Carrier | 19XRV | Specifications | Carrier 19XRV Specifications

19XR,XRV
Hermetic Centrifugal Liquid Chillers
with PIC II 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.
RISK OF INJURY OR DEATH by electrocution. High voltage is
present on motor leads even though the motor is not running when a
solid-state or wye-delta mechanical starter is used. 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, starters, or oil heater until you are sure ALL POWER IS
OFF and no residual voltage can leak from capacitors or solid-state
components.
LOCK OPEN AND TAG electrical circuits during servicing. IF
WORK IS INTERRUPTED, confirm that all circuits are deenergized
before resuming work.
AVOID SPILLING liquid refrigerant on skin or getting it into the
eyes. USE SAFETY GOGGLES. Wash any spills from the skin with
soap and water. If 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 STARTER, TOWER FAN, OR PUMPS. Open the
disconnect ahead of the starter, tower fans, or pumps.
USE only repair or replacement parts that meet the code requirements
of the original equipment.
DO NOT VENT OR DRAIN waterboxes containing industrial brines,
liquid, gases, or semisolids 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. 04-53190010-01
Printed in U.S.A.
Form 19XR-6SS
Pg 1
312
7-11
Replaces: 19XR-5SS
CONTENTS
Page
• DIFFUSER CONTROL
• DEMAND LIMITING
• CHILLER TIMERS AND STARTS COUNTER
• OCCUPANCY SCHEDULE
Safety Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Pump and Fan Control . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Shunt Trip (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Function Loss Trip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Default Screen Freeze . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Ramp Loading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Rampdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Capacity Override . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
High Discharge Temperature Control . . . . . . . . . . . . 49
Compressor Bearing Temperature. . . . . . . . . . . . . . . 49
Oil Sump Temperature and Pump Control . . . . . . . 49
Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Remote Start/Stop Controls . . . . . . . . . . . . . . . . . . . . . 51
Spare Safety and Spare Temperature Inputs. . . . . 51
Alarm (Trip) Output Contacts . . . . . . . . . . . . . . . . . . . . 51
Refrigerant Leak Detector . . . . . . . . . . . . . . . . . . . . . . . 51
Kilowatt Output. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Remote Reset of Alarms. . . . . . . . . . . . . . . . . . . . . . . . . 51
Condenser Pump Control . . . . . . . . . . . . . . . . . . . . . . . 51
Condenser Freeze Prevention . . . . . . . . . . . . . . . . . . . 52
Evaporator Freeze Protection . . . . . . . . . . . . . . . . . . . 52
Tower Fan Relay Low and High . . . . . . . . . . . . . . . . . . 52
Auto. Restart After Power Failure. . . . . . . . . . . . . . . . 52
Fast Power Source Transfers . . . . . . . . . . . . . . . . . . . . 52
Water/Brine Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
• RESET TYPE 1
• RESET TYPE 2
• RESET TYPE 3
Demand Limit Control Option . . . . . . . . . . . . . . . . . . . 53
Surge Prevention — Constant Flow and
Variable Primary Flow (VPF). . . . . . . . . . . . . . . . . . . 53
• SURGE PREVENTION ALGORITHM
Hot Gas Bypass (Optional) Algorithm . . . . . . . . . . . 54
Surge Protection (Fixed Speed Chiller) . . . . . . . . . . 55
Surge Prevention Algorithm with VFD . . . . . . . . . . . 55
Surge Protection (VFD Chiller) . . . . . . . . . . . . . . . . . . 56
VFD Start-Up Speed Control. . . . . . . . . . . . . . . . . . . . . 56
Head Pressure Reference Output. . . . . . . . . . . . . . . . 56
Lead/Lag Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
• 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
• 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 . . . . . . . . . . . . . . . 60
• ATTACHING TO OTHER CCN MODULES
Service Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
• TO ACCESS THE SERVICE SCREENS
• TO LOG OUT OF NETWORK DEVICE
• TIME BROADCAST ENABLE
• HOLIDAY SCHEDULING
START-UP/SHUTDOWN/RECYCLE
SEQUENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62-64
Local Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Shutdown Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Automatic Soft Stop Amps Threshold . . . . . . . . . . . 64
Chilled Water Recycle Mode . . . . . . . . . . . . . . . . . . . . . 64
Page
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . 1
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4,5
ABBREVIATIONS AND EXPLANATIONS . . . . . . . . . . 5
CHILLER FAMILIARIZATION . . . . . . . . . . . . . . . . . . . . . . 5
Chiller Information Nameplate . . . . . . . . . . . . . . . . . . . . 5
System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Motor-Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Control Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Factory-Mounted Starter or Variable
Frequency Drive (Optional). . . . . . . . . . . . . . . . . . . . . 5
Storage Vessel (Optional) . . . . . . . . . . . . . . . . . . . . . . . . 5
REFRIGERATION CYCLE . . . . . . . . . . . . . . . . . . . . . . . . . 5
MOTOR AND OIL COOLING CYCLE. . . . . . . . . . . . . . . 8
VFD COOLING CYCLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
LUBRICATION CYCLE . . . . . . . . . . . . . . . . . . . . . . . . . . 8,9
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Details. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Oil Reclaim System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
• PRIMARY OIL RECOVERY MODE
• SECONDARY OIL RECOVERY METHOD
STARTING EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . 9-11
Unit-Mounted Solid-State Starter
(Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Unit-Mounted Wye-Delta Starter
(Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Unit-Mounted VFD (Optional) . . . . . . . . . . . . . . . . . . . . 11
CONTROLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-62
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
• ANALOG SIGNAL
• DISCRETE SIGNAL
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
PIC II System Components . . . . . . . . . . . . . . . . . . . . . . 14
• INTERNATIONAL CHILLER VISUAL
CONTROLLER (ICVC)
• INTEGRATED STARTER MODULE (ISM)
• CHILLER CONTROL MODULE (CCM)
• OIL HEATER CONTACTOR (1C)
• OIL PUMP CONTACTOR (2C)
• HOT GAS BYPASS CONTACTOR RELAY (3C)
(Optional)
• CONTROL TRANSFORMERS (T1, T2)
• SENSORS
ICVC Operation and Menus. . . . . . . . . . . . . . . . . . . . . . 17
• GENERAL
• MODES
• ALARMS AND ALERTS
• ICVC MENU ITEMS
• BASIC ICVC OPERATIONS
• TO VIEW STATUS
• OVERRIDE OPERATIONS
• TIME SCHEDULE OPERATION
• TO VIEW AND CHANGE SET POINTS
• SERVICE OPERATION
PIC II System Functions . . . . . . . . . . . . . . . . . . . . . . . . . 40
• ALARMS AND ALERTS
• ICVC MENU ITEMS
• BASIC ICVC OPERATIONS
• FLOW DETECTION
• CAPACITY CONTROL
• FIXED SPEED APPLICATIONS
• VARIABLE SPEED (VFD) APPLICATIONS
• ECW CONTROL OPTION
• CONTROL POINT DEADBAND
• PROPORTIONAL BANDS
2
CONTENTS (cont)
Page
Perform a Control Test . . . . . . . . . . . . . . . . . . . . . . . . . . 82
• GUIDE VANE CALIBRATION
• COOLER AND CONDENSER PRESSURE TRANSDUCER AND WATERSIDE FLOW DEVICE CALIBRATION
Check Optional Pumpout System
Controls and Compressor. . . . . . . . . . . . . . . . . . . . . 84
High Altitude Locations . . . . . . . . . . . . . . . . . . . . . . . . . 84
Charge Refrigerant Into Chiller . . . . . . . . . . . . . . . . . . 84
• CHILLER EQUALIZATION WITHOUT A
PUMPOUT UNIT
• CHILLER EQUALIZATION WITH
PUMPOUT UNIT
• TRIMMING REFRIGERANT CHARGE
INITIAL START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88,89
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Dry Run to Test Start-Up Sequence . . . . . . . . . . . . . 88
Check Motor Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Check Oil Pressure and Compressor Stop . . . . . . 88
To Prevent Accidental Start-Up. . . . . . . . . . . . . . . . . . 89
Check Chiller Operating Condition . . . . . . . . . . . . . . 89
Instruct the Customer Operator . . . . . . . . . . . . . . . . . 89
• COOLER-CONDENSER
• OPTIONAL PUMPOUT STORAGE TANK AND
PUMPOUT SYSTEM
• MOTOR COMPRESSOR ASSEMBLY
• MOTOR COMPRESSOR LUBRICATION
SYSTEM
• CONTROL SYSTEM
• AUXILIARY EQUIPMENT
• DESCRIBE CHILLER CYCLES
• REVIEW MAINTENANCE
• SAFETY DEVICES AND PROCEDURES
• CHECK OPERATOR KNOWLEDGE
• REVIEW THE START-UP, OPERATION, AND
MAINTENANCE MANUAL
OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . .89,90
Operator Duties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Prepare the Chiller for Start-Up . . . . . . . . . . . . . . . . . 89
To Start the Chiller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Check the Running System . . . . . . . . . . . . . . . . . . . . . 89
To Stop the Chiller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
After Limited Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . 90
Preparation for Extended Shutdown . . . . . . . . . . . . 90
After Extended Shutdown . . . . . . . . . . . . . . . . . . . . . . . 90
Cold Weather Operation. . . . . . . . . . . . . . . . . . . . . . . . . 90
Manual Guide Vane Operation. . . . . . . . . . . . . . . . . . . 90
Refrigeration Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
PUMPOUT AND REFRIGERANT TRANSFER
PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-95
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Operating the Optional Pumpout Unit . . . . . . . . . . . 92
• TO READ REFRIGERANT PRESSURES
• POSITIVE PRESSURE CHILLERS WITH STORAGE
TANKS
• CHILLERS WITH ISOLATION VALVES
• DISTILLING THE REFRIGERANT
GENERAL MAINTENANCE . . . . . . . . . . . . . . . . . . . .95,96
Refrigerant Properties . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Adding Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Removing Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Adjusting the Refrigerant Charge . . . . . . . . . . . . . . . 95
Refrigerant Leak Testing . . . . . . . . . . . . . . . . . . . . . . . . 95
Leak Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Test After Service, Repair, or Major Leak . . . . . . . . 95
• TESTING WITH REFRIGERANT TRACER
• TESTING WITHOUT REFRIGERANT TRACER
• TO PRESSURIZE WITH DRY NITROGEN
Page
Safety Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
BEFORE INITIAL START-UP . . . . . . . . . . . . . . . . . . 65-88
Job Data Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Equipment Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Using the Optional Storage Tank
and Pumpout System . . . . . . . . . . . . . . . . . . . . . . . . . 65
Remove Shipping Packaging . . . . . . . . . . . . . . . . . . . . 65
Open Oil Circuit Valves. . . . . . . . . . . . . . . . . . . . . . . . . . 65
Tighten All Gasketed Joints and
Guide Vane Shaft Packing. . . . . . . . . . . . . . . . . . . . . 65
Check Chiller Tightness . . . . . . . . . . . . . . . . . . . . . . . . . 65
Refrigerant Tracer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Leak Test Chiller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Standing Vacuum Test . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Chiller Dehydration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Inspect Water Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Check Optional Pumpout Compressor
Water Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Check Relief Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Inspect Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Carrier Comfort Network® Interface . . . . . . . . . . . . . 70
Check Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
• MECHANICAL STARTER
• BENSHAW, INC. RediStart MX3™
SOLID-STATE STARTER
• VFD STARTER
Oil Charge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Power Up the Controls and
Check the Oil Heater . . . . . . . . . . . . . . . . . . . . . . . . . . 71
• SOFTWARE VERSION
Software Configuration . . . . . . . . . . . . . . . . . . . . . . . . . 71
Input the Design Set Points . . . . . . . . . . . . . . . . . . . . . 71
Input the Local Occupied Schedule
(OCCPC01S) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Input Service Configurations. . . . . . . . . . . . . . . . . . . . 72
• 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 (ICVC Only)
• MODIFY CONTROLLER IDENTIFICATION
IF NECESSARY
• INPUT EQUIPMENT SERVICE PARAMETERS
IF NECESSARY
• CHANGE THE BENSHAW, INC., RediStart
MX3 SOFTWARE CONFIGURATION
IF NECESSARY
VFD Field Set Up and Verification . . . . . . . . . . . . . . . 74
• USING THE KEYPAD
• MONITOR MODE (Default Mode)
• PROGRAM MODE
• ACCESSING PASSWORD PROTECTED
PARAMETERS
• LABEL LOCATIONS
• DRIVE PROTECTION AND OTHER INCOMING
WIRING
• VFD CONTROL VERIFICATION (Non-Running)
• VFD CONTROL VERIFICATION (Running)
• MODIFY SURGE LINE CONFIGURATION POINTS
IF NECESSARY
• HAND CALCULATE VARIABLE PRIMARY FLOW
(VPF) SURGE PREVENTION CONFIGURATIONS
• CONFIGURE DIFFUSER CONTROL IF
NECESSARY
• MODIFY EQUIPMENT CONFIGURATION
IF NECESSARY
3
Page
APPENDIX B — LEAD/LAG WIRING . . . . . . . . 177,178
APPENDIX C — MAINTENANCE SUMMARY
AND LOG SHEETS . . . . . . . . . . . . . . . . . . . . . . . 179-181
APPENDIX D — OPTIONAL BACNET
COMMUNICATIONS WIRING. . . . . . . . . . . . . . 182-188
INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
INITIAL START-UP CHECKLIST FOR
19XR, XRV HERMETIC CENTRIFUGAL
LIQUID CHILLER . . . . . . . . . . . . . . . . . . . .CL-1 to CL-16
CONTENTS (cont)
Page
Repair the Leak, Retest, and Apply
Standing Vacuum Test . . . . . . . . . . . . . . . . . . . . . . . . 95
Checking Guide Vane Linkage. . . . . . . . . . . . . . . . . . . 95
Trim Refrigerant Charge . . . . . . . . . . . . . . . . . . . . . . . . . 96
WEEKLY MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . 96
Check the Lubrication System. . . . . . . . . . . . . . . . . . . 96
SCHEDULED MAINTENANCE. . . . . . . . . . . . . . . . . 96-99
Service Ontime . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Inspect the Control Panel. . . . . . . . . . . . . . . . . . . . . . . . 96
Check Safety and Operating Controls
Monthly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Changing Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Oil Specification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Oil Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
• TO CHANGE THE OIL
Refrigerant Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Oil Reclaim Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Inspect Refrigerant Float System. . . . . . . . . . . . . . . . 97
Inspect Relief Valves and Piping . . . . . . . . . . . . . . . . 97
Compressor Bearing and Gear
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Inspect the Heat Exchanger Tubes
and Flow Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
• COOLER AND OPTIONAL FLOW DEVICES
• CONDENSER AND OPTIONAL FLOW DEVICES
Water Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Water Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Inspect the Starting Equipment. . . . . . . . . . . . . . . . . . 98
Recalibrate Pressure Transducers. . . . . . . . . . . . . . . 99
Optional Pumpout System Maintenance . . . . . . . . . 99
• OPTIONAL PUMPOUT COMPRESSOR OIL
CHARGE
• OPTIONAL PUMPOUT SAFETY CONTROL
SETTINGS
Ordering Replacement Chiller Parts . . . . . . . . . . . . . 99
TROUBLESHOOTING GUIDE . . . . . . . . . . . . . . . . 99-165
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Checking Display Messages. . . . . . . . . . . . . . . . . . . . 100
Checking Temperature Sensors . . . . . . . . . . . . . . . . 100
• RESISTANCE CHECK
• VOLTAGE DROP
• CHECK SENSOR ACCURACY
• DUAL TEMPERATURE SENSORS
Checking Pressure Transducers. . . . . . . . . . . . . . . . 100
• TRANSDUCER REPLACEMENT
• COOLER AND CONDENSER PRESSURE TRANSDUCER AND OPTIONAL WATERSIDE FLOW
DEVICE CALIBRATION
Control Algorithms Checkout Procedure . . . . . . . 117
Control Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Control Modules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
• RED LED (Labeled as STAT)
• GREEN LED (Labeled as COM)
Notes on Module Operation . . . . . . . . . . . . . . . . . . . . 118
Chiller Control Module (CCM) . . . . . . . . . . . . . . . . . . 118
• INPUTS
• OUTPUTS
Integrated Starter Module . . . . . . . . . . . . . . . . . . . . . . 118
• INPUTS
• OUTPUTS
Replacing Defective Processor Modules . . . . . . . 120
• INSTALLATION
Solid-State Starters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
• TESTING SILICON CONTROL RECTIFIERS IN
BENSHAW, INC. SOLID-STATE STARTERS
• SCR REMOVAL/INSTALLATION
Physical Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
APPENDIX A — ICVC PARAMETER INDEX . .166-176
INTRODUCTION
Prior to initial start-up of the 19XR 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 startup, 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.
CAUTION
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 control center.
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.
CAUTION
Do NOT punch holes or drill into the top surface of the
VFD (variable frequency drive) enclosure for field wiring.
Knockouts are provided on the side of the VFD enclosure
for field wiring connections. The top panel of the enclosure
must be removable for servicing the power module.
CAUTION
PROVIDE MACHINE PROTECTION. Store machine
and starter indoors, protected from construction dirt and
moisture. Inspect under shipping tarps, bags or crates to be
sure water has not collected during transit. Keep protective
shipping covers in place until machine is ready for
installation.
4
Control Panel — The control panel is the user interface
CAUTION
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
• shows chiller operating condition and alarm shutdown
conditions
• records the total chiller operating hours
• sequences chiller start, stop, and recycle under microprocessor control
• displays status of motor starter
• provides access to other CCN (Carrier Comfort Network) devices and energy management systems
• Languages that may be pre-installed at factory include:
English, Chinese, Japanese, and Korean.
• International language translator (ILT) is available for
conversion of extended ASCII characters.
WHEN FLUSHING THE WATER SYSTEMS isolate the
chiller from the water circuits to prevent damage to the heat
exchanger tubes.
ABBREVIATIONS AND EXPLANATIONS
Frequently used abbreviations in this manual include:
CCM
CCN
CCW
CW
ECDW
ECW
EMS
HGBP
I/O
ICVC
ISM
LCD
LCDW
LCW
LED
OLTA
PIC II
RLA
SCR
SI
TXV
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
Integrated Starter Module
Liquid Crystal Display
Leaving Condenser Water
Leaving Chilled Water
Light-Emitting Diode
Overload Trip Amps
Product Integrated Controls II
Rated Load Amps
Silicon Controlled Rectifier
International System of Units
Thermostatic Expansion Valve
Variable Frequency Drive
Factory-Mounted Starter or Variable Frequency Drive (Optional) — The starter allows for the
proper start and disconnect of electrical energy for the compressor-motor, oil pump, oil heater, and control panel.
Storage Vessel (Optional) — There are 2 sizes of
storage vessels available. The vessels have double relief valves,
a magnetically-coupled dial-type refrigerant level gage, a 1-in.
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.
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.).
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 19XR unit is located
on the back of the ICVC.
REFRIGERATION CYCLE
The compressor continuously draws refrigerant vapor from
the cooler at a rate set by the amount of guide vane opening or
compressor speed (19XRV only). 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.
CHILLER FAMILIARIZATION (Fig. 1 and 2)
Chiller Information Nameplate — The information
nameplate is located on the right side of the chiller control
panel.
System Components — The components include the
cooler and condenser heat exchangers in separate vessels,
motor-compressor, lubrication package, control panel, and motor starter. 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 lo-
cated 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.
Motor-Compressor — This component maintains system temperature and pressure differences and moves the heatcarrying refrigerant from the cooler to the condenser.
5
Description
19XR — High Efficiency Hermetic
Centrifugal Liquid Chiller
19XRV — Ultra High Efficiency Variable Speed
Hermetic Centrifugal Liquid Chiller
Special Order Indicator
– — Standard
S — Special Order
Cooler Size
10-12 (Frame 1 XR)
15-17 (Frame 1 XR)
20-22 (Frame 2 XR)
30-32 (Frame 3 XR)
35-37 (Frame 3 XR)
40-42 (Frame 4 XR)
45-47 (Frame 4 XR)
50-54 (Frame 5 XR)
5A-5C (Frame 5 XR)*
55-59 (Frame 5 XR)
5F-5H (Frame 5 XR)*
5K-5R (Frame 5 XR)
5T-5Z (Frame 5 XR)
60-64 (Frame 6 XR)
6K-6R (Frame 6 XR)
65-69 (Frame 6 XR)
6T-6Z (Frame 6 XR)
70-74 (Frame 7 XR)
7K-7R (Frame 7 XR)
75-79 (Frame 7 XR)
7T-7Z (Frame 7 XR)
80-84 (Frame 8 XR)
8K-8R (Frame 8 XR)
85-89 (Frame 8 XR)
8T-8Z (Frame 8 XR)
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
10-12 (Frame 1 XR)
15-17 (Frame 1 XR)
20-22 (Frame 2 XR)
30-32 (Frame 3 XR)
35-37 (Frame 3 XR)
40-42 (Frame 4 XR)
45-47 (Frame 4 XR)
50-54 (Frame 5 XR)
55-59 (Frame 5 XR)
60-64 (Frame 6 XR)
65-69 (Frame 6 XR)
70-74 (Frame 7 XR)
75-79 (Frame 7 XR)
80-84 (Frame 8 XR)
85-89 (Frame 8 XR)
Motor Code
Compressor Code
(First Digit Indicates Compressor Frame Size)**
MODEL NUMBER NOMENCLATURE
a19-1940
27 10 Q
19843
Week of Year
Unique Number
Year of Manufacture
Place of Manufacture
a19-1969
SERIAL NUMBER BREAKDOWN
* Refer to 19XR, 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 19XR, 19XRV Computer Selection Program for motor code details.
Fig. 1 — 19XR,XRV Identification
6
FRONT VIEW
1
2
3
4
5
17
6
1
2
3
4
5
6
7
8
16
7
8
15 14
13
—
—
—
—
—
—
—
—
9 —
10 —
11
12
13
14
15
16
17
—
—
—
—
—
—
—
LEGEND
Guide Vane Actuator
Suction Elbow
International Chiller Visual Control (ICVC)
Chiller Identification Nameplate
Cooler, Auto Reset Relief Valves
Cooler Pressure Transducer
Condenser In/Out Temperature Thermistors
Optional Condenser Waterflow Device (ICVC
Inputs available)
Cooler In/Out Temperature Thermistors
Optional Cooler Waterflow Device (ICVC
Inputs available)
Refrigerant Charging Valve
Typical Flange Connection
Oil Drain Charging Valve
Oil Level Sight Glasses
Refrigerant Oil Cooler (Hidden)
Power Panel
Compressor Motor Housing
12
9
11
10
REAR VIEW
19
18
20 21
22
34
23
18
19
20
21
—
—
—
—
22
23
24
25
26
27
28
29
30
31
32
33
34
—
—
—
—
—
—
—
—
—
—
—
—
—
LEGEND
Condenser Auto. Reset Relief Valves
Starter Circuit Breaker
Solid-State Starter Control Display (Optional)
Unit-Mounted Starter (Optional)
Solid-State Starter Shown
Motor Sight Glass
Cooler Return-End Waterbox Cover
ASME Nameplate (One Hidden)
Typical Waterbox Drain Port
Condenser Return-End Waterbox Cover
Refrigerant Moisture/Flow Indicator
Refrigerant Filter/Drier
Liquid Line Isolation Valve (Optional)
Linear Float Valve Chamber
Vessel Take-Apart Connector
Discharge Isolation Valve (Optional)
Pumpout Valve
Condenser Pressure Transducer
24
33
32
31
30
29
28 27
26
25
24
Fig. 2 — Typical 19XR,XRV Components
7
MOTOR AND OIL COOLING CYCLE
VFD COOLING CYCLE
The motor and the lubricating oil are cooled by liquid refrigerant taken from the bottom of the condenser vessel (Fig. 3).
Refrigerant flow is maintained by the pressure differential that
exists due to compressor operation. After the refrigerant flows
past an isolation valve, an in-line filter, and a sight glass/moisture indicator, the flow is split between the motor cooling and
oil cooling systems.
Flow to the motor cooling system passes through an orifice
and into the motor. Once past the orifice, the refrigerant is directed over the motor by a spray nozzle. The refrigerant collects in the bottom of the motor casing and is then drained back
into the cooler through the motor refrigerant drain line. An orifice (in the motor shell) maintains a higher pressure in the motor shell than in the cooler. The motor is protected by a temperature sensor imbedded in the stator windings. An increase in
motor winding temperature past the motor override set point
overrides the temperature capacity control to hold, and if the
motor temperature rises 10 F (5.5 C) above this set point, the
PIC II controls close 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.
The unit-mounted variable frequency drive (VFD) is cooled
in a manner similar to the motor and 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).
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).
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
smaller babbitted thrust face, designed to handle counterthrust
forces.
For compressors equipped with hydrodynamic bearings, 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 compressors equipped with rolling element bearings,
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.
The oil pump suction is fed from the oil reservoir. An oil
pressure relief valve maintains 18 to 25 psid (124 to 172 kPad)
differential pressure in the system at the pump discharge. For
compressors equipped with rolling element bearings, a range of
18 to 40 psid (124 to 172 kPad) is normal. 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 95-99,
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 to 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 or on the bearing race if the compressor is equipped
with rolling element bearings. The oil then drains into the oil
reservoir at the base of the compressor. The PIC II (Product Integrated Control II) measures the temperature of the oil in the
sump and maintains the temperature during shutdown (see Oil
Sump Temperature and Pump Control section, page 49). This
temperature is read on the ICVC default screen.
During the chiller start-up, the PIC II 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 30 seconds to postlubricate after the compressor shuts down. The oil pump can
also be energized for testing purposes during a Control Test. If
the controls are subjected to a power failure, then the controls
will energize the pump for 30 seconds every 30 minutes until
the chiller is started.
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 II will shut down the compressor.
When the oil pump is not running and the oil heater remains
energized for 30 minutes, the oil pump will be started and will
run for 30 seconds to evenly distribute the heat in the oil
system.
There are three pump-filter configurations. The original
vane pump, in which the oil filter is contained in the pump
housing, followed by the vane pump with the oil filter being
external in the oil piping between the oil pump and the oil cooler. The third configuration is the gerotor pump, also with the
external oil filter.
A gerotor pump has two rotors, one is inside the other and
their center points are offset with respect to each other. This
type of pump provides a smooth continuous flow. It is also quieter than other designs.
The gerotor pump can be most easily identified by the external location of the oil pressure regulator. The regulator is located on the bottom of the pump pointing horizontally to the left.
See Fig. 5.
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.
STARTING EQUIPMENT
The 19XR chiller requires a motor starter to operate the centrifugal hermetic compressor motor, the oil pump, and various
auxiliary equipment. The starter is the main field wiring interface for the contractor.
See Carrier Specification Z-415 for specific starter requirements, Z-416 for free-standing VFD requirements and Z-417
for unit-mounted VFD requirements. All starters must meet
these specifications in order to properly start and satisfy mechanical safety requirements. Starters may be supplied as separate, free-standing units or may be mounted directly on the
chiller (unit mounted) for low voltage units only.
Typically three separate circuit breakers are inside the starter. This includes (1) the main compressor motor circuit breaker,
(2) a circuit breaker which provides power to chiller controls
and the oil heater (provided at 115 vac), and (3) a circuit breaker which provides power at line voltage to the oil pump. The
latter two are typically wired in parallel with the first so that
power is provided to those services when the main breaker is
open. The disconnect switch on the starter front cover is connected to the main breaker.
Bearings — The 19XR 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
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
FILTER
STRAINER
OIL
HEATER
OIL PUMP
MOTOR
EDUCTOR FILTER
ISOLATION
VALVE
SIGHT
GLASS
OIL SKIMMER
LINE
a19-1965
Fig. 4 — Lubrication System
1.
2.
3.
4.
5.
6.
7.
GERATOR OIL PUMP
ISOLATION VALVE
OIL PRESSURE REGULATOR VALVE
OIL SUMP PRESSURE TRANSDUCER
OIL SUMP DRAIN
BEARING TEMPERATURE SENSOR TERMINAL BLOCK
OIL HEATER
1
2
4
6
5
7
3
Fig. 5 — Gerotor Oil Pump
10
a19-1852
starter automatically connects the phase windings into a delta
configuration. Starter control, monitoring, and motor protection is provided by Carrier’s Integrated Starter Module (ISM)
except for Benshaw MX3™ wye-delta starters which do not
use an ISM.
WARNING
The main circuit breaker on the front of the starter disconnects the main motor power only. Power is still energized
for two other circuits. Two additional circuit breakers
inside of the starter must be turned off to disconnect power
to the oil pump, PIC II controls and the oil heater. Failure to
disconnect power will result in personal injury.
Unit-Mounted VFD (Optional) — The 19XRV unit
can be equipped with a variable frequency drive motor controller mounted on the unit. See Fig. 8 and 9. This VFD is used
with low voltage motors between 380 and 480 VAC. It reduces
the starting current inrush by controlling the voltage and frequency to the compressor motor. Once the motor has accelerated to start-up speed the PIC II 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 sections, pages 11 and 99.
There is a separate display located on some unit-mounted
VFDs. 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 right surface or inside of the drive has been
provided for verification of the specific job parameters. See
Initial Start-Up Checklist section for details.
Typically, three separate circuit breakers are inside the starter. This includes (1) the VFD circuit breaker, (2) a circuit
breaker which provides power to the chiller controls and the
the oil heater (provided at 115 vac), and (3) a circuit breaker
that provides power at the line voltage to the oil pump. The
controls, oil heater and oil pump circuit breakers are wired in
parallel with the VFD circuit breaker so that power can be provided to those services when the VFD circuit breaker is open.
All starters must include a Carrier control module called the
Integrated Starter Module (ISM), excluding the Benshaw solidstate and wye-delta MX3™ starters. This module controls and
monitors all aspects of the starter. See the Controls section (following) for additional ISM information. All starter replacement parts are supplied by the starter manufacturer excluding
the ISM (contact Carrier’s Replacement Component Division
[RCD]).
Unit-Mounted Solid-State Starter (Optional) —
The 19XR chiller may be equipped with a solid-state, reducedvoltage starter (Fig. 6 and 7). This starter’s primary function is
to provide on-off control of the compressor motor. This type of
starter reduces the peak starting torque, controls the motor inrush current, and decreases mechanical shock. This capability
is summed up by the phrase “soft starting.” The solid-state
starter is available as a 19XR option (factory supplied and installed). The solid-state starters manufacturer name is located
inside the starter access door.
A solid-state, reduced-voltage starter operates by reducing
the starting voltage. The starting torque of a motor at full voltage is typically 125% to 175% of the running torque. When the
voltage and the current are reduced at start-up, the starting
torque is reduced as well. The object is to reduce the starting
voltage to adjust the voltage necessary to develop the torque required to get the motor moving. The voltage is reduced by silicon controlled rectifiers (SCRs). The voltage and current are
then ramped up in a desired period of time. Once full voltage is
reached, a bypass contactor is energized to bypass the SCRs.
WARNING
The optional main VFD circuit breaker on the front of the
VFD enclosure disconnects the VFD only. Power is still
energized for the other circuits. Two more circuit breakers
inside the starter must be turned off to disconnect power to
the oil pump, PIC II controls, and oil heater. Failure to disconnect power will result in personal injury.
WARNING
When voltage is supplied to the solid-state circuitry (CB1
is closed), the heat sinks in the starter as well as the wires
leading to the motor and the motor terminal are at line voltage. Do not touch the heat sinks, power wiring, or motor
terminals while voltage is present or serious injury will
result.
The circuit breaker that supplies power to the oil pump and
the circuit breaker that supplies power to the oil heater and
chiller controls are wired in parallel with the main VFD circuit
breaker so that power is supplied to them if the disconnect is
open. Refer to wiring schematic in Physical data section.
Other than the unit-mounted starter or drive options discussed above, 19XR chillers may be provided with other alternatives such as free-standing low voltage or medium voltage
starters, or free-standing variable frequency drives. These are
usually specified in the original sales requisition. Features and
functionality included with these alternative starters are defined
in Carrier specifications such that operation with PIC II controls remains consistent.
There is a display on the front of the Benshaw, Inc., solidstate and wye-delta starters that is useful for troubleshooting
and starter checkout. The display indicates:
• line voltage
• control voltage status
• power indication
• proper phasing for rotation
• start circuit energized
• ground fault
• current unbalance
• run state
The starter is further explained in the Check Starter and
Troubleshooting Guide sections, pages 70 and 99.
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.)
Unit-Mounted Wye-Delta Starter (Optional) —
The 19XR chiller may be equipped with a wye-delta starter
mounted on the unit. This starter is used with low-voltage motors (under 600 v). It reduces the starting current inrush by connecting each phase of the motor windings into a wye configuration. This occurs during the starting period when the motor is
accelerating up to speed. Once the motor is up to speed, the
11
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 control center protects the
chiller by monitoring the digital and analog inputs and executing capacity overrides or safety shutdowns, if required.
General — The 19XR hermetic centrifugal liquid chiller
contains a microprocessor-based control center that monitors
and controls all operations of the chiller (see Fig. 10). The microprocessor control system matches the cooling capacity of
the chiller to the cooling load while providing state-of-the-art
chiller protection. The system controls cooling load within the
set point plus the deadband by sensing the leaving chilled water
or brine temperature and regulating the inlet guide vane via a
MAIN CIRCUIT
BREAKER
TERMINAL
STRIP
MX
BOARD
OPTIONAL
VOLT AND AMP
METERS AND
SELECTOR
SWITCHES
ME
METERS
SWITCHES
KEYPAD/
DISPLAY
Fig. 6 — Benshaw Solid-State Starter, Internal View
LOW VOLTAGE
ACCESS
DOOR
a19-1896
OPTIONAL ANALOG 3-PHASE
VOLTMETER AND AMMETER
SIDE SERVICE
ACCESS PANEL
AIR INTAKE
LOUVERS
VOLTMETER/
AMMETER
SELECTOR
SWITCHES
MOTOR
POWER
DISCONNECT
HANDLE
STARTER
ACCESS
DOOR
STARTER CONTROL
DISPLAY INTERFACE
Fig. 7 — Typical Starter External View (Solid-State Starter Shown)
12
a19-1854
SPEED
VOLTS
AMPS
Hz
RUNNING
AUTO
MAN
Forward
Reverse
REMOTE
JOG
AUTO
PROGRAM
RUN
JOB
Kw
TORQUE
FORWARD
REVERSE
Password
PROGRAM
SPEED
RUNNING
VOLTS
AMPS
Hz
REMOTE
JOG
AUTO
Kw
TORQUE
FORWARD
REVERSE
Password
PROGRAM
AUTO
MAN
Forward
Reverse
PROGRAM
RUN
JOB
ENTER
ENTER
OPTIONAL
METER
PACKAGE
MANUAL RESET
Fig. 8 — LiquiFlo I Variable Frequency Drive (VFD)
INTEGRATED
STARTER
MODULE (ISM)
DISCONNECT
SWITCH
INITIAL DC BUS
MEASUREMENT
POINT
+ DANGER HIGH VOLTAGE
SPEED
VOLTS
AMPS
Hz
RUNNING
REMOTE
JOG
AUTO
Kw
TORQUE
FORWARD
REVERSE
Password
PROGRAM
AUTO
MAN
Forward
Reverse
PROGRAM
RUN
JOB
ENTER
VFD
MODULE
OIL HEATER &
CONTROL CB
COMPRESSOR
MOTOR
DISCONNECT
a19-1964
Fig. 9 — LiquiFlo I Variable Frequency Drive (VFD) Starter Internal View
13
• power panel
— 115 v control voltage transformer primaries (may be
rewired to accomodate 230 vac)
— 115 vac power for oil heater and actuators (oil heaters
may be rewired to accomodate 230 vac)
— up to 575 v for oil pump power
• starter cabinet
— chiller power wiring (per job requirement)
PIC II System Components — The chiller control
system is called the PIC II (Product Integrated Control II). See
Table 1. The PIC II controls the operation of the chiller by
monitoring all operating conditions. The PIC II 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 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 II controls provide critical protection for the compressor motor and controls the motor starter.
INTERNATIONAL CHILLER VISUAL CONTROLLER
(ICVC) — The ICVC (International Chiller Visual Controller)
is a display/processor module. It incorporates all of the functions and operational features of the CVC, but it has been designed with more memory and processing power. The most noticeable difference is that it comes preprogrammed to display
all tables in the following optional character sets (languages):
English, Mandarin Chinese, Korean, and Japanese. The language selection appears at the bottom of the Service/ICVC
Configuration screen. Other languages can be translated and
downloaded in place of the Chinese, Korean and Japanese languages in the field using the ILT (International Language
Translator) utility software. English cannot be overwritten and
will always be resident in the ICVC. Note that ICVC software
is distinct from and not interchangeable with CVC software.
The ICVC may be distinguished from the CVC by viewing
the back of the plate on which the display is mounted. (Open
up the control panel door to view.)
Table 1 — Major PIC II Components and
Panel Locations
PIC II COMPONENT
Chiller Visual Controller (ICVC) and
Display
Integrated Starter Module (ISM)
Chiller Control Module (CCM)
Oil Heater Contactor (1C)
Oil Pump Contactor (2C)
Hot Gas Bypass Relay (3C) (Optional)
Control Transformers (T1, T2)
Temperature Sensors
Pressure Transducers
PANEL LOCATION
Control Panel
Starter Cabinet
Control Panel
Power Panel
Power Panel
Power Panel
Power Panel
See Fig. 2.
See Fig. 2 and
Table 2
The PIC II can interface with the Carrier Comfort Network® (CCN) if desired. It can communicate with other PIC I,
PIC II or PIC III equipped chillers and other CCN devices.
The PIC II consists of 3 modules housed inside 3 major
components. The component names and corresponding control
voltages are listed below (also see Table 1):
• control panel
— all extra low-voltage wiring (24 v or less)
CONTROLLER
COLOR OF
PLATE
CEPL NO.
(Hardware)
SOFTWARE
NO.
ICVC
Metallic
CEPL
130455-01
CESR
131294-0x
CVC
Black
CEPL
130286-0x
CESR
131158-0x
OTHER
MARKINGS
“PIC II” marking on back
of green circuit board
CESO
130045
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. 10 — 19XR,XRV Compressor Controls and Sensor Locations
14
stopping the compressor, condenser, chilled water pumps, tower fan, spare alarm contacts, and the shunt trip. The ISM monitors starter inputs such as line voltage, motor current, ground
fault, remote start contact, spare safety, condenser high pressure, oil pump interlock, starter 1M, and run contacts. It shuts
down the chiller if communications with the ICVC are lost.
The ISM can also act as the interface for PIC II to the VFD
controller.
The ISM module directly measures current and voltage for
each phase. Calculation of power factor, power in kilowatts,
and energy in kilowatt hours is performed by software in the
ISM for constant speed starters only. All of these values are
transmitted to the ICVC on the SIO (sensor input/output) communications bus. The ISM software also defines conditions for
transition for different starter types, and it integrates I2t in monitoring motor overload.
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, refrigerant leak sensor and motor kilowatt output.
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. See Fig. 11. To change the contrast of the
display, access the adjustment on the back of the ICVC. See
Fig. 11.
English is the default language.
Three other programmed languages are available as options:
Chinese
Japanese
Korean
NOTE: Pressing any one of the four softkey buttons will activate the backlight display without implementing a softkey
function.
INTEGRATED STARTER MODULE (ISM) — This module is located in the starter cabinet. This module initiates commands from the ICVC for starter functions such as starting and
CARRIER COMFORT
NETWORK (CCN)
INTERFACE
CONTROL PANEL
DISPLAY
(FRONT VIEW)
CONTROL POWER
CIRCUIT BREAKERS
(CB1,CB2)
CHILLER
VISUAL
CONTROLLER
(ICVC)
FRONT VIEW
CHILLER CONTROL
MODULE (CCM)
a19-1956
CONTROL PANEL INTERNAL VIEW
a19-1855
DIFFUSER
SCHEDULE
SETTINGS
(FRAME 5
COMPRESSOR
AND FRAME 4
WITH SPLIT RING
DIFFUSER ONLY)
a19-1897
Fig. 11 — Control Panel
15
SURGE/HGBP
PARAMETER
LABEL
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.
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 EVAPORATOR
REFRIGERANT TEMP (from the transducer). CONDENSER APPROACH is defined as CONDENSER REFRIGERANT TEMP (derived from condenser pressure) minus LEAVING CONDENSER WATER temperature. When the 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.
OIL HEATER CONTACTOR (1C) — This contactor is located in the power panel (Fig. 12) and operates the heater at either 115 or 230 v. It is controlled by the PIC II to maintain oil
temperature during chiller shutdown. Some 19XR chillers
shipped in 2002 were equipped with oil heaters powered by
line voltage. Refer to the control panel wiring schematic.
OIL PUMP CONTACTOR (2C) — This contactor is located
in the power panel. It operates all 200 to 575-v oil pumps.
The PIC II 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 II energizes
the relay during low load, high lift conditions.
CONTROL TRANSFORMERS (T1, T2) — These transformers convert incoming control voltage to 24 vac power for the 3
power panel contactor relays, CCM, and ICVC.
SENSORS — Three types of temperature sensors are used.
Figure 13 shows a typical temperature sensor for which
sensor wells are not used, in systems having an ICVC controller. For this type, the sensor cable can be easily disconnected
from the sensor, which is in direct contact with the fluid.
The other typical temperature sensor has sensor wells. See
Fig. 14. For this type, the sensor cable cannot be separated
from the sensor itself, but the sensor can be easily removed
from the well without breaking into the fluid boundry.
The third 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 2 for a list of standard instrumentation sensors.
The PIC II control determines refrigerant temperature in the
condenser and evaporator from pressure in those vessels, read
from the corresponding pressure transducers. See Fig. 14. 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
T1-24 VAC POWER TRANSFORMER
FOR HOT GAS BYPASS RELAY,
OIL PUMP CONTACTOR, AND
OIL HEATER CONTACTOR
Fig. 13 — Control Sensors (Temperature)
T2-24 VAC POWER TRANSFORMER
FOR ICVC AND CCM
a19-1856
T2
T1
3C HOT GAS BYPASS
RELAY (OPTIONAL)
51
1 3
50
12
13
OIL HEATER
CONTACTOR
21
22
23
11
12
13
OIL PUMP
CONTACTOR
21
22
2 4
17
5 6
11
43
23
C
B
A
CONTROL PANEL
POWER CONDUIT
OIL HEATER CONDUIT
Fig. 12 — Power Panel
16
OPTIONAL HOT GAS
BYPASS CONDUIT
Table 2 — Standard Instrumentation Sensors
TYPE
Temperature
Pressure
Angular Position
Pressure Switch
Temperature Switch
LOCATION MONITORED
REMARKS
Entering Chilled Water
Cooler Inlet Nozzle
Leaving Chilled Water
Cooler Outlet Nozzle
Entering Condenser Water
Condenser Inlet Nozzle
Leaving Condenser Water
Condenser Outlet Nozzle
Evaporator Saturation
Sensor Well on Bottom of Evaporator
Compressor Discharge
Compressor Volute
Oil Sump
Compressor Oil Sump
Compressor Thrust Bearing
Redundant Sensor Provided
Motor Winding
Redundant Sensor Provided
Evaporator
Relief Valve Tee
Condenser
Relief Valve Tee
Oil Sump
Compressor Oil Sump
Oil Pump Discharge
Oil Pump Discharge Line
Diffuser (Compressor Internal)
Only in Machines Equipped with Split Ring Diffusers
Entering Chilled Water (Optional)
Cooler Inlet Nozzle
Leaving Chilled Water(Optional)
Cooler Outlet Nozzle
Entering Condenser Water
Condenser Inlet Nozzle
Leaving Condenser Water
Condenser Outlet Nozzle
Guide Vane Actuator
Potentiometer Inside of Actuator
Split Ring Diffuser Actuator (only on split ring dif- Potentiometer Inside of the Actuator (Split Ring Diffuser Position is
fuser equipped machines)
not Displayed on the ICVC)
High Condenser (Discharge) Pressure
Wired into the Starter Control Circuit
Oil Pump Motor Winding Temperature
Wired into the Oil Pump Control Circuit
• CCN — In CCN mode the PIC II accepts input from any
CCN interface or module (with the proper authority) as
well as from the local ICVC. The PIC II uses the CCN
time occupancy schedule to determine start and stop
times. The PIC II 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 II control must be in this mode for certain
operations, such as performing a Control Test or accessing ISM Configuration parameters.
Force priority — The forces from various sources apply in an
order of priority. Any force can override a force with a lower
priority. The lowest priority belongs to the normal operating
control. A higher force cannot be overridden. For example, a
Service Tool force cannot be overridden by anything but a machine safety or fire alarm. See Table 4.
SHRINK WRAP
STRAIN RELIEF
1/8” NPT
THERMOWELL
REMOVABLE
TEMPERATURE
SENSOR
a23-1624
Fig. 14 — Temperature Sensor Used
with Thermal Well
PRIMARY STATUS
MESSAGE
ICVC Operation and Menus (Table 3 and
Fig. 15-21)
SECONDARY
STATUS
MESSAGE
GENERAL — The ICVC display automatically reverts to the
default screen after 15 minutes if no softkey activity takes place
and if the chiller is not in the pumpdown mode (Fig. 15).
If a screen other than the default screen is displayed on the
ICVC, the name of that screen is in the upper right corner
(Fig. 16).
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 61.
MODES
• LOCAL — In LOCAL mode the PIC II accepts commands from the ICVC only and uses the local time occupancy schedule to determine chiller start and stop times.
The PIC II 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.
ALARM LIGHT
(ILLUMINATED
WHEN POWER ON)
CONTINUOUSLY
• BLINKS
ON FOR AN ALARM
BLINKS
TO
• CONFIRMONCE
A STOP
COMPRESSOR
ON TIME
DATE
RUNNING TEMP CONTROL
LEAVING CHILLED WATER
CHW IN
CDW IN
44.1
CDW OUT
85.0
OIL PRESS
21.8
CCN
01-01-95 11:48
28.8 HOURS
CHW OUT
55.1
TIME
EVAP REF
40.7
COND REF
95.0
98.1
OIL TEMP
AMPS %
132.9
LOCAL
RESET
93
MENU
STOP BUTTON
FOR ONE
• HOLD
SECOND TO STOP
SOFT KEYS
EACH KEY'S FUNCTION IS
DEFINED BY THE MENU DESCRIPTION
ON MENU LINE ABOVE
Fig. 15 — ICVC Default Screen
17
MENU
LINE
19XR_II
BASIC ICVC OPERATIONS (Using the Softkeys) —
To perform any of the operations described below, the PIC II
must be powered up and have successfully completed its self
test.
• Press QUIT to leave the selected decision or field without saving any changes.
SERVICE
ALARM HISTORY
CONTROL TEST
CONTROL ALGORITHM STATUS
EQUIPMENT CONFIGURATION
ISM (STARTER) CONFIGURATION DATA
EQUIPMENT SERVICE
TIME AND DATE
ATTACH TO NETWORK DEVICE
LOG OUT OF DEVICE
ICVC CONFIGURATION
• Press ENTER to leave the selected decision or field and
save changes.
Fig. 16 — ICVC Service Screen
• Press NEXT to scroll the cursor bar down in order to
highlight a point or to view more points below the current screen.
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 control center 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.
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.
ICVC MENU ITEMS — To perform any of the operations
described below, the PIC II 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 .
• 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, ISM Starter
Configuration data, Equipment Service, Time and Date,
Attach to Network Device, Log Out of Network Device,
and ICVC Configuration screens.
For more information on the menu structures, refer to
Fig. 18.
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 then appear depend on the selected table or menu. The softkey choices and
their functions are described below.
• Press PREVIOUS to scroll the cursor bar up in order to
highlight a point or to view points above the current
screen.
• Press SELECT to view the next screen level (highlighted with the cursor bar), or to override (if allowable)
the highlighted point value.
• Press EXIT to return to the previous screen level.
• Press INCREASE or DECREASE to change the highlighted point value.
TO VIEW STATUS (Fig. 17) — 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.
18
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
•VDO_STAT — Variable diffuser position 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
•ISM_STAT — Status of motor starter
•ICVC_PSWD — Service menu password forcing
access screen
19XR_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
Average 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%
Fig. 17 — Example of Status Screen
For
Analog
Points
—
Press INCREASE
or DECREASE to select the desired value.
3. Press SELECT to view the desired point status table.
3. Press ENTER to register the new value.
4. On the point status table, press NEXT or PREVIOUS
until the desired point is displayed on the screen.
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.
OVERRIDE OPERATIONS (Manual Overrides)
To Force (Manually Override) a Value or Status
1. From any point status screen, press NEXT
or PREVIOUS to highlight the desired value.
2. Press SELECT to access the highlighted value.
2. Press SELECT to select the highlighted value. Then:
3. Press RELEASE to remove the override and return the
point to the PIC II’s automatic control.
For Discrete Points — Press START or STOP to select the desired state.
Force Indication — A forced value is indicated by
“SUPVSR,” “SERVC,” or “BEST” flashing next to the point
value on the STATUS table.
19
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
• VDO_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
ISM CONFIG DA TA
EQUIPMENT SERVICE
TIME AND DATE
ATTACH TO NETWORK DEVICE
LOG OUT OF DEVICE
ICVC CONFIGURATION
NEXT
PREVIOUS
SELECT
EXIT
SEE FIGURE 19
Fig. 18 — 19XR,XRV Chiller Display Menu Structure (ICVC)
a19-1857
20
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.) See Note.
Display Alarm History
(The table holds up to 25 alarms
with the most recent alarm at
the top of the screen.) See note.
CONTROL TEST
List the Control Tests
CONTROL ALGORITHM STATUS
List the Control Algorithm Status Tables
• CAPACITY (Capacity Control)
• OVERRIDE (Override Status)
• SURGPREV (Surge Prevention)
• LL_MAINT (Lead Lag Status)
• ISM_HIST (ISM 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
NOTE: The PREVIOUS button refers to the next message towards the top of the list (cursor moving upwards) and the NEXT button refers to the
next message lower in the list (cursor moving downward) rather than the timing of the logged messages.
Fig. 19 — 19XR,XRV Service Menu Structure
a19-1858
21
SERVICE MENU CONTINUED
FROM PREVIOUS PAGE
ISM STARTER CONFIG DATA
EQUIPMENT SERVICE
4 4 4 4 (ENTER A 4-DIGIT PASSWORD)
(VALUES SHOWN AT FACTORY DEFAULT)
Service Tables:
• OPTIONS
• VDO_SRD
• SETUP1
• SETUP2
• LEADLAG
• RAMP_DEM
• TEMP_CTL
Select a Service Table
PREVIOUS
NEXT
Service Tables:
• ISM (STARTER) CONFIG PASSWORD
• ISM_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 Bus and 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
CCN
ICVC
ISM
PIC II
LEGEND
— Carrier Comfort Network
— International Chiller Visual Controller
— Integrated Starter Module
— Product Integrated Control II
a19-1859
Fig. 19 — 19XR,XRV Service Menu Structure (cont)
22
TIME SCHEDULE OPERATION (Fig. 20)
On the Menu screen, press SCHEDULE .
4. Press NEXT or PREVIOUS to highlight the desired
schedule.
OCCPC01S — LOCAL Time Schedule
OCCPC02S — ICE BUILD Time Schedule
OCCPC03S — CCN Time Schedule
Fig. 20 — Example of Time Schedule
Operation Screen
5. Press SELECT to view the desired time schedule.
10. Press EXIT to leave the period or override.
6. Press NEXT or PREVIOUS to highlight the desired
period or override to change.
11. 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.
7. Press SELECT to access the highlighted period or override.
12. The Holiday Designation (HOLIDEF table) may be
found in the Service Operation section, page 61. 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. 21)
1. To view the SETPOINT table, from the MENU screen
press SETPOINT .
8. 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.
19XR_II
SETPOINT
Base Demand Limit
Control Point
LCW Setpoint
ECW Setpoint
ICE BUILD Setpoint
Tower Fan High Setpoint
SETPOINT SELECT
100%
50.0 F
60.0 F
40.0 F
85.0 F
9. Press ENTER to register the values and to move horizontally (left to right) within a period.
Fig. 21 — Example of Set Point Screen
23
5. Press INCREASE or DECREASE to change the selected set point value.
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. The ECW
option is activated on the TEMP_CTL screen and Ice
Build is enabled on the OPTIONS screen. See the Service
Operation section, page 61. 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.
