 2.0
-6.7 to 420
-40 to 245
OFF/ON
-40 to 245
STOP/START
-40 to 245
-40 to 245
-40 to 245
NO/YES
OFF/ON
-6.7 to 420
-40 to 245
-6.7 to 420
10 to 120
0.00 to 99.9
0 to 100
0 to 100
0 to 100
No Comm/Normal
BACNET
OBJECT ID
AV:4
AV:6
AV:7
AV:11
AV:13
AV:14
AV:15
AV:16
BV:4
AV:17
BV:5
AV:18
AV:19
AV:20
BV:6
BV:7
AV:21
AV:22
AV:23
AV:24
AV:25
AV:1
AV:2
AV:3
BV:2999
BACNET
OBJECT NAME
alarm_01_1
dem_lim_1
gv_pos_1
vfd_act_1
ert_1
cwdb_1
chwpd_1
chw_dt_1
chlp_1
chw_tmp_1
chil_s_s_1
cmpd_1
mtrw_1
mtrb_1
cdw_flow_1
cdp_1
crp_1
crt_1
cdwpd_1
lcw_stpt_1
chwstpt_1
dmv_lvl_1_perct_1
dmv_lvl_2_perct_1
dmv_lvl_3_perct_1
element_stat_1
Inactive/Active
BV:20
comm_lost_alm_1
BV:8
emstop_1
AV:26
AV:27
ecw_1
ecdw_1
BV:1
element_alarm_1
AV:28
AV:13
erp_1
ert_1
-40 to 245
AV:31
lcw_1
-40 to 245
0.0 to 99999.0
0.0 to 99999.0
0 to 99
0.00 to 2.00
No Comm/Normal
NO/YES
-40 to 245
OPEN/CLOSE
0=Timeout,
1=Ready,
2=Recyle,
3=Startup,
4=Running,
5=Demand,
6=Ramping,
7=Autorest,
8=Override,
9=Tripout,
10=Control Test,
11=Lockout,
12=Pumpdown,
13=Prestart
AV:32
AV:8
AV:9
AV:30
AV:34
BV:2
BV:10
AV:33
BV:11
lcdw_1
amps_act_1
volt_act_1
linefreq_1
line_pf_1
schedule_1
occ_1
oilt_1
rem_con_1
AV:35
status_1
RANGE
APPENDIX D — OPTIONAL BACNET COMMUNICATIONS WIRING (cont)
Table G — Network Points List (cont)
Service Ontime
Surge Line Delta T
CCN
POINT NAME
S_HRS
DELTA_TX
READ/
WRITE
R/W
R
System Alert/Alarm
SYS_ALM
POINT DESCRIPTION
System Cooling Demand
Level
System Demand Limiting
Target Guide Vane Position
Target VFD Speed
Tower Fan Relay High
Tower Fan Relay Low
User Defined Analog 1
User Defined Analog 2
User Defined Analog 3
User Defined Analog 4
User Defined Analog 5
User Defined Binary 1
User Defined Binary 2
User Defined Binary 3
User Defined Binary 4
User Defined Binary 5
CHW
R
VFD
W
hr
°F
DEFAULT
VALUE
N/A
N/A
R
N/A
N/A
N/A
R
N/A
N/A
N/A
AV:9006
cool_demand_level_1
N/A
GV_TRG
VFD_OUT
TFR_HIGH
TFR_LOW
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
N/A
%
%
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
OFF
OFF
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
OFF/ON
0 to 100
0 to 100
OFF/ON
OFF/ON
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
BV:3
AV:41
AV:42
BV:13
BV:14
AV:2901
AV:2902
AV:2903
AV:2904
AV:2905
BV:2911
BV:2912
BV:2913
BV:2914
BV:2915
dem_lmt_act_1
gv_trg_1
vfd_out_1
tfr_high_1
tfr_low_1
user_analog_1_1
user_analog_2_1
user_analog_3_1
user_analog_4_1
user_analog_5_1
user_binary_1_1
user_binary_2_1
user_binary_3_1
user_binary_4_1
user_binary_5_1
UNITS
LEGEND
— Chilled Water
— Read
— Variable Frequency Drive
— Write
177
RANGE
0 to 32767
0 to 200
1=Normal,
2=Alert, 3=Alarm
BACNET
OBJECT ID
AV:36
AV:38
BACNET
OBJECT NAME
s_hrs_1
delta_tx_1
AV:40
sys_alm_1
INDEX
Abbreviations and explanations 4, 5
Adding refrigerant 84
Adjusting the refrigerant charge 84
After extended shutdown 79
After limited shutdown 79
Alarm (trip) output contacts 47
Attach to network device control 55
Automatic soft stop amps threshold 58
Auto. restart after power failure 49
Bearings 9
Before initial start-up 59-77
Capacity override 46
Carrier Comfort Network® interface 67
Changing oil filter 86
Charge refrigerant into chiller 74
Chilled water recycle mode 59
Chiller control module (CCM) 107
Chiller dehydration 65
Chiller familiarization 5-7
Chiller information nameplate 5
Chiller operating condition (check) 78
