EVERGREEN® 19XRV Hermetic Centrifugal Liquid Chillers with PIC III Controls and HFC-134a 50/60 Hz Start-Up, Operation, and Maintenance Instructions SAFETY CONSIDERATIONS Centrifugal liquid chillers are designed to provide safe and reliable service when operated within design specifications. When operating this equipment, use good judgment and safety precautions to avoid damage to equipment and property or injury to personnel.
CONTENTS Page High Discharge Temperature Control . . . . . . . . . . . . 46 Compressor Bearing Temperature. . . . . . . . . . . . . . . 46 Oil Sump Temperature and Pump Control . . . . . . . 46 Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Remote Start/Stop Controls . . . . . . . . . . . . . . . . . . . . . 47 Spare Safety and Spare Temperature Inputs. . . . . 47 Alarm (Trip) Output Contacts . . . . . . . . . . . . . . . . . . . . 47 Kilowatt Output. . . . . . .
CONTENTS (cont) Page REVIEW MAINTENANCE SAFETY DEVICES AND PROCEDURES CHECK OPERATOR KNOWLEDGE REVIEW THE START-UP, OPERATION, AND MAINTENANCE MANUAL OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . 78-80 Operator Duties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Prepare the Chiller for Start-Up . . . . . . . . . . . . . . . . . 78 To Start the Chiller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Check the Running System . . . . . . . . . . . . . . . . . .
CONTENTS (cont) CAUTION Page Optional Pumpout System Maintenance . . . . . . . . . 88 • OPTIONAL PUMPOUT COMPRESSOR OIL CHARGE • OPTIONAL PUMPOUT SAFETY CONTROL SETTINGS Ordering Replacement Chiller Parts . . . . . . . . . . . . . 88 TROUBLESHOOTING GUIDE . . . . . . . . . . . . . . . . 89-154 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 Checking Display Messages. . . . . . . . . . . . . . . . . . . . . 89 Checking Temperature Sensors . . . . . . . . . . . . .
Factory-installed additional components are referred to as options in this manual; factory-supplied but field-installed additional components are referred to as accessories. The chiller software part number of the 19XRV unit is located on the back of the ICVC. 19XRV 52 51 CHILLER FAMILIARIZATION (Fig. 1 and 2) Chiller Information Nameplate — The information nameplate is located on the right side of the chiller control panel.
• shows the chiller operating condition and the alarm shutdown conditions • records the total chiller operating hours • sequences chiller start, stop, and recycle under microprocessor control • displays the status of the VFD • provides access to other CCN (Carrier Comfort Network®) devices and energy management systems • languages pre-installed at factory include: English, Chinese, Japanese, and Korean. • International Language Translator (ILT) is available for conversion of extended ASCII characters.
FRONT VIEW 1 13 14 15 16 17 18 19 — — — — — — — LEGEND Guide Vane Actuator Split Ring Diffuser Actuator (Optional) Suction Elbow International Chiller Visual Control (ICVC) Chiller Identification Nameplate Cooler, Auto Reset Relief Valves Cooler Pressure Transducer Condenser In/Out Temperature Thermistors Condenser Waterflow Device (Optional ICVC Inputs available) Cooler Waterflow Device (Optional ICVC Inputs available) Cooler In/Out Temperature Thermistors Evaporator Saturation Temperature Sensor (Hidde
REFRIGERATION CYCLE MOTOR AND LUBRICATING OIL COOLING CYCLE The compressor continuously draws refrigerant vapor from the cooler at a rate set by the amount of guide vane opening or compressor speed. As the compressor suction reduces the pressure in the cooler, the remaining refrigerant boils at a fairly low temperature (typically 38 to 42 F [3 to 6 C]). The energy required for boiling is obtained from the water flowing through the cooler tubes.
can also be energized for testing purposes during a Control Test. Ramp loading can slow the rate of guide vane opening to minimize oil foaming at start-up. If the guide vanes open quickly, the sudden drop in suction pressure can cause any refrigerant in the oil to flash. The resulting oil foam cannot be pumped efficiently; therefore, oil pressure falls off and lubrication is poor. If oil pressure falls below 15 psid (103 kPad) differential, the PIC III will shut down the compressor.