6. Press ENTER to save the changes and return to the previous screen.
SERVICE OPERATION — To view the menu-driven programs available for Service Operation, see Service Operation
section, page 61. For examples of ICVC display screens, see
Table 3.
4. Press SELECT to modify the highlighted set point.
Table 3 — ICVC Display Data
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 asterisk (or exclamation point) indicates that the value on that line has exceeded (or is
approaching) a limit. For more information on alarms and
alerts, see the Alarms and Alerts section, page 15.
8. Index of all ICVC parameters is shown in Appendix A.
9. An abbreviation in the column to the right of POINT STATUS,
indicates that the point is being Forced and the Force level. The
CCN Force priority hierarchy is found in ICVC OPERATION
AND MENUS. (This does not apply to the DEFAULT screen).
LEGEND
CCN
— Carrier Comfort Network
CHW
— Chilled Water
CHWR — Chilled Water Return
CHWS — Chilled Water Supply
CT
— Current Transformer
ECW
— Entering Chilled Water
HGBP — Hot Gas Bypass
ICVC
— International Chiller Visual Controller
ISM
— Integrated Starter Module
LCW
— Leaving Chilled Water
LRA
— Locked Rotor Amps
mA
— Milliamps
P
— Pressure
PIC II — Product Integrated Controls II
SS
— Solid State
T
— Temperature
VFD
— Variable Frequency Drive
WSM — Water System Manager
°F
— Temperature in Degrees Fahrenheit
^F
— Temperature Difference in Degrees Fahrenheit
IMPORTANT: The following notes apply to all Table 3
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. Press the NEXT softkey twice to page forward; press
the PREVIOUS softkey twice to page back.
2. To access the information shown in Examples 11 through 26,
enter your 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 II
controls) and reverts to the default screen. If this happens, you
must re-enter your password to access the tables shown in
Examples 11 through 26.
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 45, 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 19XR CCN
literature.
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
24
Table 3 — ICVC Display Data (cont)
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 Refrigerant Temperature (See Note 1)
Entering Condenser Water
Leaving Condenser Water
Condenser Refrigerant 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
NOTES:
1. The Evaporator Refrigerant Temperature displayed is the
smaller value of EVAP REFRIG LIQUID TEMP or CALC EVAP
SAT TEMP.
REFERENCE POINT NAME
(ALARM HISTORY)
HOURS
DEG F
DEG F
DEG F
DEG F
DEG F
DEG F
PSI
DEG F
%
C_HRS
ECW
LCW
ERT_EST
ECDW
LCDW
CRT
OILPD
OILT
AMPS_%
CCN
LOCAL
RESET
DISPLAY
CHW IN
CHW OUT
EVAP REF
CDW IN
CDW OUT
COND REF
OILPRESS
OIL TEMP
AMPS%
2. The last three entries are used to indicate operating mode to
the PIC II. These values may be forced by the ICVC only.
EXAMPLE 2 — MAINSTAT 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 (See Note 7)
Chilled Water Temp (See Note 8)
†Active Demand Limit
Average Line Current
Motor Percent 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
Refrigerant Leak Sensor
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
0-20
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
mA
ENABLE/EMSTOP
NORMAL/ALARM
POINT
MODE
STATUS
T_START
OCC
SYS_ALM
CHIL_S_S
REMCON
T_RESET
LCW_STPT
CHW_TMP
DEM_LIM
AMPS_%
KW_P
AUTODEM
AUTORES
R_RESET
c_starts
STARTS
c_hrs
S_HRS
ICE_CON
REF_LEAK
ENABLE
—
RUN STATUS DEFINITIONS
Timeout: The controls are delaying the start sequence until the Start
to Start or Stop to Start timers have elapsed
Ready: The chiller is ready to begin the start sequence
Recycle: The chiller has automatically shut down until the need for
cooling resumes
Startup: The chiller has completed the prestart checks and has
energized the chilled water pump
Running: The chiller has completed ramp loading following start up
Demand: The chiller is prevented from loading further because it
has reached the an AVERAGE LINE CURRENT Limit or a MOTOR
KILOWATTS Limit
Ramping: The chiller has started and is slowly increasing its load to
control electrical demand charges
Autorest: The chiller has declared an alarm and has shut down.
Override: The chiller is prevented from reaching full load by the controls because the chiller is running close to an operational limit
Control Test: The operator has entered the Controls Test screen on
the ICVC
Lockout:The compressor is prevented from starting so that chiller
may be safely pumped down to a vacuum.
Pumpdown: The refrigerant is being pumped out of the chiller, the
controls have energized the water pumps to prevent freeze-up
Prestart: The chiller is in the process of the checks prior to energizing the compressor motor
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), Autorest (7), Override (8), Tripout
(9), Control 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.
6. An abbreviation in the column to the right of POINT STATUS,
indicates that the point is being Forced and the Force level. The
CCN Force priority hierarchy is found ICVC OPERATION AND
MENUS. (This does not apply to the DEFAULT screen).
7. The Control Point (LCW_STPT) displayed is the leaving chilled
water control point when the machine is in leaving chilled water
control and the entering chilled water control point when the
machine is in entering chilled water control.
8. The Chilled Water Temp (CHW_TMP) displayed is the leaving
water temperature when the machine is in leaving chilled water
control and the entering chilled water temperature when the
machine is in entering chilled water control.
25
312
Table 3 — ICVC Display Data (cont)
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?
STATUS
0-110
0-100
0-100
–40-245
–40-245
0-200
0-200
–40-245
0/1
0/1
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
Surge Delta % Amps Min
UNITS
%
%
%
DEG F
DEG F
^F
^F
^F
OFF/ON
NO/YES
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
0-40
^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
amps_min
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.
EXAMPLE 4 — VDO STAT DISPLAY SCREEN
To access this display from the ICVC default screen:
1. Press MENU .
2. Press STATUS .
3. Scroll down to highlight VDO STAT
4. Press SELECT .
DESCRIPTION
Actual Guide Vane Pos
Diffuser Actuator
Calc SRD A Pos (output)
Calc Low Lift SRD Pos 1
Calc Low Lift SRD Pos 2
Lift A (Actual)
Lift 1
Lift 2
Startup Timer
SRD Rotating Stall
SRD Stall Closure Timer
Surge Counts
.
STATUS
0-100
0-100
0-100
0-100
0-100
0-200
0-200
0-200
0.0-30.0
0/1
0.0-30.0
0-5
UNITS
%
%
%
%
%
^F
^F
^F
min
NO/YES
min
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.
26
POINT
GV_ACT
DIFF_ACT
SRD_A
SRD_1
SRD_2
LIFT_A
LIFT_1
LIFT_2
STRT_TMR
DIFFAULT
STALLTMR
SC
Table 3 — 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
Compressor Start Relay
Compressor Start Contact
Starter Trans Relay
Compressor Run Contact
**Tower Fan Relay Low
**Tower Fan Relay High
Starter Fault
Spare Safety Input
Shunt Trip Relay
ISM Fault Status
STATUS
0-100
0-1
0-1
0-1
0-1
0-1
–6.7-200
0-1
0-1
0-1
0-1
0-1
0-1
0-1
0-1
0-1
0-255
UNITS
%
OFF/ON
NO/YES
OFF/ON
NO/YES
OFF/ON
^PSI
OFF/ON
OPEN/CLOSED
OFF/ON
OPEN/CLOSED
OFF/ON
OFF/ON
ALARM/NORMAL
ALARM/NORMAL
OFF/ON
POINT
GV_ACT
CHWP
CHW_FLOW
CDP
CDW_FLOW
OILR
OILPD
CMPR
1CR_A
CMPTRANS
2M_AUX
TFR_LOW
TFR_HIGH
STR_FLT
SAFETY
TRIPR
ISMFLT
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.
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 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
**Target VFD Speed
**Actual VFD Speed
Surge Protection Counts
HGBP Active Region
STATUS
0-100
–2.0-2.0
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
0-110
0-110
0-5
0-2
UNITS
%
%
%
DEG F
^PSI
DEG F
DEG F
DEG F
DEG F
DEG F
DEG F
DEG F
OFF/ON
%
%
%
See Note 2
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. 0=Not Active, 1=Active, 2=Active and more than one degree
over the surge line.
27
POINT
GV_POS
GV_DELTA
GV_TRG
OILT
OILPD
CMPD
MTRB_OIL
TB_RESET
MTRB
MTRW
SPARE_T1
SPARE_T2
OILHEAT
DIFF_ACT
VFD_OUT
VFD_ACT
SPC
HGBP_ACT
Table 3 — 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 (See Note 2)
Active Delta T (See Note 2)
Surge Line Delta T (See Note 2)
Actual Guide Vane Position (See Note 3)
Active Delta Tsat (See Note 3)
Surge Line Delta Tsat (See Note 3)
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
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
%
^F
^F
%
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.
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
GV_POS
CDW_DT
DELTA_TX
HPR
2. These points apply to software Version 9 and lower.
3. These points apply to software version 10 and higher.
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
Average Line Current
Actual Line Current
Average Line Voltage
Actual Line Voltage
Power Factor
Motor Kilowatts
**Motor Kilowatt-Hours
Demand Kilowatts
Line Current Phase 1
Line Current Phase 2
Line Current Phase 3
Line Voltage Phase 1
Line Voltage Phase 2
Line Voltage Phase 3
Ground Fault Phase 1
Ground Fault Phase 2
Ground Fault Phase 3
Frequency
I2T Sum Heat-Phase 1
I2T Sum Heat-Phase 2
I2T Sum Heat-Phase 3
STATUS
0-999
0-99999
0-999
0-99999
0.0-1.0
0-99999
0-99999
0-99999
0-99999
0-99999
0-99999
0-99999
0-99999
0-99999
0-999
0-999
0-999
0-99
0-200
0-200
0-200
UNITS
%
AMPS
%
VOLTS
kW
kWH
kWH
AMPS
AMPS
AMPS
VOLTS
VOLTS
VOLTS
AMPS
AMPS
AMPS
Hz
%
%
%
NOTE: All variables with CAPITAL LETTER point names are available for CCN read operation. Those shown with (**) shall support
write operations for ICVC only.
28
POINT
AMPS_P
AMP_A
VOLT_P
VOLT_A
POW_FACT
KW
KWH
DEM_KWH
AMPS_1
AMPS_2
AMPS_3
VOLT_1
VOLT_2
VOLT_3
GF_1
GF_2
GF_3
FREQ
HEAT1SUM
HEAT2SUM
HEAT3SUM
Table 3 — ICVC Display Data (cont)
EXAMPLE 8 — ISM_STAT DISPLAY SCREEN
To access this display from the ICVC default screen:
1. Press MENU .
2. Press STATUS .
3. Scroll down to highlight ISM_STAT .
4. Press SELECT .
DESCRIPTION
ISM Fault Status
Single Cycle Dropout
Phase Loss
Overvoltage
Undervoltage
Current Imbalance
Voltage Imbalance
Overload Trip
Locked Rotor Trip
Starter LRA Trip
Ground Fault
Phase Reversal
Frequency Out of Range
ISM Power on Reset
Phase 1 Fault
Phase 2 Fault
Phase 3 Fault
1CR Start Complete
1M Start/Run Fault
2M Start/Run Fault
Pressure Trip Contact
Starter Fault
Motor Amps Not Sensed
Starter Acceleration Fault
High Motor Amps
1CR Stop Complete
1M/2M Stop Fault
Motor Amps When Stopped
Hardware Failure
STATUS
0-255
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
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
FALSE/TRUE
NORMAL/ALARM
NORMAL/ALARM
NORMAL/ALARM
NORMAL/ALARM
NORMAL/ALARM
NORMAL/ALARM
NORMAL/ALARM
FALSE/TRUE
NORMAL/ALARM
NORMAL/ALARM
NORMAL/ALARM
POINT
ISMFLT
CYCLE_1
PH_LOSS
OV_VOLT
UN_VOLT
AMP_UNB
VOLT_UNB
OVERLOAD
LRATRIP
SLRATRIP
GRND_FLT
PH_REV
FREQFLT
ISM_POR
PHASE_1
PHASE_2
PHASE_3
START_OK
1M_FLT
2M_FLT
PRS_TRIP
STRT_FLT
NO_AMPS
ACCELFLT
HIGHAMPS
STOP_OK
1M2MSTOP
AMPSTOP
HARDWARE
NOTE: All variables with CAPITAL LETTER point names are available for CCN read operation.
EXAMPLE 9 — ICVC_PSWD DISPLAY SCREEN
To access this display from the ICVC default screen:
1. Press MENU .
2. Press STATUS .
3. Scroll down to highlight ICVC
4. Press SELECT .
DESCRIPTION
Disable Service Password
**Remote Reset Option (See Note 3)
Reset Alarm?
CCN Mode?
STATUS
0-1
0-1
0-1
1
UNITS
DSABLE/ENABLE
DSABLE/ENABLE
NO/YES
YES
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. 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 ISM (Starter) Config Data screens can be accessed
POINT
PSWD_DIS
RESETOPT
REMRESET
REM_CCN
without a password. This access is cancelled the time the user
exits the Service menu/screen.
3. 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.
29
Table 3 — ICVC Display Data (cont)
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.
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
VFD Gain
VFD Load Factor
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
–2.0-2.0
0-100
0-100
0-100
0-110
0.1-1.5
0.0-1.0
0.2-2.0
40-100
DEG F
^F
^F
^F
^F
^F
%
%
%
%
%
ctrlpt
cperr
ecwdt
ecwres
lcwres
error
gvd
GV_TRG
GV_POS
VFD_OUT
VFD_ACT
vfd_gain
VFD_FACT
DEM_INH
RAMP_LMT
%
%
NOTE: All variables with CAPITAL LETTER point names are available for CCN read operation; forcing shall not be supported on maintenance
screen.
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
Calc Evap Sat Temp
Evap Sat 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
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
155-175
165-185
175-185
–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
^F
^F
DEG F
POINT
MTRW
MT_OVER
CRP
CP_OVER
ERT
ERT_OVER
CMPD
CD_ALERT
MTRB_OIL
TB_RESET
MTRB
TB_ALERT
TB_TRIP
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.
30
Table 3 — ICVC Display Data (cont)
EXAMPLE 13 — LL_MAINT 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 LL_MAINT.
Press SELECT .
DESCRIPTION
LeadLag Control
LEADLAG: Configuration
Current Mode
Load Balance Option
LAG START Time
LAG STOP Time
Prestart Fault Time
Pulldown Time
Pulldown: Delta T / Min
Satisfied?
LEAD CHILLER in Control
LAG CHILLER: Mode
Run Status
Start/Stop
Recovery Start Request
STANDBY CHILLER: Mode
Run Status
Start/Stop
Recovery Start Request
Spare Temperature 1
Spare Temperature 2
STATUS
UNITS
NOTE 1
NOTE 2
0/1
2-60
2-60
2-30
2-30
x.xx
0/1
0/1
NOTE 3
NOTE 4
NOTE 5
0/1
NOTE 3
NOTE 4
NOTE 5
0/1
–40-245
–40-245
DSABLE/ENABLE
MIN
MIN
MIN
MIN
^F
NO/YES
NO/YES
NO/YES
NO/YES
DEG F
DEG F
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, Autorest, Pumpdown, Lockout,
Control Test
POINT
leadlag
llmode
loadbal
lagstart
lagstop
preflt
pulldown
pull_dt
pull_sat
leadctrl
lagmode
lagstat
lag_s_s
lag_rec
stdmode
stdstat
std_s_s
std_rec
SPARE_T1
SPARE_T2
5. Stop, Start, Retain
6. All variables with CAPITAL LETTER point names are available
for CCN read operation; forcing shall not be supported on maintenance screens.
EXAMPLE 14A — SURGPREV DISPLAY SCREEN (Machines with Serial Numbers Prior to 1410Qxxxxx)
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?
Active Delta P
Surge Line Delta T
Active Delta T
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
0-420
0.5-284.5
0.5-9999.9
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
^PSI
^F
^F
^F
^F
%
%
%
No/Yes
No/Yes
Off/On
No/Yes
No/Yes
POINT
ACT_REG
SHG_ACT
DP_A
DT_C
DT_A
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.
31
Table 3 — ICVC Display Data (cont)
EXAMPLE 14B — SURGPREV DISPLAY SCREEN (Machines with Serial Numbers 1410Qxxxxx and Later
or Version 9 or Later Software)
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
Chilled Water Delta T
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
–40-245
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
^F
%
%
%
No/Yes
No/Yes
Off/On
No/Yes
No/Yes
POINT
ACT_REG
SHG_ACT
GV_POS
DTS_A
DTS_C
CHWDT
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 15 — ISM_HIST 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 ISM_HIST .
Press SELECT .
DESCRIPTION
ISM FAULT HISTORY
Values At Last Fault:
Line Current Phase 1
Line Current Phase 2
Line Current Phase 3
Line Voltage Phase 1
Line Voltage Phase 2
Line Voltage Phase 3
Ground Fault Phase 1
Ground Fault Phase 2
Ground Fault Phase 3
I2T Sum Heat-Phase 1
I2T Sum Heat-Phase 2
I2T Sum Heat-Phase 3
Phase 1 Faulted?
Phase 2 Faulted?
Phase 3 Faulted?
Line Frequency
ISM Fault Status
STATUS
0-99999
0-99999
0-99999
0-99999
0-99999
0-99999
0-999
0-999
0-999
0-200
0-200
0-200
0/1
0/1
0/1
0-99
0-9999
UNITS
POINT
AMPS
AMPS
AMPS
VOLTS
VOLTS
VOLTS
AMPS
AMPS
AMPS
%
%
%
NO/YES
NO/YES
NO/YES
Hz
AMPS_H1
AMPS_H2
AMPS_H3
VOLTS_H1
VOLTS_H2
VOLTS_H3
GRFT_H31
GRFT_H23
GRFT_H12
SUM1HT_H
SUM2HT_H
SUM3HT_H
PHASE_H1
PHASE_H2
PHASE_H3
FREQ_H
ISMFLT_H
NOTE: All variables with CAPITAL LETTER point names are available for CCN read operation; forcing shall not be supported on maintenance
screens.
32
Table 3 — ICVC Display Data (cont)
EXAMPLE 16 — WSMCHRLE 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 WSMCHRLE .
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
DEG F
DEG F
POINT
WSMSTAT
CHWTEMP
CHWRST
CHWRENA
CHWRVAL
CHWSTPT
NOTE: All variables with CAPITAL LETTER point names are available for CCN read operation; forcing shall not be supported on maintenance
screens.
EXAMPLE 17 — NET_OPT DISPLAY SCREEN
To access this display from the ICVC default screen:
1. Press MENU .
2. Press SERVICE .
3. Scroll down to highlight EQUIPMENT CONFIGURATION .
4. Press SELECT .
5. Scroll down to highlight NET_OPT .
6. Press SELECT .
DESCRIPTION
Loadshed Function
Group Number
Demand Limit Decrease
Maximum Loadshed Time
CCN Occupancy Config:
Schedule Number
Broadcast Option
Alarm Configuration
Re-Alarm Time
Alarm Routing
STATUS
UNITS
POINT
DEFAULT
0-99
0-60
0-120
%
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.
33
Table 3 — ICVC Display Data (cont)
EXAMPLE 18 — ISM_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 ISM (STARTER) CONFIG DATA .
Press SELECT .
Enter password (4444 Factory Default).
6. Scroll down to highlight ISM_CONF .
7. Press SELECT .
DESCRIPTION
Starter Type
(0 = Full, 1 = Red, 2 = SS/VFD)
Motor Rated Line Voltage
Volt Transformer Ratio:1
Overvoltage Threshold
Undervoltage Threshold
Over/Under Volt Time
Voltage % Imbalance
Voltage Imbalance Time
Motor Rated Load Amps
Motor Locked Rotor Trip
Locked Rotor Start Delay
Starter LRA Rating
Motor Current CT Ratio:1
Current % Imbalance
Current Imbalance Time
Grnd Fault CT’s?
Ground Fault CT Ratio:1
Ground Fault Current
Ground Fault Start Delay
Ground Fault Persistence
Single Cycle Dropout
Frequency = 60 Hz? (No = 50)
Line Frequency Faulting
STATUS
0-3
200-13200
1-115
105-115
85-95
1-10
1-10
1-10
10-5000
100-60000
1-10
100-60000
10-1000
5-40
1-10
0/1
150
1-25
1-20
1-10
0/1
0/1
0/1
UNITS
VOLTS
%
%
SEC
%
SEC
AMPS
AMPS
cycles
AMPS
%
SEC
NO/YES
AMPS
cycles
cycles
DSABLE/ENABLE
NO/YES
DSABLE/ENABLE
POINT
starter
DEFAULT
1
rlv
vt_rat
overvolt
undrvolt
ovuntime
v_unbal
vu_time
rla
mot_lra
lrs_del
str_lra
ct_ratio
c_unbal
cu_time
gf_cts
gfct_rat
gf_amps
gf_sdel
gf_pdel
1cyc_en
linefreq
freq_en
460
1
115
85
5
10
5
200
1000
5
2000
100
15
5
YES
150
15
10
5
DSABLE
YES
DSABLE
NOTE: Option 3 for VFD is available on software Version 9 or higher. All other software versions use Option 2 for VFD.
34
Table 3 — ICVC Display Data (cont)
EXAMPLE 19A — OPTIONS DISPLAY SCREEN (Machines with Serial Numbers Prior to 1410Qxxxxx)
To access this display from the ICVC default screen:
1. Press MENU .
2.
3.
4.
5.
6.
Press SERVICE .
Scroll down to highlight EQUIPMENT SERVICE .
Press SELECT .
Scroll down to highlight OPTIONS .
Press SELECT .
DESCRIPTION
Auto Restart Option
Remote Contacts Option
Soft Stop Amps Threshold
Surge / Hot Gas Bypass
Surge Limit/HGBP Option
Select: Surge=0, HGBP=1
Min. Load Point (T1,P1)
Surge/HGBP Delta T1
Surge/HGBP Delta P1
Low Load Point (T2,P2)
Surge/HGBP Delta T2
Surge/HGBP Delta P2
Mid Load Point (T3,P3)
Surge/HGBP Delta T3
Surge/HGBP Delta P3
Full Load Point (T4,P4)
Surge/HGBP Delta T4
Surge/HGBP Delta P4
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
POINT
astart
r_contac
softstop
DEFAULT
DSABLE
DSABLE
100
srg_hgbp
0
0.5-20
30-170
^F
^PSI
hgb_dt1
hgb_dp1
1.5
50
0.5-20
30-170
^F
^PSI
hgb_dt2
hgb_dp2
10
85
0.5-20
50-170
^F
^PSI
hgb_dt3
hgb_dp3
10
85
0.5-20
50-170
0.5-3
^F
^PSI
^F
hbg_dt4
hgb_dp4
hbg_db
10
85
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
35
0
NOTE: No variables are available for CCN read or write operation.
35
Table 3 — ICVC Display Data (cont)
EXAMPLE 19B — OPTIONS DISPLAY SCREEN (Machines with Serial Numbers 1410Qxxxxx and Later
or Version 9 or Later Software)
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.
EXAMPLE 20 — VDO SRD DISPLAY SCREEN (Machines with Serial Numbers 10xxQxxxxx and Later on Version 10 or higher Software)
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 VDO SRD .
Press SELECT .
DESCRIPTION
Diffuser Control
Diffuser Option
Diffuser Full Span mA
Guide Vane 25% Load (2)
Guide Vane 50% Load (2)
Guide Vane 75% Load (2)
SRD 25% Load (1)
SRD 50% Load (1)
SRD 75% Load (1)
Lift @ 25% Load (1)
Lift @ 100% Load (1)
Lift @ 25% Load (2)
SRD IGV Offset Select
Low Lift Profile Select
STATUS
0/1
15-22
0-83
0-83
0-83
0-100
0-100
0-100
0-100
0-100
0-100
1-5
1-5
UNITS
mA
%
%
%
%
%
%
^F
^F
^F
NOTE: No variables are available for CCN read or write operation.
36
POINT
DIFF_OPT
DIFF_MA
GV1_25
GV1_50
GV1_75
SRD1_25
SRD1_50
SRD1_75
LF1_25
LF1_100
LF2_25
OFF_SEL
PRO_SEL
DEFAULT
0
18.0
6.4
22.9
41.3
73.5
35.1
19.5
52.4
67.5
27.2
3
3
Table 3 — ICVC Display Data (cont)
EXAMPLE 21 — 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
Comp Discharge Alert
Comp Thrust Brg Alert
Comp Thrust Brg Trip
Thrust Brg Reset Factor
STATUS
150-200
90-165
125-200
10-20
160-185
1.0-3.0
UNITS
DEG F
PSI
DEG F
^F
DEG F
POINT
MT_OVER
CP_OVER
CD_ALERT
TB_ALERT
TB_TRIP
TB_POWER
DEFAULT
200
125
200
10
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
^F
^F
rcycr_dt
rcycs_dt
5
1
sp1_en
sp1_lim
sp2_en
sp2_lim
0
245
0
245
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
0-4
-40-245
0-4
-40-245
DEG F
DEG F
*When set to DISABLE, alarm functions as an alert.
NOTE: No variables are available for CCN read or write operation; forcing shall not be supported on service screens.
37
312
Table 3 — ICVC Display Data (cont)
EXAMPLE 22 — 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 Gain
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 Option
VFD Gain
VFD Increase Step
VFD Minimum Speed
VFD Maximum Speed
VFD Start Speed
VFD Surge Line Gain
VFD Current Limit
UNITS
POINT
DEFAULT
gv_inc
gv_dec
gv_ecw
6.5
6.0
2
%
gv_lim
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
0.1-1.5
1-5
65-100
90-100
65-100
2.0-3.5
0-99999
DSABLE/ENABLE
vfd_opt
vfd_gain
vfd_step
vfd_min
vfd_max
vfd_star
vfd_exp
vfdlim_i
DSABLE
0.75
2
70
100
100
2.0
250
2-10
2-10
1-3
%
%
%
%
Amps
* These points apply only to machines with serial numbers prior to 1410Qxxxxx.
NOTE: No variables are available for CCN read or write operation; forcing shall not be supported on service screens.
EXAMPLE 23 — 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
%
NOTE: No variables are available for CCN read or write operation.
38
POINT
DEFAULT
leadlag
0
load/bal
commsens
lag_per
lag_add
lagstart
lagstop
preft
pulltime
stnd_opt
stnd_per
stnd_add
DSABLE
DSABLE
50
92
10
10
5
2
DSABLE
50
93
Table 3 — ICVC Display Data (cont)
EXAMPLE 24 — 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
Motor Rated Kilowatts
Demand Watts Interval
STATUS
0/1
UNITS
0/1
5-20
3-15
40-100
0/1
50-9999
5-60
%/MIN
%
%
DSABLE/ENABLE
kW
MIN
POINT
ramp_opt
DEFAULT
1
dem_src
0
kw_ramp
dem_prop
dem_20ma
dem_sel
motor_kw
dw_int
10
10
40
DSABLE
145
15
NOTE: No variables are available for CCN read or write operation.
EXAMPLE 25 — 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
Select/Enable Reset Type
STATUS
UNITS
POINT
DEFAULT
0/1
2-10
DSABLE/ENABLE
^F
ecw_opt
tmp_ramp
DSABLE
3
–30- 30
^F
deg_20ma
10
–40-245
–40-245
–30-30
DEG F
DEG F
^F
res_rt1
res_rt2
deg_rt
85
65
10
0-15
0-15
–30-30
^F
^F
^F
restd_1
restd_2
deg_chw
10
0
5
res_sel
0
0-3
EXAMPLE 26 — ICVC CONFIGURATION TABLE
To access this display from the ICVC default screen:
1. Press MENU .
2. Press SERVICE .
3. Scroll down to highlight ICVC CONFIGURATION .
4. Press SELECT .
DESCRIPTION
Device Name
Description
Software Part Number
Model Number
Serial Number
Reference Number
Bus Number
Address
Baud Rate
US Imp/Metric
Password
LID Language
NOTE: Default values are shown for configurable items.
STATUS
19XRPIC2
19XR Centrifugal Chiller
CESR-131294-xx
text string
text string
VER xx
0
1
9600
US Imp
1111
ENGLISH
39
DEFAULT
0
1
9600
US Imp
1111
ENGLISH
• The SETPOINT menu allows set point adjustments, such
as the entering chilled water and leaving chilled water
setpoints.
• The SERVICE menu can be used to view or modify
information on the Alarm History, Alert History, Control
Test, Control Algorithm Status, Equipment Configuration, ISM Starter Configuration data, Equipment Service,
Time and Date, Attach to Network Device, Log Out of
Network Device, and ICVC Configuration screens. For
more information on the menu structures, refer to Fig. 18
and 19.
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 and softkeys to scroll down to the desired
item or table. Use the softkey to select that item. The softkey
choices that then appear depend on the selected table or menu.
The softkey choices and their functions are described below.
BASIC ICVC OPERATIONS (Using the Softkeys) — To
perform any of the operations described below, the PIC II must
be powered up and have successfully completed its self test.
Force priority — The forces from various sources apply in an
order of priority. Any force can override a force with a lower
priority. The lowest priority belongs to the normal operating
control. A higher force cannot be overridden. For example, a
Service Tool force cannot be overridden by anything but a machine safety or fire alarm. See Table 4.
FLOW DETECTION — Flow detection for the evaporator
and condenser is (a) a required condition for startup, and (b)
used in the freeze protection safety.
Flow and no flow conditions are detected from a combination of several measurements. The usage of water side differential pressure measurements is not standard.
Positive determination of flow on the evaporator side is
made if the following conditions are true: (1) the EVAPORATOR REFRIGERANT LIQUID TEMP reads higher than 1° F
(0.6° C) above the EVAPORATOR REFRIGERANT TRIPPOINT, and (2) EVAPORATOR SATURATION TEMPERATURE (determined from the Evaporator Pressure sensor) is
greater than the EVAPORATOR REFRIGERANT TRIPPOINT. (If when 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 CONDENSER PRESSURE OVERRIDE threshold by more than 5 psi
(34.5 kPa). In addition, if the water side differential pressure
measurement option is enabled, the water side pressure differentials (cooler and condenser) must exceed their respective
configured cutout thresholds.
PIC II System Functions — Refer to ICVC Opera-
tion and Menus section on page 17.
NOTE: 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 3 for examples of the type of information that can appear on the ICVC
screens. Figures 15-21 give an overview of ICVC operations
and menus.
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 control center 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.
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 softkey), the default ICVC screen will return to normal operation. 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.
The CCN point EMERGENCY STOP is found at the end of
the MAINSTAT SCREEN. Whenever this point is forced to a 1
the chiller will stop and the following alarm will be generated:
250->Emergency Override/Stop. The EMERGENCY STOP
can be forced from anywhere and will be honored whether the
chiller is running or not and in CCN, LOCAL or STOP modes.
ICVC MENU ITEMS — To perform any of the operations
described below, the PIC II 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.
• 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.
Table 4 — CCN Force Priority Hierarchy
LEVEL
1
2
3
4
5
6
7
8
9
10
NAME
FIRE
SAFETY
SERVCE
SUPVSR
MONITR
MINOFF
CONTROL
BEST
TEMP
LOAD
DESCRIPTION
Fire Alarm
Machine Safety
Service Tool Access
Supervisor or LID/ICVC
Offsite Building Supervisor or ComfortWorks
Minimum on/off time
Typically 3rd party access via interface
BEST control from FIDs and comfort controllers
Temperature Override (thermostat type function)
Loadshed for demand limit/shedding load
NOTE: Not all apply to chillers.
40
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 rate of the capacity control response (within
limits). See also "PROPORTIONAL BANDS" on page 42.
Parameters 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.
Maximum guide vane travel is configurable as a percent of
full travel in the SETUP2 screen. Note that the default maximum is 80%. Note the guide vane position at design conditions. Set the maximum travel approximately 5% higher. This
will prevent the vanes from opening wide during temporary
overload conditions. This will keep the vanes close to the actual working load position and they should be able to resume
control successfully when the load drops.
In addition to its response to control point error and resets,
guide vane action and response rates are affected by guide vane
position, capacity overrides (see page 49), proportional bands
and gain (see page 42), and VFD speed (see below). Parameters affecting guide vane action are displayed in the CAPACITY screen of the SERVICE/CONTROL ALGORITHM STATUS menu.
FIXED SPEED APPLICATIONS — For fixed speed applications, capacity is adjusted solely by movement of the inlet
guide vanes. Note that when operating in the surge prevention
region, the guide vanes cannot open further and may be forced
to close. (See SURGE PREVENTION.)
VARIABLE SPEED (VFD) APPLICATIONS — The PIC II
controls the machine capacity by modulating both motor speed
and inlet guide vanes in response to changes in load. During
operation, when the WATER TEMPERATURE is further from
the CONTROL POINT than 1/3 the value of the CHILLED
WATER DEADBAND, the controller will calculate a GUIDE
VANE DELTA which will cause a change to either the guide
vane position or VFD target speed. Factors considered in the
capacity control algorithm include: (1) the sign and magnitude
of GUIDE VANE DELTA (based on deviation from CONTROL
POINT, plus resets), (2) ACTUAL GUIDE VANE POSITION
compared to the GUIDE VANE TRAVEL LIMIT, (3) VFD
SPEED compared to VFD MAXIMUM 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 a
GUIDE VANE POSITION or VFD SPEED increase (within
limits). If GUIDE VANE DELTA is negative, the response will
be a GUIDE VANE POSITION or VFD SPEED decrease
(within limits). Next, the surge prevention mode is determined
based on location of the present operating point (see Note) in
relation to the configured surge curve. This mode will either be
Normal, Surge Prevention High, or Surge Prevention Low. Table 5 indicates which output is modulated first. When the first
output reaches its limit (e.g., ACTUAL GUIDE VANE POSITION reaches maximum), the second output is modulated. The
sequence is the same whether in Surge Prevention High or
Surge Prevention Low.
NOTE: For Constant Flow Surge Prevention, the operating
point is defined by CHILLED WATER DELTA T and ACTIVE
DELTA P. For Variable Primary Flow Surge Prevention the
operating point is defined by GUIDE VANE POSITION and
DELTA TSAT.
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 waterside pressure differentials as in the standard ICVC configuration. (NOTE: If the FLOW DELTA P DISPLAY is enabled, but
the standard CCM connection is retained, a differential value of
approximately 28.5 psi (197 kPa) will always be displayed.)
If waterside differential pressure transducers are used, flow
is detected from differential pressure between sensors (pressure
transducers) located in water inlet and outlet nozzles, for each
heat exchanger. The thresholds for flow determination (EVAP
FLOW DELTA P CUTOUT, COND FLOW DELTA P CUTOUT) are configured in the SETUP1 screen. If the measured
differential is less than the corresponding cutout value for 5
seconds, the determination is that flow is absent. If no flow is
detected after WATER FLOW VERIFY TIME (configured in
the SETUP1 screen) after the pump is commanded to start by
the PIC, a shutdown will result, and the corresponding loss-offlow alarm (alarm state 229 or 230) will be declared. If the
measured differential exceeds the FLOW DELTA P cutout value, flow is considered to be present.
Alternatively, normally open flow switches may be used for
flow indication. In this case, install an evaporator side flow
switch in parallel with a 4.3k ohm resistor between CCM terminals J3 17-18, replacing the jumper. 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).
CAPACITY CONTROL — Generally the chiller adjusts capacity in response to deviation of leaving or entering chilled
water temperature from its control point. CONTROL POINT is
based on the configured SETPOINT (in the SETPOINT screen:
LCW SETPOINT or ECW SETPOINT or ICE BUILD SETPOINT), 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 53) or from a CCN device. The
default reset value is 0o F so that if no reset function is configured the CONTROL POINT will equal the SETPOINT. 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,
41
Constant Flow Surge Prevention
Normal Capacity Control Mode occurs when ACTIVE
DELTA T> SURGE LINE DELTA T.
Surge Prevention Mode Level 1 occurs when ACTIVE
DELTA T  SURGE LINE DELTA T
Surge Prevention Mode Level 2 occurs when ACTIVE
DELTA T + 1  SURGE LINE DELTA T
Variable Primary Flow Surge Prevention
Normal Capacity Control Mode occurs when ACTIVE
DELTA TSAT> SURGE LINE DELTA TSAT.
Surge Prevention Mode Level 1 occurs when ACTIVE
DELTA TSAT  SURGE LINE DELTA TSAT
Surge Prevention Mode Level 2 occurs when ACTIVE
DELTA TSAT + 1  SURGE LINE DELTA TSAT
The VFD GAIN parameter allows for additional adjustment
of the VFD response. Increasing VFD GAIN will increase the
rate of speed change.
For chillers equipped with VFDs there is an additional overcurrent feature which is similar to Demand Limit Control. The
ICVC computes a projected value for motor current (VFD output current, which is not measured by the ISM). The computed
value is based on AVERAGE LINE CURRENT and TARGET
VFD SPEED. The control then compares it to VFD CURRENT
LIMIT. VFD CURRENT LIMIT is a configurable entry in the
SETUP2 screen, representing VFD output current when the
line side current equals RATED LOAD AMPS and VFD
SPEED is at its maximum. The VFD Control Configuration
Job sheet includes the recommended value for VFD CURRENT LIMIT, and that value may be further adjusted as described under the VFD Control Verification section. (See
page 77.)
If VFD LOAD FACTOR (the ratio of estimated VFD output
current to VFD CURRENT LIMIT) exceeds 0.98, then drive
speed is increased until VFD LOAD FACTOR goes below 0.96,
or until maximum speed is reached. If VFD LOAD FACTOR
exceeds 1.02 then the GUIDE VANE POSITION is made to decrease as well. This action ceases when the VFD LOAD FACTOR subsequently drops below 1.0. VFD LOAD FACTOR is
displayed in the CONTROL ALGORITHM STATUS / CAPACITY screen.
NOTE: Increasing motor speed reduces motor amp draw. This
is the current between the VFD and the motor, NOT line current. 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.
and VFD INCREASE STEP can be viewed 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 II 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 II opens or closes the guide vanes until
the temperature is within tolerance. The PIC II 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.
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.
Table 5 — Guide Vane Delta Modes
GUIDE VANE
DELTA
NORMAL
CONTROL
MODE
IGV
VFD
POSITION
SPEED
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
POSITION
SPEED
Increase
only if VFD
speed =
Increase
max and if
1st
hot gas
bypass is
present
and open
Speed
decrease
Decrease
not
allowed
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, MAXIMUM SPEED, VFD GAIN
42
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 23 shows the relationship between diffuserrelated parameters for a typical build.
Diffuser control output is enabled whenever the DIFFUSER
OPTION is enabled, whether the machine is running or not. As
shown in Fig. 23, 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 and SRD Actuator.”
Note that the diffuser actuator should NOT be forced to a greater percent than the configured 25% Load Point (maximum)
value as the diffuser will be at a mechanical stop. The diffuser
opening can be incremented from fully open to completely
closed. A 0% setting is fully open; a 100% setting is completely
closed.
Split Ring Diffuser Control — The schedule of DIFFUSER
LOAD PT versus GUIDE VANE % LOAD PT is printed on a
label on the back of the control panel cover. See Fig. 11.
Control Output
(Actuator Position)
DIFFUSER POSITION
(% CLOSED)
surge more likely
75 % Load Point
surge less likely
50 % Load Point
rotating stall
less likely
X
X
X
X
X
X
X
X
X
EXAMPLE 1
EXAMPLE 2
approx.
20 mA
100 %
a19-1861
Fig. 23 — Diffuser Control
EXAMPLE 3
a19-1957
Fig. 22 — Transient Example of ECW Gain
43
3
2.5
2
1.5
1
0.5
0
-0.5
-1
TOTAL ERROR
X
75 %
* DIFFUSER FULL SPAN MA.
X
X
50 %
GUIDE VANE POSITION (% OPEN)
X
25 %
0%
X
2 mA
(0%)
4 mA
(0.2%)
25 % Load Point
100%
Closed
°F
48.2
48
47.8
47.6
47.4
47.2
SET POINT = 47
46.8
46.6
46.4
100%
Open
Pinion Shaft Clockwise Rotation
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 ENTERING CHILLED WATER CONTROL and before tuning the ECW GAIN, the LCW 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. 22)
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. 22 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. 22 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.
DIFFUSER CONTROL (Software Version 9 and Earlier) — On all units with Frame 5 compressors and those Frame
4 compressors with the variable (split ring) diffuser option, the
PIC II adjusts the diffuser actuator position (DIFFUSER ACTUATOR on the COMPRESS screen) based on the ACTUAL
E C W (°F )
E C W -10 sec
E rror, G ain = 1
E rror, G ain = 3
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 to terminals J5-1 (-) and J5-2
(+) on the CCM. In order to use a 1 to 5 vdc input instead of 4
to 20 mA, install a 25 ohm resistor in series with the + lead at
terminal J5-2. The associated dip switch should remain in the
up (on) position despite the notation on the CCM board. See
Fig. 24.
A diffuser pressure transducer is installed on compressors
with a split ring diffuser. The CCM monitors pressure fluctuations at the inlet to the inner diffuser ring. Excessive pressure
fluctuations may indicate that the impeller is experiencing rotating stall. A Diffuser Position Fault (Alarm 247) is declared
if pressure fluctuations exceed acceptable limits.
DIFFUSER CONTROL (Software Version 10 and
Later) — On all units with Frame 5 compressors and those
Frame 4 compressors with the variable (split ring) diffuser option, the PIC II adjusts the diffuser actuator position using Variable Diffuser Optimization (VDO). Configurations for VDO
are produced by the ECAT chiller selection program and are
entered into the VDO_SRD screen. Diffuser control output is
enabled whenever the DIFFUSER OPTION is enabled, whether the machine is running or not.
The diffuser position, rather than following a specific relationship to the guide vane position, is determined based on several factors: guide vane position, lift, rotating stall and surge
conditions.
Diffuser actuator output is controlled by a 4 to 20 mA output from CCM terminals J8-3(+) and J8-4(-).
The diffuser and guide vanes will both move in Guide Vane
Control Test but the relative positions do not represent the relative position of these actuators during operation; the diffuser
and the guide vane operate independently.
The configurations for VDO Diffuser Control are found on
a label on the back of the control panel. See Fig. 11.
If you do not have the correct settings for VDO Diffuser
Control contact a Carrier Engineering Representative.
IMPORTANT: Do not alter the factory settings for VDO
Diffuser Control without consulting with Carrier Engineering. Incorrect settings could cause the machine to repeatedly shut down on rotating stall alarm or surge.
a19-1885
Fig. 24 — Auto Demand Limit Wiring (1 to 5 vdc)
DEMAND LIMITING — The PIC II 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 30, 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 57).
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 (displayed in the MAINSTAT screen). MOTOR PERCENT KILOWATTS is equal to (MOTOR KILOWATTS ÷MOTOR RATED
KILOWATTS ) ×100. MOTOR KILOWATTS is measured by
the ISM and the MOTOR RATED KILOWATTS value (100%
rated kW) is set on the RAMP_DEM screen.
If the DEMAND LIMIT SOURCE (average 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
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
II 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 (or
forced via the Service Tool) 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 stopto-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 62, for more information on this topic.
OCCUPANCY SCHEDULE — The chiller schedule, described in the Time Schedule Operation section (page 23), 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 MAIN44
Faults or protective devices within the optional VFD can
shut down the chiller.
STAT 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.
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 62.
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 23.
Figure 20 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 default setting for both
LOCAL and CCN schedules is OCCUPIED all of the time.
The CCN SCHEDULE NUMBER is configured on the
NET_OPT display screen, accessed from the EQUIPMENT
CONFIGURATION table. See Table 3, 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 the new number into the SCHEDULE screen. See
Fig. 19.
CAUTION
If compressor motor overload occurs, check the motor for
grounded or open phases before attempting a restart.
If the PIC II 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, energizes
an alarm relay in the starter, and blinks the alarm light on the
control panel. The alarm is stored in memory and can be
viewed on the ALARM HISTORY and ISM_HIST screens on
the ICVC, along with a message for troubleshooting. If the
safety shutdown was also initiated by a fault detected in the
motor starter, the conditions at the time of the fault will be
stored in ISM_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 on page 99.
Pump and Fan Control — The Carrier PIC controls
are designed to control when cooler and condenser water
pumps and tower fans are turned on and off. This is accomplished through a series of relay contacts on the ISM within the
starter or optional VFD, and interface terminals are provided at
ISM terminal strip J9 (refer to the Carrier Installation Instructions and certified drawings). If primary control of water
pumps and tower fans is provided by customer-installed devices, a parallel means for the Carrier controls to independently
operate the pumps and fans must also be provided to protect
against freeze-up.
Shunt Trip (Option) — A main circuit breaker shunt trip
device is provided standard as a safety trip with all unit-mounted starters, and is optional on other starters and some VFDs.
When a shunt trip is provided, it is wired from an output on the
ISM to the associated coil on the shunt trip equipped motor circuit breaker. The shunt trip is activated by ISM logic, based on
values entered in the ISM_CONF table, under any of the following conditions:
• Motor locked rotor amps limit exceeded
• Starter locked rotor amps rating exceeded
• Ground fault or phase-to-phase current fault limit
exceeded (when that option is included)
• Significant motor current detected more than 20 seconds
after a shutdown or otherwise when the chiller is off
• 1M and 2M auxiliary contacts closed when the chiller is
off.
In addition, starters may be designed to shunt trip based on
other starter-specific conditions or features. For example, Benshaw solid state starters include several such protective circuits.
The shunt trip is also activated if EVAPORATOR PRESSURE
drops below 0 psig (0 kPa). The Shunt Trip feature can be tested using the Control Test feature.
Safety Controls — The PIC II 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 condenser water pressure drop (optional)
• high, low, or loss of voltage
• ground fault
• voltage imbalance
• current imbalance
• excessive motor acceleration time
• excessive starter transition time
• lack of motor current signal
• excessive motor amps
• excessive compressor surge
• temperature and transducer faults
*Superheat is the difference between saturation temperature
(CONDENSER REFRIGERANT TEMPERATURE) and
sensible temperature (COMPRESSOR DISCHARGE TEMPERATURE). The high discharge temperature safety measures only sensible temperature.
Function Loss Trip — The Function Loss Trip device
is provided standard as a safety trip with all unit-mounted
VFDs. When provided, the function loss trip is wired from an
output on the ISM to the VFD regulator board on the function
loss terminal. The function loss trip is activated by ISM logic,
based on values entered in the ISM _ CONF table.
45
Table 6 — Protective Safety Limits and Control Settings
MONITORED PARAMETER
Temperature Sensors Out of
Range
Pressure Transducers Out of
Range
STATE
260-270,
272,140,
141
260-270
231
Compressor Discharge
Temperature
149
103

Motor Winding Temperature
233
Motor Winding Temperature
102
Compressor Thrust Bearing
Temperature
101
Compressor Thrust Bearing
Temperature
150
Compressor Thrust Bearing
Temperature
234
243
232
Low Refrigerant Temperature
(Freeze Protection)
104
Transducer Voltage Fault
High Condenser Pressure Control
239
High Condenser Pressure Prestart
106
Low Discharge Superheat
240
235
207
Condenser High Pressure Switch
Circuit
224
235
244
Low Condenser Pressure (Freeze
Protection)
154
Oil - Low Pressure
312
228
LIMIT
COMMENTS
Temperature <-40 deg F or >245 deg F for
3 seconds
Preset Alarm
.06>Voltage Ratio>.98 for 3 seconds, Valid Range Preset Alarm, Voltage Ratio=Input Voltage/
is > -6.7 PSI and < 420 PSI
Voltage Reference (5 Volts)
COMP DISCHARGE TEMP > 220 deg F
Preset Alarm,
(104.4 deg C)
COMP DISCHARGE TEMP > COMP DISCHARGE Configure COMP DISCHARGE ALERT in
ALERT
SETUP1 screen
COMP DISCHARGE TEMP > COMP DISCHARGE
Prestart Alert, Configure COMP DISALERT - 10 deg F(5.6 deg C)
CHARGE ALERT in SETUP1 screen
COMP MOTOR WINDING TEMP > 220 deg F
Preset Alarm, Configure COMP MOTOR
(104 deg C)
TEMP OVERRIDE in SETUP1 screen
COMP MOTOR WINDING TEMP > COMP
Prestart Alert, Configure COMP MOTOR
MOTOR TEMP OVERRIDE - 10 deg F (5.6 deg C)
TEMP OVERRIDE in SETUP1 screen
COMP THRUST BRG TEMP > COMP THRUST
Prestart Alert, Configure COMP THRUST
BRG ALERT - 10 deg F (5.6 deg C)
BRG ALERT in SETUP1 screen
Configure COMP THRUST BRG ALERT in
COMP THRUST BRG TEMP > COMP THRUST
SETUP1 screen (rolling element bearings
BRG ALERT
have higher normal operating temperature
but within limit)
Configure COMP THRUST BEARING
RESET FACTOR (default = 1.4). Trip point
COMP THRUST BRG TEMP > COMP THRUST
varied by THRUST BEARING RESET. See
BRG TRIP
PIC II Functions > COMPRESSOR BEARING TEMPERATURE.
Chiller in RECYCLE SHUTDOWN and [CALC
Preset Alarm, configure EVAP REFRIG
EVAP SAT TEMP or EVAP REFRIG LIQUID TEMP]
TRIPPOINT in SETUP1 screen
< EVAP REFRIG TRIPPOINT + 1 deg F
Water chilling: EVAP REFRIG TEMP < 33 deg F
Preset Alarm, Configure EVAP
Brine Chilling: EVAP REFRIG TEMP<0-40 deg F APPROACH ALERT, EVAP REFRIG TRIP
(configurable) and EVAP APPROACH > EVAP
POINT and CHILLED MEDIUM in SETUP1
screen
APPROACH ALERT
Water Chilling: CALC EVAP SAT TEMP or EVAP
REFRIG LIQUID TEMP < 33 deg F + REFRIG
Prestart Alert, Configure REFRIG OVEROVERRIDE DELTA T
RIDE DELTA T, EVAP REFRIG TRIPBrine Chilling: CALC EVAP SAT TEMP or EVAP POINT and CHILLED MEDIUM in SETUP1
screen
REFRIG LIQUID TEMP < EVAP REFRIG TRIPPOINT
Voltage Reference < 4.5 VDC or > 5.5 VDC
Preset Alarm
Preset
Alarm,
Configure COND PRESS
CONDENSER PRESSURE > 165 PSI
OVERRIDE in SETUP1 screen
Prestart Alert, Configure COND PRESS
CONDENSER PRESSURE > COND PRESS
OVERRIDE in SETUP1 screen. Causes
OVERRIDE - 20 PSI or CONDENSER PRESSURE
condenser pump to start and remain on
> 145 PSI
through startup.
DISCHARGE SUPERHEAT < SUPERHEAT
Preset Alarm, DISCHARGE SUPERHEAT
REQUIRED - 3 deg F(1.7 deg C) for 60 seconds.
= COMP DISCHARGE TEMP - CONSUPERHEAT REQUIRED is calculated for current
DENSER REFRIG TEMP
conditions.
High Pressure Switch Circuit Open and START = Preset Alarm, High Pressure Switch resets
YES and CONDENSER PRESSURE > 160 PSI
at 110 +/-7 PSIG
High Pressure Switch Circuit Open, START = YES Preset Alarm, High Pressure Switch resets
and CONDENSER PRESSURE < 160 PSI
at 110 +/-7 PSIG
CONDENSER PRESSURE >165
PRESET ALARM
Energizes condenser pump relay if Chiller in
PUMPDOWN mode and CONDENSER REFRIG
TEMP < CONDENSER FREEZE POINT
De-energizes condenser pump relay when [CONPreset Alarm, Configure CONDENSER
DENSER REFRIG TEMP > CONDENSER
FREEZE POINT in SETUP1 screen.
FREEZE POINT + 5 deg F (2.8 deg C)] and
[ENTERING COND LIQUID > CONDENSER
FREEZE POINT]
Energizes condenser pump relay if CONDENSER
REFRIG TEMP < CONDENSER FREEZE POINT.
De-energizes condenser pump relay when [CONPreset Alarm, Configure CONDENSER
DENSER REFRIG TEMP > CONDENSER
FREEZE POINT in SETUP1 screen.