Chiller tightness (check) 60
Chillers with isolation valves 83
Chillers with storage tanks 81
Cold weather operation 79
Compressor bearing and gear maintenance
87
Compressor bearing temperature 46
Condenser 6
Condenser freeze prevention 48
Condenser pump control 48
Control algorithms checkout procedure 90
Control panel 6
Control modules 107
Control test 72, 91
Controls 15-57
Cooler 6
Default screen freeze 43
Definitions (controls) 15
Design set points, (input) 68
Details (lubrication cycle) 9
Display messages (check) 89
Equipment required 59
Evaporator freeze protection 48
Extended shutdown (preparation for) 79
Fast power source transfers 49
Gateway status LEDs 109
General (controls) 15
General maintenance 84, 85
Ground fault troubleshooting 67
Guide vane linkage (check) 85
Head pressure reference output 51
Heat exchanger tubes and 
flow devices (inspect) 87
High altitude locations 74
High discharge temperature control 46
Ice build control 54
ICVC operation and menus 19
Initial start-up 77, 78
Initial start-up checklist for 19XRV hermetic
centrifugal liquid chiller CL-1 to CL-12
Input power wiring 66
Inspect the control panel 86
Instruct the customer operator 78
Introduction 4
Job data required 59
Kilowatt output 48
Lead/lag control 51
Lead/lag wiring 165,166
Leak rate 84
Leak test chiller 62
Liquiflo™ ICVC parameter index 155-164
Local occupied schedule (input) 68
Local start-up 57
Lubrication cycle 9, 10
Lubrication system (check) 85
Maintenance summary and log sheets
167-170
Manual guide vane operation 79
Motor and lubricating oil cooling cycle 8
Motor-compressor 6
Motor rotation (check) 77
Notes on module operation 107
Oil changes 86
Oil charge 60
Oil cooler 46
Oil pressure and compressor stop (check)
78
Oil reclaim filter 86
Oil reclaim system 9
Oil specification 86
Oil sump temperature and pump control 46
Open oil circuit valves 59
Operating instructions 78-80
Operating the optional pumpout unit 81
Operator duties 78
Optional BACnet communications wiring
171-177
Optional pumpout compressor 
water piping (check) 65
Optional pumpout system controls and
compressor (check) 74
Optional pumpout system maintenance
Ordering replacement chiller parts 88
Overview (troubleshooting guide) 89
Perform a control test 72
Physical data 110
PIC III system components 15
PIC III system functions 40
Power up the controls and check 
the oil heater 67
Preparation (initial start-up) 77
Preparation (pumpout and refrigerant 
transfer procedures) 81
Prepare the chiller for start-up 78
Pressure transducers (check) 89
Prevent accidental start-up 78
Pumpout and refrigerant transfer 
procedures 81-84
Ramp loading 46
Rampdown 46
Recalibrate pressure transducers 88
Refrigerant filter 86
Refrigerant float system (inspect) 87
Refrigerant leak testing 84
Refrigerant properties 84
Refrigerant (removing) 84
Refrigerant tracer 62
Refrigeration cycle 8
Refrigeration log 79
Relief valves (check) 65
Relief valves and piping (inspect) 87
Remote reset of alarms 48
Remote start/stop controls 47
Repair the leak, retest, and
apply standing vacuum test 85
Replacing defective processor modules
Running system (check) 78
Safety and operating controls 
(check monthly) 86
Safety considerations 1
Safety controls 43
Safety shutdown 59
Scheduled maintenance 86-88
Service configurations (input) 68
Service ontime 86
Service operation 56
Shipping packaging (remove) 59
88
Shunt trip 43
Shutdown sequence 58
Software configuration 68
Spare safety and space temperature inputs
47
Standing vacuum test 62
Starting equipment 10-14
Start-up/shutdown/recycle sequence 57-59
Start the chiller 78
Stop the chiller 79
Storage vessel 6
Summary (lubrication cycle) 9
Surge prevention 49
Surge prevention algorithm 50
Surge protection 50
System components 6
Temperature sensors (check) 89
Test after service, repair, or major leak 84
Tighten all gasketed joints and 
guide vane packing 60
Tower fan relay low and high 48
Trim refrigerant charge 85
Troubleshooting guide 89-154
Unit-mounted VFD 10
Using the optional storage tank and 
pumpout system 59
Variable frequency drive 6
VFD cooling cycle 9
VFD (identify) 65
VFD (inspect) 88
VFD refrigerant strainer 87
VFD start-up speed control 51
Water/brine reset 49
Water leaks 87
Water piping (inspect) 65
Water treatment 88
Weekly maintenance 85
Wiring (inspect) 67
108
Copyright 2011 Carrier Corporation
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Catalog No. 04-53190015-01
Printed in U.S.A.
Form 19XRV-5SS
Pg 178
312
12-11
Replaces: 19XRV-2SS
INITIAL START-UP CHECKLIST
FOR 19XRV HERMETIC CENTRIFUGAL LIQUID CHILLER
(Remove and use for job file.)
MACHINE INFORMATION:
NAME
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
******
CHILLER LINE SIDE:
OIL PUMP:
REFRIGERANT:
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.
START-UP TO BE PERFORMED IN ACCORDANCE WITH APPROPRIATE MACHINE START-UP INSTRUCTIONS
JOB DATA REQUIRED:
1. Machine Installation Instructions
Yes 
No 
2. Machine Assembly, Wiring and Piping Diagrams
Yes 
No 
3. Starting Equipment Details and Wiring Diagrams
Yes 
No 
4. Applicable Design Data (see above)
Yes 
No 
5. Diagrams and Instructions for Special Controls
Yes 
No 
INITIAL MACHINE PRESSURE:
YES
NO
Was Machine Tight?
If Not, Were Leaks Corrected?
Was Machine Dehydrated After Repairs?
CHECK OIL LEVEL AND RECORD:
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
RECORD PRESSURE DROPS:
CHARGE REFRIGERANT:
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.
Catalog No. 04-53190015-01
Printed in U.S.A.
Form 19XRV-5SS
Pg CL-1
312
12-11
Replaces: 19XRV-2SS
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
CONTROLS: SAFETY, OPERATING, ETC.
Perform Controls Test (Yes/No)
PIC III CAUTION
COMPRESSOR MOTOR AND CONTROL PANEL MUST BE PROPERLY AND INDIVIDUALLY Yes
CONNECTED BACK TO THE EARTH GROUND IN THE VFD (IN ACCORDANCE WITH CERTIFIED
DRAWINGS).
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 
*If yes, determine cause.
START MACHINE AND OPERATE. COMPLETE THE FOLLOWING:
A: Trim charge and record under Charge Refrigerant Into Chiller section on page 74.
B: Complete any remaining control calibration and record under Controls section (pages 15-57).
C: Take at least two sets of operational log readings and record.
D: After machine has been successfully run and set up, shut down and mark shutdown oil and refrigerant levels.
E: Give operating instructions to owner’s operating personnel. Hours Given:
Hours
F: Call your Carrier factory representative to report chiller start-up.
G: Register LiquiFlo2 VFD start-up at www.automation.rockwell.com/complete1/warp.
H: Return a copy of this checklist to the local Carrier Service office.