FREEZE POINT + 5 deg F (2.8 deg C)] and
[ENTERING COND LIQUID > CONDENSER
FREEZE POINT]
[OIL PRESSURE DELTA P < 18 PSID and START
= TRUE] or [ OIL PRESSURE DELTA P < 15 PSID Preset Alarm, Configure OIL PRESS VERand startup complete after OIL PRESS VERIFY
IFY TIME in SETUP1 screen
TIME elapsed]
46
Table 6 — Protective Safety Limits and Control Settings (cont)
MONITORED PARAMETER
STATE
Low Pressure
142
Oil - Pressure Sensor Fault
227
Oil - Low Temperature
105
211/145
211/145
Line Voltage - High
211/145
108
212/146
Line Voltage - Low
107
LIMIT
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 deg F and [OIL SUMP
TEMP < CALC EVAP SAT TEMP + 50 deg F(27.8
deg C)]
Line voltage > 150 % MOTOR RATED LINE VOLTAGE for 1 second
Line voltage > 115 % MOTOR RATED LINE VOLTAGE for 10 seconds
Line voltage > OVERVOLTAGE THRESHOLD for
OVER/UNDER VOLTAGE TIME
COMMENTS
Preset Alert
Preset Alarm
Prestart Alert
Preset Alarm / Alert if Autorestart is
enabled
Configure OVERVOLTAGE THRESHOLD
and OVER/UNDER VOLT TIME in
ISM_CONF screen
Configure OVERVOLTAGE THRESHOLD
in ISM_CONF screen
AVERAGE LINE VOLTAGE > OVERVOLTAGE
THRESHOLD
AVERAGE LINE VOLTAGE < 75% MOTOR RATED
LINE VOLTAGE for 1 second OR AVERAGE LINE
VOLTAGE < 80% MOTOR RATED LINE VOLTAGE
Preset Alarm/Alert Configure UNDERfor 5 seconds OR AVERAGE LINE VOLTAGE <
VOLTAGE THRESHOLD and OVER/
85% MOTOR RATED LINE VOLTAGE for 10 sec- UNDER VOLT TIME in ISM_CONF screen
onds OR AVERAGE LINE VOLTAGE < UNDERVOLTAGE THRESHOLD for > OVER/UNDER
VOLTAGE TIME
PERCENT LINE VOLTAGE < UNDERVOLTAGE
Prestart Alert, Configure UNDERVOLTAGE
THRESHOLD
THRESHOLD in ISM_CONF screen
Configure
VOLTAGE % IMBALANCE and
Line Voltage Imbalance > VOLTAGE % IMBALVOLTAGE IMBALANCE TIME in
ANCE for > VOLTAGE IMBALANCE TIME
ISM_CONF screen
Preset Alarm/Prestart Alert, Configure
Line Voltage on 2 Phases < 50% for 1 Cycle
SINGLE CYCLE DROPOUT in ISM_CONF
screen
Configure CURRENT % IMBALANCE and
Line Current Imbalance > CURRENT % IMBALCURRENT IMBALANCE TIME in
ANCE for > CURRENT IMBALANCE TIME
ISM_CONF screen
LINE FREQUENCY [<56 Hz or > 64 Hz] (60 Hz),
Preset Alarm
LINE FREQUENCY [<46 Hz or > 54 Hz] (50 HZ)
Any LINE VOLTAGE PHASE < 50% MOTOR
Condition must persist for 2 seconds
RATED LINE VOLTAGE
Minimum LINE CURRENT PHASE < 1/16 Maximum LINE CURRENT PHASE and Maximum LINE
Condition must persist for 1 seconds
CURRENT PHASE > 5% MOTOR RATED LOAD
AMPS
Loss of control power (brownout < 97 volts) to ISM
Preset Alarm
for excessive time period
Loss of control power (<18 volts) to ICVC for excesPreset Alarm
sive time period
Line Voltage - imbalance
216
Line Current -Single Cycle
Dropout
210/144
Current Imbalance
215
Power - Line Frequency Out of
Range
222
Phase Loss
209/143
Phase Loss
209/143
ISM Power on Reset
213/147
ICVC Power on Reset
214/148
Communication - Loss of
Communication
242
SIO Communication between ICVC and CCM lost
for more than 5 seconds
Preset Alarm
Loss of Communication with
Starter
241
SIO Communication between ICVC and ISM lost
for more than 5 seconds
Preset Alarm
1M Aux. contact fault
200
2M Aux. contact fault
201
Starter Fault
206
Compressor Surge
238
> 4 surge protection counts within SURGE TIME
PERIOD and VFD SPEED > 90%
Surge
236
> 4 surge protection counts within SURGE TIME
PERIOD and VFD SPEED < 90%
Aux. contacts open with 1CR = ON + 3 sec.
Aux. contacts open with 1CR/Transition = ON + 3
Sec
Starter Fault = Open w/1CR = ON
47
Preset Alarm
Preset Alarm
Preset Alarm, Check starter safety circuit
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
Table 6 — Protective Safety Limits and Control Settings (cont)
MONITORED PARAMETER
STATE
Overload Trip
217
Locked Rotor Trip
Excessive Amps
218
208
LIMIT
Any LOAD CURRENT PHASE > 108% for Excessive Time Period
Motor Locked Rotor Amps exceeded
PERCENT LOAD CURRENT > 110% for 30 sec.
Acceleration Fault (full voltage)
203
PERCENT LOAD CURRENT >100% at 10 sec
after 1CR closes (across the line)
Acceleration Fault (reduced
voltage)
203
PERCENT LOAD CURRENT >150% at 20 sec
after 1CR closes (reduced voltage)
Acceleration Fault (reduced
voltage)
203
PERCENT LOAD CURRENT >100% at 45 sec
after 1CR closes (reduced voltage)
Amps not Sensed
202
PERCENT LOAD CURRENT < 15% w/1M/2M
closed
Amps when Stopped
Failure to Stop
205
204
Failure to Stop
205
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
Starter Transition - 2M Start/Run
Fault
201
Ground Fault
220
Optional Limits - Spare
Temperature
158/159
Guide Vane Position
253
High Condenser Water Flow
254
Variable Diffuser Operation
247
Amp signal > 10% w/1M/2M open
1M/2M contacts fail to open
MOTOR AMPS WHEN STOPPED ( Amps > 10%
w/ 1CR OFF )
More than 8 starts in 12 hours
CHILLED LIQUID DELTA P < EVAP FLOW DELTA
P CUTOUT OR EVAPORATOR APPROACH >
EVAP APPROACH ALERT AND EVAP REFRIG
LIQUID TEMP < EVAP REFRIG TRIPPOINT + 1
OR CALC EVAP SAT TEMP < EVAP REFRIG
TRIPPOINT
CONDENSER LIQUID DELTA P < COND FLOW
DELTA P CUTOUT OR CONDENSER APPROACH
> CONDENSER APPROACH ALERT OR CONDENSER PRESSURE > COND PRESS OVERRIDE + 5
EVAPORATOR APPROACH > EVAP APPROACH
ALERT and startup complete
CONDENSER APPROACH > COND APPROACH
ALERT and startup complete
ACTUAL VFD SPEED > VFD SPEED OUTPUT +
10%
ISM 2M aux contact not closed after 20 sec from
start
GROUND FAULT CURRENT > GROUND FAULT
AMPS
SPARE TEMPERATURE > or < SPARE TEMP
LIMIT
During startup: ACTUAL GUIDE VANE POSITION
value> 4% after 4 minutes of closing; After startup
complete and running: (AGV) POSITION value >
103% or < -1%; (AGV) POS voltage input < 0.045
volts or > 3.25 volts
CONDENSER WATER DELTA P > CONDENSER
HIGH FLOW DELTA P LIMIT for more than
2 minutes.
Detects discharge pulses caused by incorrect diffuser position.
COMMENTS
Preset Alarm, Force ACTIVE DEMAND
LIMIT in MAINSTAT screen
Preset Alarm
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 Alarm, PERCENT LOAD CURRENT = AVERAGE LOAD CURRENT/
MOTOR RATED LOAD AMPS
Preset Alarm, PERCENT LOAD CURRENT = AVERAGE LOAD CURRENT/
MOTOR RATED LOAD AMPS
preset alarm
Shunt trip, if equipped
Shunt trip, if equipped
Preset Prestart Alert
Optional Alarm With ICVC DSABLE
FLOW DELTA P DISPLAY in SETUP1
screen Optional Alarm, All limits configurable in SETUP1 screen
Optional Alarm With ICVC DSABLE
FLOW DELTA P DISPLAY 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 30 sec.
Reduced voltage starters only
Configure GROUND FAULT AMPS in
ISM_CONF screen
Optional Alarm/Alert, Confirure SPARE
TEMP ENABLE and SPARE TEMP LIMIT
in SETUP1 screen
Preset Alarm
Optional Alarm. Configure COND HI
FLOW DEL P LIMIT in SETUP1 screen
Preset Alarm. Transducer measures
pulses, no on-screen pressure reading. No
calibration needed.
information can be viewed on the status screens and the
ISM_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.
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 (CL-15) 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
48
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 two methods of ramp loading with the PIC II.
Ramp loading can be based on chilled water temperature or on
motor load. Either method is selected from the RAMP__DEM
screen.
1. Temperature ramp loading (TEMP PULLDOWN RAMP)
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. The lowest temperature ramp loading rate will also be used if chiller power has been off for
3 hours or more (even if the motor ramp load is selected
as the ramp loading method).
NOTE: If chiller control power has been off for 3
hours or more, the next start-up (only) will follow the
minimum configurable temperature ramp 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 (MOTOR LOAD RAMP%/
MIN) limits the percent per minute rate at which the compressor motor current or compressor motor load increases. The LOAD PULLDOWN rate is configured by the
operator on the RAMP_DEM screen in amps or kilowatts. The point name is MOTOR LOAD RAMP%/MIN.
If kilowatts is selected for the DEMAND LIMIT SOURCE,
the MOTOR RATED KILOWATTS must be entered on the
RAMP_DEM screen (information found on the chiller Requisition form).
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 MOTOR LOAD
RAMP %/MIN may be viewed or modified on the
RAMP_DEM screen.
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.
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 II 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.)
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 compressor high 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. See the
Surge Prevention Algorithm section, page 53.
If the chiller is VFD-equipped, the guide vanes will be allowed to open during surge prevention if the VFD is at 100%
speed or forced and the chiller is in Ramp Loading or in Rampdown. Opening the vanes will assist in loading the compressor
to bring it out of the surge prevention range.
High Discharge Temperature Control — If the
discharge temperature 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 is then brought 5 F (2.8 C) below the control set point
temperature, the PIC II 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 control is regulated by the
PIC II, which uses 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 temperature is less than 150 F (65.6 C) and
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 is confirmed, the startup 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 temperature is less than the evaporator
refrigerant temperature plus 53 F (11.7 C). The oil heater is
turned off when the oil sump temperature is either
• more than 152 F (66.7 C), or
• more than 142 F (61.1 C) and more than the evaporator
refrigerant temperature plus 55 F (12.8 C).
Capacity Override (Table 7) — Capacity overrides can
prevent some safety shutdowns caused by exceeding the motor
amperage limit, refrigerant low temperature safety limit, motor
high temperature safety limit, and condenser high pressure
limit. In all cases there are 2 stages of compressor vane control.
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.
49
312
Table 7 — Capacity Overrides
OVERRIDE
CONDITION
(Configurable
Override
Paramter)
High Condenser
Pressure (COND
PRESS
OVERRIDE)
High Motor
Temperature
(COMP MOTOR
TEMP
OVERRIDE)
Low Evaporator
Temperature
(REFRIG
OVERRIDE
DELTA T)
High
Compressor Lift
(Surge
Prevention)
(SURGE/HGBP
DELTA T,P)
High
Compressor Lift
(Surge
Prevention)
(Tsmin, IGVmin,
Tsmax, IGVmax,
Shapefac)
Manual Guide
Vane Target
(TARGET GUIDE
VANE POS)
Manual Speed
Control
(TARGET VFD
SPEED)
FIRST STAGE SET POINT
(Capacity Inhibit)
SECOND STAGE SET POINT
(Forced Capacity Decrease)
OVERRIDE
TERMINATION
Value
Value
View/Modify on
ICVC Screen
Override Default
Value
Configurable Range
SETUP1
CONDENSER
PRESSURE > 125
PSIG (862 kPa)
90 to 165 PSIG
(621 to 1138 kPa)
SETUP1
COMP MOTOR
WINDING TEMP >
COMP MOTOR
TEMP OVERRIDE
threshold but <=
COMP MOTOR
TEMP OVERRIDE
threshold +10° F
150 to 200 F
(66 to 93 C)
SETUP1
CALC EVAP SAT
TEMP < EVAP
REFRIG TRIPPOINT + 3 F(1.7 C)
2 to 5 F
(1.1 to 2.8 C)
OPTIONS
Min T1: 1.5 F (0.8 C)
Min P1: 50 PSID
(345 kPa) Max T4:
10 F (5.6 C) Max P4:
85 PSID (586 kPad)
With VFD enabled,
VFD SPEED must
be at maximum
0.5 - 2.0 F (0.3 - 1.1 C)
30 - 170PSID (207 1172 kPad) 0.5 - 20 F
(0.3 - 11.1 C) 50 - 170
PSId (345 - 1172 kPad)
OPTIONS
Tsmain: 45 ^F
IGVmin: 5%
Tsmax: 70 ^F
IGVmax: 100%
shapefac: -0.04
0 to 150 ^F
0 to 110%
0 to 150 ^F
0 to 110%
-1 to 0
None
COMPRESS
Automatic
0 to 100%
None
COMPRESS
Motor Load
(ACTIVE
DEMAND LIMIT)
MAINSTAT
Low Discharge
Superheat
OVERRIDE
CONDENSER PRESSURE >
COND PRESS OVERRIDE + 2.4
PSIG (16.5 kPA)
CONDENSER PRESSURE < CONDENSER PRESS
OVERRIDE - 1 PSI
(6.9 kPa)
COMP MOTOR WINDING TEMP COMPR MOTOR
> COMP MOTOR TEMP OVER- WINDING TEMP <
RIDE + 10 F (5.6 C)
COMP MOTOR TEMP
OVERRIDE - 2 F
(1.1 C)
CALC EVAP SAT TEMP < EVAP
SAT OVERRIDE TEMP - 1 F (0.6
C) NOTE: EVAP SAT OVERRIDE
TEMP = EVAP REFRIG TRIPPOINT + REFRIG OVERRIDE
DELTA T
None
CALC EVAP SAT
TEMP > EVAP SAT
OVERRIDE TEMP +
2 F (1.1 C)
ACTIVE DELTA T >
SURGE/HGBP DELTA
T + SURGE/HGBP
DEADBAND
ActiveTsat < SurgeLine Tsat + Deadband Setting
Press RELEASE softkey after selecting
TARGET GUIDE
VANE POS
Press RELEASE softkey after selecting
TARGET VFD SPEED
Forced TARGET VFD SPEED
VFD MINIMUM SPEED cannot override either a capacity
to 100%
inhibit or a capacity decrease
command generated by the PIC II
AVERAGE LINE CURRENT or
AVERAGE LINE CURAVERAGE LINE
MOTOR PERCENT KILOWATTS RENT or MOTOR
CURRENT or
40 to 100%
> ACTIVE DEMAND LIMIT + 5% PERCENT KILOMOTOR PERCENT
WATTS < ACTIVE
KILOWATTS > 100%
DEMAND LIMIT
ACTUAL SUPERHEAT <
ACTUAL SUPERACTUAL SUPERSUPERHEAT REQUIRED - 0.5 F HEAT > SUPERHEAT
HEAT < SUPERNone
(0.3 C)
REQUIRED + 1 F
HEAT REQUIRED
(0.56 C)
for conditions
Automatic
50
refrigerant leak detector. Enabling REFRIGERANT LEAK OPTION (OPTIONS screen) will allow the PIC II controls to go
into an alarm state at a user configured level (REFRIGERANT
LEAK ALARM mA). The input is configured for 4 to 20 mA by
setting the DIP switch 1 on SW2 at the ON position, or configured for 1 to 5 vdc by setting switch 1 at the OFF position. The
output of the refrigerant leak detector is displayed as REFRIGERANT LEAK SENSOR on the MAINSTAT screen. For a 1 to
5 vdc input, 1 vdc input represents 4 mA displayed and 5 vdc
input represents 20 mA displayed.
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 60 seconds at the end of every 30 minutes).
The oil pump will not operate if the EVAPORATOR PRESSURE is less than –5 psig (–34.5 kPa).
Oil Cooler — The oil must be cooled when the compressor is running. This is accomplished through a small, plate-type
heat exchanger (also called the oil cooler) located behind the
oil pump. The heat exchanger uses liquid condenser refrigerant
as the cooling liquid. Refrigerant thermostatic expansion
valves (TXVs) regulate refrigerant flow to control the oil temperature entering the bearings. The bulbs for the expansion
valves are strapped to the oil supply line leaving the heat exchanger, and the valves are set to maintain 110 F (43 C).
NOTE: The TXVs are not adjustable. The oil sump temperature may be at a lower temperature during compressor operations.
Kilowatt Output — An output is available on the CCM
module [Terminal J8-1 (+) and J8-2 (–)] to represent the power
consumption of the chiller if a constant speed starter is used.
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. The output is
2 mA with the chiller off. The signal varies linearly from 4 mA
(representing 0% rated kilowatt consumption) to 20 mA (representing 100% rated kilowatt consumption). The rated peak
kilowatt consumption is configured by the user in the
RAMP_DEM display screen by the setting the MOTOR RATED KILOWATTS from the job data sheet.
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, 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. This
ensures that, if the automatic system is malfunctioning, the
chiller will not repeatedly cycle on and off.
If the REMOTE START OPTION is enabled, the remote
start contacts must be closed for the AUTO RESTART OPTION
(if enabled) to restart the chiller following a power failure.
Also, if the number of recycle shutdowns in a 4-hour period
exceeds five, then alert message 152 is displayed (and logged
into ALERT HISTORY) until the next required startup.
The contacts for remote start are wired into the starter at terminal strip J2, terminals 5 and 6 on the ISM. See the certified
drawings for further details on contact ratings. The contacts
must have 24 vac dry contact rating.
Remote Reset of Alarms — A standard feature of the
PIC II 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 can be placed back into
a normal CCN operating mode when the REMOTE RESET
OPTION (ICVC_PSWD menu) is set to ENABLE. A variety
of Carrier Comfort Network software systems including ComfortVIEW™ or Network Service Tool™ can access the PIC II
controls and reset the displayed alarm. Third party software
from building automation systems (BAS) or energy management systems (EMS) can also access the PIC II controls
through a UPC module and reset the fault displayed. Both
methods would access the ICVC_PSWD screen and force the
RESET ALARM? point to YES to reset the fault condition. If
the PIC II controls have determined that is safe to start the
chiller the CCN MODE? point (ICVC_PSWD screen) can be
forced to YES to place the chiller back into normal CCN operating mode. The only exceptions are the following alarms that
cannot be reset from a remote location: STATE numbers 100,
205, 217-220, 223, 233, 234, 247, and 250. To view alarm
codes, refer to Troubleshooting Guide, Checking Display Messages, page 100. After the alarm has been reset the PIC II control will increment the Starts in 12 Hours counter by one upon
restart. If the limit of 8 starts in a 12-hour period occurs, the
alarm (Alert State 100) will be required to be reset at the chiller
control panel (ICVC).
Spare Safety and Spare Temperature
Inputs — Normally closed (NC) discrete inputs for addi-
tional field-supplied safeties may be wired to the spare protective limits input channel in place of the factory-installed jumper. (Wire multiple inputs in series.) 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 Appendix B.
Condenser Pump Control — The chiller will moni-
tor the condenser pressure (CONDENSER PRESSURE) and
may turn on the condenser pump if the condenser pressure becomes too high while the compressor is shut down. The condenser pressure override (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 (ENTERING CONDENSER WATER) 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 or when the condenser refrigerant temperature (CONDENSER REFRIG TEMP) is
within 3 F (1.7 C) of the entering condenser water temperature (ENTERING CONDENSER WATER).
Alarm (Trip) Output Contacts — One set of alarm
contacts is provided in the starter. The contact ratings are provided in the certified drawings. The contacts are located on
ISM terminal strip J9, terminals 15 and 16.
Refrigerant Leak Detector — An input is available
on the CCM module [terminal J5-5 (–) and J5-6 (+)] for a
51
TER temperature is 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 WATER PUMP is off 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 (5.4 C).
Condenser Freeze Prevention — This control algo-
rithm helps prevent condenser tube freeze-up by energizing the
condenser pump relay. The PIC II controls the pump and, by
starting it, helps to prevent the water in the condenser from
freezing. The PIC II 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,
Potential Freeze Up) However, if the chiller is in pump down,
and when it entered pump down mode, the CONDENSING
REFRIG TEMP was more than 5° F (2.7° C) above the CONDENSER FREEZE POINT, the same low temperature condition will generate Alarm State 244 (Potential Freeze Up) 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 nonrecycle shutdown.
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. While the tower fan
relay outputs described above are not a substitute for a
complete condenser water control system, they can serve as
useful inputs to such a system.
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 fault
alerts: single cycle dropout (if enabled), line current imbalance,
high line voltage, low line voltage, ISM power on reset, and
ICVC power on reset (Alerts 143-148). With this feature enabled, these faults are treated as alerts instead of alarms, so startup proceeds as soon as the condition is rectified. The 15-minute
start-to-start 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, the compressor starts with the slowest temperature-based ramp load
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 60 seconds at the end of
every 30-minute period until the chiller is started.
Evaporator Freeze Protection — When the EVAP-
ORATOR 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.
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 starter, are controlled by the PIC II 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, and the difference between
EVAPORATOR PRESSURE 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 or the EVAP REFRIGERANT TEMP is less than
the EVAP SAT 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)
and ENTERING CONDENSER WATER TEMPERATURE is
less than 80 F (27 C).
TOWER FAN RELAY HIGH is turned on whenever the condenser water pump is running and the difference between
EVAPORATOR PRESSURE and CONDENSER PRESSURE is
more than 30 psid (206.8 kPad) and ENTERING COND WA-
Fast Power Source Transfers — When the electri-
cal 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 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
52
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.
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
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 to 20 mA input).
In order to utilize a 1 to 5 vdc input, a 25-ohm resistor must be
wired in series with the + input lead (J5-4). For either input
type, SW2 DIP switch 2 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 the chiller (DEGREES RESET). Reset Type 2 can now
be activated.
RESET TYPE 3 — Reset Type 3 is an automatic chilled water
temperature reset based on cooler temperature difference.
Reset Type 3 adds ± 30 F (± 16 C) based on the temperature
difference between the entering 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.
Surge Prevention — Constant Flow and Variable Primary Flow (VPF) — 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.
There are two possible surge prevention methods used in
the 19XR PIC II chiller. Prior to April 2010, on machines with
software version 8 or lower, Chilled Water T compared to
Cooler-Condenser P was compared to a configured surge
line. Originally the line was straight and configured with two
points. More recently the line was configured with four points.
This method was designed around constant flow chilled water
systems.
From April 2010 (serial number 1410Qxxxxx) and later,
and in machines converted to software version 9 or higher, the
Surge Prevention algorithm has been changed to eliminate the
measurement of Chilled Water T in order to accommodate
Variable Primary Flow (VPF) chilled water systems.
Variable Flow Surge prevention is the current standard for
both constant and variable primary flow chilled water systems.
Variable Primary Flow Surge Prevention does not require 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.
In both surge prevention methods 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 or stepped 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 and variable
speed drive.
SURGE PREVENTION ALGORITHM — The surge prevention algorithm first determines if corrective action is necessary. The algorithm checks 4 sets of operator-configured data
points, MIN LOAD POINT (T1/P1), the LOW LOAD POINT
(T2/P2), the MID LOAD POINT (T3/P3) and the FULL LOAD
POINT (T4/P4). These surge characteristics are factory set
based on the original selection, with the values printed on a label affixed to the bottom interior face of the control panel.
The surge prevention algorithm function and settings are
graphically displayed in Fig. 25. The four sets of load points
on the graph (sample settings are shown) describe a line the algorithm uses to determine the maximum lift of the compressor.
When the actual differential pressure between the cooler and
condenser and the temperature difference between the entering
and leaving chilled water are above the line on the graph (as
defined by the minimum and full load points), the algorithm
goes into a surge prevention mode. If the actual values are below the line and outside of the deadband region, the algorithm
takes no action. When the point defined by the ACTIVE DELTA P and ACTIVE DELTA T, moves from the region where
Demand Limit Control Option — The demand limit
control option (20 mA DEMAND LIMIT OPT) is externally
controlled by a 4 to 20 mA or 1 to 5 vdc signal from an energy
management system (EMS). The option is set up on the
RAMP_DEM screen. When enabled, 4 mA is the 100% demand set point with an operator-configured minimum demand
at a 20 mA set point (DEMAND LIMIT AT 20 mA).
The auto. demand limit is hardwired to terminals J5-1 (–)
and J5-2 (+) on the CCM. Switch setting number 3 on SW2
will determine the type of input signal. With the switch set at
the ON position the input is configured for an externally powered 4 to 20 mA signal. With the switch in the OFF position the
input is configured for an external 1 to 5 vdc signal. In order to
53
and in Table 3. The Default settings use one set of values for
the low, mid, and full load points. These surge characteristics
are factory set based on the original selection, with the values
printed on a label fixed to the bottom of interior face of the control panel. A line is drawn between these points as shown in
Fig. 25. Sample points for a four point line are shown.
Whenever the ACTIVE DELTA T (actual temperature difference between the LEAVING CHILLED WATER and ENTERING CHILLED WATER) is on the left side of the line plotted in Fig. 25, the algorithm will energize the hot gas bypass
valve to falsely load the compressor. If the ACTIVE DELTA T
falls to the right side of the line plotted in Fig 25 by more than
the HGBP DEADBAND, the hot gas bypass valve is deenergized. The HGBP valve is also deenergized if the ACTIVE
DELTA P (actual difference between CONDENSER PRESSURE and EVAPORATOR PRESSURE) falls below HGBP
DELTA P1.
If the chiller is used for other than its original design conditions, instructions to configure the MIN LOAD POINT (T1/P1)
and FULL LOAD POINT (T4/P4) are on page 73. Use the T4
value for T2 and T3 also. Use the P4 value for P2 and P3 also.
HGBP OPTION = 1 (Constant Flow Units with VFD
Option Enabled) — 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 = 1 (Variable Primary Flow Units with
VFD Option Disabled) — The algorithm determines if corrective action is necessary by checking the chiller operating
point against an operator configured threshold. The threshold is
calculated from a combination of GUIDE VANE POSITION
and the difference between CONDENSER PRESSURE and
EVAPORATOR PRESSURE. The operator configured data
points are the MINIMUM and MAXIMUM SATURATED
TEMPERATURE DIFFERENCE (Surge/HGP Delta Tsmin
and Surge/HGBP DeltaTsmax), the MAXIMUM AND MINIMUM GUIDE VANE POSITIONS (Surge/HGBP IGVmax
and Surge/HGBP IGVmin) printed on a label fixed to the bottom of interior face of the control panel. A line is calculated between these points.
Whenever the ACTUAL GUIDE VANE POSITION is on the
left side of the plotted line, the algorithm will energize the hot
gas bypass valve to falsely load the compressor. If the ACTUAL GUIDE VANE POSITION falls to the right side of the plotted line by more than the SURGE/HGBP DEADBAND, the hot
gas bypass valve is deenergized.
If the chiller is used for other than its original design conditions, instructions to adjust the Surge / Hot Gas Bypass configurations are found on page 80.
HGBP OPTION = 1 (Variable Primary Flow Units with
VFD Option Enabled) — 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 (Constant Flow and Variable Primary
Flow Units) — 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
the HOT GAS BYPASS/SURGE PREVENTION is off, the
point must pass through the deadband region to the line determined by the configured values before the HOT GAS BYPASS/SURGE PREVENTION will be turned on. As the point
moves from the region where the HOT GAS BYPASS/
SURGE PREVENTION is on, the point must pass through the
deadband region before the HOT GAS BYPASS/SURGE
PREVENTION is turned off. Information on modifying the default set points of the minimum and full load points may be
found in the Input Service Configurations section, page 55.
The state of the surge/hot gas bypass algorithm on the
HEAT_EX DISPLAY SCREEN (Surge/HGBP Active?).
Corrective action can be taken by making one of 2 choices.
If a hot gas bypass line is present and the hot gas option is selected on the OPTIONS table (SURGE LIMIT/HGBP OPTION
is set to 1), the hot gas bypass valve can be energized.
If the hot gas bypass option is not selected (SURGE LIMIT/
HGBP OPTION is set to 0), prevent the guide vane opening
from increasing. See Table 7, Capacity Overrides. Both of
these corrective actions try to reduce the lift experienced by the
compressor and help prevent a surge condition.
100
(10.3, 91)
90
HGBP/SURGE PREVENTION ON
P (psid)
80
HGBP
DEADBAND
(7.9, 76.4)
70
(2.6, 64.4)
60
HGBP/SURGE PREVENTION OFF
50
40
(0.9, 41.3)
Sample Points are not defaults
30
0
2
4
6
8
10
12
T (F)
ECW
HGBP
LCW
LEGEND
— Entering Chilled Water
— Hot Gas Bypass
— Leaving Chilled Water
P = (Condenser Pressure) – (Cooler Pressure)
T = (ECW) – (LCW)
a19-1862
Fig. 25 — 19XR Surge Prevention/Hot Gas Bypass
Option 1 (Constant Flow with VFD Option
Disabled)
Hot Gas Bypass (Optional) Algorithm — If a
hot gas bypass solenoid valve is present and the HGBP OPTION in the OPTIONS table is set to 1 or 2, this operator configurable feature can determine if load conditions are too low
for the compressor and corrective action can be taken.
HGBP OPTION = 0 — The HGBP algorithm is disabled.
HGBP OPTION = 1 (Constant Flow Units with VFD
Option Disabled) — The algorithm determines if corrective
action is necessary by checking the chiller operating point
against an operator configured threshold. The threshold is calculated from a combination of the difference between ENTERING CHILLED WATER and LEAVING CHILLED WATER
and the difference between CONDENSER PRESSURE and
EVAPORATOR PRESSURE.
The operator configured data points in version 8 software
and prior software versions are the MIN LOAD POINT (T1/
P1), the LOW LOAD POINT (T2/P2), the MID LOAD
POINT (T3/P3) and the FULL LOAD POINT (T4/P4). These
points have default settings defined in the OPTIONS screen
54
to the sum of HGBP ON DELTA T plus HGBP OFF DELTA T
See Fig. 26.
Surge Prevention Algorithm with VFD — 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.
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. This
area is illustrated in Fig. 25.
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 and 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.
SURGE PREVENTION — VERSION 8 SOFTWARE
AND EARLIER — The surge prevention algorithm first determines if corrective action is necessary. The algorithm checks
four sets of operator-configured data points, the lower surge
point (MIN. LOAD POINT [T1,P1]), the low surge point
(LOW LOAD POINT [T2,P2]), the middle surge point (MID
LOAD POINT [T3,P3]), and the upper surge point (MAX
LOAD POINT [T4,P4]). The surge characteristics vary between different chiller configurations and operating conditions.
The surge characteristics are factory set based on the original
selection with the values displayed inside the control panel of
the chiller. Since operating conditions may affect the surge prevention algorithm, some field adjustments may be necessary.
The surge prevention algorithm function and settings are
graphically displayed on Fig. 25. The two sets of load points on
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
HGBP ON
DELTA T
∆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. 26 — 19XR Hot Gas Bypass/Surge
Prevention (Option 2)
Surge Protection (Fixed Speed Chiller) — The
PIC II monitors surge, which results in a fluctuation on the
compressor motor amperage. Each time the fluctuation in amperage exceeds an operator-specified limit (SURGE DELTA %
AMPS) plus a load correction factor, both SURGE COUNTS
and SURGE PROTECTION COUNTS are incremented by
one. If more than 4 SURGE PROTECTION COUNTS occur
within an operator-specified time (SURGE TIME PERIOD),
the PIC II declares an Excessive Compressor Surge Alarm
(238) and the chiller is shut down. Both SURGE COUNTS
and SURGE PROTECTION COUNTS are decreased by one if
no surges occur within the SURGE TIME PERIOD.
With version 10 and higher software — If a surge occurs,
the guide vane position will be reduced by 10%. The guide
vanes will be prevented from increasing position until either
the Surge Time Period expires causing the SURGE PROTECTION COUNT to return to zero or the Entering Condenser
Water temperature decreases by 1 degree or the leaving condenser water temperature increases by 1 degree.
If the machine has a split ring diffuser a correction its position will be made simulatneously.
The threshold at which a current fluctuation is interpreted as
a surge can be adjusted from the OPTIONS screen. Scroll to
the SURGE DELTA % AMPS parameter and use the INCREASE or DECREASE softkey to adjust the surge threshold.
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 time duration. 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.
55
the graph (default settings are shown) describe a line the algorithm uses to determine the maximum lift of the compressor for
the particular maximum operating speed. When the actual differential pressure between the cooler and condenser (delta P)
and the temperature difference between the entering and leaving chilled water (delta T) are above the line on the graph (as
defined by the minimum and full load points), the algorithm
operates in Surge Prevention mode. This is determined when
the ACTIVE DELTA T is less than SURGE/HGBP DEADBAND.
When in Surge Prevention mode, with a command to increase capacity, the VFD speed will increase until maximum
VFD speed is reached. At VFD MAXIMUM SPEED, when Capacity still needs to increase, the IGV’s open. When in Surge
Prevention mode and with a command to decrease capacity
only the IGVs will close, the VFD speed will not decrease.
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 Setpoint. 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.
Surge Protection (VFD Chiller) — The PIC II mon-
Head Pressure Reference Output (See
Fig. 27) — The PIC II control outputs a 4 to 20 mA signal
itors surge, which results in a fluctuation on the compressor
motor amperage. Each time the fluctuation in amperage exceeds an operator-specified 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 operatorspecified time (SURGE TIME PERIOD) and the ACTUAL
VFD SPEED is greater than 90% then the PIC II 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 the TARGET VFD SPEED will be increased 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.
for the configurable Delta P (CONDENSER PRESSURE minus EVAPORATOR PRESSURE) reference curve shown in
Fig. 27. An output is available on the ISM module [Terminal
J8-3 (+), J8-4 (–) labeled spare]. The DELTA P AT 100% (chiller at maximum load condition default at 50 psi [344 kPa]),
DELTA P AT 0% (chiller at minimum load condition default at
25 psi [172.4 kPa]) 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 output 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. The output is 2 mA when the chiller is not
running.
DELTA P
AT 100%
DELTA P
MINIMUM
REFERENCE
OUTPUT
DELTA P
AT 0%
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
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 II controls internally
set the VFD TARGET SPEED to the smaller of the VFD
MAXIMUM SPEED or the VFD START SPEED. Provided
0 mA 2 mA 4 mA
(0%)
4 T0 20 mA OUTPUT
20 mA
(100%)
Fig. 27 — Head Pressure Reference Output
(Minimum Set Above 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
56
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 II 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
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 the user is 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 displayed.
The lead/lag maintenance screen (LL_MAINT) displays the
message ‘INVALID CONFIG’ in the LEADLAG: CONFIGURATION and CURRENT MODE fields. See Table below.
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. 18 and 19 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 3, Example 23.
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 3, Example 13.
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 II
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 — Refer to 19XR,XRV Lead Lag Schematics, Appendix B. Lead/lag operation does not require a common point
chilled water sensor. Common point sensors (Spare Temp#1
and #2) may be added as described below, if desired.
If using leaving chilled water control (ECW CONTROL
OPTION is set to 0 [DSABLE] on the TEMP_CTL screen) and
a common point sensor is desired (COMMON SENSOR OPTION in LEADLAG screen selected as 1) then the sensor is
wired into the Spare Temp #1 position on the CCM (terminals
J4-25 and J4-26).
If the entering chilled water control option is enabled (ECW
CONTROL OPTION is selected to 1 [configured in the
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).
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 II cannot read the value of common point sensors installed on the other chillers in the chilled water system.
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 a common point sensor should be
used (preferred), or the ENTERING CHILLED WATER sensor
of the downstream chiller must be relocated to the ENTERING
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
LEAD/LAG
CONFIGURATION
1 (Lead)
2 (Lag)
INVALID
CONDITIONS
Local Addres (Lead) = Lag Address
Standby Chiller Option = Enable AND Local
Address (Lead) = Standby Address
Standby Chiller Option = Enable AND Local
Address (Lag) = Standby Address
Local Addres (Lead) = Lag Address
Standby Chiller Option = Enable AND Local
Address (Lag) = Standby Address
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 II evaluates the need for additional capacity. If additional capacity is needed, the PIC II 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.
57
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 compressor motor average line current or
load value (MOTOR PERCENT KILOWATTS on the
MAINSTAT screen) is less than the lead chiller percent
capacity, which is defined as 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
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, based on its configured 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.
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 II 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
58
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.
CURRENT on the MAINSTAT screen) is less than the
lead chiller percent capacity.
NOTE: The use of AVERAGE LINE CURRENT or PERCENT MOTOR KILOWATTS in the Lag chiller shutdown
decision is based on the DEMAND LIMIT SOURCE configuration in the RAMP_DEM screen. If DEMAND LIMIT
SOURCE = 0 then AVERAGE LINE CURRENT will be
used. If DEMAND LIMIT SOURCE = 1 then PERCENT
MOTOR KILOWATTS will be used.
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 MAINSTAT screen). This value has limits of 40% to 100%. In addition, the CONTROL POINT for the lag chiller will 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 II 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
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 II
must be in CCN mode.
The PIC II 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 3, Example 19A or 19B.
• The ICE BUILD SETPOINT can be configured from the
SETPOINT display, which is accessed from the PIC II
main menu. See Table 3, 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. 20 and the
section on Time Schedule Operation, page 23, 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
on the OPTIONS screen.
• the REMOTE CONTACT inputs 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 set
point and the remote contact inputs 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 (OCCP02S) has
been reached.
ICE BUILD INITIATION — The ice build time schedule
(OCCPC02S) is the means for activating the ice build option.
The ice build option 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
59
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 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 — Compressor 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 remote
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.
from another CCN device, or changed by other algorithms in
the PIC II 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 II 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 remote contacts are 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 remote contacts are
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 II 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 II
goes into an ICE BUILD RECYCLE mode, and the chilled
water pump relay remains energized to keep the chilled
water flowing when the compressor shuts down. If the temperature of the LEAVING CHILLED WATER later increases
above the ICE BUILD SETPOINT plus half the RECYCLE
RESTART DELTA T value, the compressor restarts, controlling the chilled water/brine temperature to the ICE BUILD
SETPOINT.
TEMPERATURE CONTROL DURING ICE BUILD —
During ice build, the capacity control algorithm shall use the
CONTROL POINT minus 5 F (–2.8 C) for control of the
LEAVING CHILLED WATER temperature. The ECW CONTROL OPTION and any temperature reset option shall be ignored, if enabled, during ice build. Also, the following control
options will be ignored during ice build operation:
• ECW CONTROL OPTION and any temperature reset
options (configured on TEMP_CTL screen).
• 20 mA DEMAND LIMIT OPT (configured on
RAMP_DEM screen).
TERMINATION OF ICE BUILD — The ice build function
terminates under the following conditions:
1. Time Schedule — When the current time on the ice build
time schedule (OCCPC02S) is not set as an ice build time
period.
2. Entering Chilled Water Temperature — Ice build operation terminates, based on temperature, if the ICE BUILD
TERMINATION parameter is set to 0 (TEMP), the ENTERING CHILLED WATER temperature is less than the
ICE BUILD SETPOINT, and the ICE BUILD RECYCLE
is set to DSABLE. If the ICE BUILD RECYCLE OPTION is set to ENABLE, a recycle shutdown occurs and
recycle start-up depends on the LEAVING CHILLED
WATER temperature being greater than the water/brine
CONTROL POINT plus the RESTART DELTA T
temperature.
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 PIC-controlled chillers.
• upgrade software
Figure 28 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. 19. Default address for local device is
BUS 0 ADDRESS 1.
Fig. 28 — Example of Attach to Network
Device Screen
When the ATTACH TO NETWORK DEVICE screen is accessed, information can not be read from the ICVC on any device (including the local chiller) 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
60
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:
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.
ATTACHING TO OTHER CCN MODULES — If the chiller ICVC has been connected to a CCN network or other PIC
controlled chillers through CCN wiring, the ICVC can be used
to view or change parameters on the other controllers. Other
PIC II 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. 17.
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 19XR chiller 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.
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
• ISM (Starter) Config Data
• Equipment Service
• Time and Date
• Attach to Network Device
• Log Out of Device
• ICVC Configuration
See Fig. 19 for additional screens and tables available from
the SERVICE screens listed above. Use the EXIT softkey to
return to the main MENU screen.
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
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.
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. 29) — 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. 29, 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. 20.) A run time period which is enabled for holidays may
be applied to one or more non-holiday days of the week as well.
Service Operation — An overview of the tables and
screens available for the SERVICE function is shown in
Fig. 19.
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.
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
61
DAYLIGHT SAVING TIME CONFIGURATION — The
BRODEF table also defines Daylight Saving Time 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 Daylight Savings Time “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.”
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 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 daylightsavings dates throughout the network.
To access the BRODEF screen, see the SERVICE menu
structure, Fig. 19.
To view or change the holiday periods for up to 18 different
holidays, perform the following operation:
1. At the Menu screen, press SERVICE to access the Service menu.
2. If not logged on, follow the instructions for Attach to Network Device or To Log Out. Once logged on,
press NEXT until Equipment Configuration is highlighted.
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.
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.
Table 8 — Daylight Saving Time Values
ITEM
Month
Day of Week
Week
Time
Advance/Back
DEFINITION
1 = January, 2 = February, …,
12 = December.
1 = Monday,…, 7 = Sunday
1 = first occurrence of selected
Day of Week in the selected
month, 2 = second occurrence
of the selected Day, etc. This is
not necessarily what one would
conclude from looking at a
standard calendar. For example,
April 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).
START-UP/SHUTDOWN/
RECYCLE SEQUENCE (Fig. 30)
Local Start-Up — Local start-up (or a manual start-up) is
initiated by pressing the LOCAL menu softkey on the default
ICVC screen. Local start-up can proceed when the chiller
schedule indicates that the CURRENT TIME and CURRENT
DATE have been established as a run time and date, and after
the internal 15-minute start-to-start and the 1-minute stop-tostart inhibit timers have expired. These timers are represented
in the START INHIBIT TIMER and can be viewed on the
MAINSTAT screen and DEFAULT screen. The timer must expire before the chiller will start. If the timers have not expired
the RUN STATUS parameter on the MAINSTAT screen now
reads TIMEOUT.
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 23), Occupancy
Schedule (page 44), and To Prevent Accidental Start-Up
(page 89), and Fig. 20.
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.
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.
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
Fig. 29 — Example of Holiday Period Screen
9. Press SELECT to modify the month, day, or duration.
10. Press INCREASE or DECREASE to change the selected value.
11. Press ENTER to save the changes.
12. Press EXIT to return to the previous menu.
62
Failure to verify any of the requirements up to this point will
result in the PIC II aborting the start and displaying the applicable pre-start alert 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 1CR relay 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.
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 II performs a series of
pre-start tests to verify that all pre-start alerts and safeties are
within the limits shown in Table 9. 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/brine pump relay energizes, and the MAINSTAT screen line now reads STARTUP.
Five seconds later, the condenser pump relay energizes.
Thirty seconds later the PIC II 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 II turns off the condenser
pump relay and goes into a RECYCLE mode.
NOTE: The 19XR units equipped with ICVC are not available
with factory installed chilled water or condenser water flow
devices (available as an accessory for use with the CCM control board). In place of the cooler and condenser water pressure
inputs on the CCM is a 4.3 kilo-ohm resistor and a jumper
lead.
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 waits until the
PIC II closes the vanes. If the vanes are closed and the oil pump
pressure is less than 4 psi (27.6 kPa), the oil pump relay energizes. The PIC II then waits until the oil pressure (OIL PRESS
VERIFY TIME, operator-configured, default of 40 seconds)
reaches a maximum of 18 psi (124 kPa). After oil pressure is
verified, the PIC II waits 40 seconds, and the compressor start
relay (1CR) 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.
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).
Fig. 30 — Control Sequence
Table 9 — Prestart Checks
QUANTITY CHECKED
STARTS IN 12 HOURS
COMP THRUST BRG TEMP
COMP MOTOR WINDING TEMP
COMP DISCHARGE TEMP
EVAP REFRIG LIQUID TEMP
OIL SUMP TEMP
CONDENSER PRESSURE
PERCENT LINE VOLTAGE
PERCENT LINE VOLTAGE
ACTUAL GUIDE VANE POS
REQUIREMENT
< 8 (not counting recycle restarts or auto restarts after power failure)
ALERT is cleared once RESET is pressed.
< [COMP THRUST BRG ALERT] –10° F (5.6° C)
< [COMP MOTOR TEMP OVERRIDE] –10° F (5.6° C)
< [COMP DISCHARGE ALERT] –10° F (5.6° C)
< [EVAP REFRIG TRIPPOINT] + [REFRIG OVERRIDE DELTA T]
< 150° F (65.5° C) or <[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
63
ALERT STATE IF FALSE
100
101
102
103
104
105
106
107
108
109
The soft stop amps threshold function can be terminated and
the compressor motor deenergized immediately by depressing
the STOP button twice.
Shutdown Sequence — Chiller shutdown begins if
any of the following occurs:
• the STOP button is pressed continuously for at least one
second (the alarm light blinks once to confirm the stop
command)
• 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 start relay (1CR). 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, or the starter contacts remain energized,
the oil pump and chilled water pump remain energized,
the SHUNT TRIP relay is 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 (3 C).
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.
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 (3 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 RESTART DELTA T.
• in ECW CONTROL and the ENTERING CHILLED
WATER temperature is greater than the CONTROL
POINT plus the RECYCLE 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
RECYCLE 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.
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%.
When the soft stop amps threshold feature is being applied,
a status message, “SHUTDOWN IN PROGRESS, COMPRESSOR UNLOADING” displays on the ICVC.
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.
64
• 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.
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
• 19XR Installation Instructions
Check Chiller Tightness — Figure 32 outlines the
proper sequence and procedures for leak testing.
The 19XR 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) nitrogen-holding 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.
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.
Equipment Required
• mechanic’s tools (refrigeration)
• digital volt-ohmmeter (DVM)
• true RMS digital multimeter with clamp-on current
probe or true RMS digital clamp-on ammeter for at least
480 vac or 700 vdc (19XRV only).
• electronic leak detector
• absolute pressure manometer or wet-bulb vacuum
indicator (see Fig. 31)
• 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
Refrigerant Tracer — Carrier recommends the use of an
environmentally acceptable refrigerant tracer for leak testing
with an electronic detector.
Ultrasonic leak detectors can also be used if the chiller is
under pressure.
WARNING
Do not use air or oxygen as a means of pressurizing the
chiller. Mixtures of HFC-134a and air can undergo
combustion.
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. Refer to 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 pumpout procedures in the Transfer Refrigerant from Pumpout Storage Tank to Chiller section, Steps 1a-e, page 93.
Fig. 31 — Typical Wet-Bulb Type
Vacuum Indicator
Using the Optional Storage Tank and Pumpout System — Refer to Positive Pressure Chillers with
Storage Tanks section, page 92 for pumpout system preparation, refrigerant transfer, and chiller evacuation.
Remove Shipping Packaging — Remove any packaging material from the control center, power panel, guide vane
actuator, motor cooling and oil reclaim solenoids, motor and
bearing temperature sensor covers, and the factory-mounted
starter.
WARNING
Open Oil Circuit Valves — Check to ensure the oil fil-
Never charge liquid refrigerant into the chiller if the pressure in the chiller is less than 35 psig (241 kPa) for HFC134a. 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 II. Flashing of liquid refrigerant at
low pressures can cause tube freeze-up and considerable
damage.
ter isolation valves (Fig. 4) are open by removing the valve cap
and checking the valve stem.
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
c. Leak test chiller as outlined in Steps 3 - 9.
65
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
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 69.
h. Slowly raise the system pressure to a maximum of
160 psig (1103 kPa) but no less than 35 psig
(241 kPa) for HFC-134a by adding refrigerant.
Proceed with the test for small leaks (Steps 3-9).
3. Check the chiller carefully with an electronic leak detector or soap bubble solution.
4. Leak Determination — If an electronic leak detector indicates a leak, use a soap bubble solution, if possible, to
confirm. Total all leak rates for the entire chiller. Leakage
5.
6.
7.
8.
9.
66
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
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. 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.
If a leak is found after a retest, pump the refrigerant back
into the pumpout storage tank or, if isolation valves are
present, pump the refrigerant into the non-leaking vessel.
See the Transfer Refrigerant from Pumpout Storage
Tank to Chiller section on page 93.
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.)
67
Fig. 32 — 19XR Leak Test Procedures
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
68
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
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.
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 to at least 18 in. Hg vac, ref 30-in. bar
(41 kPa), using a vacuum pump or the pump out unit.
3. Valve off the pump to hold the vacuum and record the
manometer or indicator reading.
4. a. If the leakage rate is less than 0.05 in. Hg (0.17 kPa) in
24 hours, the chiller is sufficiently tight.
b. 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. 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.
5. Repair the leak, retest, and proceed with dehydration.
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.
Fig. 33 — Dehydration Cold Trap
CAUTION
Inspect Water Piping — Refer to piping diagrams pro-
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.
vided in the certified drawings and the piping instructions in
the 19XR Installation Instructions manual. 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
and condenser must meet job requirements. Measure the pressure drop across the cooler and the condenser.
WARNING
Starters must be disconnected by an isolation switch before
placing the machine under a vacuum. To be safe, isolate
any starter before evacuating the chiller if you are not sure
if there are live leads to the hermetic motor.
CAUTION
Water must be within design limits, clean, and treated to
ensure proper chiller performance and to 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.
Dehydration can be done at room temperatures. Using a
cold trap (Fig. 33) 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.
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.
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 19XR relief valves are set to relieve at the 185 psig
(1275 kPa) chiller design pressure.
69
c. Divide the 60-second resistance reading by the
10-second reading. The ratio, or polarization
index, must be one or higher. Both the 10 and
60-second readings must be at least 50 megohms.
If the readings on a field-installed starter 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.
NOTE: Unit-mounted starters do not have to be
megohm tested.
10. Tighten all wiring connections to the plugs on the ISM
and CCM modules.
11. On chillers with free-standing starters, inspect the power
panel to ensure that the contractor has fed the wires into
the bottom of the panel. The installation of wiring into the
top of the panel can cause debris to fall into the contactors. Clean and inspect the contactors if this has occurred.
Inspect Wiring
WARNING
Do not check the voltage supply without proper equipment
and precautions. Serious 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.
1. Examine the wiring for conformance to the job wiring diagrams and all applicable electrical codes.
2. On low-voltage compressors (600 v or less) connect a
voltmeter across the power wires to the compressor starter and measure the voltage. Compare this reading to the
voltage rating on the compressor and starter nameplates.
3. Compare the ampere rating on the starter nameplate to
rating on the compressor nameplate. The overload trip
amps must be 108% to 120% of the rated load amps.
4. The starter for a centrifugal compressor motor must
contain the components and terminals required for PIC II
refrigeration control. Check the certified drawings.
5. Check the voltage to the following components and compare it to the nameplate values: oil pump contact,
pumpout compressor starter, and power panel.
6. Ensure that fused disconnects or circuit breakers have
been supplied for the oil pump, power panel, and
pumpout unit.
7. Ensure all electrical equipment and controls are properly
grounded in accordance with 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. For field-installed starters only, test the chiller compressor motor and its power lead insulation resistance with a
500-v insulation tester such as a megohmmeter. (Use a
5000-v tester for motors rated over 600 v.) Factorymounted starters do not require a megohm test.
a. Open the starter main disconnect switch and follow
lockout/tagout rules.
Carrier Comfort Network® Interface — The Carrier 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:
CAUTION
SIGNAL
TYPE
If the motor starter is a solid-state starter, the motor leads
must be disconnected from the starter before an insulation
test is performed. The voltage generated from the tester can
damage the starter solid-state components.
+
Ground
–
CCN BUS
CONDUCTOR
INSULATION
COLOR
Red
White
Black
CCN TERMINAL
CONNECTION
ICVC PLUG
J1 PIN NO.
RED (+)
WHITE (G)
BLACK (–)
1
2
3
Check Starter
b. With the tester connected to the motor leads, take
10-second and 60-second megohm readings as
follows:
6-Lead Motor — Tie all 6 leads together and test
between the lead group and ground. Next tie the
leads in pairs: 1 and 4, 2 and 5, and 3 and 6. Test
between each pair while grounding the third pair.
3-Lead Motor — Tie terminals 1, 2, and 3 together
and test between the group and ground.
CAUTION
BE AWARE that certain automatic start arrangements can
engage the starter. Open the disconnect ahead of the starter
in addition to shutting off the chiller or pump.
70
• Frame 4 compressor — 10 gal (37.8 L)
• Frame 4 compressor with split ring diffuser option —
12 gal (45.0 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 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.
Use the instruction and service manual supplied by the starter manufacturer to verify the starter has been installed correctly, to set up and calibrate the starter, and for complete troubleshooting information.
CAUTION
The main disconnect on the starter front panel may not
deenergize all internal circuits. Open all internal and
remote disconnects before servicing the starter.
MECHANICAL STARTER
1. Check all field wiring connections for tightness, clearance from moving parts, and correct connection.
2. Check the contactor(s) to ensure they move freely. Check
the mechanical interlock between contactors to ensure
that 1S and 2M contactors cannot be closed at the same
time. Check all other electro-mechanical devices, such as
relays, for free movement. If the devices do not move
freely, contact the starter manufacturer for replacement
components.
3. Reapply starter control power (not main chiller power) to
check the electrical functions.
Ensure the starter (with relay 1CR closed) goes through a
complete and proper start cycle.
BENSHAW, INC. RediStart MX3™ SOLID-STATE
STARTER
Power Up the Controls and Check the Oil
Heater — Ensure that an oil level is visible in the compres-
sor and the chiller is not in an vacuum before energizing the
controls. A circuit breaker in the starter energizes the oil heater
and the control circuit. When first powered, the ICVC should
display the default screen within a short period of time.
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 II 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.
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.
WARNING
This equipment is at line voltage when AC power is connected. Pressing the STOP button does not remove voltage.
CAUTION
An isolation switch or circuit breaker must be open ahead
of any VFD or solid-state starter when the chiller is in a
vacuum. If not, damage to the machine may result.
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.
1. Ensure all wiring connections are properly terminated to
the starter.
2. Verify the ground wire to the starter is installed properly
and is sufficient size.
3. Verify the motors are properly grounded to the starter.
4. Verify the proper ac input voltage is brought into the starter according to the certified drawings.
5. Apply power to the starter
VFD STARTER
1. Turn off unit, tag and lock disconnects and wait 5 minutes.
2. Verify that the DC voltage is zero.
3. Ensure there is adequate clearance around the drive.
4. Verify that the wiring to the terminal strip and power terminals is correct.
5. Verify that wire size is within the terminal specification
and the wires are secure.
6. Inspect the field supplied branch circuit protection is
properly rated and installed.
7. Verify that the system is properly grounded.
8. Inspect all liquid cooling connections for leaks.
As the 19XR unit is configured, all configuration settings
should be written down. A log, such as the one shown on pages
CL-1 to CL-16, provides a list for configuration values.
Input the Design Set Points — Access the ICVC set
point screen and view/modify the base demand limit set point,
and either the LCW set point or the ECW set point. The PIC II
can control a set point to either the leaving or entering chilled
water. This control method is set in the EQUIPMENT SERVICE (TEMP_CTL) table.
Input the Local Occupied Schedule (OCCPC01S) —
Access the schedule OCCPC01S screen on the ICVC and set
up the occupied time schedule according to the customer’s requirements. If no schedule is available, the default is factory set
for 24 hours occupied, 7 days per week including holidays.
For more information about how to set up a time schedule,
see the Time Schedule Operation section, page 23.
The CCN Occupied Schedule (OCCPC03S) should be configured if a CCN system is being installed or if a secondary
time schedule is needed.
Oil Charge — The oil charge for the 19XR compressor depends on the compressor Frame size:
• Frame 2 compressor — 8 gal (30 L)
• Frame 3 compressor — 8 gal (30 L)
71
NOTE: The default CCN Occupied Schedule OCCPC03S is
configured to be occupied (software versions 4.0 and later).
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 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 (ICVC Only) — 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 menu has six or
seven service tables depending on the ICVC software version.
Configure SERVICE Tables — Access the SERVICE tables,
shown in Table 3, to modify or view job site parameters shown
in Table 12.
CHANGE THE BENSHAW INC., RediStart MX3™ SOFTWARE CONFIGURATION IF NECESSARY — Benshaw
starter configurations are checked and modified from the
menus in the Benshaw Redistart MX3 Default Display. See
Fig. 34 and Table 13 for default display and menu items. To access the menus to perform checks and modifications, the Benshaw starter must be powered up and its self-test must have
been successfully completed. The self-test takes place automatically after power-up. Current and Ramp Time configurations
are entered in the CFN menu. CT Ratio configuration is entered in the FUN menu. See Table 13 for menu structure and
Table 14 for settings.
1. Press the MENU softkey until the desired menu is selected on the display.
2. Press the ENTER softkey to access the displayed menu
items (Table 6).
Input Service Configurations — The following con-
figurations 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 ICVCs are initially set for a password of 1-1-1-1.
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 TODAY 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 for SI 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 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 NUMBER, BAUD RATE, US
IMP/METRIC, and PASSWORD.
2. Use the ENTER softkey to scroll to PASSWORD. The
first digit of the password is highlighted on the screen.
3. To change the digit, press the INCREASE
or DECREASE softkey. When the desired digit is seen,
press the ENTER softkey.
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.
3. Use the  or  arrow keys to scroll between menu items
until the desired item is reached on the display.
4. Press the ENTER softkey to access the value to be
changed.
5. Use the  or  arrow keys to adjust the new displayed
value. The  key increases the value while the  key decreases the value. Holding the arrow key will progressively increase the rate of change. The value will stop
changing when either the factory set minimum or maximum value is reached. To make fine adjustments press
and release the arrow key.
6. When the correct value has been selected, press
the ENTER key to store the new configuration. At this
point, there are two options. The MENU key will return
the display to the main display. The  or  arrow keys
will move the display to the next menu item. When finished press the MENU key to return to the main display.
To view other settings and troubleshooting guide consult the
Benshaw RediStart MICRO instructional manual included in
the starter.
CAUTION
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.
72
Table 12 — Job Site Parameters
PARAMETER
TABLE
ISM_CONF — Select 0 for full voltage, 1 for
Starter Type
reduced voltage, or 2 for solid state or 3 for variable frequency drive.
Motor Rated Line
ISM_CONF — Motor rated voltage from chiller
Voltage
information nameplate.
ISM_CONF — Enter ratio (reduced to a ratio to
Volt Transformer
1) of power transformer wired to terminal J3 of
Ratio
ISM. If no transformer is used enter 1.
Motor Rated
ISM_CONF — Per chiller nameplate data. RL
Load Amps
AMPS on compressor nameplate.
Motor Locked
ISM_CONF — Per chiller identification nameRotor Trip
plate.
ISM_CONF — Enter value from nameplate in
Starter LRA
starter cabinet MAXIMUM FUSE. This value
Rating
shall always be “9999” for Benshaw RediStart
MX3 wye-delta and solid-state starters.
ISM_CONF — Enter ratio (reduced to a ratio to
1) of current transformers wired to terminal J4 of
Motor Current
ISM. This value shall always be “100” for BenCT Ratio
shaw RediStart MX3 wye-delta and solid-state
starters.
ISM_CONF — Current imbalance trip threshold.
Current% Imbalance
Enter up to 100% for starter type 3 (VFD).
Ground Fault
ISM_CONF — Enter 0 if no ground fault CTs are
Current
wired to terminal J5 of ISM. Enter 1 if ground
Transformers
fault CTs are used.
Ground Fault
ISM_CONF — Enter ratio (reduced to a ratio to
CT Ratio
1) of ground fault CT.
ISM_CONF — ENABLE if motor protection
Single Cycle
required from drop in line voltage within one
Dropout
cycle.
ISM_CONF — Enter YES for 60 Hz or NO for
Line Frequency
50 Hz.
ISM_CONF — ENABLE if motor
Line Frequency
protection required for drop in line
Faulting
frequency.
Surge Limit/Hot Gas
OPTIONS — Enter 1 if HGBP is installed. Enter
Bypass Option
0 otherwise.
OPTIONS — Per Chiller Requisition (DT1, DP1)
Minimum Load
if available or per job data — See modify load
Points (T1, P1)
points section. For VFD units refer to table
located in control panel.
OPTIONS — Per Chiller Requisition (DT2, DP2)
if available or per job data — See modify load
Low Load Points (T2, P2) points section. For VFD units refer to table
located in control panel.
PARAMETER
TABLE
OPTIONS — Per Chiller Requisition (DT3, DP3)
if available or per job data — See modify load
Mid Load (T3, P3)
points section. For VFD units refer to table
located in control panel.
OPTIONS — Per Chiller Requisition (DT4, DP4)
Full (Maximum)
if available or per job data — See modify load
Load Points (T4, P4)
points section. For VFD units refer to table
located in control panel.
OPTIONS — Per Chiller Requisition (Tsmin,
Minimum Load
IGVmin) if available or per job data — See modPoints (Tsmin, IGVmin) ify load points section. Refer to table located in
the control panel.
OPTIONS — Per Chiller Requisition (Tsmax,
Full (Maximum) Load
IGVmax) if available or per job data — See modPoints (Tsmax, IGVmax) ify load points section. Refer to table located in
the control panel.
Surge Line Shape Factor OPTIONS — Per Chiller Requisition (shapefac).
(shapefac)
Refer to table located in the control panel.
Chilled Medium
SETUP1 — Enter water or brine.
Evaporator
SETUP1 — Usually 3° F (1.7° C) below design
Refrigerant
refrigerant temperature.
Trippoint
SETUP1 — Per Chiller Requisition if available or
Evaporator Flow
enter 50% of design pressure drop to 0.5 psi
Delta P Cutout
(3.4 kPa).*
SETUP1 — Per Chiller Requisition if available or
Condenser Flow
enter 50% of design pressure drop to 0.5 psi
Delta P Cutout
(3.4 kPa).*
High Condenser Water
SETUP1 — Enter the maximum allowable value
Delta P
for condenser water pressure drop.
Diffuser Option
SETUP2 — ENABLE for 4 and 5 size compres(Compressors with Split sor with split ring diffusers. See model number
Ring Diffusers)
nomenclature.
Diffuser Option —
VDO_SRD ENABLE for Frame 4 and 5 compresSoftware Version 10 and sors with Split Ring Diffusers. See model number
Higher (Compressors
nomenclature.
with Split Ring Diffusers)
SETUP2 VDO_SRD (Software version 10 and
Diffuser Full Span mA
higher) — Enter diffuser actuator full span mA
(Compressors with Split rating for 4 and 5 size compressor. Value is
Ring Diffusers)
located on label on side of diffuser actuator
motor.
RAMP_DEM — Enter value from chiller requisiMotor Rated
tion form (product data submittal) if DEMAND
Kilowatts
LIMIT SOURCE is set to kW.
*With variable flow systems this point may be configured to the lower end of
the range.
NOTE: Other parameters: Screens are normally left at the default settings;
they may be changed by the operator as required. The time and persistence
settings on the ISM_CONF table can be adjusted to increase or decrease the
sensitivity to a fault condition. Increasing time or persistence decreases sensitivity. Decreasing time or persistence increases sensitivity to the fault
condition.
73
•
•
•
•
Output Voltage
Output Current
Kilowatts
Torque
PROGRAM MODE — This mode displays and modifies
the configuration parameters of the VFD microprocessor. Particular parameters, parameter numbers, and error log information can be displayed when in Program mode.
Press the PROGRAM softkey until the PROGRAM LED is
illuminated to enter the Program mode.
VFD Field Setup and Verification
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. Speed control and starting the drive
have been disabled at the VFD keypad. All command functions must be initiated from the ICVC.
USING THE KEYPAD — The keypad display is used to monitor, view fault history and adjust the program of the VFD
microprocessor. It operates in two modes: Monitor mode and
Program mode:
Use the  and  keys to move through the menus
Press ENTER softkey to select the desired menu.
Use the  and  keys to:
• Step through the drive parameter menus and error log
when the keypad/display is in Program mode.
• Increase or decrease a numeric value such as the reference or parameter value.
• Hold down these keys to increase the scroll speed.
Use the ENTER softkey to:
• Display a parameter or a selection value in Program
mode.
• Save a value.
• Move through each monitor display item when in Monitor mode.
MONITOR MODE (Default Mode) — Specific drive conditions may be monitored on the keypad when in this mode. An
LED will be illuminated next to the description of what is displayed on the keypad. Use the ENTER softkey to scroll
through and monitor the following selections:
• All LEDs on — Speed request from the ICVC
• Motor Speed
• Output Frequency
a19-1958
Fig. 34 — Benshaw RediStart
MICRO Default Display
Table 13 — Benshaw RediStart MX3 Menu Structure
ISM MENU
CFN MENU
Shows parameters entered
Initial Current as % RLA
on the ISM_CONF screen on Max. Current As% LRA
the ICVC
Ramp Time (seconds)
FUN MENU
Meter #1 display
Meter #2 display
CT Ratio
Time & Date Format
Time
Date
Passcode
FL MENU
Fault Log (9 faults)
E MENU
Event Log (99 events)
Table 14 — Benshaw RediStart MX3 Menu Items*
DESCRIPTION
INITIAL CURRENT
MAX. CURR AS % LRA
RAMP TIME
CT RATIO
BENSHAW PARAMETER
CFN01
CFN02
CFN03
FUN03
RANGE
50-300
30-70
5-30
2640-5760
*These values are not displayed in the ISM_CONF table.
†Current Transformer Ratio
Starter Frame Size
(Amps)
200 Amps
Motor RLA Range
(Amps)
95-135 Amps
200 Amps
136-200 Amps
2640:1
300 Amps
201-231 Amps
2640:1
300 Amps
232-300 Amps
2640:1
480 Amps
301 -340 Amps
2640:1
CT Ratio
864:1
480 Amps
341-480 Amps
3900:1
600 Amps
481-580 Amps
3900:1
3900:1
600 Amps
581-600 Amps
740 Amps
601-740 Amps
3900:1
1250 Amps
741-855 Amps
5760:1
1250 Amps
856-1250 Amps
5760:1
74
UNITS
%
%
SEC
DEFAULT
125
55
15
†
Press  and  keys to move through following parameters.
P.nnn
— General Parameters
U.nnn
— Vector Control Parameters*
H.nnn
— Volts/Hertz Control Parameters
R.nnn
— RMI Remote Monitor Interface
Parameters
E.nnn
— Error Log (See fault codes)
A United Technologies Company
TM
REFRIGERATION MACHINE
MODEL NUMBER
SERIAL NO.
MACHINE
COMP'R
COOLER
CONDENSER
ECON
STOR TANK
*Vector control is not used in this configuration.
Press ENTER softkey to select a parameter menu screen.
RATED TONS
RATED iKW
LBS.
REFRIGERANT
R-
Press  and  keys to adjust the selected parameter.
KGS.
CHARGED
COMPRESSOR MOTOR DATA
VOLTS/PHASE/HERTZ
Press the PROGRAM softkey until the PROGRAM LED
turns off to exit the program.
AC
RL AMPS
LR AMPS
Y-
OLT AMPS
LR AMPS
D-
MAX FUSE/CIRCUIT BKR
MIN. CIRCUIT AMPACITY
TEST PRESSURE
CAUTION
PSI
KPA
DESIGN PRESSURE
PSI
KPA
CLR.WATER PRESSURE
PSI
KPA
COND.WATER PRESSURE
PSI
KPA
CARRIER CHARLOTTE
9701 OLD STATESVILLE ROAD
CHARLOTTE, NORTH CAROLINA 28269
Changing parameters may adversely affect chiller
operation.
MADE IN USA
PRODUCTION YEAR: 20XX
SAFETY CODE CERTIFICATION
THIS UNIT IS DESIGNED,CONSTRUCTED,
AND TESTED IN CONFORMANCE WITH
ANSI/ASHRAE 15 (LATEST REVISION),
SAFETY CODE FOR MECHANICAL
REFRIGERATION.
THE COMPRESSOR MOTOR CONTROLLER
AND OVERLOAD PROTECTION MUST BE
IN ACCORDANCE WITH CARRIER
SPECIFICATION Z-415.
ACCESSING PASSWORD PROTECTED PARAMETERS — Although the VFD controller has been preconfigured as the factory, the user will need to be able to access the
parameters to verify the job specific parameters are correct,
tune the controller or correct a problem. The two passwords
protecting the VFD configuration are Parameter Set Display
(P.006) password and Program Disable (P.051) password. The
Parameter Set Display password restricts viewing. P.nnn parameters above 007 and all H.nnn and R.nnn screens. The password can be accessed at parameter P.006 and will switch between enabled and disabled each time the password 107 is entered. The Program Disable password restricts the changing of
the drive parameter set. To enable or disable changes select parameter P.051 and enter the password 26.
NOTE: Some of the parameters can be changed only when the
drive is stopped.
a19-1881
19XR05009801
CHILLER ID NAMEPLATE — CONSTANT SPEED CHILLER
a19-1882
WARNING
It is the operator’s responsibility to distribute access to the
passwords. Carrier is not responsible for unauthorized
access violations within the operator’s organization. Failure
to observe this warning could result in bodily injury.
See the Initial Start-Up Checklist section for VFD Job Specific Configuration table. For job specific parameters see inside
of the VFD enclosure door, next to the keypad. Refer to the
VFD Configuration table for the entire list of parameters.
NOTE: Restoring the default parameter P.050 will require all
the Carrier default parameters to be restored manually.
LABEL LOCATIONS — Verify the following labels have
been installed properly and match the chiller requisition:
• Surge Parameters — Located inside the chiller control
panel.
• Chiller identification nameplate — Located on the right
side of the control panel. (See Fig. 35.)
• VFD Parameter — Located to the right of the VFD controller keypad on the VFD module.
• VFD Enclosure Nameplate — Located on the right side
of the VFD as viewed from its front. (See Fig. 35.)
• Record all nameplate information on the unit-mounted
VFD configuration sheet. (See page CL-14.)
DRIVE PROTECTION AND OTHER INCOMING
WIRING
1. Verify that the branch disconnects or other local disconnects are open and properly tagged out.
a19-1883
VFD ENCLOSURE
NAMEPLATE
CHILLER ID NAMEPLATE —
VFD-EQUIPPED CHILLER
Fig. 35 — Machine Electrical Data Nameplates
2. Verify that the branch circuit protection and AC input
wiring to the VFD are in accordance with NEC/CEC
(National Electrical Code/California Energy Commission) and all other local codes.
3. Verify that the fuses are per the field wiring diagram.
4. Verify that the incoming source does not exceed 85 kA.
5. Verify the power lugs in the VFD and branch protection
are properly secured. Inspect the ground cable and ensure
it is properly connected at the branch and to the ground
lug in the VFD.
75
Press the PROGRAM softkey to access the parameter
screen to modify or view the following job specific parameters:
6. Verify the conduit for the power wiring in securely connected to the VFD flanged cover and runs continuously to
the branch protection.
7. Verify that the incoming and outgoing wires have been
properly connected inside of the line reactor enclosure if a
separate line reactor has been added to the chiller.
8. Ensure the control and signal wires connected to the chiller controller or the VFD are in separate conduit.
VFD Cooling System Leak Inspection
1. Check for leaks on the refrigerant cooling flange connections to the VFD enclosure.
2. Check for leaks on all tubing internal to the VFD enclosure, the tubing flair connection to the VFD module and
the TXV valve.
3. Verify that the VFD refrigerant cooling system TXV
valve control bulb is securely inserted into the VFD drive
module heat sink.
Power Up Verification
1. Inspect control wiring inside the VFD and verify the integrity of the connections between the integrated starter
module (ISM) and the VFD module.
2. Close the control power switch in the VFD enclosure.
3. Close the oil pump power switch inside the VFD
enclosure.
4. Verify the VFD disconnect switch is in the open position.
5. Close and latch the doors of the VFD enclosure.
6. Apply power to the VFD enclosure. Remove lock outs
and close all disconnects.
7. Verify that the ICVC display powers up and goes to the
default screen.
8. Close the VFD disconnect switch.
9. Verify the following actions during the VFD start-up self
test:
• The display shows SELF and all LEDs are illuminated for 5 to 6 seconds.
• The display reads a 0 after the diagnosis is
complete.
• If Err is displayed a fault has been detected. Perform manual reset by establishing a reset through
the small hole under the VFD Keypad. If this does
not correct the fault contact your Carrier representative.
• If AR (automatic reset) with a counting down
number is displayed wait for the number to count
to 0 and the display should then revert to a 0. If
the counter starts over at 30 contact Carrier representative.
The VFD is configured to attempt an automatic reset of minor faults every 30 seconds. After a total of 10 failed attempts
to reset a fault, the fault code will be shown and the VFD will
be disabled.
Configure VFD Parameters — The VFD controller must have
job specific parameters set as defined by the component nameplates and labels. The parameters come preset by the factory,
but must be verified prior to start-up by accessing the
PROGRAM MODE of the VFD controller keypad. For information on how to access the VFD keypad see page 77.
VFD
PARAMETER
P.004
P.006
P.028
H.000
H.001
TITLE
Maximum
Speed
Motor
Amps
H.021
Line
Voltage
Over
Frequency
Limit
Input and
Output
Gains and
Offset
P.009, P.010,
r.002, r.003
Line Frequency selected. Per
Compressor Nameplate. 60 for
60 Hz selection.
107
60 for 60 Hz selection and
50 for 50 Hz selection
Password
Speed
Display
Scaling
Motor
Voltage
Frequency
H.002
H.022
SETTING
VOLTAGE from "Load Side" section
of the VFD enclosure nameplate
Line Frequency selected. Per
Compressor Nameplate. 60 for
60 Hz selection, 50 for 50 Hz
selection
1.08 x Motor FLA from "Load Side"
section of the VFD enclosure nameplate
VOLTAGE from "Line Side" section of
the VFD enclosure nameplate
69 for 60 Hz selection, 57 for 50 Hz
selection
Calibrate per instructions on
page 77.
ICVC Parameters for VFD — The chiller controller must have
its job specific parameters set as defined by the job sheet or
installed nameplates. Below are the job specific parameters
that must be set:
To access the ISM_CONF screen:
1. Press ENTER .
2. Press SERVICE .
3. Enter the password 1111.
4. Select ISM (CONFIG STARTER DATA)
5. Scroll down and select the ISM_CONF DATA screen to
modify or view the ISM parameters:
DESCRIPTION
STARTER TYPE
(3 = VFD)
MOTOR RATED
LINE VOLTAGE
MOTOR RATED
LOAD AMPS
MOTOR LOCKED
ROTOR TRIP
STARTER LRA RATING
MOTOR CURRENT
CT RATIO:1
3 GRND FAULT CT?
(1=NO)
FREQUENCY-60HZ
(YES=60)
76
SETTING
3
VOLTAGE from "Load Side" section of
the VFD enclosure nameplate.
CHILLER FL AMPS from "Line Side"
section of the VFD enclosure
nameplate
MOTOR LRA from "Load Side" section of the VFD enclosure nameplate
600 for VFD
part #19XVR0414XXX
750 for VFD
part #19XVR0500XXX
900 for VFD
part #19XVR0643XXX
163 (500A and 643A VFDs)
120 (414A VFDs)
NO
YES for 60 Hz selection
NO for 50 Hz selection
2. Adjust VFD parameter P.009 (Input offset) if outside the
tolerance. The VFD will declare an "Aln" Alarm if P.009
is too small.
3. Verify that the actual speed signal feedback to the chiller
controller is 0% by accessing the ACTUAL VFD SPEED
in the ICVC COMPRESS screen.
4. Verify ACTUAL VFD SPEED is 0% to 1% on the ICVC.
5. Adjust VFD parameter r.002 (Analog Output Offset) if
outside the tolerance. A "C" will be displayed next to ACTUAL VFD SPEED if r.002 is too small. The "C" stands
for communications fault.
Set TARGET VFD SPEED to 100%.
1. Press MENU .
2. Press STATUS .
3. Press COMPRESS .
4. Press SELECT .
5. Set TARGET VFD SPEED to 100%.
Verify that the VFD Speed Reference shown on the VFD
display corresponds to the 50 or 60 Hz setting (100% TARGET
VFD SPEED).
1. Confirm that the VFD Speed reference displays the TARGET VFD SPEED frequency within ± 1 Hz.
2. Adjust parameter P.010 (input Gain) if outside the tolerance.
3. Release the TARGET VFD SPEED so that it can operate
in automatic mode. (Refer to Override Operations Section on page 19.)
VFD CONTROL VERIFICATION (Running)
Preparation
1. Disconnect power to the VFD. Verify that the branch disconnects or other local disconnects are open and properly
tagged out.
2. Connect a voltmeter and ampmeter to the line side of the
VFD. Locate meters safely away from the power cables.
3. Reconnect power to the VFD.
4. Measure the voltage on the line side of the drive.
5. Verify it is within 10% of the chiller nameplate voltage.
6. Set up the ICVC set point per the requirements of the job.
7. Start the chiller and verify the rotation of the compressor
just as it starts.
8. Allow the chiller to load up. Verify that the chiller loads
up smoothly.
NOTE: One or two surges may be counted during the first
minute of operation.
Verify That Actual VFD Speed is 100% (±2%)
1. Set the TARGET VFD SPEED in the COMPRESS screen
to 100%.
2. Verify that the ACTUAL VFD SPEED is 100% (± 2%).
3. If outside the tolerance, adjust r.003 (Output Analog
Gain).
4. Leave running for the next test.
ISM Current Calibration Check
1. With the TARGET VFD SPEED at 100%, load the chiller
so that the ICVC default display shows 75% to 100% under the display title AMPS %. A higher load is preferred.
2. Measure the incoming current of all three input phases
with a separate true RMS amp meter.
3. Calculate an average Amp Meter Current of the three input phases.
6. Press to the SAVE softkey to save changes when exiting
the ISM_CONF screeen.
7. Press the EXIT softkey to and exit the ISM Configuration Screen.
VFD Enable Configuration — To access the parameters:
1. Press MENU .
2. Press SERVICE .
3. Select EQUIPMENT SERVICE.
4. Scroll down and select SETUP2.
5. Verify the following parameters:
VFD OPTION
VFD CURRENT LIMIT
ENABLED
MOTOR FLA from "Load Side" section
of the VFD enclosure nameplate
Configure Surge Parameters
1. Press MENU .
2. Press SERVICE .
3. Select EQUIPMENT SERVICE and OPTIONS to verify
that the parameters in the applicable table below match
the surge prevention parameters for the design conditions
of the chiller. These parameters are found on a label on
the bottom surface of the inside of the chiller control
panel.
SOFTWARE VERSION 9 AND LOWER
DESCRIPTION
SURGE/HGBP
DELTA T1
SURGE/HGBP
DELTA P1
SURGE/HGBP
DELTA T2
SURGE/HGBP
DELTA P2
SETTINGS
Surge parameter label
Surge parameter label
Surge parameter label
Surge parameter label
SOFTWARE VERSION 10 AND HIGHER
DESCRIPTION
SURGE/HGBP
DELTA TSMIN
SURGE/HGBP
IGVMIN
SURGE/HGBP
DELTA TSMAX
SURGE/HGBP
IGVMAX
SURGE LINE
SHAPE FACTOR
SETTINGS
Surge parameter label
Surge parameter label
Surge parameter label
Surge parameter label
Surge parameter label
VFD CONTROL VERIFICATION (Non-Running) — In
order to verify and, if necessary, tune the speed control signal
of the chiller controller to the VFD (ISM terminal J8-1 labeled
4-20 mA OUT VFD) and the speed feedback signal from the
VFD to the chiller controller (ISM terminal J8-2 labeled VFD
HZ), follow the steps below.
Set TARGET VFD SPEED to 0%.
1. Press MENU .
2. Press STATUS .
3. Press COMPRESS .
4. Press SELECT .
5. Set TARGET VFD SPEED to 0%.
Verify that the VFD SPEED REFERENCE shown on the
VFD display is within 0 to 1 Hz of zero.
1. Press the ENTER softkey on the VFD keypad until all
LEDs on the left side of the keypad are illuminated except the Password LED.
NOTE: The value shown in the VFD display is the frequency at which the VFD is being commanded to
operate. This value is called the VFD Speed reference.
77
3. Use the  arrow key to increment the value to 26. This is
the password number.
4. Press the ENTER softkey to save the value. P.051 will by
displayed.
NOTE: Parameter programming is disabled when the
PASSWORD LED is on and enabled when the PASSWORD LED is off.
5. Select parameter P.006 from the VFD Keypad.
6. Press the ENTER softkey to access the parameter.
7. Use the  arrow key to increment the value to 107. This
is the password number to restrict displaying the remaining P, and all of the H and r parameters.
8. Press the ENTER softkey to save the value.
MODIFY SURGE LINE CONFIGURATION POINTS IF
NECESSARY (Machines with serial number prior to
1410Qxxxxx) (See Fig. 36) — If configuring a chiller with a
Four Point Hot Gas Prevention curve and settings are not available, calculate Maximum and Minimum load points as follows.
Use the minimum load point values for MINIMUM LOAD
POINT (ΔT1/ ΔP1) only. Use the maximum load point values
for all three points: LOW LOAD POINT ((ΔT2/ ΔP2) MID
LOAD POINT (ΔT3/ ΔP3) and FULL LOAD POINT (ΔT4/
ΔP4). This will result in a 2 point surge curve. When adjusting
this curve when surge prevention comes in too early or too late,
adjust as a 2 point curve but remember to adjust the LOW, MID
and HIGH LOAD points by the same amount.
4. Calculate the line side error ratio using the following
equation:
Error Ratio =
Amp Meter current – ACTUAL LINE CURRENT*
Amp Meter current
* in POWER screen.
5. Shut down the chiller.
6. If the Line Side Error Ratio is greater than ± 0.02 adjust
the ICVC reading by adjusting the MOTOR CURRENT CT RATIO in the ISM_CONF screen. This
screen can only be accessed when the chiller is not running.
Change CT Ratio
1. New MOTOR CURRENT CT RATIO = Present MOTOR CURRENT CT RATIO multiplied by (1+ Line Side
Error Ratio).
To access the ISM_CONF screen:
2. Press ENTER .
3. Press SERVICE .
4. Enter the password 1111.
5. Select ISM (STARTER) CONFIG DATA.
6. Enter password 4444.
7. Select ISM_CONF.
8. Change present MOTOR CURRENT CT RATIO to new
ratio using calculation above.
9. Press to the SAVE softkey to save changes.
10. Press the EXIT softkey to exit the ISM_CONF screen.
11. Repeat ISM Current Calibration Check.
VFD Current Control Calibration Check
1. With the TARGET VFD SPEED at 100%, load the chiller so that the ICVC default display shows 75% to 100%
under the ICVC default screen display title AMPS %. A
higher load is preferred.
2. Access the current on the keypad of the VFD. Determine
the Load Side Current Ratio, using the equation below.
Load Side
=
Current Ratio
(∆T4/∆P4)
(∆T3/∆P3)
(INC)
(∆T2/∆P2)
Delta
P
(∆T1/∆P1)
VFD Actual Load Amps (from VFD)
VFD CURRENT LIMIT (in SETUP2)
A
Next, access the VFD LOAD FACTOR on the Capacity
Control screen. Calculate the Load Side Error Ratio using
the equation below:
Load Side
Error Ratio
=
Delta T
VFD LOAD FACTOR – Load Side Current Ratio
Load Side Current Ratio
C
B
(INC)
a19-1867
Fig. 36 — Four Point Surge Prevention Curve
3. If the load side error ratio is greater than ± 0.02, adjust the
VFD LOAD FACTOR by changing the VFD CURRENT LIMIT on the Setup 2 screen.
a. The new VFD CURRENT LIMIT = old VFD
CURRENT LIMIT multiplied by (1+ Load Side
Error Ratio).
b. Recheck the VFD Current Control Calibration.
c. Release the Speed Control by accessing the TARGET VFD SPEED control.
Press MENU .
Press STATUS .
Press COMPRESS .
(Refer to Override Operations section on page 19.)
Protecting the VFD Configuration
1. Select parameter P.051 from the VFD keypad.
2. Press the ENTER softkey to access the parameter. A zero
will be displayed.
Hand 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)
Maximum Load T4:
54 – 44 = 10º F (12.2 – 6.7 = 5.5º C)
Maximum Load P4:
120 – 37 = 83 psid (827 – 255 = 572 kPad)
78
If surge prevention occurs too soon or too late at a load that
falls between two SURGE/HGBP DELTA T points it is acceptable to change the two adjacent SURGE/HGBP DELTA P
points simultaneously to keep the slope of the modified surge
prevention curve nearer to the original curve.
This is illustrated in Fig. 36. If the adjustment is needed between (∆T1, ∆P1) and (∆T2, ∆P2) adjust both P1 and P2 by the
same amount. Do the same between any two points.
HAND CALCULATE VARIABLE PRIMARY FLOW
(VPF) SURGE PREVENTION CONFIGURATIONS
(Machines with S/N 1410Qxxxxx and Larger and Machines
with Version 9 Software or Higher) — 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 in the preceding section. 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 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. 37.)
• 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. 38.)
• 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.
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. 39.)
To avoid unnecessary surge prevention, add about 10 psid
(70 kPad) to P2 from these conditions:
T4 = 10º F (5.5º C)
P4 = 93 psid (642 kPad)
Hand 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)
Again, to avoid unnecessary surge prevention, add 20 psid
(140 kPad) at P1 from these conditions:
T1 = 2 F (–16.7 C)
P1 = 53 psid (365.3 kPad)
The Options screen can be configured with up to four distinct pairs of HGBP/Surge Prevention points to represent the
surge line of the compressor. The version of Chiller Builder
used to select the chiller and the ICVC software version at the
time the chiller was manufactured will determine if either two
pairs of points or four pairs of points were generated. Either
two pairs of four pairs of points will also be displayed on a label on the inside of the control panel.
If software requires four points of HGBP surge prevention
and only 2 points of data are available — Enter the MIN
LOAD POINT (T1/P1) and the FULL LOAD POINT (T2/P2)
from the Chiller Builder Selection in the spaces provided in the
MIN LOAD POINT (T1/P1) and FULL LOAD POINT (T4/
P4) section of the OPTIONS screen. Also, enter the FULL
LOAD POINT (T2/P2) data from ChillerBuilder in the LOW
LOAD POINT (T2/P2) section and the MID LOAD POINT
(T3/P3) section of the OPTIONS screen.
If surge prevention occurs too soon or too late:
LOAD
At Low Loads (<50%)
At High Loads (>50%)
SURGE PREVENTION
OCCURS TOO SOON
Increase SURGE/HGBP
DELTA P1 by 2 PSID
(14 kPaD)
Increase SURGE/HGBP
DELTA P2, SURGE/
HGBP DELTA P3 and
SURGE/HGBP DELTA
P4 by 2 PSID (14 kPaD)
SURGE PREVENTION
OCCURS TOO LATE
Decrease SURGE/
HGBP DELTA P1 by
2 PSID (14 kPaD)
Decrease SURGE/
HGBP DELTA P2,
SURGE/HGBP DELTA
P3 and SURGE/HGBP
DELTA P4 by 2 PSID
(14 kPaD)
If software requires four points of HGBP surge prevention
and 4 points of data are available — Enter the MIN LOAD
POINT(T1/P1), LOW LOAD POINT (T2/P2), MID LOAD
POINT (T3/P3) and the FULL LOAD POINT (T4/P4) from
the Chiller Builder Selection in the spaces provided in the OPTIONS screen.
If surge prevention occurs too soon or too late:
SURGE PREVENTION
OCCURS TOO SOON
Increase SURGE/HGBP
Near Min Load Delta T1
DELTA P1 by 2 PSID
(14 kPaD)
Increase SURGE/HGBP
Near Low Load Delta T2
DELTA P2 by 2 PSID
(14 kPaD)
Increase SURGE/HGBP
Near Mid Load Delta T3
DELTA P3 by 2 PSID
(14 kPaD)
Increase SURGE/HGBP
Near Full Load Delta T4
DELTA P4 by 2 PSID
(14 kPaD)
LOAD
SURGE PREVENTION
OCCURS TOO LATE
Decrease SURGE/
HGBP DELTA P1 by
2 PSID (14 kPaD)
Decrease SURGE/
HGBP DELTA P2 by
2 PSID (14 kPaD)
Decrease SURGE/
HGBP DELTA P3 by
2 PSID (14 kPaD)
Decrease SURGE/
HGBP DELTA P4 by
2 PSID (14 kPaD)
79
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.
• 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. 40.)
• 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.
Fine Tuning VPF Surge Prevention — Figures 37-40 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
• 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.
40
35
30
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. 37 — 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. 38 — Effect of SURGE/HGBP DELTA TSMAX
on Surge Prevention
80
GUIDE VANE POSITION less than 30) or if Step 4
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. 11.
Compressors with variable diffuser control have actuators
tested and stamped with the milliamp (mA) value that results in
100% actuator rotation. In addition to the diffuser position
schedule, the DIFFUSER FULL SPAN mA of the split ring
diffuser actuator must be entered in the SETUP2 screen. This
information is printed on a label affixed under the solid state
controller box on the right side of the split ring diffuser actuator
when viewing the compressor from the suction end.
Units with VFD — On units with VFD 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
• Entering chilled water control (Enable/Disable)
• 4 to 20 mA demand limit
• Auto restart option (Enable/Disable)
• Remote contact option (Enable/Disable)
See PIC II System Functions (page 40) for description of
these functions.
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 (for
software versions 4.0 and later). 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
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. 39 — 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. 40 — Effect of SURGE LINE SPEED FACTOR
on Surge Prevention
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 4 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
81
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 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) or ServiceLink™ 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. 41.
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.
Table 15 — Control Test Menu Functions
TESTS TO BE
PERFORMED
1. CCM Thermistors
2. CCM Pressure
Transducers
3. Pumps
4. Discrete Outputs
5. IGV and SRD
Actuator
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
Autodial Gateway
Local Building Supervisors(s)
or ComfortWORKS
6. Head Pressure
Output
7. Diffuser Actuator
8. Pumpdown Lockout
1
1
0
1
0
0
a19-1627
0
0
Default Value
10000000
Open/Close (independent of guide
vanes)
When using pumpdown/lockout,
observe freeze up precautions when
removing charge:
Starts chilled water and condenser
water pumps and confirms flows.
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.
00000000 to 11111111
0 = Disabled, 1 = Enabled
Increase/Decrease 4-20 mA output
Instructs operator which valves to
close and when.
unused
Allowable Entries
DEVICES TESTED
Entering Chilled Water
Leaving Chilled Water
Entering Condenser Water
Leaving Condenser Water
Evap Saturation Temp
Comp Discharge Temp
Comp Thrust Brg Temp
Oil Sump Temp
Comp Motor Winding Temp
Spare Temperature 1
Spare Temperature 2
Remote Reset Sensor
Evaporator Pressure
Condenser Pressure
Oil Pump Delta P
Condenser Water Delta P
Transducer Voltage Ref
Oil Pump — Confirm Delta P
Chilled Water — Confirm flow and
Delta P
Condenser Water — Confirm flow and
Delta P
Oil Heater Relay
Hot Gas Bypass Relay
Tower Fan Relay Low
Tower Fan Relay High
Alarm Relay
Shunt Trip Relay
Open/Close
Software version 10 or higher:
Guide vanes and diffuser will both
move. The relative movement during
Control Test does not apply to operation. During operation, guide vane and
diffuser are controlled independently.
Earlier software versions:
If present, split ring diffuser will operate in coordination with the guide
vanes per configured schedule.
Monitors
Evaporator pressure
Condenser pressure
Evaporator temperature during
pumpout procedures
Turns pumps off after pumpdown.
9. Terminate Lockout
Fig. 41 — Alarm Control and Alarm Routing
Locks out compressor.
Starts pumps and monitors flows.
Instructs operator which valves to
open and when.
Perform a Control Test — Check the safety controls
status by performing an automated control test. Press the
STOP button on the ICVC to place the chiller in STOP mode.
The CONTROL TEST screen can only be accessed when the
chiller is in STOP mode. Access the CONTROL TEST table
and select a test to be performed function (Table 15).
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 rating plate value. The compressor can be put in OFF mode by pressing the STOP pushbutton 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.
Monitors
Evaporator pressure
Condenser pressure
Evaporator temperature during
charging process
10. Guide Vane
Calibration
CCM
IGV
SRD
Terminates compressor lockout.
Automatic, displays guide vane position signal voltage. This test is required
before first startup with new actuator,
new controller, or new software.
Calibrates guide vane input on CCM.
LEGEND
— Chiller Control Module
— Inlet Guide Vane
— Spilt Ring Diffuser
*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 the diffuser control is
enabled.
82
If the transducer value is not within the calibration range,
the transducer will return 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 supply voltage signal (TRANSDUCER VOLTAGE
REF displayed in CONTROL TEST menu in the CCM
PRESSURE TRANSDUCERS screen) or measure
across the positive (+ red) and negative (– black) leads of
the transducer. For example, the condenser transducer
voltage input is measured at CCM terminals J2-4 and J25. The voltage ratio must be between 0.80 and 0.11 for
the software to allow calibration. Rotate the waterside
flow pressure device from the inlet nozzle to the outlet
nozzle and repeat this step. If rotating the waterside flow
device does not allow calibration then 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) maximum 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
high altitude locations must be compensated for, so the
chiller temperature/pressure relationship is correct.
The PIC II does not allow calibration if the transducer is too
far out of calibration. In this case, a new transducer must be
installed and recalibrated.
GUIDE VANE ACTUATOR CALIBRATION — This automated procedure is performed at the factory prior to new chiller
shipment. During this test, the CCM outputs a discrete 24-v signal from terminal J11 to fully open and fully close the guide
vanes. A 0.1 to 3.0 V nominal signal is fed back to the terminals
J4-9 and J4-10 to indicate the position of the guide vanes to the
CCM. This calibration will need to be repeated if the guide
vane actuator or ICVC controller is replaced, or if new controller software is downloaded. A prestart alert message will remind the user prior to the next start-up if this has not been done.
Select the last item in the Controls Test menu. Press YES to
proceed with calibration per the prompt. The guide vanes will
close fully, then open to 100% (regardless of the position configured at maximum opening). The system will store voltages
corresponding to 0% and 100%, then indicate the the calibration is complete.
NOTE: Enter guide vane calibration to calibrate guide
input on CCM (Plug J4 upper terminal 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 the Table 15.
COOLER AND CONDENSER PRESSURE TRANSDUCER AND WATERSIDE FLOW DEVICE CALIBRATION (waterside device optional with CCM inputs
available) — 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 CCM. 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). Wiring is shown in Fig. 42. To calibrate
these transducers:
1. Shut down the compressor and the 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 keep transducer in
place.
NOTE: If the cooler or condenser vessels are at 0 psig
(0 kPa) or are open to atmospheric pressure, the transducers can be calibrated for zero without removing the transducer from the vessel.
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 waterside 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 PUMP DELTA P or flow
devices.
a19-1866
Fig. 42 — CCM Inputs for Optional
Waterside Delta P Transducers
OPTIONAL THERMAL DISPERSION FLOW SWITCH
CALIBRATION — Set the flow through the water circuit to
the minimum safe flow that will be encountered.
Reduce the sensitivity of the switch by turning the adjustment counter-clockwise until the yellow LED turns off. This
indicates that the switch is now open.
Access the HEAT_EX screen in the STATUS tables. Select
the CHILLED WATER DELTA P or CONDENSER WATER
DELTA P. It should read zero psi (0 kPa). If it does not, the value may be set to zero by pressing the SELECT soft key while
the appropriate transducer parameter is highlighted in the
HEAT_EX screen. Then press the ENTER key. The value will
now go to zero. High end calibration is not necessary.
83
3. Slowly open the refrigerant cooling isolation valve. The
chiller cooler and condenser pressures will gradually
equalize. This process takes approximately 15 minutes.
4. Once the pressures have equalized, the cooler isolation
valve, the condenser isolation valve, and the hot gas isolation valve may now be opened. Refer to Fig. 43 and 44
for the location of the valves.
Increase the sensitivity of the flow switch by turning the adjustment potentiometer clockwise until the yellow LED is lit.
In case of nuisance trips at low flow increase the sensitivity
of the switch by turning the potentiometer clockwise.
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, and a refrigerant high pressure
cutout. The high pressure cutout is factory set to open at
185 psig (1275 kPa) and reset at 140 psig (965 kPa). Ensure the
water-cooled condenser has been connected. Open the compressor suction and discharge the service valves. 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 90 and
99, for details on the transfer of refrigerant, oil specifications,
etc.
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.
CHILLER EQUALIZATION WITH PUMPOUT UNIT —
The following steps describe how to equalize refrigerant pressure on an isolated 19XR 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.
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.
Charge Refrigerant into Chiller
3. Open valve 4 on the pumpout unit and open valves 1a and
1b on the chiller cooler and condenser, Fig. 43 and 44.
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.
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.
CAUTION
WARNING
Always operate the condenser and chilled water pumps
during charging operations to prevent freeze-ups.
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.
The standard 19XR chiller is shipped with the refrigerant
already charged in the vessels. However, the 19XR 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.
CHILLER EQUALIZATION WITHOUT A PUMPOUT
UNIT
The full refrigerant charge on the 19XR 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 16A and 16B.
CAUTION
CAUTION
When equalizing refrigerant pressure on the 19XR 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 the charging hose (connected between the pumpout valves on top of the cooler
and condenser) should be used as the equalization valve.
Always operate the condenser and chilled water pumps
whenever charging, transferring, or removing refrigerant
from the chiller.
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. 43 and 44, 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 (241 kPa) for HFC134a. 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. 43 and
44, valve 7) can be used to charge liquid to the cooler if the
cooler isolation valve (11) is present and is closed. Do not
charge liquid through the linear float to the condenser.
To equalize the pressure differential on a refrigerant isolated
19XR chiller, 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 19XR 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.
84
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. 43 — 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. 44 — Typical Optional Pumpout System Piping Schematic without Storage Tank
85
Table 16A — Refrigerant (HFC-134a) Charge with Compressor End Cooler Nozzles
Code
10*
11*
12*
15*
16*
17*
20
21
22
30
31
32
35
36
37
40
41
42
45
46
47
50
51
52
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
English
Machine Charge
Refrigerant
Weight (lb)
Cooler
Condenser
290
200
310
200
330
200
320
250
340
250
370
250
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
Metric (SI)
Machine Charge
Refrigerant
Weight (kg)
Cooler
Condenser
132
91
141
91
150
91
145
113
154
113
168
113
156
102
175
102
197
102
159
118
191
118
222
118
181
141
218
141
249
141
254
127
286
127
313
127
290
150
327
150
358
150
340
181
381
181
408
181
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
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
*Not used on 19XRV units.
86
English
Metric (SI)
Machine Charge
Refrigerant
Weight (lb)
Cooler
Condenser
Machine Charge
Refrigerant
Weight (kg)
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
—
—
—
—
—
—
—
—
—
—
—
—
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 16B — 19XR Heat Exchanger Data — Drive End Entering Cooler Water
Code
10*
11*
12*
15*
16*
17*
20
21
22
30
31
32
35
36
37
40
41
42
45
46
47
50
51
52
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
English
Machine Charge
Refrigerant
Weight (lb)
Cooler
Condenser
328
226
357
226
387
226
405
275
441
275
477
275
416
252
459
252
505
252
510
308
565
308
626
308
577
349
639
349
709
349
726
338
783
338
840
338
821
383
874
383
949
383
897
446
974
446
1021
446
1010
446
987
446
1014
504
1101
504
1154
504
1143
504
1116
504
491
—
510
—
532
—
553
—
575
—
600
—
673
—
706
—
742
—
641
—
678
—
709
—
768
—
801
—
843
—
730
—
769
—
805
—
1091
479
1150
479
1202
479
1202
479
1178
479
1241
542
1309
542
1369
542
1359
542
1332
542
Metric (SI)
Machine Charge
Refrigerant
Weight (kg)
Cooler
Condenser
149
103
162
103
176
103
184
125
200
125
217
125
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
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
*Not used on 19XRV units.
87
English
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
—
Metric (SI)
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
—
5. The PIC II eventually shows an alarm for motors amps
not sensed. Reset this alarm and continue with the initial
start-up.
6. Disengage the main VFD disconnect. Open the VFD enclosure, move the VFD Test/Run switch into the “RUN”
position. Close the VFD enclosure and engage the main
VFD disconnect.
TRIMMING REFRIGERANT CHARGE — The 19XR
chiller is shipped with the correct charge for the design duty of
the chiller. Trimming the charge can best be accomplished
when the design load is available. To trim the charge, check the
temperature difference between the leaving chilled water temperature and cooler refrigerant temperature at full load design
conditions. If necessary, add or remove refrigerant to bring the
temperature difference to design conditions or minimum
differential.
Table 16A or 16B list the 19XR chiller refrigerant charges
for each cooler and condenser code. Total refrigerant charge is
the sum of the cooler and condenser charge.
Check Motor Rotation
1. Disengage the main VFD disconnect. Open the VFD enclosure and engage the control power circuit breaker.
2. Then engage the oil pump circuit breaker located in the
same section of the starter cabinet. Close the VFD enclosure door.
3. Finally, close the main disconnect on the front of the VFD
enclosure.
4. The ISM mounted in the VFD enclosure checks for proper phase rotation as soon as power is applied to the starter
and the PIC II controls power up.
5. 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 starter and reapply power.
The motor is now ready for a rotation check.
6. After the default screen status message states ‘Ready to
Start’ press the LOCAL softkey. The PIC II control performs start-up checks.
7. When the starter is energized and the motor begins to
turn, check for clockwise motor rotation (Fig. 45).
INITIAL START-UP
Preparation — Before starting the chiller, verify:
1. Power is on to the main starter, oil pump relay, tower fan
starter, 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.
4. Oil is at the proper level in the reservoir sight glasses.
5. Oil reservoir temperature is above 140 F (60 C) or above
CALC EVAP SAT TEMP 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.
IMPORTANT: Do not check motor rotation during coastdown. Rotation may have reversed during equalization of
vessel pressures.
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.
Check Oil Pressure and Compressor Stop
1. When the motor is at full speed, note the differential oil
pressure reading on the ICVC default screen. It should be
between 18 and 40 psid (124 to 206 kPad).
2. Press the Stop button and listen for any unusual sounds
from the compressor as it coasts to a stop.
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.
Dry Run to Test Start-Up Sequence
For unit-mounted Rockwell VFDs.
1. Disengage the main motor disconnect on the VFD front
panel. This should only disconnect the motor power.
Power to the controls, oil pump, and starter control circuit
should still be energized. Open the VFD enclosure, move
the VFD Test/Run switch into the “TEST” position.
Close the VFD enclosure and engage the main VFD disconnect.
2. Observe the default screen on the ICVC: the status message in the upper left-hand corner reads, “Manually
Stopped,” Press the CCN or LOCAL softkey to start. If
the chiller controls do not go into a start mode (“Unoccupied Mode” is displayed) go to the SCHEDULE screen
and override the schedule or change the occupied time.
Press the LOCAL softkey to begin the start-up
sequences.
3. View the STARTUP display screen and verify the chilled
water and condenser water pumps have energized.
4. Verify the oil pump has started and is pressurizing the
lubrication system. After the oil pump has run about
11 seconds, the starter energizes (COMPRESSOR START
CONTACT is closed) and goes through its start-up
sequence.
Fig. 45 — Correct Motor Rotation
88
REVIEW THE START-UP OPERATION, AND MAINTENANCE MANUAL.
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.
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:
• 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 62.
The default ICVC screen message line indicates which
command is in effect.
OPERATING INSTRUCTIONS
Operator Duties
1. Become familiar with the chiller and related equipment
before operating the chiller.
2. Prepare the system for start-up, start and stop the chiller,
and place the system in a shutdown condition.
3. Maintain a log of operating conditions and document any
abnormal readings.
4. Inspect the equipment, make routine adjustments, and
perform a Control Test. Maintain the proper oil and refrigerant levels.
5. Protect the system from damage during shutdown periods.
6. Maintain the set point, time schedules, and other PIC
functions.
Prepare the Chiller for Start-Up — Follow the steps
described in the Initial Start-Up section, page 88.
To Start the Chiller
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 62.
Check Chiller Operating Condition — Check
to
be 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 — Starters and disconnects,
separate electrical sources, pumps, and cooling tower.