SIGNATURES:
CARRIER
TECHNICIAN
CUSTOMER
REPRESENTATIVE
DATE
DATE
CL-2
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -- - - - - - - - - - - - - - - - - - - CUT ALONG DOTTED LINE
CUT ALONG DOTTED LINE
INSPECT WIRING AND RECORD ELECTRICAL DATA:
RATINGS:
Motor Voltage
Motor RLA
Chiller LRA Rating
Actual Line Voltages: VFD
Oil Pump
Controls/Oil Heater
Verify 6-in. clearance surrounding all VFD enclosure louvers: Yes

No 
Visually inspect down through top of power module for debris: Yes

No 
VFD Manufacturer ___________________________
VFD Nameplate I.D. Number ___________________
VFD Serial Number __________________________
VFD Nameplate Input Rating ___________________
Mfd in _____________________________________
on ________________________________________
FIELD-INSTALLED VFDs ONLY:
Check continuity T1 to T1, etc. (Motor to VFD, disconnect motor leads T1, T2, T3.) Do not megger VFD; 
disconnect leads to motor and megger the leads.
19XRV PIC III SETPOINT TABLE CONFIGURATION SHEET
DESCRIPTION
Base Demand Limit
LCW Setpoint
ECW Setpoint
Ice Build Setpoint
Tower Fan High Setpoint
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)
Upload all control configuration tables via service tool?
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 
ICVC Software Part Number (See ICVC Configuration Screen):
ICVC Controller Identification (See ICVC Configuration Screen): BUS:
VFD Gateway Version Number (See VFD_STAT Screen):
VFD Inverter Version Number (See VFD_STAT Screen):
VFD Rectifier Version Number (See VFD_STAT Screen):
CL-3
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.
19XRV PIC III CCN TIME SCHEDULE CONFIGURATION SHEET OCCPC03S
Day Flag
M T W T F S
Period 1:
Period 2:
Period 3:
Period 4:
Period 5:
Period 6:
Period 7:
Period 8:
NOTE: Default setting is OCCUPIED 24 hours/day.
CL-4
S H
Occupied
Time
Unoccupied
Time
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -- - - - - - - - - - - - - - - - - - - CUT ALONG DOTTED LINE
CUT ALONG DOTTED LINE
19XRV PIC III LOCAL TIME SCHEDULE CONFIGURATION SHEET OCCPC01S
19XRV PIC III VFD_CONF TABLE CONFIGURATION SHEET
DESCRIPTION
Motor Nameplate Voltage
Compressor 100% Speed
Line Freq=60 Hz? (No=50)
* Rated Line Voltage
* Rated Line Amps
* Rated Line Kilowatts
* Motor Rated Load KW
* Motor Rated Load Amps
Motor Nameplate Amps
Motor Nameplate RPM
Motor Nameplate KW
Inverter PWM Frequency
(0=4 k Hz, 1=2 k Hz)
Skip Frequency 1
Skip Frequency 2
Skip Frequency 3
Skip Frequency Band
Line Voltage % Imbalance
Line Volt Imbalance Time
Line Current % Imbalance
Line Current Imbal Time
Motor Current % Imbalance
Motor Current Imbal Time
Increase Ramp Time
Decrease Ramp Time
Single Cycle Dropout
RANGE
346 to 480
45.0 to 62.0
0/1
346 to 600
10 to 1500
0 to 7200
0 to 7200
10 to 1500
10 to 1500
1500 to 3600
0 to 5600
UNITS
VOLTS
Hz
NO/YES
VOLTS
AMPS
kW
kW
AMPS
AMPS
kW
0/1
0.0 to 102.0
0.0 to 102.0
0.0 to 102.0
0.0 to 102.0
1 to 10
1 to 10
5 to 40
1 to 10
5 to 40
1 to 10
5 to 60
5 to 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
DESCRIPTION
Auto Restart Option
Remote Contacts Option
Soft Stop Amps Threshold
Surge / Hot Gas Bypass