DESCRIBE CHILLER CYCLES — Refrigerant, motor
cooling, lubrication, and oil reclaim.
REVIEW MAINTENANCE — Scheduled, routine, and extended shutdowns, importance of a log sheet, importance of
water treatment and tube cleaning, and importance of maintaining a leak-free chiller.
SAFETY DEVICES AND PROCEDURES — Electrical disconnects, relief device inspection, and handling refrigerant.
CHECK OPERATOR KNOWLEDGE — Start, stop, and
shutdown procedures, safety and operating controls, refrigerant
and oil charging, and job safety.
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
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 40 psid (124
to 207 kPad) differential, as seen on the ICVC default
screen. Typically the reading will be 18 to 35 psid (124 to
241 kPad) at initial start-up.
5. The moisture indicator sight glass on the refrigerant motor cooling line should indicate refrigerant flow and a dry
condition.
6. The condenser pressure and temperature varies with the
chiller design conditions. Typically the pressure will
range between 60 and 135 psig (390 to 950 kPa) with a
corresponding temperature range of 60 to 105 F (15 to
41 C). The condenser entering water temperature should
be controlled below the specified design entering water
temperature to save on compressor kilowatt
requirements.
 7. Cooler pressure and temperature also will vary with the
design conditions. Typical pressure range will be between
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).
8. 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
89
312
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 3, Example 24).
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.
NOTE: Manual control overrides the configured pulldown rate
during start-up and permits the guide vanes to open at a faster
rate. Motor current above the electrical demand setting, capacity overrides, and chilled water temperature below the control
point override the manual target and close the guide vanes. For
descriptions of capacity overrides and set points, see the Controls section.
To Stop the Chiller
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, StartUp/Shutdown/Recycle Sequence section, page 62. 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.
Refrigeration Log — A refrigeration log (as shown in
Fig. 46), 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. 46. Automatic recording of PIC II data is possible by using CCN devices such
as the Data Collection module and a Building Supervisor.
Contact a Carrier representative for more information.
If the chiller is stopped by an alarm condition, 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 lbs (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.
PUMPOUT AND REFRIGERANT
TRANSFER PROCEDURES
Preparation — The 19XR 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 evacuation.
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 65.
Recharge the chiller by transferring refrigerant from the
pumpout storage tank (if supplied). Follow the Pumpout and
Refrigerant Transfer Procedures section, below. 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 CALC EVAP SAT TEMP plus 50 F
(27 C).
CAUTION
The power to the pumpout compressor oil heater must be
on whenever any valve connecting the pumpout compressor to the chiller or storage tank is open. Leaving the heater
off will result in oil dilution by refrigerant and can lead to
compressor failure.
If the compressor is found with the heater off and a
valve open the heater must be on for at least 4 hours to
drive the refrigerant from the oil. When heating the oil the
compressor suction must be open to a vessel to give the refrigerant a means to leave the compressor.
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.
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 II controls have a low limit tower fan output
that can be used to assist in this control (terminal J9-11 and J912 on ISM).
Manual Guide Vane Operation — It is possible to
manually operate the guide vanes in order to check control
90
91
Press.
Temp
Refrigerant
In
Water
Out
GPM
Pressure
COOLER
In
Out
Temp
MACHINE MODEL NO.
Press.
Temp
Refrigerant
In
Out
GPM
Pressure
Water
CONDENSER
In
Out
Temp
MACHINE SERIAL NO.
BEARING
TEMP
Fig. 46 — Refrigeration Log
REMARKS: Indicate shutdowns on safety controls, repairs made and oil or refrigerant added or removed. Include amounts.
TIME
DATE
Plant
Press.
Diff.
Temp
(reservoir)
Oil
Level
COMPRESSOR
Amperage
(or vane
position)
Motor
FLA
REFRIGERANT TYPE
REFRIGERATION LOG CARRIER 19XR HERMETIC CENTRIFUGAL REFRIGERATION MACHINE
OPERATOR
INITIALS
DATE
REMARKS
POSITIVE PRESSURE CHILLERS WITH STORAGE
TANKS — In the Valve/Condition tables that accompany these
instructions, the letter “C” indicates a closed valve. Figures 43
and 44 show the locations of the valves.
DANGER
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 the release of refrigerant which will result in
personal injury or death.
CAUTION
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.
CAUTION
Do not mix refrigerants from chillers that use different
compressor oils. Compressor damage can result.
CONTROL
PANEL
Operating the Optional Pumpout Unit
(Fig. 47) — Oil should be visible in the pumpout unit com-
pressor sight glass under all operating conditions and during
shutdown. If oil is low, add oil as described under Optional
Pumpout System Maintenance section, page 99. The pumpout
unit control wiring schematic is detailed in Fig. 48.
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. 2) 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. 43 and 44 for valve locations and numbers.
VALVE
2
FRAME
ASSEMBLY
VALVE
3
VALVE
4
COMPRESSOR
OIL
HEATER
VALVE
5
ENTERING
WATER
LEAVING
WATER
CONDENSER
OIL
SEPARATOR
OIL FILL
FITTING
Fig. 47 — Pumpout Unit
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.
C
2 OL
C
2 OL
C
2 OL
L1
FIELD
POWER
SUPPLY
L2
MTR-1
L3
GND
L1
8
H1
1
X2
X2
55-1
OFF
AUTO ON
2
3
CRANKCASE HEATER
240-600v
27-40 WATT
C
FU
GND
HTR
MTR
NC
OL
SS
0.5A
FU3
HIGH PRESSURE
SAFETY
NC OPEN > 185psig
2
7
H4
CONTROL POWER
TRANSFORMER X1
XFMR-1
69 VA
2
HTR-1
0.25A
FU1
0.25A
FU2
L2
PUMP OUT
COMPRESSOR
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
4
5
C
X2
a23-1615
Fig. 48 — Pumpout Unit Wiring Schematic
92
a23-1546
b. Slowly open valve 5 and refrigerant charging
valves 7 and 10 to allow liquid refrigerant to drain
by gravity into the storage tank.
Transfer Refrigerant from Pumpout Storage Tank to Chiller
WARNING
VALVE
CONDITION
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.
1a
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
VALVE
CONDITION
1a
1b
2
3
C
4
C
5
6
7
C
10
C
1a
C
1b
C
2
C
3
C
4
C
5
C
6
C
7
C
10
C
VALVE
CONDITION
1a
1b
2
C
3
4
C
5
C
6
7
C
10
C
5
6
7
10
11
1a
1b
2
3
C
4
C
5
6
7
10
11
1a
1b
2
3
C
4
C
5
6
7
C
10
C
11
1a
1b
2
C
3
4
5
C
6
7
C
10
C
11
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
VALVE
CONDITION
1a
C
1b
C
2
C
3
C
4
C
5
C
6
C
7
C
10
C
11
g. Turn off the pumpout condenser water.
4. Establish vacuum for service. To conserve refrigerant,
operate the pumpout compressor as described in Step 3e
until the chiller pressure is reduced to 18 in. Hg
vacuum (41 kPa absolute).
This operation can be done in Automatic or On mode.
In Automatic mode, the compressor will stop 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. 43 and
44. Valve 7 remains closed.
11
11
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:
k. Turn off pumpout condenser water.
Transfer the Refrigerant from Chiller to Pumpout Storage
Tank
1. Equalize refrigerant pressure.
a. Valve positions:
VALVE
CONDITION
4
C
3. Remove any remaining refrigerant.
a. Turn on chiller water pumps.
b. Turn on pumpout condenser water.
c. Place valves in the following positions:
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
CONDITION
3
c. Turn off the pumpout compressor.
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
2
C
b. Run the pumpout compressor in automatic mode
until vacuum switch is satisfied and compressor
stops. Close valves 7 and 10.
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
1b
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.
VALVE
CONDITION
1a
VALVE
CONDITION
11
93
1a
1b
2
3
C
4
C
5
11
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
1b
2
C
3
4
5
C
VALVE
CONDITION
11
C
VALVE
CONDITION
1b
C
2
C
3
C
5
C
1a
1b
2
3
C
4
C
5
1a
1b
2
3
C
4
C
5
1a
VALVE
CONDITION
4
C
5
C
11
C
1b
2
C
3
4
C
5
C
11
C
1b
2
C
3
4
C
5
11
C
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.
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.
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.
VALVE
CONDITION
3
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
1a
VALVE
CONDITION
4
C
2
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
1b
C
h. Turn off pumpout condenser water.
i. Turn off chiller water pumps and lock out chiller
compressor.
Return Refrigerant to Normal Operating Conditions
1. Be sure that the chiller vessel that was opened has been
evacuated.
2. Turn on chiller water pumps.
3. Open valves 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
1a
C
VALVE
CONDITION
1a
1b
2
C
3
4
C
5
C
6
7
C
10
C
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.
11
C
c. Turn on pumpout condenser water.
94
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.
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
11
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.
WARNING
11
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.
4. Drain the contaminants from the bottom of the storage
tank into a container. Dispose of contaminants safely.
GENERAL MAINTENANCE
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.
Refrigerant Properties — The standard refrigerant for
the 19XR chiller is HFC-134a. At normal atmospheric pressure, HFC-134a 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.
DANGER
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 96.
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 possible freeze-up
when the chiller pressure is below 30 psig (207 kPa) for
HFC-134a.
Repair the Leak, Retest, and Apply Standing
Vacuum Test — After pressurizing the chiller, test for
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 (page 69) in the Before Initial Start-Up section.
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 96.
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. 49. 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.
Refrigerant Leak Testing — Because HFC-134a is
above atmospheric pressure at room temperature, leak testing
can be performed with refrigerant in the chiller. Use an electronic halogen 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
be taken off line immediately and repaired if the refrigerant
95
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. 49 — Guide Vane Actuator Linkage
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 II 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 II 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 II does not permit compressor start-up if the oil
temperature is too low. The PIC II continues with start-up only
after the temperature is within allowable limits.
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 — If, to obtain optimal chill-
er performance, it becomes necessary to adjust the refrigerant
charge, operate the chiller at design load and then add or remove refrigerant slowly until the difference between the leaving chilled water temperature and the cooler refrigerant temperature reaches design conditions or becomes a minimum. Do
not overcharge.
Refrigerant may be added either through the storage tank or
directly into the chiller as described in the Charge Refrigerant
into Chiller section.
To remove any excess refrigerant, follow the procedure in
Transfer Refrigerant from Chiller to Pumpout Storage Tank
section, Steps 1a and b, page 70.
SCHEDULED MAINTENANCE
Establish a regular maintenance schedule based on your 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.
WEEKLY MAINTENANCE
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.
Check the Lubrication System — Mark the oil lev-
el 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 19XR 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 (45.0 L)
• Frame 5 compressor — 18 gal (67.8 L)
The added oil must meet Carrier specifications for the
19XR. Refer to Changing Oil Filter and Oil Changes section
on page 97. Any additional oil that is added should be logged
by noting the amount and date. Any oil that is added due to oil
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 isolated when cleaning and
tightening connections inside the VFD enclosure. Failure
to disconnect power could result in electrocution. The oil
filter housing is at a high pressure. Relieve this pressure
slowly. Failure to do so could result in serious personal
injury.
96
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 II 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 amount shown in Step 2.
Check Safety and Operating Controls Monthly —
To ensure chiller protection, the automated Control Test
should be performed at least once per month. See Table 6
for safety control settings. See Table 15 for Control Test
functions.
Changing Oil Filter — Change the oil filter on a
yearly basis or when the chiller is opened for repairs. The
19XR has an isolatable oil filter so that the filter may be
changed with the refrigerant remaining in the chiller. Early
19XR compressors were designed with the oil filter housing
attached to the oil pump. The following procedure applies
to later 19XR compressors which have the oil filter separate
from the oil pump. Use the following procedure:
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 the
power panel, on the 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 Schrader 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 (Fig. 2) 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
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.
Inspect Refrigerant Float System — Perform this
inspection only if the following symptoms are seen.
• There is a simultaneous drop in cooler pressure and
increase in condenser pressure. This will be accompanied by an increase in kW/Ton.
• The liquid line downstream of the float valve feels warm.
This indicates condenser gas flowing past the float. An
increase in kW/Ton will also occur.
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. 50 for a view of the float valve design. Inspect the
orientation of the float slide pin. It must be pointed toward the bubbler tube for proper operation.
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 your local Carrier representative.
 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.
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.
97
312
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
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
your Carrier representative to obtain these brushes. Do not use
wire brushes.
Hard scale may require chemical treatment for its prevention or removal. Consult a water treatment specialist for proper
treatment.
1
2
3
4
5
6
7
8
1
2
3
4
5
6
7
8
—
—
—
—
—
—
—
—
a23-1632
LEGEND
Refrigerant Inlet from FLASC Chamber
Linear Float Assembly
Float Screen
Bubbler Line
Float Cover
Bubbler Line Connection
Refrigerant Outlet to Cooler
Gasket
Fig. 50 — 19XR/XRV Float Valve Design
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.
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
or damage may result. See Chiller Dehydration section,
page 69.
Compressor Bearing and Gear Maintenance —
Water Treatment — Untreated or improperly treated wa-
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. Annual oil analyses are recommended.
Excessive bearing wear can sometimes be detected through
increased vibration or increased bearing temperature. Gears,
babbitted journal, and thrust bearings should be examined for
signs of wear based on the results of the annual oil analysis and
vibration levels. 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, 4 and 5
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.
ter 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.
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 Starting Equipment — Before working
on any starter, shut off the chiller, open and tag all disconnects
supplying power to the starter.
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.
Inspect the Heat Exchanger Tubes and Flow
Devices
COOLER AND OPTIONAL FLOW DEVICES — Inspect
and clean the cooler tubes at the end of the first operating season. Because these tubes have internal ridges, a rotary-type
98
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. 51) — 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.
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
severe 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 the
internal parts with a high-velocity, low-pressure blower.
Power connections on newly installed starters 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.
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, 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 Troubleshooting Guide section. Oil differential pressure (OIL PUMP
DELTA P on the COMPRESS screen) should be zero whenever the compressor is off.
Recalibrate Pressure Transducers —
a19-1569
TRANSFORMER
Fig. 51 — Pumpout Control Box (Interior)
TROUBLESHOOTING GUIDE
Overview — The PIC II has many features to help the operator and technician troubleshoot a 19XR 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, SURGPREV,
LL_MAINT, ISM_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.
• The control test feature facilitates the proper operation
and test of temperature sensors, pressure transducers, the
guide vane actuator, diffuser actuator (if equipped), oil
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.
99
See Fig. 2 for sensor locations. The sensors are immersed
directly in the refrigerant or water circuits. When installing a
new sensor, apply a pipe sealant or thread sealant to the sensor
threads.
An additional thermistor, factory installed in the bottom of
the cooler barrel, will read as EVAPORATOR REFRIGERANT
TEMP on the HEAT_EX display screen. This thermistor provides additional protection against a loss of water flow.
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.
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 table.
• Review the ALERT HISTORY table to view other less
critical events which may have occurred. Compare timing of relevant events and alarms.
Checking Display Messages — The first area to
check when troubleshooting the 19XR is the ICVC display. If
the alarm light is flashing, check the primary and secondary
message lines on the ICVC default screen (Fig. 15). These
messages will indicate where the fault is occurring. These messages contain the alarm message with a specified code. This
code or state appears with each alarm and alert message. The
ALARM and ALERT HISTORY tables on the ICVC SERVICE menu also contain an alarm or alert message to further
expand on the alarm or alert. For a complete list of possible
alarm messages, see Table 17. 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.
A “C” to the right of a parameter’s value means that there is
a communications fault on that channel.
Checking Pressure Transducers — There are 4
factory-installed pressure transducers measuring refrigerant
and oil pressure. There is a fifth pressure transducer measuring
pressure variations at the compressor discharge on compressors
equipped with a split ring diffuser (SRD). This transducer is
not displayed and does not require calibration.
Except for the discharge transducer, these 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 ± 0.5 v displayed in CONTROL TEST under
CCM Pressure Transducers. If the TRANSDUCER VOLTAGE REF supply voltage is correct, the transducer should be
recalibrated or replaced.
Also check that inputs on the CCM J5-1 through J5-6 have
not been grounded and are not receiving anything other than a
4 to 20 mA signal.
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.
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
Tables 18A and 18B.
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
Tables 18A and 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.
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 a large leak and
possible injury to personnel.
CAUTION
Relieve all refrigerant pressure or drain the water before
removing any thermowell 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 (0.25 C) graduations. The sensor in question
should be accurate to within 2 F (1.2 C).
100
COOLER AND 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.
(continued on page 117)
Table 17 — ICVC Primary and Secondary Messages and
Custom Alarm/Alert Messages with Troubleshooting Guides
A. MANUAL STOP
PRIMARY MESSAGE
MANUALLY STOPPED — PRESS
TERMINATE PUMPDOWN MODE
SHUTDOWN IN PROGRESS
SECONDARY MESSAGE
CCN OR LOCAL TO START
TO SELECT CCN OR LOCAL
SHUTDOWN IN PROGRESS
COMPRESSOR UNLOADING
COMPRESSOR DEENERGIZED
ICE BUILD
SHUTDOWN IN PROGRESS
OPERATION COMPLETE
RECYCLE RESTART PENDING
PROBABLE CAUSE/REMEDY
PIC II 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.
Low Load Shutdown
B. READY TO START
PRIMARY MESSAGE
READY TO START IN XX MIN
READY TO START IN XX MIN
SECONDARY MESSAGE
UNOCCUPIED MODE
REMOTE CONTACTS OPEN
READY TO START IN XX MIN
STOP COMMAND IN EFFECT
READY TO START IN XX MIN
OCCUPIED MODE
REMOTE CONTACTS CLOSED
READY TO START IN XX MIN
START COMMAND IN EFFECT
READY TO START IN XX MIN
READY TO START IN XX MIN
RECYCLE RESTART PENDING
UNOCCUPIED MODE
READY TO START
REMOTE CONTACTS OPEN
READY TO START
STOP COMMAND IN EFFECT
READY TO START
READY TO START
READY TO START
OCCUPIED MODE
REMOTE CONTACTS CLOSED
START COMMAND IN EFFECT
READY TO START
STARTUP INHIBITED
LOADSHED IN EFFECT
PROBABLE CAUSE/REMEDY
Time schedule for PIC II is unoccupied. Chillers will start only
when occupied. Check OCCPCnnS and HOLIDAYS screens.
Remote contacts are open. Close contacts on ISM J2-5 and
J2-6 to start.
Chiller START/STOP on MAINSTAT manually forced to STOP.
Release SUPERVISOR Force or send Start Force to start.
Chiller timer counting down. Unit ready to start.
Chiller timer counting down. Unit will proceed to start. Remote
contact Enabled and Closed. The chiller will stop when the
remote contacts are opened.
Chiller START/STOP on MAINSTAT manually forced to
START. Release SUPERVISOR force to start under normal
control.
Chiller is in recycle mode.
Time schedule for PIC II is UNOCCUPIED in OCCPC01S
screen. Chiller will start when state changes to OCCUPIED.
Make sure the CURRENT TIME and DATE are correct in the
TIME AND DATE screen.
Remote contacts have stopped the chiller. Close contacts on
ISM J2-5 and J2-6 to start.
Chiller START/STOP on MAINSTAT manually forced to STOP.
Release SUPERVISOR force to start.
Chiller timer countdown is complete. Unit will proceed to start.
Chiller timer count down complete. Unit will proceed to start.
Chiller START/STOP on MAINSTAT has been manually forced
to START. Chiller will start regardless of time schedule or
remote contact status.
CCN loadshed module commanding chiller to stop.
C. IN RECYCLE SHUTDOWN
PRIMARY MESSAGE
RECYCLE RESTART PENDING
RECYCLE RESTART PENDING
RECYCLE RESTART PENDING
RECYCLE RESTART PENDING
SECONDARY MESSAGE
OCCUPIED MODE
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.
REMOTE CONTACT CLOSED
START COMMAND IN EFFECT
ICE BUILD MODE
LEGEND TO TABLES 17A-17K
CCM
CHW
ICVC
ISM
PIC II
VFD
—
—
—
—
—
—
Chiller Control Module
Chilled Water
International Chiller Visual Control
Integrated Starter Module
Product Integrated Controls II
Variable Frequency Drive
101
Table 17 — ICVC Primary and Secondary Messages and
Custom Alarm/Alert Messages with Troubleshooting Guides (cont)
D. PRE-START ALERTS: These alerts only delay start-up. When alert is corrected, the start-up will continue. No reset is necessary.
FAULT
STATE
100
101
PRIMARY
MESSAGE
PRESTART
ALERT
SECONDARY
MESSAGE
STARTS LIMIT
EXCEEDED
PRIMARY CAUSE
ADDITIONAL CAUSE/REMEDY
100->Excessive compressor starts (8
in 12 hours)
HIGH BEARING TEMPERATURE
"101->Comp Thrust Bearing Temp
[VALUE] exceeded limit of [LIMIT]*.
Check STARTS IN 12 HOURS in MAINSTAT screen.
Depress the RESET softkey if additional start is required.
Reassess start-up requirements. (Recycle restarts and auto
restarts after power failure are not counted.)
Check COMP THRUST BRG TEMP in COMPRESS screen.
Check oil heater and oil cooler for proper operation.
Check for low oil level, partially closed oil supply valves,
clogged oil filters.
Check the Thrust Bearing Temperature sensor wiring and
accuracy to CCM J4-19 and J4-20.
Check Resistance of thermistor vs. temperature.
Check COMP THRUST BRG ALERT setting in SETUP1
screen.
Check Resistance of thermistor vs. temperature.
Check COMP MOTOR WINDING TEMP in COMPRESS
screen.
Check motor temperature sensor for wiring and accuracy to
CCM J4-23 and J4-24.
Check Resistance of thermistor vs. temperature
Check motor cooling line and isolation valves for proper operation, or restrictions, check refrigerant filter/drier.
Check for excessive starts within a short time span.
Check COMP MOTOR TEMP OVERRIDE setting in SETUP1
screen.
Check COMP DISCHARGE TEMP in COMPRESS screen.
Allow compressor discharge temperature sensor to cool.
Check compressor discharge temperature sensor wiring and
accuracy to CCM J4-17 and J4-18.
Check Resistance of thermistor vs. temperature Check for
excessive starts.
Check COMP DISCHARGE ALERT setting in SETUP1
screen.
Check EVAPORATOR PRESSURE, CALC EVAP SAT TEMP,
and EVAP REFRIG LIQUID TEMP in HEAT_EX screen.
Check Evaporator Pressure transducer and Evaporator
Refrigerant Liquid Temperature sensor wiring and accuracy.
Check Resistance of thermistor vs. temperature.
Check for low chilled water supply temperatures.
Check refrigerant charge. Check REFRIG OVERRIDE DELTA
T and EVAP REFRIG TRIPPOINT in SETUP1 screen.
Check OIL SUMP TEMP in ICVC default screen. Check 1C oil
heater contactor/relay and power.
Check Oil Sump Temperature Sensor wiring and accuracy.
Check Resistance of thermistor vs. temperature. Check oil
level and oil pump operation.
Check EVAPORATOR PRESSURE, CALC EVAP SAT TEMP,
and EVAP REFRIG LIQUID TEMP in HEAT_EX screen.
Check CONDENSER PRESSURE in HEAT_EX screen.
Check Condenser Pressure transducer wiring and accuracy.
Check for high condenser water temperatures. Check COND
PRESS OVERRIDE in SETUP1 screen.
Check ACTUAL LINE VOLTAGE in POWER screen. Check
UNDERVOLTAGE THRESHOLD in ISM_CONF screen.
Check voltage supply.
Check wiring to ISM J3-L1, J3-L2, and J3-L3. Check voltage
transformers and switch gear. Consult power utility if voltage
is low.
Check ACTUAL LINE VOLTAGE in POWER screen.
Check OVERVOLTAGE THRESHOLD in ISM_CONF screen.
Check voltage supply.
Check voltage transformers and switch gear. Consult power
utility if voltage is high.
Press STOP button on ICVC and perform Guide Vane Calibration in CONTROLS TEST screen. Check guide vane actuator feedback potentiometer and wiring to CCM J4-9 and J410.
PRESTART
ALERT
HIGH MOTOR TEMPER- 102->Comp Motor Winding Temp
ATURE
[VALUE] exceeded limit of [LIMIT]*.
102
103
104
PRESTART
ALERT
HIGH DISCHARGE
TEMP
103->Comp Discharge Temp
[VALUE] exceeded limit of [LIMIT]*.
LOW REFRIGERANT
TEMP
104->Evaporator Refrig Temp
[VALUE] exceeded limit of [LIMIT]*.
LOW OIL TEMPERATURE
105->Oil Sump Temp [VALUE]
exceeded limit of [LIMIT]*.
HIGH CONDENSER
PRESSURE
106->Condenser Pressure [VALUE]
exceeded limit of [LIMIT]*.
LOW LINE VOLTAGE
107Average Line Voltage [VALUE]
exceeded limit of [LIMIT]*.
HIGH LINE VOLTAGE
108->Average Line Voltage [VALUE]
exceeded limit of [LIMIT]*.
GUIDE VANE
CALIBRATION
109Actual Guide Vane Pos Calibration Required Before Startup
PRESTART
ALERT
PRESTART
ALERT
105
PRESTART
ALERT
106
PRESTART
ALERT
107
PRESTART
ALERT
108
PRESTART
ALERT
109
PRESS STOP,
PERFORM
*[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. "Exceeded Limit" in Alarm or Alert messages may mean the value is
above or below a threshold.
102
Table 17 — ICVC Primary and Secondary Messages and
Custom Alarm/Alert Messages with Troubleshooting Guides (cont)
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 (OCCUPIED? = YES)
Chiller is starting. REMOTE CONTACTS OPTION is set to ENABLE. Remote
start contact input on ISM terminals J2-5 and J2-6 is closed.
START COMMAND IN EFFECT Chiller is starting. Chiller START/STOP in MAINSTAT is manually forced to
START.
OCCUPIED MODE
Chiller is starting after power failure. Time schedule is Occupied (OCCUPIED? = YES).
REMOTE CONTACT CLOSED
Chiller is starting after power failure. REMOTE CONTACTS OPTION is set to
ENABLE. Remote start contact input on ISM terminals J2-5 and J2-6 is
closed.
START COMMAND IN EFFECT Chiller is starting after power failure. Chiller START/STOP on MAINSTAT
screen is manually forced to START.
F. NORMAL RUN
PRIMARY MESSAGE
SECONDARY MESSAGE
BY 4-20 mA SIGNAL
RUNNING — RESET ACTIVE
REMOTE TEMP SENSOR
RUNNING — RESET ACTIVE
CHW TEMP DIFFERENCE
RUNNING — RESET ACTIVE
LEAVING CHILLED WATER
RUNNING — TEMP CONTROL
ENTERING CHILLED WATER
RUNNING — TEMP CONTROL
RUNNING — TEMP CONTROL
RUNNING — DEMAND LIMITED
RUNNING — DEMAND LIMITED
TEMPERATURE RAMP
LOADING
BY DEMAND RAMP LOADING
BY LOCAL DEMAND SETPOINT
BY 4-20 mA SIGNAL
RUNNING — DEMAND LIMITED
BY CCN SIGNAL
RUNNING — DEMAND LIMITED
BY LOADSHED/REDLINE
RUNNING — DEMAND LIMITED
HOT GAS BYPASS
RUNNING — TEMP CONTROL
RUNNING — DEMAND LIMITED
RUNNING —TEMP CONTROL
BY LOCAL SIGNAL
ICE BUILD MODE
IN VFD RAMPDOWN
RUNNING —TEMP CONTROL
RUNNING —TEMP CONTROL
HGBP IS ADDING LOAD
CAUSE/REMEDY
Auto chilled water reset active based on external input. ENABLE RESET TYPE
=1. A non-zero temperature reset based on a 4-20 mA Auto Chilled Water Reset
signal on CCM J5-3 and J5-4 is being added to the SETPOINT to determine the
CONTROL POINT. See TEMP_CTL screen
Auto chilled water reset active based on external input. ENABLE RESET TYPE
=2. A non-zero temperature reset based on the Remote Temperature Reset sensor signal on CCM J4-13 and J4-14 is being added to the SETPOINT to determine
the CONTROL POINT. See TEMP_CTL screen
Auto chilled water reset active based on cooler chilled water temperature difference. ENABLE RESET TYPE =3. A non-zero temperature reset based on the difference between the ENTERING CHILLED WATER and LEAVING CHILLED
WATER is being added to the SETPOINT to determine the CONTROL POINT.
See TEMP_CTL screen.
Default method of temperature control. ECW CONTROL OPTION = DSABLE.
Chiller capacity is being controlled so the LEAVING CHILLED WATER temperature is being maintained within 1/2 of the CHILLED WATER DEADBAND on either
side of the CONTROL POINT. See TEMP_CTL screen
Entering Chilled Water (ECW) control enabled. ECW CONTROL OPTION =
ENABLE. Chiller capacity is being controlled so the ENTERING CHILLED WATER
temperature is being maintained within 1/2 of the CHILLED WATER DEADBAND
on either side of the CONTROL POINT. See TEMP_CTL screen.
Ramp Loading based on LEAVING CHILLED WATER or ENTERING CHILLED
WATER is in effect. PULLDOWN RAMP TYPE = 0. Capacity inhibit is in effect
because LEAVING CHILLED WATER or ENTERING CHILLED WATER has fallen
below the ramping temperature pulldown Setpoint. See RAMP_DEM screen.
Ramp Loading based on AVERAGE LINE CURRENT or MOTOR PERCENT
KILOWATTS is in effect. PULLDOWN RAMP TYPE = 0. Capacity inhibit is in effect
because AVERAGE LINE CURRENT or MOTOR PERCENT KILOWATTS has
exceeded the ramping active demand limit. See RAMP_DEM screen.
Actual demand has exceeded ACTIVE DEMAND LIMIT. 20mA DEMAND LIMIT
OPT is DISABLED. ACTIVE DEMAND LIMIT is set equal to BASE DEMAND
LIMIT. AVERAGE LINE CURRENT or MOTOR PERCENT KILOWATTS is greater
than ACTIVE DEMAND LIMIT.
Actual demand has exceeded ACTIVE DEMAND LIMIT. 20mA DEMAND LIMIT
OPT is ENABLED. ACTIVE DEMAND LIMIT is adjusted based on 4-20 mA Auto
Demand Limit signal received on CCM J5-1 and J5-2. AVERAGE LINE CURRENT
or MOTOR PERCENT KILOWATTS is greater than ACTIVE DEMAND LIMIT.
Actual demand has exceeded ACTIVE DEMAND LIMIT. Chiller CONTROL MODE
= CCN. Value of ACTIVE DEMAND LIMIT is being forced by a CCN device. AVERAGE LINE CURRENT or MOTOR PERCENT KILOWATTS is greater than ACTIVE
DEMAND LIMIT.
Actual demand has exceeded ACTIVE DEMAND LIMIT. Chiller CONTROL MODE
= CCN. Value of ACTIVE DEMAND LIMIT was set equal to AVERAGE LINE CURRENT or MOTOR PERCENT KILOWATTS at the time a Redline command was
received by the loadshed POC. AVERAGE LINE CURRENT of MOTOR PERCENT KILOWATTS is greater than ACTIVE DEMAND LIMIT. See LOADSHED
screen.
SURGE LIMIT/HGBP OPTION = 1 and HOT GAS BYPASS RELAY is ON. See
surge prevention description and OPTIONS screen. If VFD OPTION is ENABLED
then TARGET VFD SPEED = VFD MAXIMUM SPEED or the TARGET VFD
SPEED is forced.
ACTIVE DEMAND LIMIT has been manually forced on MAINSTAT screen. Chiller
CONTROL MODE = LOCAL.
ICE BUILD OPTION is set to ENABLE and chiller is running under Ice Build temperature control. OCCPC02S Ice Build Schedule is OCCUPIED.
VFD OPTION is ENABLED. VFD Rampdown goes into effect following the completion of start-up Ramp Loading and when the water temperature is within or
below the CHILLED WATER DEADBAND.
SURGE LIMIT/HGBP OPTION = 2. CHILLED WATER DELTA T is less than HGBP
ON DELTA T. See OPTIONS and SURGPREV screens.
103
Table 17 — ICVC Primary and Secondary Messages and
Custom Alarm/Alert Messages with Troubleshooting Guides (cont)
G. NORMAL RUN WITH OVERRIDES
ICVC
FAULT
STATE
120
121
PRIMARY MESSAGE
SECONDARY MESSAGE
PRIMARY CAUSE
HIGH CONDENSER
PRESSURE
120->Condenser Pressure
[VALUE] exceeded limit of
[LIMIT]*.
HIGH MOTOR TEMPERATURE
121->Comp Motor Winding
Temp [VALUE] exceeded limit
of [LIMIT]*.
RUN CAPACITY
LIMITED
RUN CAPACITY
LIMITED
LOW EVAP REFRIG TEMP 122->Evaporator Refrig Temp
[VALUE] exceeded limit of
[LIMIT]*.
122
RUN CAPACITY
LIMITED
123
RUN CAPACITY
LIMITED
124
RUN CAPACITY
LIMITED
125
HIGH COMPRESSOR LIFT 123->Surge Prevention Override: Lift Too High For Compressor
MANUAL GUIDE VANE
TARGET
124->Run Capacity Limited:
Manual Guide Vane Target.
LOW DISCHARGE
SUPERHEAT
No Alert message
RUN CAPACITY
LIMITED
ADDITIONAL
CAUSE/REMEDY
Check condenser water pump operation.
Check for high condenser water temperatures
or low flow rate.
Check cooling tower bypass valves and condenser water strainers. Verify that chiller isolation valves are open.
Check COND PRESS OVERRIDE setting in
SETUP1 screen.
Check for closed valves or restrictions in motor
cooling lines.
Check for closed refrigerant isolation valves.
Check COMP MOTOR TEMP OVERRIDE setting in SETUP1.
Check refrigerant filter drier.
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 water temperature.
Check that condenser inlet and outlet water
nozzles are piped correctly.
Check for waterbox division plate gasket
bypass.
Check REFRIG OVERRIDE DELTA T setting
in SETUP1 screen.
Check for high condenser water temperature
or low evaporator refrigerant temperature.
Check for high EVAPORATOR APPROACH or
CONDENSER APPROACH.
Check SURGE/HOT GAS BYPASS 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 from compressor or excess
oil charge.
Check for excess refrigerant charge. Verify
that the valves in the oil reclaim lines are
open.
Check oil reclaim strainers.
Check ACTUAL SUPERHEAT in OVERRIDE
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 has recorded at the time of the fault condition.
"Exceeded Limit" in Alarm or Alert messages may mean the value is above or below a threshold.
104
Table 17 — ICVC Primary and Secondary Messages and
Custom Alarm/Alert Messages with Troubleshooting Guides (cont)
H. OUT-OF-RANGE SENSOR ALARMS
STATE
260
261
262
263
264
265
266
267
268
269
270
271
272
PRIMARY MESSAGE
SECONDARY MESSAGE
PRIMARY CAUSE
LEAVING CHILLED WATER
260->Sensor Fault: Check Leaving Chilled Water Sensor
ENTERING CHILLED WATER
261->Sensor Fault: Check Entering Chilled Water Sensor
CONDENSER PRESSURE
262->Sensor Fault: Check Condenser Pressure Sensor
EVAPORATOR PRESSURE
263->Sensor Fault: Check Evaporator Pressure Sensor
COMPRESSOR BEARING TEMP
264->Sensor Fault: Check Comp
Thrust Brg Temp Sensor
COMPRESSOR MOTOR TEMP
265->Sensor Fault: Check Comp
Motor Winding Temp Sensor
COMP DISCHARGE TEMP
266->Sensor Fault: Check Comp
Discharge Temp Sensor
OIL SUMP TEMP
267->Sensor Fault: Check Oil
Sump Temp Sensor
COMP OIL PRESS DIFF
268->Sensor Fault: Check Oil
Pump Delta P Sensor
CHILLED WATER FLOW
269->Sensor Fault: Check Chilled
Water Delta P Sensor
COND WATER FLOW
270->Sensor Fault: Check Cond
Water Delta P Sensor
VFD SPEED OUT OF RANGE
271->Sensor Fault: Check Actual
VFD Speed
EVAP REFRIG LIQUID TEMP
272->Sensor Fault: Check Evap
Refrig Liquid Temp Sensor
SENSOR FAULT
SENSOR FAULT
SENSOR FAULT
SENSOR FAULT
SENSOR FAULT
SENSOR FAULT
SENSOR FAULT
SENSOR FAULT
SENSOR FAULT
SENSOR FAULT
SENSOR FAULT
SENSOR FAULT
SENSOR FAULT
105
ADDITIONAL
CAUSE/REMEDY
Check sensor resistance or voltage drop
against Table 18A or 18B.
Check for proper wiring between LEAVING
CHILLED WATER Temperature Sensor and
CCM J4-3 and J4-4. Check for disconnected,
grounded, or shorted wiring.
Check sensor resistance or voltage drop
against Table 18A or 18B.
Check for proper wiring between ENTERING
CHILLED WATER Temperature Sensor and
CCM J4-1 and J4-2. Check for disconnected,
grounded, or shorted wiring.
Check CONDENSER PRESSURE transducer
wiring. Confirm that 5 V reference signal is
available between CCM J2-4 and J2-6. Check
for disconnected, grounded, or shorted wiring.
Check for condensation in transducer
connector.
Check EVAPORATOR PRESSURE transducer
wiring. Confirm that 5 V reference signal is
available between CCM J2-1 and J2-3. Check
for disconnected, grounded, or shorted wiring.
Check for condensation in transducer
connector.
Check sensor resistance or voltage drop
against Table 18A or 18B.
Check for proper wiring between COMP
THRUST BRG TEMP Sensor and CCM J4-19
and J4-20. Check for disconnected, grounded,
or shorted wiring.
Check sensor resistance or voltage drop
against Table 18A or 18B.
Check for proper wiring between COMP
MOTOR WINDING TEMP Sensor and CCM J423 and J4-24. Check for disconnected,
grounded, or shorted wiring.
Check sensor resistance or voltage drop
against Table 18A or 18B.
Check for proper wiring between COMP DISCHARGE TEMP Sensor and CCM J4-17 and
J4-18. Check for disconnected, grounded, or
shorted wiring.
Check sensor resistance or voltage drop
against Table 18A or 18B.
Check for proper wiring between OIL SUMP
TEMP and CCM J4-21 and J4-22. Check for
disconnected, grounded, or shorted wiring.
Check Oil Sump Pressure and Oil Pump Discharge Pressure sensor wiring and accuracy.
Confirm that 5 V reference signal is available
between CCM J3-1 and J3-3 and J3-4 and J36. Check for disconnected, grounded, or
shorted OIL PUMP DELTA P wiring.
Check CHILLED WATER DELTA P transducer
wiring and accuracy. Check FLOW DELTA P
DISPLAY setting in SETUP1 screen. Confirm
that 5 V reference signal is available between
CCM J3-13 and J3-15 and J3-16 and J3-18.
Check for disconnected, grounded, or shorted
wiring. If pressure transducers are not installed,
check for presence of resistors and jumpers
CCM terminals J3-13 through J3-18. See
Chiller Controls Schematic if flow switches are
used.
Check CONDENSER WATER DELTA P transducer wiring and accuracy. Check FLOW
DELTA P DISPLAY setting in SETUP1 screen.
Confirm that 5 V reference signal is available
between CCM J3-19 and J3-21 and J3-22 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 0 - 5 V DC input from VFD to ISM terminals J6-1 and J6-2.
Check VFD speed feedback signal calibration.
Check VFD configuration, jumpers, and dip
switch settings. Check for disconnected,
grounded, or shorted wiring.
Check sensor resistance or voltage drop
against Table 18A or 18B.
Check for proper wiring between EVAP
REFRIG LIQUID TEMP Sensor and CCM J4-11
and J4-12. Check for disconnected, grounded,
or shorted wiring.
Table 17 — ICVC Primary and Secondary Messages and
Custom Alarm/Alert Messages with Troubleshooting Guides (cont)
I. CHILLER PROTECTIVE LIMIT FAULTS (cont)
ICVC
FAULT
STATE
227
228
229
230
231
232
PRIMARY MESSAGE
SECONDARY MESSAGE
PRIMARY CAUSE
OIL PRESS SENSOR FAULT
227->Oil Pump Delta P [VALUE]
exceeded limit of [LIMIT]*
LOW OIL PRESSURE
228->Oil Pump Delta P [VALUE]
exceeded limit of [LIMIT]*
LOW CHILLED WATER FLOW
229->Low Chilled Water Flow; Check
Delta P Config and Calibration
LOW CONDENSER WATER
FLOW
230->Low Condenser Water Flow;
Check Delta P Config and Calibration
HIGH DISCHARGE TEMP
231->Comp Discharge Temp [VALUE]
exceeded Limit of [LIMIT]*
LOW REFRIGERANT TEMP
232->Evaporator Refrig Temp [VALUE]
exceeded limit of [LIMIT]*.
PROTECTIVE LIMIT
PROTECTIVE LIMIT
PROTECTIVE LIMIT
PROTECTIVE LIMIT
PROTECTIVE LIMIT
PROTECTIVE LIMIT
ADDITIONAL
CAUSE/REMEDY
OIL PUMP DELTA P > 4 PSI when oil pump is off.
Select OIL PUMP DELTA P in the COMPRESS
screen to calibrate pressure transducers. Check
Oil Sump Pressure and Oil Pump Discharge Pressure transducer wiring leading to CCM J3-1
through J3-6. Confirm that 5.0 V reference voltage
is available between CCM J3-1 and J3-2 and CCM
J3-4 and J3-6. Check power supply to oil pump.
Check oil pump operation and isolation valves.
Check oil level sight glasses on compressor base.
Check for partially closed oil filter and oil reclaim
isolation valves. Select OIL PUMP DELTA P in the
COMPRESS screen to calibrate pressure transducers. Check Oil Sump Pressure and Oil Pump
Discharge Pressure transducer wiring leading to
CCM J3-1 through J3-6. Confirm that 5.0 V reference voltage is available between CCM J3-1 and
J3-2 and CCM J3-4 and J3-6. Check power supply
to oil pump fuses, 2C contactor, and oil pump.
Check oil pump operation in CONTROLS TEST
screen. Check oil filter. Check for foaming oil at
start-up. Check oil pressure regulator valve.
Perform Chilled Water pump test in CONTROLS
TEST screen. Check EVAP REFRIG LIQUID
TEMP and LEAVING CHILLED WATER temperature sensor accuracy and wiring to CCM. Check
chilled water valves, pumps, and strainers. Check
EVAP REFRIG TRIPPOINT, EVAP APPROACH
ALERT, EVAP FLOW DELTA P CUTOUT, and
WATER FLOW VERIFY TIME settings. Check load
resistors, optional water flow switches or water
flow delta P transducer calibration and wiring to
CCM J3-13 through J3-18. Check for 5.0 V reference voltage between CCM J3-13 and J3-15 and
J3-16 and J3-18. Activate Pumpdown Mode in
CONTROLS TEST screen before removing refrigerant charge.
Perform Condenser Water pump test in CONTROLS TEST screen. Check CONDENSER
PRESSURE transducer and LEAVING CONDENSER WATER temperature sensor accuracy
and wiring.
Check condenser water valves and strainers.
Check COND PRESS OVERRIDE, COND
APPROACH ALERT, COND FLOW DELTA P CUTOUT, and WATER FLOW VERIFY TIME settings.
Check for CONDENSER PRESSURE > 165 PSIG.
Check load resistors, optional water flow switches
or water flow delta P transducer calibration and
wiring to CCM terminals J3-19 to J3-24. Check for
5.0 V reference voltage between CCM J3-19 and
J3-21 and J3-22 and J3-24.
Check for closed compressor discharge isolation
valve. Check if chiller was operating in surge conditions. Check COMP DISCHARGE TEMP sensor resistance or voltage drop.
Check for proper wiring to CCM J4-17 and J4-18.
Check for proper condenser flow and temperature.
Check for proper inlet guide vane and optional diffuser actuator operation. Check for COMP DISCHARGE TEMP > 220 deg F. Check for fouled
tubes, plugged water strainers, or noncondensibles in the condenser.
Check for proper refrigerant charge.
Check float valve operation. Check for closed condenser liquid line isolation valve. If problem occurs
at high load, check for low condenser pressure
which causes inadequate refrigerant flow through
condenser flasc orifices. Check for proper chilled
water flow and temperature. Confirm that condenser water enters bottom row of condenser
tubes first, reversed condenser water flow may
cause refrigerant to stack in the condenser. Check
EVAPORATOR PRESSURE transducer and EVAP
REFRIG LIQUID TEMP and LEAVING CHILLED
WATER sensors. Check for division plate gasket
bypass. Check for fouled tubes. Check pressure
transducer and temperature sensor wiring to the
CCM.
*[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. "Exceeded Limit" in Alarm or Alert messages may mean the value is above or
below a threshold.
106
Table 17 — ICVC Primary and Secondary Messages and
Custom Alarm/Alert Messages with Troubleshooting Guides (cont)
I. CHILLER PROTECTIVE LIMIT FAULTS (cont)
ICVC
FAULT
STATE
PRIMARY MESSAGE
SECONDARY MESSAGE
HIGH MOTOR TEMPERATURE
233
PRIMARY CAUSE
233->Comp Motor Winding Temp
[VALUE] exceeded limit of [LIMIT]*.
PROTECTIVE LIMIT
HIGH BEARING TEMPERATURE 234->Comp Thrust Brg Temp [VALUE]
exceeded limit of [LIMIT]*.
234
PROTECTIVE LIMIT
HIGH CONDENSER PRESSURE 235->Condenser Pressure [VALUE]
exceeded limit of [LIMIT]*.
235
PROTECTIVE LIMIT
236
PROTECTIVE LIMIT
237
PROTECTIVE LIMIT
238
239
COMPRESS SURGE/LOW
SPEED
236->Compressor Surge: Check condenser water temp and flow
SPARE SAFETY DEVICE
237->Spare Safety Device
EXCESSIVE COMPR SURGE
238->Compressor Surge: Check condenser water temp and flow
TRANSDUCER VOLTAGE FAULT
239->Transducer Voltage Ref [VALUE]
exceeded limit of [LIMIT]*.
PROTECTIVE LIMIT
PROTECTIVE LIMIT
ADDITIONAL
CAUSE/REMEDY
Check COMP MOTOR WINDING TEMP accuracy
and wiring to CCM J4-23 and J4-24.
Check motor cooling line and spray nozzle for
proper operation, or restrictions. Check motor
cooling filter/drier and isolation valves. Look for
refrigerant flow through motor cooling line sight
glass.
Check for excessive starts within a short time
span. Check temperature after switching to spare
COMP MOTOR WINDING TEMP sensor.
Check oil heater for proper operation, confirm that
oil heater is de-energized when compressor is running. Check for low oil level, partially closed oil line
isolation valves, or clogged oil filter. Check oil
cooler refrigerant thermal expansion valves, confirm that expansion valve bulbs are secured to the
oil lines and insulated. Check COMP THRUST
BRNG TEMP sensor accuracy and wiring to CCM
J4-19 and J4-20. Check temperature after switching to spare COMP THRUST BRNG TEMP sensor. This fault can result from excessive operation
at low load with low water flow to the evaporator or
condenser. Very high discharge and volute temperatures may increase the oil sump temperature.
Elevated sump temperature may result from an
excessively high oil level reaching the bottom of
the bull gear causing it to churn the oil.
Check CONDENSER PRESSURE. Check for high
Condenser Water temperatures, low water flow,
fouled tubes. Check for division plate/gasket
bypass or plugged condenser water strainers.
Check for noncondensables in condenser. Check
CONDENSER PRESSURE transducer wiring and
accuracy to CCM J2-4 through J2-6. Configure
COND PRESS OVERRIDE in SETUP1 screen.
This Alarm is not caused by the High Condenser
Pressure Switch.
Surge prevention alarm declared before ACTUAL
VFD SPEED reached 90%. Check for high CONDENSER PRESSURE, high Condenser Water
temperatures, low water flow, fouled tubes. Check
condenser water strainers. Check CONDENSER
APPROACH. Check for division plate/gasket
bypass. Check for noncondensables in condenser.
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 ISM J2-1 and J2-2.
Five SURGE PROTECTION COUNTS occurred
within SURGE TIME PERIOD. VFD Only: Surge
prevention alarm declared when ACTUAL VFD
SPEED is at least 90%. Check for high condenser
water temperatures, low water flow, fouled tubes.
Check CONDENSER APPROACH. Check condenser water strainers. Check for division plate/
gasket bypass. Check for noncondensables in
condenser. Check surge prevention parameters in
OPTIONS screen. Compare cooling tower control
settings and performance against design/selection
temperatures across the entire operating range of
the chiller. Check EVAPORATOR APPROACH and
chilled water flow.
Check that TRANSDUCER VOLTAGE REF is
between 4.5 V and 5.5 V in the CCM PRESSURE
TRANSDUCERS screen. Check that none of the
pressure transducers are shorted to ground. Confirm TRANSDUCER VOLTAGE REF by measuring
voltage across a CCM Pressure Transducer (e.g.
CCM J2-1 to J2-3). Check TRANSDUCER VOLTAGE REF after temporarily disconnecting chiller
from CCN and disconnecting field wiring from
CCM terminal blocks J5 and J8. 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. Check for 24V across
CCM J1-1 and J1-2. Call Carrier Service.
*[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. "Exceeded Limit" in Alarm or Alert messages may mean the value is above or
below a threshold.
107
Table 17 — ICVC Primary and Secondary Messages and
Custom Alarm/Alert Messages with Troubleshooting Guides (cont)
I. CHILLER PROTECTIVE LIMIT FAULTS (cont)
ICVC
FAULT
STATE
PRIMARY MESSAGE
240
PROTECTIVE LIMIT
241
LOSS OF
COMMUNICATION
242
LOSS OF
COMMUNICATION
243
PRIMARY CAUSE
LOW DISCHARGE SUPERHEAT
240->Check for Oil in Refrigerant or
Overcharge of Refrigerant.
WITH STARTER MODULE
241->Loss of Communication With
Starter.
WITH CCM MODULE
242->Loss of Communication With
CCM.
EVAP PRESS/TEMP TOO LOW
243->Evaporator Refrig Temp [VALUE]
exceeded limit of [LIMIT]*.
COND PRESS/TEMP TOO LOW
244->Condenser Refrig Temp [VALUE]
exceeded limit of [LIMIT]*.
HIGH VFD SPEED
245->Actual VFD Speed exceeded limit
of Target VFD Speed + 10%.
INVALID DIFFUSER CONFIG
246->Diffuser Control Invalid Configuration: Check SETUP2 Entries
DIFFUSER POSITION FAULT
247->Diffuser Position Fault: Check
Guide Vane and Diffuser Actuators
POTENTIAL FREEZEUP
244
POTENTIAL FREEZEUP
245
PROTECTIVE LIMIT
246
PROTECTIVE LIMIT
247
SECONDARY MESSAGE
PROTECTIVE LIMIT
ADDITIONAL
CAUSE/REMEDY
Check ACTUAL SUPERHEAT and SUPERHEAT
REQUIRED in OVERRIDE screen. Check the oil
level in the compressor oil sump. Excessive oil in
the evaporator may cause foaming and cause carryover into the compressor. The refrigerant level in
the evaporator may be too low resulting in ineffective oil reclaim at low loads. If the chiller is overcharged, the oil reclaim may be recovering below
the oil rich mixture on the top of the cooler refrigerant level. Excessive refrigerant charge may cause
liquid carry over into compressor. Look for oil and
refrigerant mixture flowing through both oil reclaim
sight glasses. If the refrigerant charge is correct,
inadequate oil reclaim may be caused by plugged
oil reclaim eductors, plugged strainers, or closed
isolation valves on the oil reclaim lines. Confirm
that the oil reclaim eductors are installed correctly.
Check calibration of EVAPORATOR PRESSURE
and CONDENSER PRESSURE transducers.
Check calibration and wiring of COMP DISCHARGE TEMP sensor to CCM J4-17 and J4-18.
SIO communications between the CCM and ISM
have been lost for an excessive time period. Check
wiring from ISM terminal J7 to CCM terminal J7.
Check power and communication status LEDs on
ISM.
SIO communications between the ICVC and CCM
have been lost for an excessive time period. Check
wiring from CCM terminal J6 to ICVC terminal J7.
Check power and communication status LEDs on
CCM. Confirm that all CCM SW1 switches are in
the "Off" position.
Check CALC EVAP SAT TEMP, EVAP REFRIG
LIQUID TEMP, and EVAP REFRIG TRIPPOINT.
Check for proper refrigerant charge.
Check float valve operation. Confirm that optional
refrigerant liquid line isolation valve is open.
Check for proper Chilled Water flow and temperature. Confirm that condenser water enters bottom
row of condenser tubes first, reversed condenser
water flow may cause refrigerant to stack in the
condenser. Check EVAPORATOR PRESSURE
transducer and EVAP REFRIG LIQUID TEMP sensor. Check for evaporator waterbox division plate
gasket bypass. Check for fouled tubes.
Chiller is in Pumpdown/Lockout and the CONDENSER REFRIG TEMP is less than the CONDENSER FREEZE POINT. Check CONDENSER
FREEZE POINT in SETUP1 screen. Condenser
water too cold or chiller shut down with brine below
32 deg F in cooler so equalization temperature in
chiller approached 32 def F. Check CONDENSER
PRESSURE transducer and wiring to CCM J2-4
through J2-6. Check Condenser Water Temperature sensors and wiring to CCM J4. Check refrigerant charge.
ACTUAL VFD SPEED in COMPRESS screen has
exceeded TARGET VFD SPEED by more than
10%. Check calibration of 0 - 5 volt VFD speed
feedback signal to ISM J6-1 and J6-2.
Check 23%, 50%, and 75% Guide Vane and Diffuser Load Point entries in SETUP2 screen
against Diffuser Schedule Settings Label on the
back of the Control Panel cover.
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 DIFFUSER CONTROL
Schedule in SETUP2 screen. Check DIFFUSER
PRESSURE rotating stall transducer wiring to
CCM J3-10, J3-11 and J3-12. Confirm that 4.3
kilohm load resistor is installed between CCM J3-7
and J3-8. Confirm that DIFFUSER PRESSURE
transducer is secured to the threaded fitting on the
compressor housing. Check for proper operation
of diffuser and inlet guide vane actuators including
inlet guide vane calibration. Check wiring between
CCM J4-9 and J4-10 and the guide vane position
feedback potentiometer. Check diffuser and guide
vane actuator couplings for rotational slip. Check
for electrical noise in CCM Diffuser Pressure wiring. Install noise suppressor in parallel with Motor
Temperature sensor on CCM J4-23 and J4-24. Do
not continue to operate compressor except for
diagnostic purposes.
*[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. "Exceeded Limit" in Alarm or Alert messages may mean the value is above or below a threshold.
108
Table 17 — ICVC Primary and Secondary Messages and
Custom Alarm/Alert Messages with Troubleshooting Guides (cont)
I. CHILLER PROTECTIVE LIMIT FAULTS (cont)
ICVC
FAULT
STATE
248
249
250
PRIMARY MESSAGE
SPARE TEMPERATURE #1
248->Spare Temperature #1 [VALUE]
exceeded limit of [LIMIT]*.
SPARE TEMPERATURE #2
249->Spare Temperature #2 [VALUE]
exceeded limit of [LIMIT]*.
REFRIGERANT LEAK SENSOR
250->Refrigerant Leak Sensor [VALUE]
exceeded limit of [LIMIT]*
ISM CONFIG CONFLICT
251->ISM Config Conflict; Verify and
Save ISM Config Data to Reset
Not Used
GUIDE VANE CALIBRATION
252->Not Used
253->Guide Vane Fault [VALUE]. Check
Calibration
HIGH COND WATER FLOW
254->High Flow: Condenser Water Delta
P Limit (VALUE) exceeded limit of
[LIMIT]*
PROTECTIVE LIMIT
PROTECTIVE LIMIT
PROTECTIVE LIMIT
252
Not Used
254
PRIMARY CAUSE
PROTECTIVE LIMIT
251
253
SECONDARY MESSAGE
PROTECTIVE LIMIT
PROTECTIVE LIMIT
ADDITIONAL
CAUSE/REMEDY
Check component that SPARE TEMPERATURE
#1 is monitoring. Check SPARE TEMP #1
ENABLE and SPARE TEMP #1 LIMIT in SETUP1
screen. Check SPARE TEMPERATURE #1 sensor
resistance or voltage drop. Check SPARE TEMPERATURE #1 wiring to CCM J4-25 and J4-26.
Check component that SPARE TEMPERATURE
#2 is monitoring. Check SPARE TEMP #2
ENABLE and SPARE TEMP #2 LIMIT in SETUP1
screen. Check SPARE TEMPERATURE #2 sensor
resistance or voltage drop. Check SPARE TEMPERATURE #2 wiring to CCM J4-27 and J4-28.
REFRIGERANT LEAK OPTION is Enabled and
the REFRIGERANT LEAK SENSOR output
exceeded REFRIGERANT LEAK ALARM mA.
Check for refrigerant leaks. Check leak detector for
proper operation. Check REFRIGERANT LEAK
ALARM mA setting in the OPTIONS screen.
Check 4-20 mA or 1-5 V output from refrigerant
leak sensor to CCM J5-5 and J5-6. Confirm that
CCM SW2 dip switch 1 is in the correct position.
The ISM_CONF table stored in the ISM does not
match that which is stored in the ICVC. This is a
normal fault if an ICVC has been uploaded with
software when it was not attached to the CCM. In
order to recall parameters stored in the ISM: Enter
ISM_CONF screen and then immediately exit
ISM_CONF screen by pressing EXIT then CANCEL. Next, re-enter the ISM_CONF screen a second time so parameters stored in the ISM will be
uploaded into the ICVC. Confirm that the settings
in the ISM_CONF screen are correct. Press EXIT
then SAVE to store the ISM_CONF screen settings in both the ICVC and ISM.
Alarm before start indicates guide vane opening
has not closed to less than 4%. Alarm while running indicates guide vane position is < -1% or >
103%, or feedback voltage between CCM J4-9
and J4-10 is < .045 or > 3.15 VDC. Enter CONTROL TEST and conduct Guide Vane Calibration.
Check wiring between the guide vane feedback
potentiometer and CCM terminals J4-9 and J4-10.
Check the 10,000 ohm guide vane position feedback potentiometer.
COND HI FLOW ALARM OPT is enabled 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 and accuracy. Confirm that
5 V reference signal is available between CCM J319 and J3-21 and J3-22 and J3-24. Check for disconnected, grounded, or shorted wiring. If condenser water 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.
*[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. "Exceeded Limit" in Alarm or Alert messages may mean the value is above or below a threshold.
J. CHILLER ALERTS
STATE
140
PRIMARY
MESSAGE
SECONDARY
MESSAGE
LEAVING COND
WATER TEMP
PRIMARY CAUSE
140->Sensor Fault: Check Leaving Cond Water Sensor
SENSOR ALERT
141
SENSOR ALERT
142
LOW OIL
PRESSURE
ALERT
ENTERING
COND WATER
TEMP
141->Sensor Fault: Check Entering Cond Water Sensor
CHECK OIL FILTER
142->Low Oil Pressure Alert.
Check Oil Filter
ADDITIONAL
CAUSE/REMEDY
LEAVING CONDENSER WATER temperature sensor reading is out of
range. Check LEAVING CONDENSER WATER sensor resistance or
voltage drop.
Check for proper wiring to CCM J4-7 and J4-8. Check for grounded sensor leads.
ENTERING CONDENSER WATER temperature sensor reading is out of
range. Check LEAVING CONDENSER WATER sensor resistance or
voltage drop.
Check for proper wiring to CCM J4-7 and J4-8. Check for grounded sensor leads.
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 Oil Sump Pressure and Oil Pump Discharge Pressure transducer
accuracy and wiring to CCM J3-1 through J3-6.
*[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. "Exceeded Limit" in Alarm or Alert messages may mean the value is above or below a threshold
109
Table 17 — ICVC Primary and Secondary Messages and
Custom Alarm/Alert Messages with Troubleshooting Guides (cont)
J. CHILLER ALERTS (cont)
STATE
PRIMARY
MESSAGE
143
AUTORESTART
PENDING
144
AUTORESTART
PENDING
SECONDARY
MESSAGE
LINE PHASE
LOSS
LINE VOLTAGE
DROPOUT
HIGH LINE VOLTAGE
145
AUTORESTART
PENDING
LOW LINE VOLTAGE
146
AUTORESTART
PENDING
STARTER MODULE RESET
147
AUTORESTART
PENDING
POWER LOSS
148
AUTORESTART
PENDING
HIGH DISCHARGE TEMP
149
SENSOR ALERT
HIGH BEARING
TEMPERATURE
150
SENSOR ALERT
151
CONDENSER
PRESSURE
ALERT
152
RECYCLE ALERT
153
no message:
ALERT only
PUMP RELAY
ENERGIZED
EXCESSIVE
RECYCLE
STARTS
no message;
ALERT only
PRIMARY CAUSE
ADDITIONAL
CAUSE/REMEDY
143->Line Current Loss; Check
Any LINE VOLTAGE < 50% MOTOR RATED LINE VOLTAGE or there is
ISM Fault History to Identify Phase an excessive difference between the smallest LINE CURRENT and the
largest LINE CURRENT. AUTORESTART OPTION is Enabled, chiller is
automatically restarting. Check the ISM_HIST screen. Check MOTOR
RATED LINE VOLTAGE in ISM_CONF screen. Check phase to phase
and phase to ground power distribution bus voltage. Check current transformer wiring leading to ISM terminal block J4 and line voltage wiring
leading to ISM terminal block J3. Check wiring and hardware between
building power supply and motor. Current imbalance may improve if
power or motor leads are rotated in the same phase sequence. Consult
power company. Medium voltage applications only: Check voltage potential transformers and VOLT TRANSFORMER RATIO in ISM_CONF
screen.
144->Single Cycle Line Voltage
Temporary loss of voltage. SINGLE CYCLE DROPOUT and AUTOREDropout
START OPTION are Enabled, chiller is automatically restarting. Two
LINE VOLTAGES < 50% MOTOR RATED LINE VOLTAGE. Check
ISM_HIST screen. Disable Single Cycle Dropout in ISM_CONF screen.
Monitor chiller utility power for disruptions. Consult power company.
145>High Average Line voltage
High LINE VOLTAGE for an excessive amount of time. Check LINE
[VALUE]
VOLTAGE in ISM_HIST screen. AUTORESTART OPTION is Enabled,
chiller is automatically restarting. Check MOTOR RATED LINE VOLTAGE and OVERVOLTAGE THRESHOLD in ISM_CONF screen. Check
phase to phase and phase to ground line power. Consult power company. Medium voltage applications only: Check voltage potential transformers and VOLT TRANSFORMER RATIO in ISM_CONF screen.
Check wiring to ISM J3-VL1, J3-VL2 and J3-VL3.
146->Low Average Line voltage
Low LINE VOLTAGE for an excessive amount of time. AUTORESTART
[VALUE]
OPTION is Enabled and chiller is automatically restarting. Check LINE
VOLTAGE in ISM_HIST screen. Check MOTOR RATED LINE VOLTAGE
and UNDERVOLTAGE THRESHOLD in ISM_CONF screen. Check
phase to phase and phase to ground distribution bus voltage. Consult
power company. Medium voltage applications only: Check voltage potential transformers and VOLT TRANSFORMER RATIO in ISM_CONF
screen. Check wiring to ISM J3-VL1, J3-VL2 and J3-VL3.
147->Starter Module Power-On
AUTORESTART OPTION in OPTIONS screen is enabled and there was
Reset When Running
a temporary loss of 115 V ISM control voltage supply. Chiller will automatically restart when power is restored within acceptable limits. Check
ISM_HIST screen. Check wiring leading to ISM terminals J1-LL1 and J1LL2. Check control power circuit breaker, control power transformer and
control power circuit fuses. Monitor chiller utility power for disruptions.
Improve ISM ground connection, apply measures to reduce electrical
noise to ISM. Consult power company.
148->Control Power-Loss When
AUTO RESTART OPTION in OPTIONS screen is Enabled and there was
Running
a temporary loss of 24 VAC power to the ICVC. The chiller will automatically restart when power is restored within acceptable limits. Check 115
VAC control power transformer. Check 24 VAC T2 transformer and wiring
leading to ICVC terminals J1-4 and J1-5 . Check CB1 circuit breaker in
the control panel. Check phase to phase and phase to ground utility
power voltage. Monitor chiller utility power for disruptions. Consult power
company.
149->Comp Discharge Temp
Check for proper inlet guide vane and optional diffuser actuator opera[VALUE] Exceeded Limit of
tion. Check COMP DISCHARGE ALERT threshold. Check for proper
[LIMIT]*
condenser water flow and temperatures. Check for high lift or low load.
Check for closed compressor discharge isolation valve. Check if chiller
was operating in surge conditions. Check COMP DISCHARGE TEMP
sensor resistance or voltage drop. Check for proper wiring to CCM J4-17
and J4-18. Check for proper inlet guide vane and optional diffuser actuator operation. Check for fouled tubes, plugged water strainers, or noncondensibles in the chiller.
150->Comp Thrust Brg Temp
Check oil heater for proper operation, confirm that oil heater is de-ener[VALUE] exceeded limit of [LIMIT]* gized when compressor is running. Check COMP THRUST BRG ALERT
threshold. Check for low oil level, partially closed oil line isolation valves,
or clogged oil filter. Check oil cooler refrigerant thermal expansion
valves, confirm that expansion valve bulbs are secured to the oil lines
and insulated. Check COMP THRUST BRNG TEMP sensor accuracy
and wiring to CCM J4-19 and J4-20. Check temperature after switching
to spare COMP THRUST BRNG TEMP sensor. This fault can result from
excessive operation at low load with low water flow to the evaporator or
condenser.
151->High Condenser Pressure
Check for high Condenser Water temperatures, low water flow, fouled
[VALUE]: Pump Energized to
tubes. Check CONDENSER PRESSURE OVERRIDE threshold. Check
Reduce Pressure.
for division plate/gasket bypass or plugged condenser water strainers.
Check for noncondensables in condenser. Check CONDENSER PRESSURE transducer wiring and accuracy to CCM J2-4 through J2-6. This
Alert is not caused by the High Pressure Switch.
152->Excessive recycle starts.
Chiller load is too low to keep compressor on line and there has been
more than 5 starts in 4 hours.
Increase chiller load, adjust hot gas bypass to open at a higher load,
increase recycle RESTART DELTA T in SETUP1 Screen. Check hot gas
bypass isolation valve position.
153->Lead/Lag Disabled: DupliIllegal chiller address configuration in LEADLAG screen. Lead chiller, lag
cate Chiller Address; Check Conchiller, and optional standby chiller must all be on the same bus but they
figuration
must all be assigned a different address in the ICVC CONFIGURATION
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. "Exceeded Limit" in Alarm or Alert messages may mean the value is above or
below a threshold.
110
Table 17 — ICVC Primary and Secondary Messages and
Custom Alarm/Alert Messages with Troubleshooting Guides (cont)
J. CHILLER ALERTS (cont)
STATE
PRIMARY
MESSAGE
154
POTENTIAL
FREEZE-UP
155
OPTION SENSOR
FAULT
156
OPTION SENSOR
FAULT
157
OPTION SENSOR
FAULT
158
SENSOR ALERT
159
SENSOR ALERT
160
Not Used
161
LOSS OF
COMMUNICATION
162
SENSOR ALERT
163
SENSOR ALERT
164
VFD SPEED
ALERT
165
MACHINE ALERT
SECONDARY
MESSAGE
COND PRESS/
TEMP TOO LOW
PRIMARY CAUSE
ADDITIONAL
CAUSE/REMEDY
154->Condenser freeze up preven- The chiller is not in Pumpdown Mode and the CONDENSER REFRIG
tion
TEMP is less than the CONDENSER FREEZE POINT. The CONDENSER PRESSURE transducer is reading a pressure that could freeze
the condenser tubes. Check CONDENSER FREEZE POINT in SETUP1
screen.
Check for condenser refrigerant leaks. Check CONDENSER PRESSURE transducer and wiring to CCM J2-4 through J2-6. Check Condenser Water Temperature sensors and wiring to CCM J4. Place the
chiller in PUMPDOWN mode if the vessel is evacuated. Condenser
water too cold or chiller shut down with brine below 32 deg F in cooler so
equalization temperature in chiller approached 32 def F.
REMOTE RESET 155->Sensor Fault/Option DisType 2 Temperature Reset is Enabled and Remote Temperature Reset
SENSOR
abled: Remote Reset Sensor
sensor is out of range. Check ENABLE RESET TYPE and TEMPERATURE RESET settings in TEMP_CNTL screen. Check Remote Temperature Reset sensor resistance or voltage drop.
Check for proper wiring to CCM J4-13 and J4-14.
AUTO CHILLED
156->Sensor Fault/Option DisType 1 Temperature Reset is Enabled and Auto Chilled Water Reset
WATER RESET
abled: Auto Chilled Water Reset
input on CCM J5-3 and J5-4 is < 2 mA. Check ENABLE RESET TYPE
and TEMPERATURE RESET settings in TEMP_CNTL screen. Confirm
that Auto Chilled Water Reset input is between 4 mA and 20 mA. Confirm that wiring to CCM J5-3 and J5-4 is not grounded.
AUTO DEMAND
157->Sensor Fault/Option Dis20mA DEMAND LIMIT OPT is Enabled, Ice Build is not Active, and Auto
LIMIT INPUT
abled: Auto Demand Limit Input
Demand Limit Input on CCM J5-1 and J5-2 is < 2 mA. Check 20 mA
DEMAND LIMIT OPT and DEMAND LIMIT AT 20 mA in RAMP_DEM
screen. Confirm that Auto Demand Limit Input is between 4 mA and 20
mA. Confirm that wiring to CCM J5-1 and J5-2 is not grounded.
SPARE TEMPER- 158->Spare Temperature #1
Check component that SPARE TEMPERATURE #1 is monitoring. Check
ATURE #1
[VALUE] exceeded limit of [LIMIT].* SPARE TEMP #1 ENABLE and SPARE TEMP #1 LIMIT in SETUP1
screen. Check SPARE TEMPERATURE #1 sensor resistance or voltage
drop. Check SPARE TEMPERATURE #1 wiring to CCM J4-25 and J426.
SPARE TEMPER- 159->Spare Temperature #2
Check component that SPARE TEMPERATURE #2 is monitoring. Check
ATURE #2
[VALUE] exceeded limit of [LIMIT].* SPARE TEMP #2 ENABLE and SPARE TEMP #2 LIMIT in SETUP1
screen. Check SPARE TEMPERATURE #2 sensor resistance or voltage
drop. Check SPARE TEMPERATURE #2 wiring to CCM J4-27 and J428.
Not Used
160->Not Used
WITH WSM
161->WSM Cool Source - Loss of Check settings in WSMDEFME screen. Check CCN communications link
Communication
with WSM (Water System Manager) Module. Check Supervisory Part of
WSM.
EVAPORATOR
162->Evaporator Approach
Check EVAP APPROACH ALERT setting in SETUP1 screen. Check
APPROACH
[VALUE] Exceeded Limit of
Evaporator Water Flow. Check EVAP REFRIG LIQUID TEMP and LEAV[LIMIT}*
ING CHILLED WATER temperature sensor resistances and voltage
drop. Check EVAP REFRIG LIQUID TEMP and LEAVING CHILLED
WATER temperature sensor wiring to the J4 CCM terminal block. Check
for oil loss or low refrigerant charge. Check oil reclaim line isolation
valves and strainers. Confirm that the optional refrigerant Liquid Line Isolation Valve is open. Check for float valve operation and for refrigerant
stacking in the condenser. Check chilled water valves and strainers.
Check for air in the evaporator waterbox or division plate bypass. Check
for fouled tubes. Confirm that the oil reclaim system is working.
CONDENSER
163->Condenser Approach
Check COND APPROACH ALERT setting in SETUP1 screen. Check
APPROACH
[VALUE] Exceeded Limit of
Condenser Water Flow. Check CONDENSER PRESSURE transducer
[LIMIT]*
and LEAVING CONDENSER WATER temperature sensor resistance or
voltage drop. Check condenser shell temperature against condenser
pressure measured with a refrigerant gage for evidence of non-condensibles in refrigerant charge. Check for condenser waterbox division plate
bypass. Check CONDENSER PRESSURE transducer and LEAVING
CONDENSER WATER sensor wiring to the CCM. Check for air in the
condenser waterbox. Confirm that the condenser tubes are not fouled.
LOW VFD
164->Actual VFD Speed exceeded ACTUAL VFD SPEED in COMPRESS screen must be at least 90% of
SPEED
limit of Target VFD Speed -10%
TARGET VFD SPEED. Check wiring and calibration of 4 - 20 mA speed
control signal from ISM J8-1 and J8-2 to the VFD. Check VFD configuration parameters, jumpers, and dip switch settings.
HIGH COND
165->High Flow: Condenser Water COND HI FLOW ALARM OPT is disabled and CONDENSER WATER
WATER FLOW
Delta P [VALUE] Exceeded Limit of DELTA P has exceeded configured limit. Check FLOW DELTA P DIS[LIMIT]*
PLAY and COND HI FLOW DEL P LIMIT in SETUP1 screen. Check
optional condenser water pressure transducer wiring and accuracy. Confirm that 5 V reference signal is available between CCM J3-19 and J3-21
and J3-22 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.
*[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. "Exceeded Limit" in Alarm or Alert messages may mean the value is above or
below a threshold.
111
Table 17 — ICVC Primary and Secondary Messages and
Custom Alarm/Alert Messages with Troubleshooting Guides (cont)
K. ISM ALARMS
ICVC
FAULT
STATE
200
201
202
PRIMARY MESSAGE
1M CONTACT FAULT
200->1M Aux Contact Fault; Check 1M
Contactor and Aux
2M CONTACT FAULT
201->2M Aux Contact Fault; Check 2M
Contactor and Aux
MOTOR AMPS NOT SENSED
202->Motor Amps Not Sensed — Average Line Current [VALUE]
EXCESS ACCELERATION TIME
203->Motor Acceleration Fault - Average
Line Current [VALUE]
1M/2M CONTACT FAULT
204->1M/2M Aux Contact Stop Fault;
Check 1M/2M Contactors and Aux
MOTOR AMPS WHEN
STOPPED
205->Motor Amps When Stopped Average Line Current [VALUE]
STARTER FAULT
206->Starter Fault Cutout; Check
Optional Starter Contacts
PROTECTIVE LIMIT
PROTECTIVE LIMIT
FAILURE TO START
204
FAILURE TO STOP
206
PRIMARY CAUSE
PROTECTIVE LIMIT
203
205
SECONDARY MESSAGE
FAILURE TO STOP
PROTECTIVE LIMIT
HIGH CONDENSER PRESSURE 207->High Cond Pressure Cutout.
[VALUE] exceeded limit of [LIMIT]*
207
PROTECTIVE LIMIT
EXCESSIVE MOTOR AMPS
208
208->Average Line Current [VALUE]
exceeded limit of [LIMIT]*.
PROTECTIVE LIMIT
ADDITIONAL
CAUSE/REMEDY
1M aux contact is open when it should be closed
during start or run mode. Confirm starter 1M aux
contact closes when ISM 1CR contact closes and
terminal J9-2 is energized with 115V. Check wiring
leading to ISM J2-9 and J2-10. Check MOTOR
RATED LOAD AMPS in ISM_CONF screen. WyeDelta Starters: Check for failed or incomplete transition. Check S-2M mechanical interlock operation.
2M aux contact closure was delayed after 1M has
closed. Confirm starter 2M aux contact closes following the 1M aux contact closure and the starter
energizes the motor. Check wiring leading to ISM
J2-11 and J2-12. Check MOTOR RATED LOAD
AMPS and confirm that the correct STARTER
TYPE has been selected in the ISM_CONF
screen. Wye Delta Starters Only: Check wiring
from ISM J9-4 to transition contactor.
The ISM has not sensed sufficient current for an
excessive delay after 1M has closed. Check the
MOTOR CURRENT CT RATIO and the MOTOR
RATED LOAD AMPS in the ISM_CONF screen.
Check VFD OPTION in SETUP 2 screen. Check
for wiring of current transformers to the J4 ISM terminals. Check if main circuit breaker has tripped.
Check ISM_HIST screen
Any line current remains high for an excessive time
duration following 1M aux and either 2M aux or
transition contact closure. Check that inlet guide
vanes are fully closed at start up. Check
ISM_HIST screen.
Check Motor Rated Load Amps in ISM_CONF
screen. Reduce condenser pressure if possible.
The 1M aux or 2M aux contacts are closed during
power up or the 1M aux or 2M aux contacts remain
closed for an excessive delay following a STOP
command. Check wiring and dry contacts leading
to ISM J2-9 and J2-10 and J2-11 and J2-12.
High line current measured on any phase after
power up or STOP command. Check the MOTOR
CURRENT CT RATIO and the MOTOR RATED
LOAD AMPS in the ISM_CONF screen. Check
VFD OPTION in SETUP 2 screen. Check
ISM_HIST screen. Check for high inrush current
during power-up. Confirm that the starter de-energizes the motor when the ISM removes 115V from
ISM J9-2. Confirm that the correct STARTER
TYPE has been selected in the ISM_CONF
screen.
The ISM has received a start command and the
starter has declared a Fault. The dry contacts connected to ISM J2-7 and J2-8 are open. See starter
display for starter Fault Code. For Benshaw Inc.
RediStart starters, view RediStart MICRO display.
For VFD, check VFD display Fault History. Clear
VFD faults with VFD keypad. For Allen-Bradley
wye delta starters with RLA > 718 A, the TR3 timer
may have expired as a result of a delayed transition.
Check Compressor Discharge High Pressure
switch wiring and accuracy. Check for high condenser water temperatures, low water flow, fouled
tubes. Check for division plate/gasket bypass.
Check for noncondensables in refrigerant. If
[Value] is less that [Limit], the 1M aux contact was
open for an excessive time following a start command. Check High Pressure Relay contacts and
115 V wiring leading to ISM J9-1. Verify that 115
VAC is present on J9-1 with oil pump on. Check
115 V wiring leading from ISM J9-2 to the 1M aux
coil and base. Check for 115 VAC at 1M coil during
a startup attempt. Check the 24V circuit leading
from power panel terminal 50 to the 2C aux contact and High Pressure Switch. Check the 24V circuit leading from power panel terminals 17 and 43
leading to the High Pressure Relay coil and base.
AVERAGE LINE CURRENT > 110% for an excessive amount of time. Check MOTOR RATED LOAD
AMPS and MOTOR CURRENT CT RATIO in
ISM_CONF time. Check ISM_HIST screen. Check
for conditions that cause excessive lift. Check
guide vane actuator for proper operation. Confirm
that guide vanes will fully close prior to start-up.
*[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. "Exceeded Limit" in Alarm or Alert messages may mean the value is above or
below a threshold.
112
Table 17 — ICVC Primary and Secondary Messages and
Custom Alarm/Alert Messages with Troubleshooting Guides (cont)
K. ISM ALARMS (cont)
ICVC
FAULT
STATE
209
210
211
212
213
214
215
216
PRIMARY MESSAGE
SECONDARY MESSAGE
PRIMARY CAUSE
LINE PHASE LOSS
209->Line Phase Loss; Check ISM Fault
History to Identify Phase
LINE VOLTAGE DROPOUT
210->Single Cycle Line Voltage Dropout
HIGH LINE VOLTAGE
211->High Average Line Voltage
[VALUE]
LOW LINE VOLTAGE
212->Low Average Line Voltage
[VALUE]
STARTER MODULE RESET
213->Starter Module Power-On Reset
When Running
POWER LOSS
214->Control Power - Loss When Running
LINE CURRENT IMBALANCE
215->Line Current Imbalance;Check
ISM Fault History to Identify Phase
LINE VOLTAGE IMBALANCE
216->Line Voltage Imbalance; Check
ISM Fault History to Identify Phase.
PROTECTIVE LIMIT
PROTECTIVE LIMIT
PROTECTIVE LIMIT
PROTECTIVE LIMIT
PROTECTIVE LIMIT
PROTECTIVE LIMIT
PROTECTIVE LIMIT
PROTECTIVE LIMIT
ADDITIONAL
CAUSE/REMEDY
Any LINE VOLTAGE < 50% MOTOR RATED LINE
VOLTAGE or there is an excessive difference
between the smallest LINE CURRENT and the
largest LINE CURRENT. Check the ISM_HIST
screen. Check MOTOR RATED LINE VOLTAGE in
ISM_CONF screen. Check phase to phase and
phase to ground power distribution bus voltage.
Check current transformer wiring leading to ISM
terminal block J4 and line voltage wiring leading to
ISM terminal block J3. Check wiring and hardware
between building power supply and motor. Current
imbalance may improve if power or motor leads
are rotated in the same phase sequence. Consult
power company. Medium voltage applications
only: Check voltage potential transformers and
VOLT TRANSFORMER RATIO in ISM_CONF
screen.
Temporary loss of voltage. SINGLE CYCLE
DROPOUT in the ISM_CONF screen is Enabled
and two LINE VOLTAGES < 50% MOTOR RATED
LINE VOLTAGE. Check ISM_HIST screen. Disable
Single Cycle Dropout in ISM_CONF screen.
High LINE VOLTAGE for an excessive amount of
time. Check LINE VOLTAGE in ISM_HIST screen.
Check MOTOR RATED LINE VOLTAGE and
OVERVOLTAGE THRESHOLD in ISM_CONF
screen. Check phase to phase and phase to
ground distribution bus voltage. Consult power
company. Medium voltage applications only:
Check voltage potential transformers and VOLT
TRANSFORMER RATIO in ISM_CONF screen.
Check wiring to ISM J3-VL1, J3-VL2 and J3-VL3.
Low LINE VOLTAGE for an excessive amount of
time. Check LINE VOLTAGE in ISM_HIST screen.
Check MOTOR RATED LINE VOLTAGE and
UNDERVOLTAGE THRESHOLD in ISM_CONF
screen. Check phase to phase and phase to
ground distribution bus voltage. Check connections to ISM terminal block J3. Consult power company. Medium voltage applications only: Check
voltage potential transformers and VOLT TRANSFORMER RATIO in ISM_CONF screen. Check
wiring to ISM J3-VL1, J3-VL2 and J3-VL3.
AUTO RESTART OPTION in OPTIONS screen is
disabled and there was a temporary loss of 115 V
ISM control voltage supply. Check ISM_HIST
screen. Check wiring leading to ISM terminals J1LL1 and J1-LL2. Check control power circuit
breaker, control power transformer and control
power circuit fuses. Monitor chiller utility power for
disruptions. Improve ISM ground connection,
apply measures to reduce electrical noise to ISM.
Consult power company.
AUTO RESTART OPTION in OPTIONS screen is
disabled and there was a temporary loss of 24
VAC power to the ICVC. Check 115 VAC control
power transformer. Check 24 VAC T2 transformer
and wiring leading to ICVC terminals J1-4 and J15 . Check CB1 circuit breaker in the control panel.
Check phase to phase and phase to ground distribution bus voltage. Monitor chiller utility power for
disruptions. Consult power company.
Current imbalance > CURRENT % IMBALANCE
for greater than the CURRENT IMBALANCE
TIME. Check settings in ISM_CONF screen.
Check ISM_HIST screen. Check current transformer wiring leading to ISM terminal block J4.
Verify phase to phase and phase to ground line
voltage. Check wiring and hardware between
building power supply and motor. Current imbalance may improve if power or motor leads are
rotated in the same phase sequence.
Voltage Imbalance > VOLTAGE % IMBALANCE for
greater than the VOLTAGE IMBALANCE TIME.
Check settings in ISM_CONF screen. Check
ISM_HIST screen. Check line voltage wiring leading to ISM terminal block J3. Verify phase to phase
and phase to ground line voltage. Check wiring
and hardware between building power supply and
motor.
*[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. "Exceeded Limit" in Alarm or Alert messages may mean the value is above or
below a threshold.
113
Table 17 — ICVC Primary and Secondary Messages and
Custom Alarm/Alert Messages with Troubleshooting Guides (cont)
K. ISM ALARMS (cont)
ICVC
FAULT
STATE
217
218
219
PRIMARY MESSAGE
217->Motor Overload Trip; Check ISM
Configurations
MOTOR LOCKED ROTOR TRIP
218->Motor Locked Rotor Amps
Exceeded;Check Motor and ISM Config
STARTER LOCK ROTOR TRIP
219->Starter Locked Rotor Amps Rating
Exceeded
GROUND FAULT
220->Ground Fault Trip; Check Motor
and Current Transformers
PHASE REVERSAL TRIP
221-> Phase Reversal Trip; Check
Power Supply
LINE FREQUENCY TRIP
222->Line Frequency - [VALUE]
exceeded limit of [LIMIT]*; Check Power
Supply.
STARTER MODULE FAILURE
223->Starter Module Hardware Failure
1CR START CIRCUIT FAULT
224->Check 115v Wiring to 1CR (ISM)
and to 1M Coil
PROTECTIVE LIMIT
221
PROTECTIVE LIMIT
224
MOTOR OVERLOAD TRIP
PROTECTIVE LIMIT
PROTECTIVE LIMIT
223
PRIMARY CAUSE
PROTECTIVE LIMIT
220
222
SECONDARY MESSAGE
PROTECTIVE LIMIT
PROTECTIVE LIMIT
PROTECTIVE LIMIT
ADDITIONAL
CAUSE/REMEDY
Any phase current > 108% RLA for excessive time
period. Alarm can result from significant load side
current imbalance when running at full load. Check
ISM_HIST screen. Check entering condenser
water temperature and water flow rate. Check
MOTOR RATED LOAD AMPS and STARTER LRA
RATING in ISM_CONF screen. VFD applications
only: Any phase current > 120% for excessive time
period.
Any LINE CURRENT > MOTOR LOCKED ROTOR
TRIP for excessive time while running after the
LOCKED ROTOR START DELAY has expired.
Check MOTOR LOCKED ROTOR TRIP and
MOTOR CURRENT CT RATIO in ISM_CONF
screen. Check motor nameplate data. Check
ISM_HIST screen. Check motor wiring and motor
winding resistance. Temporarily enable SINGLE
CYCLE DROP OUT to capture power disturbances.
Any LINE CURRENT > STARTER LRA RATING.
Check STARTER LRA RATING and MOTOR CURRENT CT RATIO in ISM_CONF screen. Check
ISM_HIST screen. Check starter label data. Check
motor wiring and motor winding resistance.
Any GROUND FAULT current > GROUND FAULT
CURRENT threshold for a duration > GROUND
FAULT PERSISTENCE after the GROUND FAULT
START DELAY has expired. Check these settings
and GROUND FAULT CT RATIO in ISM_CONF
screen. Check ISM_HIST screen. Confirm that
ground fault current transformer orientation is correct and that the correct motor leads have been
routed through the ground fault current transformers in the right direction. Check for condensation
on motor terminals or inside of motor leads. Check
motor power leads for phase to phase or phase to
ground shorts. Disconnect motor from starter and
megger motor windings to ground and phase to
phase. Call Carrier Service.
The ISM has detected that the input power is
phased BAC instead of ABC. Confirm that the
phase sequence wired to ISM terminal block J3 is
consistent with the power wiring to the starter.
Swap two power leads at the starter.
LINE FREQUENCY FAULTING in ISM_CONF
screen is enabled and the LINE FREQUENCY has
deviated approximately 7% from nominal value.
Check ISM_HIST screen. Check FREQUENCY =
60 HZ? In ISM_CONF screen. Check line frequency. If operating from a generator, check generator size and speed.
Internal ISM power supply is outputting incorrect
voltage. Check ISM status lights. Confirm that 115
V is applied to terminals J1-LL1 and J1-LL2. Confirm that excessive voltage has not been improperly applied to any of the ISM terminals before
installing replacement ISM.
The 1M aux contact is open for an excessive time
following a start command and the CONDENSER
PRESSURE < 160 PSI. Check High Pressure
Relay contacts and 115 V wiring leading to ISM
J9-1. Check 115 V wiring leading from ISM J9-2 to
the 1M aux coil and base. Check the 24V circuit
leading from power panel terminal 50 to the 2C
aux contact and High Pressure Switch. Check the
24V circuit leading from power panel terminals 17
and 43 leading to the High Pressure Relay coil and
base.
*[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. "Exceeded Limit" in Alarm or Alert messages may mean the value is above or below a threshold.
114
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 II
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 II
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
115
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 II
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 II
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
116
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
changes, control point overrides, hot gas bypass, surge prevention, etc. The tables are:
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.
CAPACITY
Capacity
Control
OVERRIDE
Override
Status
Surge/
HGBP
Status
SURG_PREV
HEAT_EX
LL_MAINT
OCCDEFCM
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
high altitude locations must be compensated for, so the
chiller temperature/pressure relationship is correct.
This table shows all values used
to calculate the chilled water/brine
control point.
Details of all chilled water control
override values.
The surge and hot gas bypass
control algorithm status is viewed
from this screen. All
values dealing with this control
are displayed.
All sensor inputs and calculated
values related to the heat
Exchangers. Also some of the
surge control points are shown.
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.
Heat
Exchanger
Points
Status
LEAD/LAG
Status
Time
Schedules
Status
WSMDEFME
Water
System
Manager
Status
ISM_HIST
ISM Alarm
History
Loadshed
Status
Current
Alarm Status
Surge Prevention Status
LOADSHED
CUR_ALARM
SURGPREV
Displays ISM values at last fault.
Displays Loadshed (Demand
Limit) status.
Displays current chiller alarms.
Displays all information used or
supplied by the surge prevention
algorithm.
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, shunt trip relay, oil
heater, 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 Terminate Lockout feature ends the
Pumpdown/Lockout after the pumpdown procedure is reversed
and refrigerant is added.
Control Modules
The PIC II 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.
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 (lightemitting diodes) located on the circuit board of the ICVC and
CCM.
There is one green and one red LED located on the CCM
and ICVC boards.
RED LED (Labeled as STAT) — If the red LED:
• blinks continuously at a 2-second interval, the module is
operating properly
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 are very useful in helping to determine how the control temperature is calculated and guide
vane positioned and for observing the reactions from load
117
3. Power is supplied to the modules within the control panel
via 24-vac power sources.
The transformers are located within the power panels.
In the power panel, T1 supplies power to the compressor
oil heater, oil pump, and optional hot gas bypass, and T2
supplies power to both the ICVC and CCM.
T3 provides 24-v power to the optional modules.
Power is connected to Plug J1 on each module.
• is lit continuously, there is a problem that requires
replacing the module
• is off continuously, the power should be checked
• blinks 3 times per second, a software error has been 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.
GREEN 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. 53)
INPUTS — Each input channel has 2 or 3 terminals. Refer to
individual chiller wiring diagrams for the correct terminal
numbers for your application.
OUTPUTS — Output is 24 vac. There are 2 terminals per output. Refer to the chiller wiring diagram for your 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
CCM is accomplished through the SIO (Sensor Input/
Output) bus, which is a phone 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) (Fig. 52 and 53). Confirm all
switches are in OFF position.
All system operating intelligence resides in the ICVC.
Outputs are controlled by the CCM as well.
Integrated Starter Module (Fig. 54)
INPUTS — Inputs on strips J3 through J6 are analog inputs
and J2 is discrete (on/off) input. The specific application of the
chiller determines which terminals are used. Refer to the individual chiller wiring diagram for the correct terminal numbers
for your application.
OUTPUTS — Outputs are rated for 115-277 vac and wired to
strip J9. There are 2 terminals per output.
CCN INTERFACE
CONNECTION
MODULE PART NUMBER
SOFTWARE PART NUMBER
ICVC
BACK OF CVC
J7 SIO
J1 POWER/
CCN
SW1
J8 SERVICE
a19-1868
Fig. 52 — Rear of ICVC (International Chiller Visual Controller)
118
J11
DISCRETE
OUTPUTS
J12
DISCRETE
OUTPUTS
SW1 (S10 ADDRESS
DIP SWITCH)
SET ALL TO OFF
J1
24 VAC
ANALOG OUT
J8
SIO
J7
SIO
J6
SW2 (V/I
CONFIGURATION
DIP SWITCH)
V/I INPUTS
J5
COMM
STAT
a19-1869
THERMISTORS
J4
PRESSURE
J2
DIFF PRESSURE
J3
Fig. 53 — Chiller Control Module (CCM)
STAT
COM
G + G +
- G + 1
J7
-
J9
1
1
J8
CBA
4-20 MA OUT
SPARE VFD
COMM
TRIP
ALARM
HI
FAN
LO
FAN
COND
PUMP
EVAP SHUNT TRANS
PUMP TRIP
1CR
DISCONNECT POWER BEFORE SERVICING
HIGH VOLTAGE
WARNING
DISCRETE CONTROL CONTACTS
WARNING
HIGH VOLTAGE
00001328
DISCONNECT POWER BEFORE SERVICING
ISM 19XR04012201 9925
CEPL13025901 PCB05
CEPP130173-03-04-01
INTERGRATED STARTER MODULE
R
INTEGRATEDSTARTERMODULE
CONTACT INPUTS
115 VAC
LL1 LL2
FUSE
1A
SPAR ICE REM STRT 1M 2M
SFTY BLD STRT FLT AUX AUX
L1
LINE VOLTAGES
L2
L3
GROUND
FAULTS VFD
1/4 2/5 3/6 HZ
LINE CURRENTS
IL1
IL2
IL3
J5
1A
1
J1
J4
J2
1 + C + C + C + C + C + C
J6
J3-1
J3-2
J3-3
1
+
Fig. 54 — Integrated Starter Module (ISM)
119
-
+
-
+
-
1 + G + G + G1 + G
8. 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-13.)
If the correct VFD Configuration values are displayed in
the ISM_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, 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
(refer to pages 99 and 100). Check that the CURRENT
TIME and DATE in the TIME AND DATE screen are correct.
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 71.
See Table 19 for ICVC hardware/software compatibility.
CAUTION
Electrical shock can cause personal injury. Disconnect all
electrical power before servicing.
 Table 19 — ICVC Hardware/Software Compatibility
ICVC
HARDWARE
VERSION
PART NO.
CEPL130445-01
1
CEPL130445-02
2
CEPL130445-03
3
Solid-State Starters — Troubleshooting information pertaining to the Benshaw, Inc., solid-state starter may be found
in the following paragraphs and in the Carrier RediStart MX3
Instruction Manual supplied by the starter vendor.
Attempt to solve the problem by using the following preliminary checks before consulting the troubleshooting tables found
in the Benshaw manual.
COMPATIBLE
ICVC SOFTWARE
19XR/XRV PIC II Versions 1-4
19XR/XRV PIC II Versions 1-7
19XRV PIC III Versions 1 and 2
23XRV PIC III Version 1
19XR/XRV PIC II Versions 8-10
19XRV PIC III Versions 3 and 4
23XRV PIC III Version 2
WARNING
1. Motor terminals or starter output lugs or wire should
not be touched without disconnecting the incoming
power supply. The silicon control rectifiers (SCRs)
although technically turned off still have AC mains
potential on the output of the starter.
2. Power is present on all yellow wiring throughout the
system even though the main circuit breaker in the
unit is off.
NOTE: ICVC screen lockup reported on green ICVC with Made in
China label while running version 4.
INSTALLATION
1. Verify the existing ICVC module is defective by using the
procedure described in the Troubleshooting Guide section, page 99, and the Control Modules section, page 117.
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 through CL-13 are provided for this purpose.
Default values are shown so that only deviations from
these need to be recorded.
If a CCN Building Supervisor or Service Tool is 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.
3. To install this module, record values for the TOTAL
COMPRESSOR STARTS and the COMPRESSOR
ONTIME from the MAINSTAT screen on the ICVC.
4. Power off the controls.
5. Remove the old ICVC.
6. Install the new ICVC module. Turn the control power
back on.
7. The ICVC now automatically attaches to the local network device.
312
With power off:
• Inspect for physical damage and signs of arcing, overheating, etc.
• Verify the wiring to the starter is correct.
• Verify all connections in the starter are tight.
• Check the control transformer fuses.
TESTING SILICON CONTROL RECTIFIERS IN THE
BENSHAW, INC., SOLID-STATE STARTERS — If an SCR
is suspected of being defective, use the following procedure as
part of a general troubleshooting guide.
1. Verify power is applied.
2. Verify the state of each SCR light-emitting diode (LED)
on the micropower card.
NOTE: All LEDs should be lit. If any red or green side of
these LEDs is not lit, the line voltage is not present or one
or more SCRs has failed.
3. Check incoming power. If voltage is not present check
the incoming line. If voltage is present, proceed to Steps 4
through 11.
NOTE: If after completing Steps 4 - 11 all measurements
are within specified limits, the SCRs are functioning normally. If after completing Steps 4 - 11 resistance measurements are outside the specified limits, the motor leads on
the starter power lugs T1 through T6 should be removed
and the steps repeated. This will identify if abnormal resistance measurements are being influenced by the motor
windings.
4. Remove power from the starter unit.
120
3. Place the SCR between the roll pins on the heat sink
assemblies so the roll pins fit into the small holes in each
side of the SCR.
NOTE: Ensure the SCR is installed so the cathode side is
the side from which the red wire extends. The heatsink is
labeled to show the correct orientation.
4. Finger tighten the clamp. Ensure both bolts are tightened
an equal amount so that the loader bar is square in the
heatsink. See Fig. 55.
5. Tighten the bolts equally in 1/8 turn increments until the
indicator washer(s), which are under the nut(s) in the center of the loader bar becomes loose indicating that the
clamp is tight. See Fig. 55. On the loader bars with two
indicator washers, it may be necessary to tighten or loosen one side of the clamp to get both indicator washers
free. Reconnect the red (cathode) wire from the SCR and
the white (anode-gate) wire to the appropriate location on
the firing card (i.e., SCR1 wires to firing card terminal
G1-white wire, and K1-red wire).
6. Reconnect all other wiring and bus work.
7. Return starter to normal operation.
5. Using an ohmmeter, perform the following resistance
measurements and record the results:
MEASURE
BETWEEN
T1 and T6
T2 and T4
T3 and T5
6.
7.
8.
9.
10.
SCR PAIRS
BEING
CHECKED
3 and 6
2 and 5
1 and 4
RECORDED
VALUE
If all measured values are greater than 5K ohms, proceed
to Step 10. If any values are less than 5K ohms, one or
more of the SCRs in that pair is shorted.
Remove both SCRs in the pair (See SCR Removal/
Installation).
Using an ohmmeter, measure the resistance (anode to
cathode) of each SCR to determine which device has
failed.
NOTE: Both SCRs may be defective, but typically, only
one is shorted. If both SCRs provide acceptable resistance
measurements, proceed to Step 10.
Replace the defective SCR(s).
Retest the “pair” for resistance values indicated above.
On the right side of the firing card, measure the resistance
between the red and white gate/cathode leads for each
SCR (1 through 6). A measurement between 5 and
50 ohms is normal. Abnormally high values may indicate
a failed gate for that SCR.
LOADER BAR
INDICATOR
WASHER (S)
CAUTION
If any red or white SCR gate leads are removed from the
firing card or an SCR, care must be taken to ensure the
leads are replaced EXACTLY as they were (white wires to
gates, and red wires to cathodes on both the firing card and
SCR), or damage to the starter and/or motor may result.
BOLTS
11. Replace the SCRs and retest the pair.
SCR REMOVAL/INSTALLATION
1. Remove the SCR by loosening the clamping bolts on
each side of the SCR.
2. After the SCR has been removed and the bus work is
loose, apply a thin coat of either silicon based thermal
joint compound or a joint compound for aluminum or
copper wire connections to the contact surfaces of the replacement SCR. This allows for improved heat dissipation and electrical conductivity.
a19-1884
Fig. 55 — SCR Installation
Physical Data — Tables 20A-27 and Fig. 56-69 provide
additional information on component weights, compressor fits
and clearances, physical and electrical data, and wiring schematics for the operator’s convenience during troubleshooting.
121
Table 20A — 19XR Heat Exchanger Data — Drive End Entering Cooler Water
English
Code
10†
11†
12†
15†
16†
17†
20
21
22
30
31
32
35
36
37
40
41
42
45
46
47
50
51
52
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
2707
2777
2848
2969
3054
3141
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
2704
2772
2857
2984
3068
3173
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
6782
7894
8102
8182
8258
Metric (SI)
Dry Rigging Weight
(kg)*
Machine Charge
Refrigerant
Weight (lb)
Cooler Condenser
328
226
357
226
387
226
405
275
441
275
477
275
416
252
459
252
505
252
510
308
565
308
626
308
577
349
639
349
709
349
726
338
783
338
840
338
821
383
874
383
949
383
897
446
974
446
1021
446
1010
446
987
446
1014
504
1101
504
1154
504
1143
504
1116
504
491
—
510
—
532
—
553
—
575
—
600
—
673
—
706
—
742
—
641
—
678
—
709
—
768
—
801
—
843
—
730
—
769
—
805
—
1091
479
1150
479
1202
479
1202
479
1178
479
1241
542
1309
542
1369
542
1359
542
1332
542
Water Weight
(lb)
Cooler Condenser
283
348
309
374
335
407
327
402
359
435
391
475
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
1704
1587
1735
1530
1667
1610
1753
1674
1838
1711
1875
1743
1911
Cooler
Only
Condenser
Only
1229
1261
1293
1348
1387
1426
1547
1614
1685
1848
1931
2018
1972
2066
2165
2228
2305
2373
2435
2524
2601
2594
2697
2762
2788
2811
2841
2959
3034
3065
3092
2326
2350
2380
2532
2561
2595
2267
2311
2345
2289
2329
2367
2463
2512
2551
2490
2535
2578
3050
3130
3195
3225
3251
3356
3448
3523
3558
3589
1228
1258
1297
1355
1393
1441
1531
1607
1682
1677
1770
1861
2091
2197
2301
2288
2375
2462
2543
2644
2744
2765
2852
2935
2964
2992
3080
3181
3276
3310
3343
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
3071
3155
3237
3268
3298
3079
3584
3678
3715
3749
*Rigging weights are for standard tubes of standard wall thickness (0.025-in. [0.635 mm] wall).
†Not used on 19XRV units.
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 19XR/XRV Computer Selection Program.
4. All weights for standard 2-pass NIH (nozzle-in-head) design.
122
Machine Charge
Refrigerant
Weight (kg)
Cooler Condenser
149
103
162
103
176
103
184
125
200
125
217
125
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
128
158
140
170
152
185
148
183
163
197
178
216
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 20A — 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).
†Not used on 19XRV units.
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 19XR/XRV Computer Selection Program.
4. All weights for standard 2-pass NIH (nozzle-in-head) design.
123
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 20B — 19XR Heat Exchanger Data — Compressor End Entering Cooler Water
English
Code
10†
11†
12†
15†
16†
17†
20
21
22
30
31
32
35
36
37
40
41
42
45
46
47
50
51
52
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
2707
2777
2848
2968
3054
3141
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
2704
2772
2857
2984
3068
3173
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
290
200
310
200
330
200
320
250
340
250
370
250
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
283
348
309
374
335
407
327
402
359
435
391
475
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
1228
1260
1292
1346
1385
1425
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
1227
1257
1296
1354
1392
1439
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).
†Not used on 19XRV units.
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 19XR/XRV Computer Selection Program.
4. All weights for standard 2-pass NIH (nozzle-in-head) design.
124
Machine Charge
Refrigerant
Weight (kg)
Cooler Condenser
132
91
141
91
150
91
145
113
154
113
168
113
156
102
175
102
197
102
159
118
191
118
222
118
181
141
218
141
249
141
254
127
286
127
313
127
290
150
327
150
358
150
340
181
381
181
408
181
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
128
158
140
170
152
185
148
182
163
197
177
215
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 20B — 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).
†Not used on 19XRV units.
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 19XR/XRV Computer Selection Program.
4. All weights for standard 2-pass NIH (nozzle-in-head) design.
125
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 21 — 19XR 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
*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).
126
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
Table 22 — 19XR Compressor 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.
FRAME 5
COMPRESSOR
WEIGHT
lb
407
325
1000
1200
500
3700
350
185
65
50
kg
185
147
454
544
227
1678
159
84
29
23
91
235
107
1910
7285
3304
NOTE: The weights indicated do not include motor, stator, rotor, low
speed shaft, motor case, motor end cover, or any other related components. See Tables 23A-23E.