Surge Limit/HGBP Option
Select: Surge=0, HGBP=1
Low Load HGBP=2
Minimum Load Point
Surge/HGBP Delta Tsmin
Surge/HGBP IGVmin
Full Load Point
Surge/HGBP Delta Tsmax
Surge/HGBP IGVmax
Surge Line Shape Factor
Surge Line Speed Factor
Surge Line High Offset
Surge/HGBP Deadband
RANGE
0/1
0/1
40 to 100
UNITS
DSABLE/ENABLE
DSABLE/ENABLE
%
0/1/2
DEFAULT
DSABLE
DSABLE
100
0
0.0 to 150.0
(0.0 to 83.3)
0.0 to 110.0
ˆF
(ˆC)
%
45
(25.0)
5.0
0.0 to 150.0
(0.0 to 83.3)
0.0 to 110.0
–1.000 to 0.000
0.00 to 3.00
0.1 to 3.0
(0.1 to 1.7)
0.5 to 3
(0.3 to 1.7)
ˆF
(ˆC)
%
ˆF
(ˆC)
ˆF
(ˆC)
70
(38.9)
5.0
–0.040
1.85
1.0
(0.6)
1.0
(0.6)
0.5 to 10.0
(0.3 to 5.6)
1.0 to 10.0
(0.3 to 5.6)
ˆF
(ˆC)
ˆF
(ˆC)
2.0
(1.1)
4.0
(2.2)
5 to 20
7 to 10
%
MIN
10
8
0/1
0 to 2
DSABLE/ENABLE
DSABLE
0
0/1
0/1
4 to 20
DSABLE/ENABLE
DSABLE/ENABLE
mA
DSABLE
DSABLE
20
20 to 85
(138 to 586)
20 to 85
(138 to 586)
0 to 100
PSI
(kPa)
PSI
(kPa)
%
25
(172)
50
(345)
0
Low Load HGBP
HGBP On Delta T
HGBP Off Delta T
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
Refrigerant Leak Option
Refrigerant Leak Alarm mA
Head Pressure Reference
Delta P at 0% (4mA)
Delta P at 100% (20mA)
Minimum Output
CL-6
VALUE
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -- - - - - - - - - - - - - - - - - - - CUT ALONG DOTTED LINE
CUT ALONG DOTTED LINE
19XRV PIC III OPTIONS TABLE CONFIGURATION SHEET
19XRV PIC III SETUP1 TABLE CONFIGURATION SHEET
DESCRIPTION
Comp Motor Temp Override
Cond Press Override
Rectifier Temp Override
Inverter Temp Override
Comp Discharge Alert
Comp Thrust Brg Alert
 Comp Thrust Brg Trip
 Thrust Brg Reset Factor
Chilled Medium
Chilled Water Deadband
Evap Refrig Trippoint
Refrig Override Delta T
Evap Approach Alert
Cond Approach Alert
Condenser Freeze Point
Flow Delta P Display
Evap Flow Delta P Cutout
Cond Flow Delta P Cutout
 Cond Hi Flow Delta P Limit
 Cond Hi Flow Alarm Option
Water Flow Verify Time
Oil Press Verify Time
Recycle Control
Restart Delta T
Shutdown Delta T
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)
160 to 185
(71 to 85)
1.0 to 3.0
UNITS
DEG F
(DEG C)
PSI
(kPa)
DEG F
(DEG C)
DEG F
(DEG C)
DEG F
(DEG C)
DEG F
(DEG C)
DEG F
(DEG C)
DEFAULT
200
(93)
125
(862)
160
(71)
160
(71)
200
(93)
175
(79)
185
(85)
1.4
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)
WATER/BRINE
ˆF
(ˆC)
DEG F
(DEG C)
ˆF
(ˆC)
ˆF
(ˆC)
ˆF
(ˆC)
DEG F
(DEG C)
WATER
1.0
(0.6)
33.0
(0.6)
3.0
(1.7)
5.0
(2.8)
6.0
(3.3)
34
(1.1)
0/1
0.5 to 50.0
(3.4 to 344.8)
0.5 to 50.0
(3.4 to 344.8)
0.5 to 50.0
(3.4 to 344.8)
0/1
0.5 to 5
15 to 300
DSABLE/ENABLE
PSI
(kPa)
PSI
(kPa)
PSI
(kPa)
DSABLE/ENABLE
MIN
SEC
DSABLE
5.0
(34.5)
5.0
(34.5)
50.0
(344.8)
DSABLE
5
40
2.0 to 10.0
(1.1 to 5.6)
0.5 to 4.0
(0.3 to 2.2)
DEG F
(DEG C)
DEG F
(DEG C)
5.0
(2.8)
1.0
(.0.6)
VALUE
Spare Alert/Alarm Enable
Disable=0, Lo=1/3, Hi=2/4
Spare Temp #1 Enable
Spare Temp #1 Limit
Spare Temp #2 Enable
Spare Temp #2 Limit
0 to 4
–40 to 245
(–40 to 118)
0 to 4
–40 to 245
(–40 to 118)
DEG F
(DEG C)
DEG F
(DEG C)
0
245
(118)
0
245
(118)
NOTE: No variables are available for CCN read operation. Forcing shall not be supported on service screens.