Table 23A — 19XR Compressor and Motor Weights — Compressor Frame Size 2
ENGLISH
SI
50 Hz
End Bell
End Bell Compressor
MOTOR Compressor
Cover
Cover
CODE
Stator
Rotor
Stator
Rotor
Stator
Rotor
Stator
Rotor
Weight**
Weight**
Weight†† Weight Weight†† Weight Weight
Weight†† Weight Weight†† Weight Weight
(kg)
(lb)
(kg)
(lb)
(lb)
(lb)
(lb)
(lb)
(kg)
(kg)
(kg)
(kg)
60 Hz
60 Hz
50 Hz
STANDARD-EFFICIENCY MOTORS / LOW VOLTAGE (200-575v)
BDS
2300
900
190
915
205
185
1043
408
86
415
93
84
BES
2300
915
200
965
220
185
1043
415
91
438
100
84
BFS
2300
975
215
1000
230
185
1043
442
98
454
104
84
BGS
2300
1000
230
1060
250
185
1043
454
104
481
113
84
BHS
2300
1030
240
1105
265
185
1043
467
109
501
120
84
BJS
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 Fig. 1 on page 6.
**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.
127
Table 23B — 19XR Compressor and Motor Weights — Compressor Frame Size 3
ENGLISH
SI
50 Hz
End Bell
End Bell
MOTOR Compressor
Compressor
Cover
Cover
CODE
Rotor
Stator
Rotor
Stator
Rotor
Stator
Rotor
Stator
Weight**
Weight**
Weight†† Weight Weight†† Weight Weight
Weight†† Weight Weight†† Weight Weight
(kg)
(lb)
(kg)
(lb)
(lb)
(lb)
(lb)
(kg)
(kg)
(kg)
(kg)
(lb)
60 Hz
60 Hz
50 Hz
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 Fig. 1 on page 6.
**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.
128
Table 23B — 19XR Compressor and Motor Weights — Compressor Frame Size 3 (cont)
ENGLISH
SI
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
(kg)
(lb)
(kg)
(lb)
(lb)
(lb)
(lb)
(lb)
(kg)
(kg)
(kg)
(kg)
60 Hz
60 Hz
50 Hz
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 Fig. 1 on page 6.
**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.
129
Table 23C — 19XR Compressor and Motor Weights — Compressor Frame Size 4
ENGLISH
SI
60 Hz
60 Hz
50 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
1554 / 1910
732
147
792
163
107
DFS
3425 / 4211
1675
347
1811
381
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)
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)
236
(60 Hz)
DJS
3425 / 4211
1769
365
2101
464
318 (50 Hz)
STANDARD-EFFICIENCY MOTORS / MEDIUM VOLTAGE (6300-6900v)
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 Fig. 1 on page 6.
**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.
130
Table 23D — 19XR Compressor and Motor Weights — Compressor Frame Size 4 (cont)
ENGLISH
SI
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
(kg)
(lb)
(kg)
(lb)
(lb)
(lb)
(lb)
(lb)
(kg)
(kg)
(kg)
(kg)
60 Hz
60 Hz
50 Hz
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
144
DFH
3425 / 4211
2025
429
2100
452
318
1554 / 1910
919
195
953
205
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 Fig. 1 on page 6.
**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.
131
Table 23E — 19XR Compressor and Motor Weights — Compressor Frame Size 5
ENGLISH
SI
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
(kg)
(lb)
(kg)
(lb)
(lb)
(lb)
(lb)
(lb)
(kg)
(kg)
(kg)
(kg)
60 Hz
60 Hz
50 Hz
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 Fig. 1 on page 6.
**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.
132
Table 23E — 19XR Compressor and Motor Weights — Compressor Frame Size 5 (cont)
ENGLISH
SI
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
(kg)
(lb)
(kg)
(lb)
(lb)
(lb)
(lb)
(lb)
(kg)
(kg)
(kg)
(kg)
60 Hz
60 Hz
50 Hz
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 Fig. 1 on page 6.
**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.
133
Table 24A — 19XR Waterbox Cover Weights — English (lb)
FRAMES 1, 2, and 3 — COOLER
Frame 1
WATERBOX DESCRIPTION
Frame 2
Flanged
Flanged
282
318
282
318
287
340
287
340
196
294
310
294
310
136
136
243
243
243
243
—
—
315
315
315
315
Flanged
177
204
185
218
NIH, 3 Pass Cover, 150 psig
180
NIH Plain End Cover, 150 psig
NIH, 1 Pass Cover, 150 psig
NIH, 2 Pass Cover, 150 psig
MWB End Cover, 150 psig
Frame 3
Standard
Nozzles
Standard
Nozzles
Standard
Nozzles
MWB Return Cover, 150 psig
—
—
243
243
243
243
NIH, 1 Pass Cover, 300 psig
248
301
411
486
411
486
NIH, 2 Pass Cover, 300 psig
255
324
411
518
411
518
NIH, 3 Pass Cover, 300 psig
253
288
433
468
433
468
NIH Plain End Cover, 300 psig
175
175
291
291
291
291
MWB End Cover, 300 psig
—
—
619
619
619
619
MWB Return Cover, 300 psig
—
—
445
445
445
445
FRAMES 1, 2, and 3 — CONDENSER
Frame 1
WATERBOX DESCRIPTION
Frame 2
Frame 3
Standard
Nozzles
Flanged
Standard
Nozzles
Flanged
Standard
Nozzles
Flanged
NIH, 1 Pass Cover, 150 psig
177
204
282
318
282
318
NIH, 2 Pass Cover, 150 psig
185
218
287
340
287
340
NIH, 3 Pass Cover, 150 psig
180
196
294
310
294
310
NIH Plain End Cover, 150 psig
136
136
225
225
225
225
MWB End Cover, 150 psig
—
—
234
234
234
234
MWB Return Cover, 150 psig
—
—
225
225
225
225
NIH, 1 Pass Cover, 300 psig
248
301
411
486
411
486
NIH, 2 Pass Cover, 300 psig
255
324
411
518
411
518
NIH, 3 Pass Cover, 300 psig
253
288
433
468
433
468
NIH Plain End Cover, 300 psig
175
175
270
270
270
270
MWB End Cover, 300 psig
—
—
474
474
474
474
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 20A and 20B.
134
Table 24A — 19XR Waterbox Cover Weights — English (lb) (cont)
FRAMES 4, 5, and 6 — COOLER
Frame 4
WATERBOX DESCRIPTION
Frame 5
Frame 6
Standard
Nozzles
Flanged
Standard
Nozzles
Flanged
Standard
Nozzles
Flanged
NIH, 1 Pass Cover, 150 psig
148
185
168
229
187
223
NIH, 2 Pass Cover, 150 psig
202
256
222
276
258
331
NIH, 3 Pass Cover, 150 psig
472
488
617
634
765
791
NIH Plain End Cover, 150 psig
138
138
154
154
172
172
MWB End Cover, 150 psig
314
314
390
390
487
487
MWB Return Cover, 150 psig
138
138
154
154
172
172
NIH, 1 Pass Cover, 300 psig
633
709
764
840
978
1053
NIH, 2 Pass Cover, 300 psig
626
733
760
867
927
1078
NIH, 3 Pass Cover, 300 psig
660
694
795
830
997
1050
NIH/MWB End Cover, 300 psig
522
522
658
658
834
834
FRAMES 4, 5, and 6 — CONDENSER
Frame 4
WATERBOX DESCRIPTION
Frame 5
Frame 6
Standard
Nozzles
Flanged
Standard
Nozzles
Flanged
Standard
Nozzles
Flanged
NIH, 1 Pass Cover, 150 psig
148
185
168
229
187
223
NIH, 2 Pass Cover, 150 psig
191
245
224
298
245
318
NIH, 3 Pass Cover, 150 psig
503
519
628
655
772
799
NIH Plain End Cover, 150 psig
138
138
154
154
172
172
MWB End Cover, 150 psig
314
314
390
390
487
487
MWB Return Cover, 150 psig
138
138
154
154
172
172
NIH, 1 Pass Cover, 300 psig
633
709
764
840
978
1053
NIH, 2 Pass Cover, 300 psig
622
729
727
878
926
1077
NIH, 3 Pass Cover, 300 psig
655
689
785
838
995
1049
NIH/MWB End Cover, 300 psig
522
522
658
658
834
834
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 20A and 20B.
135
Table 24A — 19XR Waterbox Cover Weights — English (lb) (cont)
FRAMES 7 and 8 — COOLER
FRAME 7
WATERBOX DESCRIPTION
Standard Nozzles
FRAME 8
Flanged
Standard Nozzles
Flanged
NIH, 1 Pass Cover, 150 psig
329
441
417
NIH, 2 Pass Cover, 150 psig
426
541
531
685
NIH, 3 Pass Cover, 150 psig
1250
1291
1629
1687
NIH Plain End Cover, 150 psig
315
315
404
404
MWB End Cover, 150 psig
844
844
1339
1339
MWB Return Cover, 150 psig
494
315
315
404
404
NIH, 1 Pass Cover, 300 psig
1712
1883
2359
2523
NIH, 2 Pass Cover, 300 psig
1662
1908
2369
2599
NIH, 3 Pass Cover, 300 psig
1724
1807
2353
2516
NIH/MWB End Cover, 300 psig
1378
1378
1951
1951
FRAMES 7 and 8 — CONDENSER
Frame 7
WATERBOX DESCRIPTION
Standard
Nozzles
NIH, 1 Pass Cover, 150 psig
NIH, 2 Pass Cover, 150 psig
NIH, 3 Pass Cover, 150 psig
Frame 8
Flanged
Standard
Nozzles
Flanged
329
441
417
494
404
520
508
662
1222
1218
1469
1527
NIH Plain End Cover, 150 psig
315
315
404
404
MWB End Cover, 150 psig
781
781
1007
1007
Bolt On MWB End Cover, 150 PSI
700
700
1307
1307
MWB Return Cover, 150 psig
315
315
404
404
NIH, 1 Pass Cover, 300 psig
1690
1851
1986
2151
NIH, 2 Pass Cover, 300 psig
1628
1862
1893
2222
NIH, 3 Pass Cover, 300 psig
1714
1831
1993
2112
NIH/MWB End Cover, 300 psig
1276
1276
1675
1675
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 20A and 20B.
136
Table 24B — 19XR Waterbox Cover Weights — SI (kg)
FRAMES 1, 2, and 3 — COOLER
FRAME 1
WATERBOX DESCRIPTION
FRAME 2
FRAME 3
Flanged
Standard
Nozzles
Flanged
128
144
128
144
130
154
130
154
89
133
141
133
141
62
62
110
110
110
110
—
—
143
143
143
143
Flanged
Standard
Nozzles
80
93
84
99
NIH, 3 Pass Cover, 1034 kPa
82
NIH Plain End Cover, 1034 kPa
MWB End Cover, 1034 kPa
Standard
Nozzles
NIH, 1 Pass Cover, 1034 kPa
NIH, 2 Pass Cover, 1034 kPa
MWB Return Cover, 1034 kPa
—
—
110
110
110
110
NIH, 1 Pass Cover, 2068 kPa
112
137
186
220
186
220
NIH, 2 Pass Cover, 2068 kPa
116
147
186
235
186
235
NIH, 3 Pass Cover, 2068 kPa
115
131
196
212
196
212
NIH Plain End Cover, 2068 kPa
79
79
132
132
132
132
MWB End Cover, 2068 kPa
—
—
281
281
281
281
MWB Return Cover, 2068 kPa
—
—
202
202
202
202
FRAMES 1, 2, and 3 — CONDENSER
Frame 1
WATERBOX DESCRIPTION
Frame 2
Frame 3
Standard
Nozzles
Flanged
Standard
Nozzles
Flanged
Standard
Nozzles
Flanged
NIH, 1 Pass Cover, 1034 kPa
80
93
128
144
128
144
NIH, 2 Pass Cover, 1034 kPa
84
99
130
154
130
154
NIH, 3 Pass Cover, 1034 kPa
82
89
133
141
133
141
NIH Plain End Cover, 1034 kPa
62
62
102
102
102
102
MWB End Cover, 1034 kPa
—
—
106
106
106
106
MWB Return Cover, 1034 kPa
—
—
102
102
102
102
NIH, 1 Pass Cover, 2068 kPa
112
137
186
220
186
220
NIH, 2 Pass Cover, 2068 kPa
116
147
186
235
186
235
NIH, 3 Pass Cover, 2068 kPa
115
131
196
212
196
212
NIH Plain End Cover, 2068 kPa
79
79
122
122
122
122
MWB End Cover, 2068 kPa
—
—
215
215
215
215
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 20A and 20B.
137
Table 24B — 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
101
125
117
150
NIH, 3 Pass Cover, 1034 kPa
214
221
280
288
347
359
63
63
70
70
78
78
142
142
177
177
221
221
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
287
322
347
381
444
478
NIH, 2 Pass Cover, 2068 kPa
284
332
345
393
420
489
NIH, 3 Pass Cover, 2068 kPa
299
315
361
376
452
476
NIH/MWB End Cover, 2068 kPa
237
237
299
298
378
378
FRAMES 4, 5, and 6 — CONDENSER
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
87
111
102
135
111
144
NIH, 3 Pass Cover, 1034 kPa
228
235
285
297
350
362
NIH Plain End Cover, 1034 kPa
MWB End Cover, 1034 kPa
63
63
70
70
78
78
142
142
177
177
221
221
MWB Return Cover, 1034 kPa
63
63
70
70
78
78
NIH, 1 Pass Cover, 2068 kPa
287
322
347
381
444
478
NIH, 2 Pass Cover, 2068 kPa
282
331
330
398
420
489
NIH, 3 Pass Cover, 2068 kPa
297
313
356
380
451
476
NIH/MWB End Cover, 2068 kPa
237
237
298
298
378
378
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 Table 20A and 20B.
138
Table 24B — 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
567
586
739
765
NIH Plain End Cover, 1034 kPa
143
143
183
183
MWB End Cover, 1034 kPa
383
383
607
607
MWB Return Cover, 1034 kPa
143
143
183
183
NIH, 1 Pass Cover, 2068 kPa
777
854
1070
1144
NIH, 2 Pass Cover, 2068 kPa
754
865
1075
1179
NIH, 3 Pass Cover, 2068 kPa
782
820
1067
1141
NIH/MWB End Cover, 2068 kPa
625
625
885
885
FRAMES 7 and 8 — CONDENSER
FRAME 7
WATERBOX DESCRIPTION
Standard
Nozzles
NIH, 1 Pass Cover, 1034 kPa
NIH, 2 Pass Cover, 1034 kPa
FRAME 8
Flanged
Standard
Nozzles
Flanged
149
200
189
224
183
236
230
300
NIH, 3 Pass Cover, 1034 kPa
554
552
666
693
NIH Plain End Cover, 1034 kPa
143
143
183
183
MWB End Cover, 1034 kPa
354
354
457
457
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
767
840
901
976
NIH, 2 Pass Cover, 2068 kPa
738
845
859
1008
NIH, 3 Pass Cover, 2068 kPa
777
831
904
958
NIH/MWB End Cover, 2068 kPa
579
579
760
760
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 20A and 20B.
139
Table 25 — 19XR 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 27 — Motor Voltage Code
Table 26 — 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
140
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
*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
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.
Fig. 56 — Compressor Fits and Clearances
141
SEE VIEW A1 OR A2
A
3
2
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
a19-1635
COMPRESSOR, TRANSMISSION AREA
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
Fig. 56 — Compressor Fits and Clearances (cont)
142
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, ORIGINAL DESIGN (OIL FILM BEARINGS) AND IMPELLER SECTION
0.025
0.005
+0.0007
-0.0007
0.0050
0.0020
+0.0007
-0.0007
THRUST
0.0011
0.0013
INTERFERENCE
0.0011
0.0013
INTERFERENCE
0.0012
0.0004
a19-1640
VIEW B — HIGH SPEED SHAFT WITH ROLLING ELEMENT BEARINGS
Fig. 56 — Compressor Fits and Clearances (cont)
143
N
M
a19-1641
VIEW C — HIGH SPEED SHAFT RING SEAL
a19-1642
a19-1643
MOTOR LEAD INSTALLATION LABELS
19XR COMPRESSOR ASSEMBLY TORQUES
COMPRESSOR
Code
1
Oil Heater Retaining Nut — ft-lb (N·m)
2
Bull Gear Retaining Bolt — ft-lb (N·m)
3
Demister Bolts — ft-lb (N·m)
4
Impeller bolt Torque — ft-lb (N·m)
5*
Guide Vane Shaft Seal Nut — ft-lb (N·m)
* Not shown.
ITEM
FRAME 2
201-299, 2ZZ
N/A
80-90 (108-122)
15-19 (20-26)
32-48 (43-65)
25 (34)
FRAME 3
321-389, 3ZZ
18-22 (25-30)
80-90 (108-122)
15-19 (20-26)
55-60 (75-81)
25 (34)
FRAME 4
421-487, 4B1-4W7
18-22 (25-30)
80-90 (108-122)
15-19 (20-26)
55-60 (75-81)
25 (34)
Fig. 56 — Compressor Fits and Clearances (cont)
144
FRAME 5
501-599
18-22 (25-30)
80-90 (108-122)
15-19 (20-26)
160-225 (217-305)
25 (34)
a19-1870
Fig. 57 — PIC II Control Panel Wiring Schematic (Frame 2, 3, 4 Compressors without Split Ring Diffuser)
145
a19-1870
Fig. 57 — PIC II Control Panel Wiring Schematic (Frame 2, 3, 4 Compressors without Split Ring Diffuser)
(cont)
146
a19-1871
Fig. 58 — PIC II Control Panel Wiring Schematic (Frame 4 and 5 Compressors with Split Ring Diffuser)
147
AUX
BRG
C
CB
CCM
CCN
COMP’R
COND
DISCH
DL/DP
ENT
EVAP
EXT
FR
GND
G.V.
HGBP
HT EXCH
ICVC
ISM
L
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
LEGEND
Auxiliary
Bearing
Contactor
Circuit Breaker
Chiller Control Module
Carrier Comfort Network
Compressor
Condenser
Discharge
Datalink or Dataport
Entering
Evaporator
External
Frame
Ground
Guide Vane
Hot Gas Bypass
Heat Exchanger
International Chiller Visual Controller
Integrated Starter Module
Main Supply Power
LVG
N.O.
PRESS
REQM’T
TEMP
TB
UPC
—
—
—
—
—
—
—
Leaving
Normally Open
Pressure
Requirement
Temperature
Terminal Board
UPC Open Controller
Denotes Control Panel Terminal
Denotes Oil Pump Terminal
Denotes Power Panel Terminal
**
Denotes Motor Starter Panel Conn.
Denotes Component Terminal
Wire Splice
Denotes Conductor Male/Female Connector
Option Wiring
Fig. 58 — PIC II Control Panel Wiring Schematic (Frame 4 and 5 Compressors with Split Ring Diffuser)
(cont)
148
149
AUX
C
CB
CCM
COMM
COMPR
DISCH
—
—
—
—
—
—
—
Auxiliary
Contactor
Circuit Breaker
Chiller Control Module
Communication
Compressor
Discharge
FR
G
GRD
GVA
HGBP
HT EXCH
ISM
—
—
—
—
—
—
—
Frame
Ground
Ground
Guide Vane Actuator
Hot Gas Bypass
Heat Exchanger
Integrated Starter Module
—
—
—
—
—
—
Main Supply Power
Normally Open
Pressure
Requirement
Transformer
Terminal Board
LEGEND
*
**
Option Wiring
Denotes Conductor Male/Female Conne
Wire Splice
Denotes Power Panel Terminal
Denotes Mach. Control Panel Conn.
Denotes Motor Starter Panel Conn.
Denotes Component Terminal
Denotes Oil Pump Terminal
Fig. 59 — Power Panel Wiring Schematic
L
N.O.
PRESS
REQM’T
T
TB
a19-1872
LEGEND
AUX
C
CB
CT
DS
FU
G
HPR
—
—
—
—
—
—
—
—
Auxiliary
Contactor
Circuit Breaker
Current Transformer
Disconnect Switch
Fuse
Ground
High Pressure Relay
ISM
L
LL
M
RES
S
TB
UPC
—
—
—
—
—
—
—
—
Integrated Starter Module
Main Supply Power
Control Power Supply
Contactor
Resistor
Contactor
Terminal Block
UPC Open Controller
NOTES:
1. Power factor correction capacitors (when required) are connected ahead of all current
transformers for proper calibration and sensing by the ISM and IQDP4130.
2. For phase to phase ground fault protection refer to Fig. 62.
3. For metering information refer to Fig. 63.
Fig. 60 — Cutler-Hammer Wye Delta Unit Mounted Starter Sizes 3-5DP
150
LEGEND
AUX
C
CB
CT
DS
FU
G
—
—
—
—
—
—
—
Auxiliary
Contactor
Circuit Breaker
Current Transformer
Disconnect Switch
Fuse
Ground
HPR
ISM
L
LL
M
RES
S
TB
—
—
—
—
—
—
—
—
High Pressure Relay
Integrated Starter Module
Main Supply Power
Control Power Supply
Contactor
Resistor
Contactor
Terminal Block
NOTES:
1. Power factor correction capacitors (when required) are connected ahead of all current
transformers for proper calibration and sensing by the ISM and IQDP4130.
2. For metering option see Fig. 63.
Fig. 61 — Cutler-Hammer Wye Delta Unit Mounted Starter Size 6DP
151
CT
ISM
VFD
LEGEND
— Current Transformer
— Integrated Starter Module
— Variable Frequency Drive
Represents Twisted Wire
To Door
Fig. 62 — Ground Fault Phase Current Option
AM
CT
L
VM
—
—
—
—
LEGEND
Ammeter
Current Transformer
Main Power Supply
Voltmeter
Represents Twisted Wire
To Door
Fig. 63 — Separate Metering Option
152
Fig. 64 — Benshaw, Inc. Wye-Delta Unit Mounted Starter Wiring Schematic (Low Voltage)
a19-1873
153
LEGEND
AUX
BR
CB
CR
COND
CPU
CVC/
ICVC
CT
EVAP
FU
GND
—
—
—
—
—
—
—
—
—
—
—
Auxiliary
Bridge Rectifier
Circuit Breaker
Control Relay
Condenser
Central Processing Unit
Chiller Visual Controller
Current Transformer
Evaporator
Fuse
Ground
HPR
L
LL
M
O/L
PFCC
—
—
—
—
—
—
RLA
SCR
ST
TB
—
—
—
—
High Pressure Relay
Main Supply Power
Control Power Supply
Contactor
Overload Reset
Power Factor
Correction Capacitor
Rated Load Amps
Silicone Controller Rectifier
Shunt Trip
Terminal Block
NOTES:
1 LED status with power applied and prior to run command.
Wire Node Symbol
may have terminal block
Benshaw supplied
terminal block
PC Board Terminals
Twisted Pair
Twisted Shielded Pair
Terminal Strip
Shield Wire
Power Connection
Field Wiring
a19-1874
"ON"
"OFF"
5
Transformer T1 primary fuses FU1/FU2 value dependent on system voltage and model, per Chart 1.
Transformer connections per transformer nameplate connection diagram.
MOVs are used on power stack assemblies for system voltages of 200 through 460 vac (as shown).
Resistor/capacitor networks (DVDTs) are used on power stack assemblies in place of MOVs for a system
voltage of 575 vac (not shown).
K3 relay shown in deenergized state. K3 contact will close when power is supplied. K3 contact will open
on stop command or system fault.
CT1-CT3 are sized per Chart 2.
6
Optional.
2
3
4
Fig. 64 — Benshaw, Inc. Wye-Delta Unit Mounted Starter Wiring Schematic (Low Voltage) (cont)
154
NOTES:
1 LED status with power applied and prior to RUN command.
"ON"
"OFF "
2
Transformer T1 primary fuses FU1/FU2 value dependent on
system voltage and model, per Chart 1. Transformer connections per transformer nameplate connection diagram.
3
4
5
CT1-CT3 are sized per Chart 2.
Optional for all starters.
6
7
8
CT7-CTI2 are optional for all starters.
9
Circuit breaker CB2 rated at 30 amps for models 19XRA,
19XRC, 19XTR.
Fig. 65 — Benshaw, Inc. Solid-State Unit Mounted Starter Wiring Schematic
155
SYSTEM
VOLTAGE
200
230
346
380
400
415
480
575
CHART 1
3 KVA XFMR 2 KVA XFMR
FU1-2 AMPS FU1-2 AMPS
30
20
30
20
20
12
20
12
15
12
15
12
15
10
12
8
1 KVA XFMR
FU1-2 AMPS
12
10
7
6
6
6
5
4
CHART 2
STARTER RLA
MX3 CT RATIO
RANGE
95-135
864:1
136-200
2640:1
201-231
2640:1
232-300
2640:1
301-340
2640:1
341-480
3900:1
481-580
3900:1
581-600
3900:1
601-740
3900:1
741-855
5760:1
856-1250
5760:1
STARTER
RLA RANGE
95-205
206-259
260-298
299-398
399-501
502-597
598-687
688-791
792-854
855-979
980-1194
1195-1390
CHART 3
L1, L2, L3 CONDUCTORS
PER PHASE (Load Side)
262 MCM DLO BLK
1 cond per phase
373 MCM DLO BLK
1 cond per phase
373 MCM DLO BLK
1 cond per phase
262 MCM DLO BLK
2 cond per phase
262 MCM DLO BLK
2 cond per phase
373 MCM DLO BLK
2 cond per phase
373 MCM DLO BLK
2 cond per phase
444 MCM DLO BLK
2 cond per phase
444 MCM DLO BLK
2 cond per phase
373 MCM DLO BLK
3 cond per phase
444 MCM DLO BLK
3 cond per phase
444 MCM DLO BLK
3 cond per phase
Fig. 65 — Benshaw, Inc. Solid-State Unit Mounted Starter Wiring Schematic (cont)
156
a19-1875
157
Fig. 66 — Typical Across-the-Line Starter Wiring Schematic (Medium Voltage)
—
—
—
—
—
—
LEGEND
Auxiliary
Contactor
Circuit Breaker
Communication
Condenser
Control Power
Transformer
CR
— Control Relay
CT
— Current Transformer
DS
— Disconnect Switch
EVAP — Evaporator
FU
— Fuse
G
— Ground
GFCT — Ground Fault Current
Transformer
HPR
— High Pressure Relay
ISM
— Integrated Starter
Module
L
— Main Power Supply
LL
— Control Power Supply
LVG
— Leaving
M
— Contactor
MTR
— Motor
PRESS — Pressure
PT
— Power Transformer
ST
— Shunt Trip
STAT
— Status
TB
— Terminal Block
TRANS — Transition
VFD
— Variable Frequency
Drive
VL
— Wire Label
Starter Vendor
Power Wiring
Starter Vendor
Control Wiring
Field Installed
Power Wiring
(supplied by others)
Field Installed
Control Wiring
(supplied by others)
Option — Starter
Vendor Wiring
Twisted Pair Wiring
by Starter Vendor
Customer Terminal
Connection
AUX
C
CB
COMM
COND
CPT
a19-1876
158
Fig. 67 — Typical Primary Reactor Starter Wiring Schematic (Medium Voltage)
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
AUX
C
CB
COMM
COND
CPT
CR
CT
DS
EVAP
FU
G
GFCT
HPR
ISM
L
LL
LVG
M
MTR
PRESS
PT
ST
STAT
TB
TRANS
VFD
VL
LEGEND
Auxiliary
Contactor
Circuit Breaker
Communication
Condenser
Control Power
Transformer
Control Relay
Current Transformer
Disconnect Switch
Evaporator
Fuse
Ground
Ground Fault Current
Transformer
High Pressure Relay
Integrated Starter
Module
Main Power Supply
Control Power Supply
Leaving
Contactor
Motor
Pressure
Power Transformer
Shunt Trip
Status
Terminal Block
Transition
Variable Frequency
Drive
Wire Label
Starter Vendor
Power Wiring
Starter Vendor
Control Wiring
Field Installed
Power Wiring
(supplied by others)
Field Installed
Control Wiring
(supplied by others)
Option — Starter
Vendor Wiring
Twisted Pair Wiring
by Starter Vendor
Customer Terminal
Connection
Fig. 68 — Typical Autotransformer Starter Wiring Schematic (Medium Voltage)
1A
159
—
—
—
—
—
—
LEGEND
Auxiliary
Contactor
Circuit Breaker
Communication
Condenser
Control Power
Transformer
CR
— Control Relay
CT
— Current Transformer
DISCH — Discharge
DS
— Disconnect Switch
EVAP
— Evaporator
FU
— Fuse
GFCT — Ground Fault Current
Transformer
HPR
— High Pressure Relay
ISM
— Integrated Starter
Module
L
— Main Power Supply
LL
— Control Power Supply
MTR
— Motor
PRESS — Pressure
PT
— Power Transformer
ST
— Shunt Trip
STAT
— Status
TB
— Terminal Block
TC
— Transition Clear
TRANS — Transition
VFD
— Variable Frequency
Drive
VL
— Wire Label
Starter Vendor
Power Wiring
Starter Vendor
Control Wiring
Field Installed
Power Wiring
(supplied by others)
Field Installed
Control Wiring
(supplied by others)
Option — Starter
Vendor Wiring
Twisted Pair Wiring
by Starter Vendor
Customer Terminal
Connection
AUX
C
CB
COMM
COND
CPT
a19-1878
160
Fig. 69 — Typical Variable Frequency Drive (VFD) Wiring Schematic
161
Fig. 69 — Typical Variable Frequency Drive (VFD) Wiring Schematic (cont)
162
Fig. 69 — Typical Variable Frequency Drive (VFD) Wiring Schematic (cont)
a19-1879
163
Fig. 69 — Typical Variable Frequency Drive (VFD) Wiring Schematic (cont)
Fig. 69 — Typical Variable Frequency Drive (VFD) Wiring Schematic (cont)
164
a19-1880
LEGEND FOR FIG. 69
AUX
CB
CCM
CCN
COMM
CT
DP/DL
DS
FD
FR
FU
G
GV
HGBP
HPR
HPS
HX
ICVC
IGBT
IGV
ISM
J
LEM
MAB
MOV
RC
RMI
ST
T
TB
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
Auxiliary
Circuit Breaker
Chiller Control Module
Carrier Comfort Network
Communications
Current Transformer
Data Port/Data Link
Disconnect Switch
Fused Disconnect
Fan Relay
Fuse
Chassis Ground
Guide Vane
Hot Gas Bypass
High Discharge Pressure Relay
High Pressure Switch
Heat Exchanger
International Chiller Visual Controller
Insulated Gate Bipolar Transistor
Inlet Guide Vane
Integrated Starter Module
Junction
Current Detector
Module Adapter Board
Metal Oxide Varistor
Regulator Controller
Remote Metering Interface
Shunt Trip
Transformer
Terminal Block
VFD
1C
1M
2C
3C
—
—
—
—
—
Variable Frequency Drive
Compressor Oil Heater Contactor
Start Contactor
Oil Pump Contactor
Hot Gas Bypass Relay
Field Control Wiring
Field Power Wiring
Factory Wiring
Pressure Switch
Shielded Cable
Chassis Ground
Twisted Pair Wiring
Male/Female Connector
Terminal Block Connection
Wire Splice or Junction
Cam Switch
Component Terminal
Thermistor
+
Compr Oil Pump Terminal
Cartridge Fuse
Earth Ground
Resistor
Light
Temperature Switch
Common Potential
Dry Contact
VFD Terminal
Current Transformer, Polarized
(Direction Determined by •)
Transformer
Transducer
IGBT
Fusible Link
Diode
Potentiometer
Silicon Controlled Rectifier
165
APPENDIX A — ICVC PARAMETER INDEX
1CR Start Complete
MENU
SOFTKEY
STATUS
1CR Stop Complete
STATUS
ISM_STAT
1M Start/Run Fault
STATUS
ISM_STAT
1M/2M Stop Fault
STATUS
ISM_STAT
PARAMETER
20 mA Demand Limit Opt
2M Start/Run Fault
SERVICE
TABLE
SCREEN NAME
ISM_STAT
EQUIPMENT SERVICE
STATUS
RAMP_DEM
X
ISM_STAT
Active Delta P
SERVICE
CONTROL ALGORITHM STATUS
SURGPREV
Active Delta T
SERVICE
CONTROL ALGORITHM STATUS
SURGPREV
Active Delta Tsat
SERVICE
CONTROL ALGORITHM STATUS
SURGPREV
Active Delta Tsat
STATUS
VPFSTAT
Active DeltaP
STATUS
HEAT_EX
Active DeltaT
STATUS
HEAT_EX
Active DeltaTsat
STATUS
HEAT_EX
Active Demand Limit
STATUS
MAINSTAT
Active Region
SERVICE
CONTROL ALGORITHM STATUS
Actual Guide Vane Position
SERVICE
CONTROL ALGORITHM STATUS
Actual Guide Vane Position
STATUS
Actual Guide Vane Position
STATUS
HEAT_EX
Actual Guide Vane Position
STATUS
STARTUP
Actual Guide vane position
STATUS
VPFSTAT
Actual Guide Vane Position
STATUS
VDO_STAT
Actual Line Current
STATUS
SURGPREV
CAPACITY
COMPRESS
POWER
Actual Superheat
SERVICE
CONTROL ALGORITHM STATUS
Actual VFD Speed
SERVICE
CONTROL ALGORITHM STATUS
Actual VFD Speed
STATUS
OVERRIDE
CAPACITY
COMPRESS
Actuators Test IGV & SRD
SERVICE
Address
SERVICE
ICVC CONFIGURATION
STATUS
MAINSTAT
Alarm Relay
CONFIGURABLE
CONTROL TEST
IGV & SRD ACTUATOR
X
Alarm Routing
SERVICE
EQUIPMENT CONFIGURATION
NET_OPT
X
Amps or Kw Ramp %/min.
SERVICE
EQUIPMENT SERVICE
RAMP_DEM
X
Amps/kW Ramp
SERVICE
CONTROL ALGORITHM STATUS
CAPACITY
Attach ICVC Screen to device
SERVICE
ATTACH TO NETWORK DEVICE
Auto Chilled Water Reset
Auto Demand Limit Input
Auto Restart Option
STATUS
STATUS
SERVICE
Average Line Current
STATUS
Average Line Current
STATUS
X
MAINSTAT
MAINSTAT
EQUIPMENT SERVICE
OPTIONS
X
MAINSTAT
POWER
Average Line Current
DEFAULT
Base Demand Limit
SETPOINT
Base Demand Limit
SETPOINT
X
X
Baud Rate
Broadcast Option, CCN Occupancy
Configuration.
Bus Number
SERVICE
Calc Evap Sat temp
SERVICE
Calc Evap Sat Temp
STATUS
HEAT_EX
Calc Low Lift SRD Pos 1
STATUS
VDO_STAT
Calc Low Lift SRD Pos 2
STATUS
VDO_STAT
Calc SRD A Pos (output)
STATUS
VDO_STAT
Calc. Evap. Sat. temp.
STATUS
VPFSTAT
Calibrate Guide Vane
SERVICE
CONTROL TEST
GUIDE VANE CALIBRATION
Capacity Control Prop DEC Band
SERVICE
EQUIPMENT SERVICE
SETUP2
X
Capacity Control Prop ECW Gain
SERVICE
EQUIPMENT SERVICE
SETUP2
X
Capacity Control Prop INC Band
SERVICE
EQUIPMENT SERVICE
SETUP2
X
SERVICE
EQUIPMENT CONFIGURATION
SERVICE
CONTROL ALGORITHM STATUS
166
ICVC CONFIGURATION
X
NET_OPT
X
ICVC CONFIGURATION
X
OVERRIDE
APPENDIX A — ICVC PARAMETER INDEX (cont)
MENU
SOFTKEY
TABLE
SCREEN NAME
CCM Pressure Transducers Test
SERVICE
CONTROL TEST
CCM Thermistors Test
SERVICE
CONTROL TEST
CCM PRESS
TRANSDUCERS
CCM THERMISTORS
PARAMETER
CCN Mode
STATUS
CCN Time Schedule
SCHEDULE
CCN Time Schedule
SERVICE
Chill Water Pulldown/Min
CONFIGURABLE
ICVC_PSWD
EQUIPMENT CONFIGURATION
STATUS
OCCPC03S
X
OCCDEFCS
X
HEAT_EX
Chilled Medium
SERVICE
EQUIPMENT SERVICE
SETUP1
X
Chilled Water Deadband
SERVICE
Chilled Water Delta T
SERVICE
EQUIPMENT SERVICE
SETUP1
X
CONTROL ALGORITHM STATUS
SURGPREV
Chilled Water Delta T
STATUS
VPFSTAT
Chilled Water DeltaP
STATUS
HEAT_EX
Chilled Water DeltaT
STATUS
HEAT_EX
Chilled Water Flow
STATUS
STARTUP
Chilled Water Pump
STATUS
Chilled Water Temp
SERVICE
Chilled Water Temp
STATUS
MAINSTAT
Chiller Start/Stop
STATUS
MAINSTAT
STARTUP
CONTROL ALGORITHM STATUS
WSMDEFME
CHW Delta T —> Full Reset
SERVICE
EQUIPMENT SERVICE
TEMP_CTL
X
CHW Delta T —> No Reset
SERVICE
EQUIPMENT SERVICE
TEMP_CTL
X
CHW Setpoint Reset Value
SERVICE
CONTROL ALGORITHM STATUS
WSMDEFME
Commandeered State
SERVICE
CONTROL ALGORITHM STATUS
WSMDEFME
Common Sensor Option
SERVICE
EQUIPMENT SERVICE
LEADLAG
Comp Discharge Alert
SERVICE
CONTROL ALGORITHM STATUS
OVERRIDE
Comp Discharge Alert
SERVICE
EQUIPMENT SERVICE
SETUP1
Comp Discharge Temp.
SERVICE
CONTROL ALGORITHM STATUS
OVERRIDE
Comp Discharge Temperature
STATUS
X
COMPRESS
Comp Motor Temp Override
SERVICE
CONTROL ALGORITHM STATUS
OVERRIDE
Comp Motor Temp Override
SERVICE
EQUIPMENT SERVICE
SETUP1
Comp Motor Winding Temp
SERVICE
CONTROL ALGORITHM STATUS
Comp Motor Winding Temp
STATUS
Comp Motor Winding Temp
X
X
OVERRIDE
COMPRESS
STATUS
COMPRESS
Comp Thrust Brg Alert
SERVICE
CONTROL ALGORITHM STATUS
OVERRIDE
 Comp Thrust Brg Alert
SERVICE
EQUIPMENT SERVICE
SETUP1
Comp Thrust Brg Reset
SERVICE
CONTROL ALGORITHM STATUS
Comp Thrust Brg Reset
STATUS
Comp Thrust Brg Temp
SERVICE
Comp Thrust Brg Temp
STATUS
X
OVERRIDE
COMPRESS
CONTROL ALGORITHM STATUS
OVERRIDE
COMPRESS
Comp Thrust Brg Trip
SERVICE
CONTROL ALGORITHM STATUS
OVERRIDE
 Comp Thrust Brg Trip
SERVICE
EQUIPMENT SERVICE
SETUP1
Comp Thrust Lvg Oil Temp
SERVICE
CONTROL ALGORITHM STATUS
Comp Thrust Lvg Oil Temp
STATUS
COMPRESS
Compressor Ontime
STATUS
MAINSTAT
Compressor Run Contact
STATUS
STARTUP
Compressor Start Contact
STATUS
STARTUP
Compressor Start Relay
STATUS
Compressor Ontime
X
OVERRIDE
DEFAULT
STARTUP
Cond Approach Alert
SERVICE
EQUIPMENT SERVICE
SETUP1
X
Cond Flow Delta P Cutout
SERVICE
EQUIPMENT SERVICE
SETUP1
X
Cond Hi Flow Alarm Option
SERVICE
EQUIPMENT SERVICE
SETUP1
X
Cond Hi Flow Delta P Limit
SERVICE
EQUIPMENT SERVICE
SETUP1
X
Cond Press Override
SERVICE
EQUIPMENT SERVICE
SETUP1
X
Cond Pressure Override
SERVICE
CONTROL ALGORITHM STATUS
OVERRIDE
Condenser Approach
STATUS
HEAT_EX
167
312
APPENDIX A — ICVC PARAMETER INDEX (cont)
Condenser Freeze Point
MENU
SOFTKEY
SERVICE
Condenser Pressure
SERVICE
Condenser Pressure
STATUS
HEAT_EX
Condenser Refrig Temp
STATUS
HEAT_EX
PARAMETER
Condenser Refrig. Temp.
STATUS
Condenser Refrig. Temp.
SERVICE
TABLE
SCREEN NAME
CONFIGURABLE
EQUIPMENT SERVICE
SETUP1
X
CONTROL ALGORITHM STATUS
OVERRIDE
VPFSTAT
CONTROL ALGORITHM STATUS
Condenser Refrigerant Temperature
OVERRIDE
DEFAULT
Condenser Water DeltaP
STATUS
HEAT_EX
Condenser Water Flow
STATUS
STARTUP
Condenser Water Pump
STATUS
STARTUP
Configuration, Lead/Lag
Consumable Points for CCN Data
Collection
Control Mode
SERVICE
EQUIPMENT SERVICE
LEADLAG
X
SERVICE
EQUIPMENT CONFIGURATION
CONSUME
X
Control Point
SERVICE
CONTROL ALGORITHM STATUS
CAPACITY
Control Point
SETPOINT
CONTROL ALGORITHM STATUS
CAPACITY
Control Point
STATUS
MAINSTAT
STATUS
MAINSTAT
Control Point Error
SERVICE
Current % Unbalance
SERVICE
ISM CONFIGURATION DATA
pswd —> ISM_CONF
Current CHW Setpoint
SERVICE
CONTROL ALGORITHM STATUS
WSMDEFME
Current Imbalance
STATUS
X
ISM_STAT
Current Imbalance Time
SERVICE
ISM CONFIGURATION DATA
pswd —> ISM_CONF
Current Mode, Lead-Lag
SERVICE
CONTROL ALGORITHM STATUS
LL_MAINT
Daylight Savings
SERVICE
EQUIPMENT CONFIGURATION
BRODEF
X
Degrees Reset
SERVICE
EQUIPMENT SERVICE
TEMP_CTL
X
Degrees Reset At 20mA
Delta P at 0% (4 mA), Head Press
Ref.
Delta P at 100% (20 mA), Head Press
Ref.
Demand Kilowatts
SERVICE
EQUIPMENT SERVICE
TEMP_CTL
X
SERVICE
EQUIPMENT SERVICE
OPTIONS
X
SERVICE
EQUIPMENT SERVICE
OPTIONS
X
Demand Limit at 20 mA
SERVICE
EQUIPMENT SERVICE
RAMP_DEM
X
Demand limit Decrease
SERVICE
EQUIPMENT CONFIGURATION
NET_OPT
X
Demand Limit Inhibit
SERVICE
CONTROL ALGORITHM STATUS
CAPACITY
Demand Limit Prop. Band
SERVICE
EQUIPMENT SERVICE
RAMP_DEM
X
Demand Limit Source
SERVICE
EQUIPMENT SERVICE
RAMP_DEM
X
Demand Watts Interval
SERVICE
EQUIPMENT SERVICE
RAMP_DEM
X
Description, Device
SERVICE
Device Name
SERVICE
Diffuser 25% Load Point
SERVICE
EQUIPMENT SERVICE
SETUP2
X
Diffuser 50% Load Point
SERVICE
EQUIPMENT SERVICE
SETUP2
X
Diffuser 75% Load Point
SERVICE
EQUIPMENT SERVICE
SETUP2
X
STATUS
X
POWER
ICVC CONFIGURATION
ICVC CONFIGURATION
Diffuser Actuator
STATUS
COMPRESS
Diffuser Actuator
STATUS
VPFSTAT
Diffuser Actuator
STATUS
VDO_STAT
Diffuser Actuator Test
SERVICE
Diffuser Full Span mA
SERVICE
EQUIPMENT SERVICE
SETUP2
X
Diffuser Full Span mA
SERVICE
EQUIPMENT SERVICE
VDO_SRD
X
Diffuser Opt Diffuser % Load Pt
SERVICE
EQUIPMENT SERVICE
SETUP2
X
Diffuser Opt Guide Vane % Load Pt
SERVICE
EQUIPMENT SERVICE
SETUP2
X
Diffuser Option
SERVICE
EQUIPMENT SERVICE
SETUP2
X
Diffuser Option
SERVICE
EQUIPMENT SERVICE
VDO_SRD
X
Diffuser Option Enable
SERVICE
EQUIPMENT SERVICE
SETUP2
X
Disable Service Password
Discharge Alert
CONTROL TEST
STATUS
SERVICE
DIFFUSER ACTUATOR
ICVC_PSWD
CONTROL ALGORITHM STATUS
168
OVERRIDE
APPENDIX A — ICVC PARAMETER INDEX (cont)
Discharge Alert
MENU
SOFTKEY
SERVICE
Discharge Temperature
SERVICE
CONTROL TEST
DISCRETE OUTPUTS
PARAMETER
Discharge Temperature
TABLE
SCREEN NAME
CONFIGURABLE
EQUIPMENT SERVICE
SETUP1
X
CONTROL ALGORITHM STATUS
OVERRIDE
STATUS
COMPRESS
Discrete Outputs Test
SERVICE
ECW Control Option
SERVICE
EQUIPMENT SERVICE
TEMP_CTL
ECW Delta T
SERVICE
CONTROL ALGORITHM STATUS
CAPACITY
SERVICE
CONTROL ALGORITHM STATUS
CAPACITY
ECW Reset
ECW Setpoint
SETPOINT
ECW Setpoint
SETPOINT
Emergency Stop
X
X
STATUS
MAINSTAT
Entering Chilled Water
SERVICE
Entering Chilled Water
STATUS
CONTROL ALGORITHM STATUS
HEAT_EX
STATUS
HEAT_EX
Entering Chilled Water
Entering Condenser Water
X
CAPACITY
DEFAULT
Entering Condenser Water
DEFAULT
Equipment Status
SERVICE
CONTROL ALGORITHM STATUS
WSMDEFME
Evap Approach Alert
SERVICE
EQUIPMENT SERVICE
SETUP1
X
Evap Flow Delta P Cutout
SERVICE
EQUIPMENT SERVICE
SETUP1
X
Evap Refigerant Liquid Temp
STATUS
HEAT_EX
Evap Refrig Trip point
SERVICE
EQUIPMENT SERVICE
SETUP1
Evap Sat Override Temp
SERVICE
CONTROL ALGORITHM STATUS
OVERRIDE
Evaporator Approach
STATUS
HEAT_EX
Evaporator Pressure
STATUS
HEAT_EX
Evaporator Refrigerant Temperature
Flow Delta P Display
Frequency
Frequency = 60Hz? (No = 50Hz)
Frequency Out of Range
Ground Fault
X
DEFAULT
SERVICE
EQUIPMENT SERVICE
STATUS
SERVICE
SETUP1
X
POWER
ISM CONFIGURATION DATA
STATUS
pswd —> ISM_CONF
X
ISM_STAT
STATUS
ISM_STAT
Ground Fault CT Ratio:1
SERVICE
ISM CONFIGURATION DATA
pswd —> ISM_CONF
X
Ground Fault Current
SERVICE
ISM CONFIGURATION DATA
pswd —> ISM_CONF
X
Ground Fault Persistence
SERVICE
ISM CONFIGURATION DATA
pswd —> ISM_CONF
X
Ground Fault Phase 1
SERVICE
CONTROL ALGORITHM STATUS
ISM_HIST
CONTROL ALGORITHM STATUS
ISM_HIST
Ground Fault Phase 1
STATUS
Ground Fault Phase 2
SERVICE
Ground Fault Phase 2
STATUS
Ground Fault Phase 3
SERVICE
Ground Fault Phase 3
STATUS
POWER
POWER
CONTROL ALGORITHM STATUS
ISM_HIST
POWER
Ground Fault Protection?
SERVICE
ISM CONFIGURATION DATA
pswd —> ISM_CONF
Ground Fault Start Delay
SERVICE
ISM CONFIGURATION DATA
pswd —> ISM_CONF
X
Group Number, Loadshed
SERVICE
EQUIPMENT CONFIGURATION
NET_OPT
X
Guide Vane 25% Load (2)
SERVICE
EQUIPMENT SERVICE
VDO_SRD
X
Guide Vane 25% Load Point
SERVICE
EQUIPMENT SERVICE
SETUP2
X
Guide Vane 50% Load (2)
SERVICE
EQUIPMENT SERVICE
VDO_SRD
X
Guide Vane 50% Load Point
SERVICE
EQUIPMENT SERVICE
SETUP2
X
Guide Vane 75% Load (2)
SERVICE
EQUIPMENT SERVICE
VDO_SRD
X
Guide Vane 75% Load Point
SERVICE
EQUIPMENT SERVICE
SETUP2
X
Guide Vane Calibration
SERVICE
CONTROL TEST
GUIDE VANE CALIBRATION
Guide Vane Delta
SERVICE
CONTROL ALGORITHM STATUS
CAPACITY
Guide Vane Delta
SERVICE
CONTROL ALGORITHM STATUS
SURGPREV
Guide Vane Delta
STATUS
COMPRESS
Guide Vane Position, Actual
STATUS
STARTUP
Guide Vane Position, Actual
STATUS
169
X
APPENDIX A — ICVC PARAMETER INDEX (cont)
Guide Vane Position, Actual
MENU
SOFTKEY
SERVICE
Guide Vane Position, Actual
STATUS
PARAMETER
Guide Vane Position, Actual
Guide Vane Travel Limit
Hardware Failure
TABLE
CONTROL ALGORITHM STATUS
CONFIGURABLE
CAPACITY
COMPRESS
STATUS
SERVICE
SCREEN NAME
STARTUP
EQUIPMENT SERVICE
STATUS
SETUP2
X
ISM_STAT
Head Press Ref. Delta P at 0% (4 mA)
Head Press Ref. Delta P at 100% (20
mA)
Head Press Ref., Minimum Output
SERVICE
EQUIPMENT SERVICE
OPTIONS
X
SERVICE
EQUIPMENT SERVICE
OPTIONS
X
SERVICE
EQUIPMENT SERVICE
OPTIONS
X
Head Press. Ref DeltaP at 0%
SERVICE
EQUIPMENT SERVICE
OPTIONS
X
Head Press. Ref DeltaP at 100%
SERVICE
EQUIPMENT SERVICE
OPTIONS
X
Head Press. Ref Min. Output
SERVICE
EQUIPMENT SERVICE
OPTIONS
X
Head Pressure Output Test
SERVICE
CONTROL TEST
HEAD PRESSURE OUTPUT
SURGPREV
Head Pressure Reference
STATUS
HEAT_EX
HGBP Off Delta T
SERVICE
CONTROL ALGORITHM STATUS
HGBP Off Delta T
SERVICE
EQUIPMENT SERVICE
OPTIONS
X
HGBP Off DeltaT
SERVICE
EQUIPMENT SERVICE
OPTIONS
X
HGBP On Delta T
SERVICE
CONTROL ALGORITHM STATUS
SURGPREV
HGBP On Delta T
SERVICE
EQUIPMENT SERVICE
OPTIONS
X
HGBP On DeltaT
SERVICE
EQUIPMENT SERVICE
OPTIONS
X
HGBP/VFD Active
SERVICE
CONTROL ALGORITHM STATUS
SURGPREV
High Motor Amps
STATUS
Holiday Schedule
SERVICE
EQUIPMENT CONFIGURATION
HOLIDAYS
Hot Gas Bypass Relay
SERVICE
CONTROL ALGORITHM STATUS
SURGPREV
Hot Gas Bypass Relay
STATUS
Hot Gas Bypass Relay
STATUS
I2T Sum Heat-Phase 1
SERVICE
I2T Sum Heat-Phase 1
STATUS
I2T Sum Heat-Phase 2
SERVICE
ISM_STAT
X
HEAT_EX
VPFSTAT
CONTROL ALGORITHM STATUS
ISM_HIST
CONTROL ALGORITHM STATUS
ISM_HIST
CONTROL ALGORITHM STATUS
ISM_HIST
POWER
I2T Sum Heat-Phase 2
STATUS
I2T Sum Heat-Phase 3
SERVICE
I2T Sum Heat-Phase 3
STATUS
POWER
Ice Build Contact
STATUS
MAINSTAT
Ice Build Option
SERVICE
EQUIPMENT SERVICE
OPTIONS
X
Ice Build Recycle
SERVICE
EQUIPMENT SERVICE
OPTIONS
X
Ice Build Setpoint
SETPOINT
Ice Build Setpoint
SETPOINT
Ice Build Termination
SERVICE
POWER
X
X
EQUIPMENT SERVICE
OPTIONS
OCCPC02S
X
OCCDEFCS
X
Ice Build Time Schedule
SCHEDULE
Ice Build Time Schedule
SERVICE
EQUIPMENT CONFIGURATION
ISM Fault Status
SERVICE
CONTROL ALGORITHM STATUS
ISM Fault Status
STATUS
ISM Fault Status
STATUS
STARTUP
ISM Power On Reset
STATUS
ISM_STAT
X
ISM_HIST
ISM_STAT
LAG % Capacity
SERVICE
EQUIPMENT SERVICE
LEADLAG
X
LAG % Capacity
SERVICE
EQUIPMENT SERVICE
LEADLAG
X
LAG Address
SERVICE
EQUIPMENT SERVICE
LEADLAG
X
LAG CHILLER Run Status
LAG CHILLER Recovery Start
Request
LAG CHILLER Start/Stop
SERVICE
CONTROL ALGORITHM STATUS
LL_MAINT
SERVICE
CONTROL ALGORITHM STATUS
LL_MAINT
SERVICE
CONTROL ALGORITHM STATUS
LL_MAINT
LAG START Time
SERVICE
CONTROL ALGORITHM STATUS
LL_MAINT
LAG START Timer
SERVICE
EQUIPMENT SERVICE
LEADLAG
LAG STOP Time
SERVICE
CONTROL ALGORITHM STATUS
LL_MAINT
170
X
APPENDIX A — ICVC PARAMETER INDEX (cont)
TABLE
SCREEN NAME
CONFIGURABLE
LAG STOP Timer
MENU
SOFTKEY
SERVICE
EQUIPMENT SERVICE
LEADLAG
X
LAG STOP Timer
SERVICE
EQUIPMENT SERVICE
LEADLAG
X
LCW Reset
SERVICE
CONTROL ALGORITHM STATUS
CAPACITY
PARAMETER
LCW Setpoint
SETPOINT
LCW Setpoint
SETPOINT
X
X
LEAD CHILLER in Control
SERVICE
CONTROL ALGORITHM STATUS
LL_MAINT
LEAD/LAG Configuration
SERVICE
CONTROL ALGORITHM STATUS
LL_MAINT
LEAD/LAG Configuration
SERVICE
EQUIPMENT SERVICE
LEADLAG
LEAD/LAG Current Mode
SERVICE
CONTROL ALGORITHM STATUS
LL_MAINT
Leaving Chilled Water
SERVICE
CONTROL ALGORITHM STATUS
CAPACITY
Leaving Chilled Water
STATUS
HEAT_EX
STATUS
HEAT_EX
LID Language
SERVICE
ICVC CONFIGURATION
X
Lift @ 25% Load (1)
SERVICE
EQUIPMENT SERVICE
VDO_SRD
X
Lift @ 25% Load (2)
SERVICE
EQUIPMENT SERVICE
VDO_SRD
X
Lift @ 50% Load (1)
SERVICE
EQUIPMENT SERVICE
VDO_SRD
X
Leaving Chilled Water
Leaving Condenser Water
DEFAULT
Leaving Condenser Water
DEFAULT
Lift 1
STATUS
VDO_STAT
Lift 2
STATUS
VDO_STAT
Lift A (Actual)
X
STATUS
Line Current Phase 1
SERVICE
Line Current Phase 1
STATUS
Line Current Phase 2
SERVICE
VDO_STAT
CONTROL ALGORITHM STATUS
ISM_HIST
CONTROL ALGORITHM STATUS
ISM_HIST
CONTROL ALGORITHM STATUS
ISM_HIST
POWER
Line Current Phase 2
STATUS
Line Current Phase 3
SERVICE
Line Current Phase 3
STATUS
POWER
Line Current, Actual
STATUS
POWER
Line Current, Actual
STATUS
POWER
Line Current, Average
STATUS
Line Frequency
SERVICE
Line Frequency Faulting
Line Voltage Phase 1
POWER
POWER
CONTROL ALGORITHM STATUS
ISM_HIST
SERVICE
ISM CONFIGURATION DATA
pswd —> ISM_CONF
SERVICE
CONTROL ALGORITHM STATUS
ISM_HIST
CONTROL ALGORITHM STATUS
ISM_HIST
X
Line Voltage Phase 1
STATUS
Line Voltage Phase 2
SERVICE
POWER
Line Voltage Phase 2
STATUS
Line Voltage Phase 3
SERVICE
Line Voltage Phase 3
STATUS
Load Balance Option
SERVICE
Load Balance Option
SERVICE
EQUIPMENT SERVICE
LEADLAG
X
Loadshed Group Number
SERVICE
EQUIPMENT CONFIGURATION
NET_OPT
X
OCCPC01S
X
POWER
CONTROL ALGORITHM STATUS
ISM_HIST
CONTROL ALGORITHM STATUS
LL_MAINT
POWER
Local Time Schedule
SCHEDULE
Local Time Schedule
SERVICE
EQUIPMENT CONFIGURATION
OCCDEFCS
X
Locked Rotor Start Delay
SERVICE
ISM CONFIGURATION DATA
pswd —> ISM_CONF
X
Locked Rotor Trip
STATUS
ISM_STAT
Lockout Termination
Log out of Password Protected
Screens
Low Lift Profile Select
SERVICE
CONTROL TEST
SERVICE
LOG OUT OF DEVICE
SERVICE
EQUIPMENT SERVICE
VDO_SRD
X
Low Load HGBP
SERVICE
EQUIPMENT SERVICE
OPTIONS
X
Maximum Loadshed Time
SERVICE
EQUIPMENT CONFIGURATION
NET_OPT
X
Message, Primary
X
DEFAULT
Message, Secondary
Minimum Output, Head Press Ref.
TERMINATE LOCKOUT
DEFAULT
SERVICE
EQUIPMENT SERVICE
171
OPTIONS
X
APPENDIX A — ICVC PARAMETER INDEX (cont)
Model Number
MENU
SOFTKEY
SERVICE
Model Number
SERVICE
ICVC CONFIGURATION
Motor Amps Not Sensed
STATUS
ISM_STAT
Motor Amps When Stopped
STATUS
ISM_STAT
PARAMETER
Motor Current CT Ratio:1
Motor Kilowatt-Hours
Motor Kilowatts
SERVICE
TABLE
ISM CONFIGURATION DATA
Motor Percent Kilowatts
STATUS
pswd —> ISM_CONF
X
X
POWER
STATUS
SERVICE
CONFIGURABLE
ICVC CONFIGURATION
STATUS
Motor Locked Rotor Trip
SCREEN NAME
POWER
ISM CONFIGURATION DATA
pswd —> ISM_CONF
X
MAINSTAT
Motor Rated Kilowatts
SERVICE
EQUIPMENT SERVICE
RAMP_DEM
X
Motor Rated Line Voltage
SERVICE
ISM CONFIGURATION DATA
pswd —> ISM_CONF
X
Motor Rated Load Amps.
SERVICE
ISM CONFIGURATION DATA
pswd —> ISM_CONF
X
Motor Temp Override
SERVICE
CONTROL ALGORITHM STATUS
OVERRIDE
Motor Temp Override
SERVICE
EQUIPMENT SERVICE
SETUP1
Motor Winding Temp
SERVICE
CONTROL ALGORITHM STATUS
OVERRIDE
Occupied?
STATUS
MAINSTAT
Oil Heater Relay
STATUS
COMPRESS
Oil Pressure
Oil Pressure Verify Time
DEFAULT
SERVICE
EQUIPMENT SERVICE
SETUP1
Oil Pump Delta P
STATUS
COMPRESS
Oil Pump DeltaP
STATUS
STARTUP
Oil Pump Relay
STATUS
STARTUP
Oil Sump Temp
STATUS
COMPRESS
Oil Sump Temperature
Over/Under Volt Time
Overload Trip
X
X
DEFAULT
SERVICE
ISM CONFIGURATION DATA
STATUS
pswd —> ISM_CONF
X
ISM_STAT
Override Decrease Active
SERVICE
CONTROL ALGORITHM STATUS
SURGPREV
Override Inhibit Active
SERVICE
CONTROL ALGORITHM STATUS
SURGPREV
ISM CONFIGURATION DATA
pswd —> ISM_CONF
X
ICVC CONFIGURATION
X
Overvoltage
STATUS
Overvoltage Threshold
SERVICE
Password
SERVICE
Phase 1 Fault
Phase 1 Faulted?
Phase 2 Fault
Phase 2 Faulted?
Phase 3 Fault
Phase 3 Faulted?
ISM_STAT
STATUS
SERVICE
ISM_STAT
CONTROL ALGORITHM STATUS
STATUS
SERVICE
CONTROL ALGORITHM STATUS
STATUS
SERVICE
ISM_HIST
ISM_STAT
ISM_HIST
ISM_STAT
CONTROL ALGORITHM STATUS
ISM_HIST
Phase Loss
STATUS
ISM_STAT
Phase Reversal
STATUS
ISM_STAT
Power Factor
STATUS
POWER
Pressure Trip Contact
STATUS
ISM_STAT
Prestart FAULT Time
SERVICE
CONTROL ALGORITHM STATUS
LL_MAINT
PRESTART FAULT Timer
SERVICE
EQUIPMENT SERVICE
LEADLAG
Primary Message
X
DEFAULT
Proportional Dec Band
SERVICE
EQUIPMENT SERVICE
SETUP2
X
Proportional ECW Gain
SERVICE
EQUIPMENT SERVICE
SETUP2
X
Proportional Inc Band
SERVICE
EQUIPMENT SERVICE
SETUP2
X
Pull down DeltaT/Min.
SERVICE
CONTROL ALGORITHM STATUS
LL_MAINT
Pulldown Ramp Type
SERVICE
EQUIPMENT SERVICE
RAMP_DEM
Pulldown Satisfied?
SERVICE
CONTROL ALGORITHM STATUS
LL_MAINT
Pulldown Time
SERVICE
CONTROL ALGORITHM STATUS
LL_MAINT
PULLDOWN Timer
SERVICE
EQUIPMENT SERVICE
LEADLAG
Pump Down/Lockout
SERVICE
CONTROL TEST
PUMPDOWN LOCKOUT
172
X
X
APPENDIX A — ICVC PARAMETER INDEX (cont)
Pumps Test
MENU
SOFTKEY
SERVICE
CONTROL TEST
PUMPS
Ramp Loading Active
SERVICE
CONTROL ALGORITHM STATUS
SURGPREV
Re-Alarm Time
SERVICE
EQUIPMENT CONFIGURATION
NET_OPT
X
Recycle Restart Delta T
SERVICE
EQUIPMENT SERVICE
SETUP1
X
Recycle Shutdown Delta T
SERVICE
EQUIPMENT SERVICE
SETUP1
X
Reference Number
SERVICE
Refrig Override Delta T
SERVICE
EQUIPMENT SERVICE
SETUP1
X
Refrigerant Leak Alarm mA
SERVICE
EQUIPMENT SERVICE
OPTIONS
X
Refrigerant Leak Option
SERVICE
EQUIPMENT SERVICE
OPTIONS
X
Refrigerant Leak Sensor
STATUS
Remote Contacts Option
SERVICE
PARAMETER
TABLE
SCREEN NAME
ICVC CONFIGURATION
MAINSTAT
EQUIPMENT SERVICE
OPTIONS
Remote Reset Option
STATUS
ICVC_PSWD
Remote Reset Sensor
STATUS
MAINSTAT
Remote Start Contact
STATUS
X
MAINSTAT
Remote Temp —> Full Reset
SERVICE
EQUIPMENT SERVICE
RemoteTemp —> No Reset
SERVICE
EQUIPMENT SERVICE
Reset Alarm?
CONFIGURABLE
STATUS
TEMP_CTL
X
TEMP_CTL
X
ICVC_PSWD
Reset Type Select/Enable
SERVICE
EQUIPMENT SERVICE
TEMP_CTL
X
Restart Delta T
SERVICE
EQUIPMENT SERVICE
SETUP1
X
Run Status
Runtime Points for CCN Data
Collection
Schedule CCN Time
Schedule CCN Time
Schedule Holidays
STATUS
SERVICE
EQUIPMENT CONFIGURATION
RUNTIME
OCCPC03S
X
SERVICE
EQUIPMENT CONFIGURATION
OCCDEFCS
X
SERVICE
EQUIPMENT CONFIGURATION
HOLIDAYS
X
SCHEDULE
Schedule Ice Build Time
SCHEDULE
Schedule Ice Build Time
SERVICE
Schedule Local Time
MAINSTAT
X
OCCPC02S
X
EQUIPMENT CONFIGURATION
OCCDEFCS
X
OCCPC01S
X
Schedule Local Time
Schedule Number, CCN Occupancy
Configuration.
Secondary Message
SCHEDULE
SERVICE
EQUIPMENT CONFIGURATION
OCCDEFCS
X
SERVICE
EQUIPMENT CONFIGURATION
NET_OPT
X
Select/Enable Type Reset
SERVICE
Serial Number
SERVICE
Service Ontime
STATUS
MAINSTAT
Service Password, Disable
STATUS
ICVC_PSWD
DEFAULT
EQUIPMENT SERVICE
TEMP_CTL
X
ICVC CONFIGURATION
Shunt Trip Relay
STATUS
Shutdown Delta T
SERVICE
EQUIPMENT SERVICE
SETUP1
X
Single Cycle Dropout
SERVICE
ISM CONFIGURATION DATA
pswd —> ISM_CONF
X
Single Cycle Dropout
STATUS
Soft Stop Amps Threshold
SERVICE
Software Part Number
SERVICE
Spare Alarm/Alert Enable
SERVICE
Spare Safety Input
STARTUP
ISM_STAT
EQUIPMENT SERVICE
OPTIONS
X
ICVC CONFIGURATION
EQUIPMENT SERVICE
STATUS
SETUP1
X
STARTUP
Spare Temp #1 Alert/Alarm Enable
SERVICE
EQUIPMENT SERVICE
SETUP1
X
Spare Temp #1 Alert/Alarm Limit
SERVICE
EQUIPMENT SERVICE
SETUP1
X
Spare Temp #1 Enable
SERVICE
EQUIPMENT SERVICE
SETUP1
X
Spare Temp #1 Limit
SERVICE
EQUIPMENT SERVICE
SETUP1
X
Spare Temp #2 Alert/Alarm Enable
SERVICE
EQUIPMENT SERVICE
SETUP1
X
Spare Temp #2 Alert/Alarm Limit
SERVICE
EQUIPMENT SERVICE
SETUP1
X
Spare Temp #2 Enable
SERVICE
EQUIPMENT SERVICE
SETUP1
X
Spare Temp #2 Limit
SERVICE
EQUIPMENT SERVICE
SETUP1
X
Spare Temperature 1
SERVICE
CONTROL ALGORITHM STATUS
LL_MAINT
Spare Temperature 1
STATUS
COMPRESS
173
APPENDIX A — ICVC PARAMETER INDEX (cont)
Spare Temperature 2
MENU
SOFTKEY
SERVICE
Spare Temperature 2
STATUS
PARAMETER
TABLE
CONTROL ALGORITHM STATUS
SCREEN NAME
CONFIGURABLE
LL_MAINT
COMPRESS
Speed Change in Effect
SERVICE
CONTROL ALGORITHM STATUS
SURGPREV
SRD 25% Load (1)
SERVICE
EQUIPMENT SERVICE
VDO_SRD
X
SRD 50% Load (1)
SERVICE
EQUIPMENT SERVICE
VDO_SRD
X
SRD 75% Load (1)
SERVICE
EQUIPMENT SERVICE
VDO_SRD
X
SRD IGV Offset Select
SERVICE
EQUIPMENT SERVICE
VDO_SRD
X
SRD Rotating Stall
STATUS
VDO_STAT
SRD Stall Closure Timer
STATUS
STANDBY Chiller Option
SERVICE
EQUIPMENT SERVICE
VDO_STAT
LEADLAG
X
STANDBY % Capacity
SERVICE
EQUIPMENT SERVICE
LEADLAG
X
STANDBY Address
SERVICE
EQUIPMENT SERVICE
LEADLAG
X
STANDBY CHILLER Run Status
SERVICE
CONTROL ALGORITHM STATUS
LL_MAINT
STANDBY CHILLER Start/Stop
STANDBY CHILLER Recovery Start
Request
STANDBY CHILLER Mode
SERVICE
CONTROL ALGORITHM STATUS
LL_MAINT
SERVICE
CONTROL ALGORITHM STATUS
LL_MAINT
SERVICE
CONTROL ALGORITHM STATUS
LL_MAINT
STANDBY Chiller Option
SERVICE
EQUIPMENT SERVICE
LEADLAG
Start Inhibit Timer
STATUS
MAINSTAT
Starter Acceleration Fault
STATUS
ISM_STAT
Starter Fault
STATUS
ISM_STAT
Starter Fault
STATUS
Starter LRA Rating
Starter LRA Trip
Starter Trans Relay
Starter Type
Starts in 12 Hours
Startup Timer
SERVICE
STARTUP
ISM CONFIGURATION DATA
STATUS
pswd —> ISM_CONF
X
ISM_STAT
STATUS
SERVICE
X
STARTUP
ISM CONFIGURATION DATA
STATUS
pswd —> ISM_CONF
X
MAINSTAT
STATUS
VDO_STAT
Superheat Required
SERVICE
CONTROL ALGORITHM STATUS
OVERRIDE
Superheat, Actual
SERVICE
CONTROL ALGORITHM STATUS
OVERRIDE
Surge /HGBP Deadband
SERVICE
EQUIPMENT SERVICE
OPTIONS
X
Surge /HGBP DeltaP 1-4
SERVICE
EQUIPMENT SERVICE
OPTIONS
X
Surge /HGBP DeltaT 1-4
SERVICE
EQUIPMENT SERVICE
OPTIONS
X
Surge Counts
SERVICE
CONTROL ALGORITHM STATUS
SURGPREV
Surge Counts
STATUS
Surge Delta % Amps
SERVICE
Surge Delta % Amps
STATUS
VDO_STAT
EQUIPMENT SERVICE
OPTIONS
Surge Delta % Amps Min.
STATUS
Surge Limit/HGBP Option
SERVICE
CONTROL ALGORITHM STATUS
SURGPREV
Surge Limit/HGBP Option
SERVICE
EQUIPMENT SERVICE
OPTIONS
Surge Line Delta T
SERVICE
CONTROL ALGORITHM STATUS
SURGPREV
Surge Line delta T sat
SERVICE
CONTROL ALGORITHM STATUS
SURGPREV
Surge Line Delta Tsat
SERVICE
CONTROL ALGORITHM STATUS
SURGPREV
Surge Line Delta Tsat
STATUS
VPFSTAT
Surge Line DeltaT
STATUS
HEAT_EX
Surge Line DeltaTsat
VPFSTAT
STATUS
Surge Line High Offset
SERVICE
Surge Line High Offset
STATUS
Surge Line Shape Factor
SERVICE
Surge Line Shape Factor
STATUS
Surge Line Speed Factor
SERVICE
Surge Line Speed Factor
STATUS
Surge Prevention Active?
SERVICE
Surge Prevention Active?
STATUS
X
VPFSTAT
X
HEAT_EX
EQUIPMENT SERVICE
OPTIONS
X
VPFSTAT
EQUIPMENT SERVICE
OPTIONS
X
VPFSTAT
EQUIPMENT SERVICE
OPTIONS
VPFSTAT
CONTROL ALGORITHM STATUS
SURGPREV
HEAT_EX
174
X

APPENDIX A — ICVC PARAMETER INDEX (cont)
Surge Prevention Active?
MENU
SOFTKEY
STATUS
Surge Protection Counts
SERVICE
PARAMETER
Surge Protection Counts
TABLE
SCREEN NAME
CONTROL ALGORITHM STATUS
SURGPREV
CONFIGURABLE
VPFSTAT
STATUS
COMPRESS
Surge Time Period
SERVICE
EQUIPMENT SERVICE
OPTIONS
X
Surge Time Period
SERVICE
EQUIPMENT SERVICE
OPTIONS
X
Surge Time Period
STATUS
VPFSTAT
Surge/HGBP Delta P1
SERVICE
EQUIPMENT SERVICE
OPTIONS
X
Surge/HGBP Deadband
SERVICE
EQUIPMENT SERVICE
OPTIONS
X
Surge/HGBP Delta P2
SERVICE
EQUIPMENT SERVICE
OPTIONS
X
Surge/HGBP Delta P3
SERVICE
EQUIPMENT SERVICE
OPTIONS
X
Surge/HGBP Delta P4
SERVICE
EQUIPMENT SERVICE
OPTIONS
X
Surge/HGBP Delta T1
SERVICE
EQUIPMENT SERVICE
OPTIONS
X
Surge/HGBP Delta T2
SERVICE
EQUIPMENT SERVICE
OPTIONS
X
Surge/HGBP Delta T3
SERVICE
EQUIPMENT SERVICE
OPTIONS
X
Surge/HGBP Delta T4
SERVICE
EQUIPMENT SERVICE
OPTIONS
X
Surge/HGBP Delta Tsmax
STATUS
Surge/HGBP Delta Tsmin
STATUS
Surge/HGBP DeltaTsmax
SERVICE
EQUIPMENT SERVICE
OPTIONS
X
Surge/HGBP DeltaTsmin
SERVICE
EQUIPMENT SERVICE
OPTIONS
X
Surge/HGBP IGVmax
SERVICE
EQUIPMENT SERVICE
OPTIONS
X
EQUIPMENT SERVICE
OPTIONS
Surge/HGBP IGVmax
STATUS
Surge/HGBP IGVmin
SERVICE
Surge/HGBP IGVmin
STATUS
System Alert/Alarm
VPFSTAT
VPFSTAT
VPFSTAT
STATUS
MAINSTAT
Target Guide Vane Position
SERVICE
CONTROL ALGORITHM STATUS
CAPACITY
Target Guide Vane Position
SERVICE
CONTROL ALGORITHM STATUS
SURGPREV
Target Guide Vane Position
STATUS
COMPRESS
Target VFD Speed
SERVICE
CONTROL ALGORITHM STATUS
CAPACITY
Target VFD Speed
SERVICE
CONTROL ALGORITHM STATUS
SURGPREV
Target VFD Speed
STATUS
COMPRESS
Target VFD Speed
STATUS
VPFSTAT
Temp Pulldown Ramp
SERVICE
EQUIPMENT SERVICE
TEMP_CTL
Temperature Reset
STATUS
Terminate Lockout
SERVICE
CONTROL TEST
Test CCM Pressure Transducers
SERVICE
CONTROL TEST
Test CCM Thermistors
SERVICE
CONTROL TEST
TERMINATE LOCKOUT
CCM PRESS
TRANSDUCERS
CCM THERMISTORS
Test Diffuser Actuator
SERVICE
CONTROL TEST
DIFFUSER ACTUATOR
Test Discrete Outputs
SERVICE
CONTROL TEST
DISCRETE OUTPUTS
Test Head Pressure Output
SERVICE
CONTROL TEST
HEAD PRESSURE OUTPUT
Test IGV & SRD Actuators
SERVICE
CONTROL TEST
IGV & SRD ACTUATOR
Test Pumps
SERVICE
CONTROL TEST
PUMPS
Thrust Brg Alert
SERVICE
EQUIPMENT SERVICE
SETUP1
Thrust Brg Reset
STATUS
Thrust Brg Reset Factor
Thrust Brg Temp
SERVICE
EQUIPMENT SERVICE
STATUS
SETUP1
X
COMPRESS
EQUIPMENT SERVICE
SETUP1
Thrust Lvg Oil Temp
SERVICE
CONTROL ALGORITHM STATUS
OVERRIDE
STATUS
X
COMPRESS
SERVICE
TIME AND DATE
Time Broadcast Enable
SERVICE
EQUIPMENT CONFIGURATION
Total Compressor Starts
STATUS
Time & Date Display
Total Error + Resets
X
COMPRESS
SERVICE
Time & Date Configure
X
MAINSTAT
Thrust Brg Trip
Thrust Lvg Oil Temp
X
VPFSTAT
X
DEFAULT
SERVICE
BRODEF
X
MAINSTAT
CONTROL ALGORITHM STATUS
175
CAPACITY
312
APPENDIX A — ICVC PARAMETER INDEX (cont)
PARAMETER
Tower Fan High Setpoint
Tower Fan Relay High
Tower Fan Relay Low
Tower High Fan Setpoint
Undervoltage
MENU
SOFTKEY
SETPOINT
TABLE
SCREEN NAME
X
STATUS
STARTUP
STATUS
STARTUP
SETPOINT
X
STATUS
Undervoltage Threshold
SERVICE
US Imp / Metric
SERVICE
VFD Current Limit
SERVICE
VFD Gain
CONFIGURABLE
ISM_STAT
ISM CONFIGURATION DATA
pswd —> ISM_CONF
X
ICVC CONFIGURATION
X
EQUIPMENT SERVICE
SETUP2
X
SERVICE
CONTROL ALGORITHM STATUS
CAPACITY
VFD Gain
SERVICE
EQUIPMENT SERVICE
SETUP2
X
VFD Increase Step
SERVICE
EQUIPMENT SERVICE
SETUP2
X
VFD Load Factor
SERVICE
CONTROL ALGORITHM STATUS
CAPACITY
VFD Load Factor
SERVICE
CONTROL ALGORITHM STATUS
SURGPREV
VFD Maximum Speed
SERVICE
EQUIPMENT SERVICE
SETUP2
X
VFD Minimum Speed
SERVICE
EQUIPMENT SERVICE
SETUP2
X
VFD Option
SERVICE
EQUIPMENT SERVICE
SETUP2
X
VFD Rampdown Active
SERVICE
CONTROL ALGORITHM STATUS
SURGPREV
VFD Speed Factor
SERVICE
CONTROL ALGORITHM STATUS
SURGPREV
VFD Speed, Actual
SERVICE
CONTROL ALGORITHM STATUS
VFD Speed, Actual
STATUS
CAPACITY
COMPRESS
VFD Start Speed
SERVICE
EQUIPMENT SERVICE
SETUP2
VFD Surge Line Gain
SERVICE
EQUIPMENT SERVICE
SETUP2
X
Volt Transformer Ratio:1
SERVICE
ISM CONFIGURATION DATA
pswd —> ISM_CONF
X
Voltage % Imbalance
SERVICE
ISM CONFIGURATION DATA
pswd —> ISM_CONF
X
Voltage Imbalance
STATUS
Voltage Imbalance Time
SERVICE
Water Flow Verify Time
SERVICE
WSM Active?
SERVICE
X
ISM_STAT
ISM CONFIGURATION DATA
pswd —> ISM_CONF
X
EQUIPMENT SERVICE
SETUP1
X
CONTROL ALGORITHM STATUS
WSMDEFME
176
19XR Lead Lag Schematic Series Cooler Flow
APPENDIX B — LEAD/LAG WIRING
a19-1655
177
19XR Lead Lag Schematic Parallel Cooler Flow
APPENDIX B — LEAD/LAG WIRING (cont)
a19-1717
178
APPENDIX C — MAINTENANCE SUMMARY AND LOG SHEETS
19XR,XRV 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
None.
Perform an Automated Controls test.
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.
179
312
APPENDIX C — MAINTENANCE SUMMARY AND LOG SHEETS
19XR,XRV Monthly Maintenance Log
Month
Date
Operator
UNIT SECTION
Compressor
Cooler
180
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 and 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
UNIT
yes/no
yes/no
yes/no
ppm
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.
2
/ /
3
/ /
4
/ /
5
/ /
6
/ /
ENTRY
7
/ /
8
/ /
9
/ /
10
/ /
11
/ /
12
/ /
APPENDIX C — MAINTENANCE SUMMARY AND LOG SHEETS
19XR,XRV Seasonal Shutdown Log
Month
Date
Operator
UNIT SECTION
Cooler
Condenser
Controls
1
/ /
2
/ /
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.
3
/ /
4
/ /
5
/ /
6
/ /
ENTRY
7
/ /
8
/ /
9
/ /
10
/ /
11
/ /
12
/ /
181
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).
182
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 terminals labeled Gnd and HOT. The controller reads the DIP
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
DS8
Off
DS7
Off
DS6
Off
DS5
Off
DS4
On
Wire the controllers on an MS/TP network segment in a daisy-chain configuration. Wire specifications for the cable are 22
AWG (American Wire Gage) or 24 AWG, low-capacitance,
twisted, stranded, shielded copper wire. The maximum length
is 2000 ft.
Install a BT485 terminator on the first and last controller on
a network segment to add bias and prevent signal distortions
due to echoing. See Fig. A, D, and E.
To wire the UPC Open controller to the BAS network:
1. Pull the screw terminal connector from the controller's
BAS Port.
2. Check the communications wiring for shorts and
grounds.
3. Connect the communications wiring to the BAS port’s
screw terminals labeled Net +, Net -, and Shield.
NOTE: Use the same polarity throughout the network
segment.
4. Insert the power screw terminal connector into the UPC
Open controller's power terminals if they are not currently connected.
5. Verify communication with the network by viewing a
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.
DS3
Off
Verify that the EIA-485 jumpers below the CCN Port are set
to EIA-485 and 2W.
The example in Fig. C shows the BAS Port DIP Switches
set for 76.8k (Carrier default) and MS/TP.
Set the BAS Port DIP Switches DS2 and DS1 for the appropriate communications speed of the MS/TP network (9600,
19.2k, 38.4k, or 76.8k bps). See Fig. C and Table B.
Table B — Baud Selection Table
BAUD RATE
9,600
19,200
38,400
76,800
DS2
Off
On
Off
On
A488580
DS1
Off
Off
On
On
WIRING THE UPC OPEN CONTROLLER TO THE MS/
TP NETWORK — The UPC Open controller communicates
using BACnet on an MS/TP network segment communications
at 9600 bps, 19.2 kbps, 38.4 kbps, or 76.8 kbps.
A48-8581
Fig. D — Network Wiring
183
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
184
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
Contractors
Connect Air
Belden RMCORP
Wire and Cable
International
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
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.
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.
A48-8583
Fig. F — BACview6 Device Connection
185
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
186
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
LCW
R
LCDW
AMPS_ACT
VOLT_ACT
LINEFREQ
LINE_PF
N/A
OCC
OILT
REM_CON
R
R
R
R
R
R
R
R
R/W
STATUS
R
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
RAT
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
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
RANGE
BV:1
element_alarm_1
N/A
N/A
ENABLE/
EMSTOP
-40 to 245
-40 to 245
Comm Normal
Comm Lost
-6.7 to 420
-40 to 245
AV:28
AV:13
erp_1
ert_1
°F
N/A
-40 to 245
AV:31
lcw_1
°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
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
N/A
N/A
-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:35
status_1
LEGEND
— Chilled Water
— Read
— Return Air Temperature
— Variable Frequency Drive
— Write
187
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
RAT
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
— Return Air Temperature
— Variable Frequency Drive
— Write
188
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, 5
Accidental Start-Up (Prevent), 89
Adding Refrigerant, 95
Adjusting the Refrigerant Charge, 95
After Extended Shutdown, 90
After Limited Shutdown, 90
Alarm (Trip) Output Contacts, 51
Attach to Network Device Control, 60
Automatic Soft Stop Amps Threshold, 64
Auto. Restart After Power Failure, 52
Bearings, 9
Before Initial Start-Up, 65
Capacity Override, 49
Carrier Comfort Network Interface, 70
Changing Oil Filter, 97
Charge Refrigerant Into Chiller, 84
Chilled Water Recycle Mode, 64
Chiller Control Module (CCM), 118
Chiller Dehydration, 69
Chiller Familiarization, 5
Chiller Information Nameplate, 5
Chiller Operating Condition (Check), 89
Chiller Tightness (Check), 65
Chillers with Isolation Valves, 93
Chillers with Storage Tanks, 92
Cold Weather Operation, 90
Compressor Bearing and Gear
Maintenance, 98
Compressor Bearing Temperature, 49
Condenser, 5
Condenser Freeze Prevention, 52
Condenser Pump Control, 51
Control Algorithms Checkout Procedure, 117
Control Panel, 5
Control Modules, 117
Control Test, 82, 117
Controls, 11
Cooler, 5
Default Screen Freeze, 48
Definitions (Controls), 11
Demand Limit Control Option, 53
Design Set Points, (Input), 71
Display Messages (Check), 100
Dry Run to Test Start-Up Sequence, 88
Equipment Required, 65
Evaporator Freeze Protection, 52
Extended Shutdown (Preparation for), 90
Factory-Mounted Starter or Variable
Frequency Drive, 5
Function Loss Trip, 45
Guide Vane Linkage (Check), 95
Head Pressure Reference Output, 56
Heat Exchanger Tubes and Flow Devices
(Inspect), 98
High Altitude Locations, 84
High Discharge Temperature Control, 49
Hot Gas bypass Algorithm, 54
Ice Build Control, 59
ICVC Operation and Menus, 17
ICVC Parameter Index, 166
Initial Start-Up, 88
Initial Start-Up Checklist for 19XR,XRV
Hermetic Centrifugal Liquid Chiller, CL-1
Inspect the Control Panel, 96
Instruct the Customer Operator, 89
Integrated Starter Module (ISM), 118
Introduction, 4
Job Data Required, 65
Kilowatt Output, 51
Lead/Lag Control, 56
Lead/Lag Wiring, 177
Leak Rate, 95
Leak Test Chiller, 65
Local Occupied Schedule (Input), 71
Local Start-Up, 62
Lubrication Cycle, 8
Lubrication System (Check), 96
Maintenance, 95
Maintenance Summary and Log Sheets, 179
Manual Guide Vane Operation, 90
Motor and Oil Cooling Cycle, 8
Motor-Compressor, 5
Motor Rotation (Check), 88
Notes on Module Operation, 118
Oil Changes, 97
Oil Charge, 71
Oil Cooler, 51
Oil Pressure and Compressor Stop
(Check), 88
Oil Reclaim Filter, 97
Oil Reclaim System, 9
Oil Specification, 97
Oil Sump Temperature and Pump Control, 49
Open Oil Circuit Valves, 65
Operating Instructions, 89
Operating the Optional Pumpout Unit, 92
Operator Duties, 89
Optional BACnet Communications
Wiring, 182
Optional Pumpout Compressor Water
Piping (Check), 69
Optional Pumpout System Controls and
Compressor (Check), 84
Optional Pumpout System Maintenance, 99
Optional Storage Tank and Pumpout
System, 65
Ordering Replacement Chiller Parts, 99
Overview (Troubleshooting Guide), 99
Physical Data, 121
PIC II System Components, 14
PIC II System Functions, 40
Power Up the Controls and Check the Oil
Heater, 71
Prepare the Chiller for Start-Up, 89
Pressure Transducers (Check), 100
Pressure Transducers (Recalibrate), 99
Prevent Accidental Start-Up, 89
Pump and Fan Control, 45
Pumpout and Refrigerant Transfer
Procedures, 90
Rampdown, 49
Ramp Loading, 49
Refrigerant Filter, 97
Refrigerant Float System (Inspect), 97
Refrigerant Leak Detector, 51
Refrigerant Leak Testing, 95
Refrigerant Properties, 95
Refrigerant (Removing), 95
Refrigerant Tracer, 65
Refrigeration Cycle, 5
Refrigeration Log, 90
Relief Valves (Check), 69
Relief Valves and Piping (Inspect), 97
Remote Reset of Alarms, 51
Remote Start/Stop Controls, 51
Repair the Leak, Retest, and
Apply Standing Vacuum Test, 95
Replacing Defective Processor Modules, 120
Running System (Check), 89
Safety and Operating Controls (Check
Monthly), 97
Safety Considerations, 1
Safety Controls, 45
Safety Shutdown, 64
Scheduled Maintenance, 96
Service Configurations (Input), 72
Service Ontime, 96
Service Operation, 61
189
Shipping Packaging (Remove), 65
Shunt Trip (Option), 45
Shutdown Sequence, 64
Software Configuration, 71
Solid-State Starters, 120
Spare Safety Inputs and Spare Temperature
Inputs, 51
Standing Vacuum Test, 69
Starter (Check), 70
Starting Equipment, 9
Starting Equipment (Inspect), 98
Start-Up (Initial), 88
Start-Up/Shutdown/Recycle Sequence, 62
Start the Chiller, 89
Stop the Chiller, 90
Storage Vessel, 5
Surge Prevention Algorithm with VFD, 55
Surge Prevention - Constant Flow and
Variable Primary Flow (VPF), 53
Surge Protection (Fixed Speed Chillers), 55
Surge Protection (VFD Chiller), 56
System Components, 5
Temperature Sensors (Check), 100
Test After Service, Repair, or Major Leak, 95
Tighten All Gasketed Joints and Guide Vane
Shaft Packing, 65
Tower Fan Relay Low and High, 52
Trim Refrigerant Charge, 96
Troubleshooting Guide, 99
Unit-Mounted Solid-State Starter, 11
Unit-Mounted VFD, 11
Unit-Mounted Wye-Delta Starter, 11
VFD Cooling Cycle, 8
VFD Field Set Up and Verification, 74
VFD Start-Up Speed Control, 56
Water/Brine Reset, 52
Water Leaks, 98
Water Piping (Inspect), 69
Water Treatment, 98
Weekly Maintenance, 96
Wiring (Inspect), 70
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. 04-53190010-01
Printed in U.S.A.
Form 19XR-6SS
Pg 190
312
7-11
Replaces: 19XR-5SS
INITIAL START-UP CHECKLIST
FOR 19XR, XRV 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
BRINE
FLOW
RATE
TEMPERATURE
IN
TEMPERATURE PRESSURE
OUT
DROP
PASS
SUCTION
TEMPERATURE
COOLER
CONDENSER
COMPRESSOR:
STARTER:
OIL PUMP:
CONDENSER
TEMPERATURE
******
******
Volts
Mfg
Volts
RLA
Type
RLA
115
OLTA
S/N
OLTA
230
CONTROL/OIL HEATER:
REFRIGERANT: Type:
Volts
CARRIER OBLIGATIONS:
Assemble... . . . . . . . . . . . . . . . .
Leak Test . . . . . . . . . . . . . . . . . . .
Dehydrate . . . . . . . . . . . . . . . . . .
Charging . . . . . . . . . . . . . . . . . . .
Operating Instructions
Charge
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
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. 04-53190010-01
Printed in U.S.A.
Form 19XR-6SS
Pg CL-1
312
7-11
Replaces: 19XR-5SS
Motor Voltage
Line Voltages:
Motor(s) Amps
Motor
Oil Pump Voltage
Oil Pump
Starter LRA Rating
Controls/Oil Heater
CONTROLS: SAFETY, OPERATING, ETC.
Perform Controls Test (Yes/No)
PIC II CAUTION
COMPRESSOR MOTOR AND CONTROL PANEL MUST BE PROPERLY AND INDIVIDUALLY Yes
CONNECTED BACK TO THE EARTH GROUND IN THE STARTER (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?
Yes 
Yes 
Yes 
Condenser Water Flow
Chilled Water Flow
Pump Interlocks
No 
No 
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 section.
B: Complete any remaining control calibration and record under Controls section.
C: For unit mounted VFD complete page CL-14.
D: Take at least two sets of operational log readings and record.
E: After machine has been successfully run and set up, shut down and mark shutdown oil and refrigerant levels.
F: Give operating instructions to owner’s operating personnel.
Hours Given:
Hours
G: Call your Carrier factory representative to report chiller start-up.
SIGNATURES:
CARRIER
TECHNICIAN
CUSTOMER
REPRESENTATIVE
DATE
DATE
CL-2
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -- - - - - - - - - - - - - - - - - - - CUT ALONG DOTTED LINE
CUT ALONG DOTTED LINE
INSPECT WIRING AND RECORD ELECTRICAL DATA:
RATINGS:
19XR, XRV PIC II 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
-9.4 to 48.9
15 to 120
-12.2 to 48.9
15 to 60
-9.4 to 15.6
55 to 105
13 to 41
UNITS
%
DEG F
DEG C
DEG F
DEG C
DEG F
DEG C
DEG F
DEG C
ICVC Software Version Number:
ICVC Controller Identification: BUS:
ADDRESS:
CL-3
DEFAULT
100
50.0
10.0
60.0
15.6
40.0
4.4
75
24
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 19XR, XRV PIC II 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.
19XR, XRV PIC II 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
19XR, XRV PIC II TIME SCHEDULE CONFIGURATION SHEET OCCPC01S
19XR, XRV PIC II ISM_CONF TABLE CONFIGURATION SHEET
DESCRIPTION
Starter Type*
(0=Full, 1=Red, 2=SS/VFD, 3=VFD)
Motor Rated Line Voltage
Volt Transformer Ratio: 1
Overvoltage Threshold
Undervoltage Threshold
Over/Under Volt Time
Voltage% Imbalance
Voltage Imbalance Time
Motor Rated Load Amps
Motor Locked Rotor Trip
Locked Rotor Start Delay
Starter LRA Rating
Motor Current CT Ratio: 1
Current% Imbalance
Current Imbalance Time
Grnd Fault CT’s?
Ground Fault CT Ratio: 1
Ground Fault Current
Ground Fault Start Delay
Ground Fault Persistence
Single Cycle Dropout
Frequency-60 Hz? (No=50)
Line Frequency Faulting
RANGE
UNITS
0 to 3
DEFAULT
VALUE
1
200 to 13200
1 to 115
105 to 115
85 to 95
1 to 10
1 to 10
1 to 10
10 to 5000
100 to 60000
1 to 10
100 to 60000
10 to 1000
5 to 100
1 to 10
0/1
150
1 to 25
1 to 20
1 to 10
0/1
0/1
0/1
VOLTS
%
%
SEC
%
SEC
AMPS
AMPS
cycles
AMPS
%
SEC
NO/YES
AMPS
cycles
cycles
DSABLE/ENABLE
NO/YES
DSABLE/ENABLE
460
1
115
85
5
10
5
200
1000
5
2000
100
15
5
YES
150
15
10
5
DSABLE
YES
DSABLE
* Option 3 for VFD is available on software version 9 or higher. All
other software versions use Option 2 for VFD.
19XR, XRV PIC II OPTIONS TABLE CONFIGURATION SHEET — MACHINES WITH SERIAL NUMBERS PRIOR TO
1410QXXXXX
DESCRIPTION
Auto Restart Option
Remote Contacts Option
Soft Stop Amps Threshold
RANGE
0/1
0/1
40 to 100
Surge/Hot Gas Bypass
Surge Limit/HGBP Option
Select: Surge=0, HGBP=1
Min. Load Point (T1, P1)
0/1
Surge/HGBP Delta T1
Surge/HGBP Delta P1
UNITS
DSABLE/ENABLE
DSABLE/ENABLE
%
DEFAULT
DSABLE
DSABLE
100
0
0.5 to 20
0.3 to 11.1
30 to 170
207 to 1172
ˆF
ˆC
PSI
kPa
1.5
0.83
50
344
0.5 to 20
0.3 to 11.1
30 to 170
207 to 1172
ˆF
ˆC
PSI
kPa
10
5.5
85
586
Low Load Point (T2, P2)
Surge/HGBP Delta T2
Surge/HGBP Delta P2
CL-5
VALUE
DESCRIPTION
Mid Load Point (T3, P3)
Surge/HGBP Delta T3
Surge/HGBP Delta P3
RANGE
UNITS
DEFAULT
0.5 to 20
0.3 to 11.1
50 to 170
207 to 1172
ˆF
ˆC
PSI
kPa
10
5.5
85
586
0.5 to 20
0.3 to 11.1
50 to 170
207 to 1172
0.5 to 3
0.3 to 1.7
ˆF
ˆC
PSI
kPa
ˆF
ˆC
10
5.5
85
586
1.0
0.6
0.5 to 10.0
0.3 to 5.6
1.0 to 10.0
0.6 to 5.6
ˆF
ˆC
ˆF
ˆC
2
1.1
4
2.2
5 to 20
7 to 10
%
MIN
10
8
0/1
DSABLE/ENABLE
DSABLE
Full Load Point (T4, P4)
Surge/HGBP Delta T4
Surge/HGBP Delta P4
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
0 to 2
0
0/1
DSABLE/ENABLE
DSABLE
0/1
4 to 20
DSABLE/ENABLE
mA
DSABLE
20
PSI
kPa
PSI
kPa
%
25
172
35
345
0
Head Pressure Reference
Delta P at 0% (4 mA)
Delta P at 100% (20 mA)
Minimum Output
20 to 85
138 to 586
20 to 85
138 to 586
0 to 100
CL-6
VALUE
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -- - - - - - - - - - - - - - - - - - - CUT ALONG DOTTED LINE
CUT ALONG DOTTED LINE
19XR, XRV PIC II OPTIONS TABLE CONFIGURATION SHEET — MACHINES WITH SERIAL NUMBERS PRIOR TO
1410QXXXXX (cont)
19XR, XRV PIC II OPTIONS TABLE CONFIGURATION SHEET — MACHINES WITH SERIAL NUMBERS
1410QXXXXX AND LATER OR VERSION 9 OR LATER SOFTWARE
DESCRIPTION
Auto Restart Option
Remote Contacts Option
Soft Stop Amps Threshold
Surge / Hot Gas Bypass
Surge Limit/HGBP Option
Select: Surge=0, HGBP=1
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
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
0.6
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
35
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
NOTE: No variables are available for CCN read or write operation.
CL-7
VALUE
DESCRIPTION
Diffuser Control
Diffuser Option
Diffuser Full Span mA
Guide Vane 25% Load (2)
Guide Vane 50% Load (2)
Guide Vane 75% Load (2)
SRD 25% Load (1)
SRD 50% Load (1)
SRD 75% Load (1)
Lift @ 25% Load (1)
Lift @ 100% Load (1)
Lift @ 25% Load (2)
SRD IGV Offset Select
Low Lift Profile Select
RANGE
0/1
15 to 22
0 to 83
0 to 83
0 to 83
0 to 100
0 to 100
0 to 100
0 to 100
0 to 55.6
0 to 100
0 to 55.6
0 to 100
0 to 55.6
1 to 5
1 to 5
UNITS
DEFAULT
0
18.0
6.4
22.9
41.3
73.5
35.1
19.5
52.4
29.1
67.5
37.5
27.2
15.1
3
3
mA
%
%
%
%
%
%
^F
^C
^F
^C
^F
^C
NOTE: No variables are available for CCN read or write operation.
CL-8
VALUE
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -- - - - - - - - - - - - - - - - - - - CUT ALONG DOTTED LINE
CUT ALONG DOTTED LINE
19XR, XRV PIC II VDO SRD TABLE CONFIGURATION SHEET — MACHINES WITH SERIAL NUMBERS
10XXQXXXXX AND LATER OR VERSION 10 OR LATER SOFTWARE.
19XR, XRV PIC II SETUP1 TABLE CONFIGURATION SHEET
DESCRIPTION
Comp Motor Temp Override
Cond Press 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 Alarm Option
Cond Hi Flow Del P Limit
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
125 to 200
52 to 93
10 to 20
6 to 11
160 to 185
71 to 85
1.0 to 3.0
0/1
0.5 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
1.1 to 2.8
0.5 to 15
0.3 to 8.3
–20 to 35
-28.9 to 1.7
0/1
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 50.0
3.4 to 344.8
0.5 to 5
15 to 300
2.0 to 10.0
1.1 to 5.6
0.5 to 4.0
0.3 to 2.2
UNITS
DEG F
DEG C
PSI
kPa
DEG F
DEG C
ˆF
ˆC
DEG F
DEG C
WATER/BRINE
ˆF
ˆC
DEG F
DEG C
ˆF
ˆC
ˆF
ˆC
ˆF
ˆC
DEG F
DEG C
DSABLE/ENABLE
ˆPSI
ˆkPa
ˆPSI
ˆkPa
DSABLE/ENABLE
PSI
kPa
MIN
SEC
ˆF
ˆC
ˆF
ˆC
DEFAULT
200
93
125
862
200
93
10
6
185
85
1.4
VALUE
WATER
1.0
0.6
33
0.6
3
1.7
5
2.8
6
3.3
34
1.1
DSABLE
5.0
34.5
5.0
34.5
DSABLE
50.0
344.8
5
40
5
2.8
1
0.6
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
CL-9
0
245
118
0
245
118
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
50
0
18
VFD Speed Control
VFD Option
VFD Gain
VFD Increase Step
VFD Minimum Speed
VFD Maximum Speed
VFD Start Speed
VFD Surge Line Gain
VFD Current Limit
0/1
0.1 to 1.5
1 to 5
65 to 100
90 to 100
65 to 100
2.0 to 3.5
0 to 99999
DSABLE/ENABLE
DSABLE
0.75
2
70
100
100
2.0
250
6.5
6.0
2.0
%
%
%
%
Amp
* The diffuser control points are not used on machines with variable
diffuser optimization (VDO).
CL-10
VALUE
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -- - - - - - - - - - - - - - - - - - - CUT ALONG DOTTED LINE
CUT ALONG DOTTED LINE
19XR, XRV PIC II SETUP2 TABLE CONFIGURATION SHEET
19XR, XRV PIC II 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-11
DSABLE
DSABLE
50
92
10
10
5
2
DSABLE
50
93
VALUE
DESCRIPTION
Pulldown Ramp Type:
Select: Temp=0, Load=1
Demand Limit + kW Ramp
Demand Limit Source
Select: Amps=0, kW=1
Motor Load Ramp% Min
Demand Limit Prop Band
Demand Limit At 20 mA
20 mA Demand Limit Opt
Motor Rated Kilowatts
Demand Watts Interval
RANGE
UNITS
DEFAULT
0/1
1
0/1
0
5 to 20
3 to 15
40 to 100
0/1
50 to 9999
5 to 60
%
%
DSABLE/ENABLE
kW
MIN
VALUE
10
10
40
DSABLE
145
15
19XR, XRV PIC II TEMP_CTL TABLE CONFIGURATION SHEET
DESCRIPTION
Control Point
ECW Control Option
Temp Pulldown Deg/Min
RANGE
UNITS
DEFAULT
0/1
2 to 10
0.6 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
0 to 15
0 to 8
0 to 15
0 to 8
–30 to 30
–17 to 17
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
CHW Delta T -> Full Reset
Degrees Reset
Select/Enable Reset Type
0 to 3
0
CL-12
VALUE
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -- - - - - - - - - - - - - - - - - - - CUT ALONG DOTTED LINE
CUT ALONG DOTTED LINE
19XR, XRV PIC II 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-13
DEFAULT
DSABLE
4
7
3
02:00
60
10
7
3
02:00
60
VALUE
DESCRIPTION
Maximum Speed
Speed Display Scaling
Motor Voltage
Frequency
Motor Amps
Line Voltage
Over Frequency Limit
PARAMETER
P.004
P.028
H.000
H.001
H.002
H.021
H.022
RANGE
DEFAULT
COMMENTS
15 to H.022
*
Job Sheet; 60 for 60 Hz
10 to 999
*
Job Sheet; 60 for 60 Hz
100 to 690
*
Selected line voltage
30 to 200
*
60 for 60 Hz
Power Module Dependent
*
Selected motor 100% amps
300 to 565
*
Selected line voltage
30 to 210
*
60 for 60 Hz
*Variable by job — refer to component nameplates and labels.
CL-14
VALUE
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -- - - - - - - - - - - - - - - - - - - CUT ALONG DOTTED LINE
CUT ALONG DOTTED LINE
UNIT-MOUNTED VFD CONFIGURATION SHEET
ICVC DISPLAY AND ALARM SHUTDOWN STATE RECORD SHEET
PRIMARY MESSAGE:
DATE:
SECONDARY MESSAGE:
COMPRESSOR ONTIME:
TIME:
CHW IN
CHW OUT
EVAP REF
CDW IN
CDW OUT
COND REF
OILPRESS
OIL TEMP
AMPS %
COMMUNICATION MESSAGE
CCN
LOCAL
RESET
CL-15
MENU
PRIMARY MESSAGE:
DATE:
SECONDARY MESSAGE:
COMPRESSOR ONTIME:
TIME:
CHW IN
CHW OUT
EVAP REF
CDW IN
CDW OUT
COND REF
OILPRESS
OIL TEMP
AMPS %
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. 04-53190010-01
Printed in U.S.A.
Form 19XR-6SS
Pg CL-16
312
7-11
Replaces: 19XR-5SS
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -- - - - - - - - - - - - - - - - - - - CUT ALONG DOTTED LINE
CUT ALONG DOTTED LINE
ICVC DISPLAY AND ALARM SHUTDOWN STATE RECORD SHEET
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