CL-7
312
DESCRIPTION
Capacity Control
Proportional Inc Band
Proportional DEC Band
Proportional ECW Gain
STATUS
UNITS
DEFAULT
2 to 10
2 to 10
1 to 3
Guide Vane Travel Limit
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
VFD Speed Control
VFD Gain
VFD Increase Step
VFD Minimum Speed
VFD Maximum Speed
VFD Start Speed
VFD Surge Line Gain
VFD Encl Temp Correction
0.1 to 1.5
1 to 5
65 to 100
90 to 100
65 to 100
2.0 to 3.5
-40 to 20.0
%
%
%
%
%
%
0.75
2
70
100
100
2.0
0.0
6.5
6.0
2.0
CL-8
VALUE
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -- - - - - - - - - - - - - - - - - - - CUT ALONG DOTTED LINE
CUT ALONG DOTTED LINE
19XRV PIC III SETUP2 TABLE CONFIGURATION SHEET
19XRV PIC III LEADLAG TABLE CONFIGURATION SHEET
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
PULLDOWN Timer
STANDBY Chiller Option
STANDBY% Capacity
STANDBY Address
RANGE
UNITS
0 to 3
0/1
0/1
25 to 75
1 to 236
2 to 60
2 to 60
2 to 30
1 to 30
0/1
25 to 75
1 to 236
DEFAULT
0
DSABLE/ENABLE
DSABLE/ENABLE
%
MIN
MIN
MIN
MIN
DSABLE/ENABLE
%
CL-9
DSABLE
DSABLE
50
92
10
10
5
2
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
VFD Overload Decrease
VFD Overload Delta
Demand Watts Interval
RANGE
UNITS
DEFAULT
0/1
1
0/1
0
5 to 20
3 to 15
40 to 100
0/1
25 to 50
3 to 15
5 to 60
%
%
DSABLE/ENABLE
%
%
MIN
VALUE
10
10
40
DSABLE
30
5
15
19XRV PIC III TEMP_CTL TABLE CONFIGURATION SHEET
DESCRIPTION
Control Point
ECW Control Option
Temp Pulldown Deg/Min
RANGE
UNITS
DEFAULT
0/1
2 to 10
(1.1 to 5.6)
DSABLE/ENABLE
ˆF
(ˆC)
DSABLE
3
(1.7)
–30 to 30
(–17 to 17)
ˆF (ˆC)
10
(6)
–40 to 245
(–40 to 118)
–40 to 245
(–40 to 118)
–30 to 30
(–17 to 17)
DEG F
(DEG C)
DEG F
(DEG C)
ˆF
(ˆC)
85
(29)
65
(18)
10
(6)
ˆF
(ˆC)
ˆF
(ˆC)
ˆF
(ˆC)
10
(6)
0
(0)
5
(3)
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
0 to 15 (0 to 8)
CHW Delta T -> Full Reset
0 to 15 (0 to 8)
Degrees Reset
–30 to 30
(–17 to 17)
Enable Reset Type
0 to 3
0
CL-10
VALUE
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -- - - - - - - - - - - - - - - - - - - CUT ALONG DOTTED LINE
CUT ALONG DOTTED LINE
19XRV PIC III RAMP_DEM TABLE CONFIGURATION SHEET
BROADCAST (BRODEF) CONFIGURATION SHEET
DESCRIPTION
Time Broadcast Enable
Daylight Savings
Start Month
Start Day of Week
Start Week
Start Time
Start Advance
Stop Month
Stop Day of Week
Stop Week
Stop Time
Stop Back
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
UNITS
HH:MM
MIN
MIN
CL-11
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
Copyright 2011 Carrier Corporation
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Catalog No. 04-53190015-01
Printed in U.S.A.
Form 19XRV-5SS
Pg CL-12
312
12-11
Replaces: 19XRV-2SS
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -- - - - - - - - - - - - - - - - - - - CUT ALONG DOTTED LINE
CUT ALONG DOTTED LINE
ICVC DISPLAY AND ALARM SHUTDOWN STATE RECORD SHEET