REAR MOTOR BEARING FWD MOTOR BEARING OIL SUPPLY TO FORWARD HIGH SPEED BEARING LABYRINTH GAS LINE MOTOR COOLING LINE OIL FILTER FLOW SIGHT GLASS ISOLATION VALVE TXV BULB PRESSURE TRANSDUCER OIL PUMP ISOLATION VALVES OIL COOLER OIL PUMP MOTOR FILTER STRAINER OIL HEATER EDUCTOR FILTER SIGHT GLASS ISOLATION VALVE OIL SKIMMER LINE a19-1965 Fig. 4 — Lubrication System Circuit breaker CB2 supplies 115-v power to the oil pump control panel, oil heater, and portions of the VFD controls.
OPTIONAL METER PACKAGE a19-1718 442A AND 608A VFDs a19-1725 900A AND 1200A VFDs Fig.
1, 2 3 4 6 5 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Fuse Block, 30A, 600V, Class CC Fuse, Class CC, 600V, 20A (3) AC Contactor (3) — Pre-Charge Input Conductor Assembly Pre-Charge Resistor Assembly Power Module Assembly Power Module Namplate Terminal Block, 10-Position (2) Line Sync Board Cover Line Sync PC Board Assembly Fuse, Class CC, 600V, 1A (3) Capacitor Bank Assembly Fan, 115V (3) Fuse, Class CC, 600V, 5A (1) Fuse, Class CC, 600V, 20A (1) Circuit Breaker, Control Power, 600V, 15A 17 — Transform
1 2 5 3 4 6 7 8 25 9 10 11 6 7 3 8 12 10 4 11 8 1 13 14 15 Door Open 16 20 23 17 18 26 25 20 24 19 21 a23-1627stacked 22 Door Closed 1 2 3 4 5 6 7 8 9 — — — — — — — — — Wire Harness Assembly, Gate Driver Current Feedback Device, 1000 A Wire Harness Assembly, Power Supply, Logic 80 W Power Supply Assembly Terminal Block, 2-Position Cable Assembly, 40-Pin Cable Assembly, 30-Pin Wire Harness Assembly, Power Supply, Upper Gate Inverter Power Interface Assembly 10 11 12 13 14 15 16 17 18 —
2 1 3 4 5 UNDER TOP COVER 18 17 16 2X 3 15 14 6X 13 a19-1728 6 Door Open 12 11 10 9 8 2X 7 a19-1729 Door Closed 1 — Wire Harness Assembly, Internal Fan 2 — Wire Harness Assembly, DC Power 3 — Wire Harness Assembly, Current Feedback Device, Rectifier Side 4 — Wire Harness Assembly, Current Feedback Device, Inverter Side 5 — Wire Harness Assembly, DC Bus Resistors 6 — Internal Fan, 24 VDC 7 — Cable, Mini DIN, 8 Pos.
fans to turn them on when required. It continually checks all safeties to prevent any unsafe operating condition. It also regulates the oil heater while the compressor is off and regulates the hot gas bypass valve, if installed. The PIC III controls provide critical protection for the compressor motor and controls the VFD. The PIC III can interface with the Carrier Comfort Network® (CCN) system if desired. It can communicate with other PIC I, PIC II, or PIC III equipped chillers and other CCN devices.
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
CARRIER COMFORT NETWORK (CCN) INTERFACE CONTROL POWER CIRCUIT BREAKERS OPTIONAL DATAPORT/DATALINK CIRCUIT BREAKERS HUMIDITY SENSOR SURGE/HGBP PARAMETER LABEL a19-1607 CHILLER CONTROL MODULE (CCM) a19-1609 CONTROL PANEL INTERNAL VIEW CONTROL PANEL SIDE VIEW REMOVABLE BOLT HINGE a19-1610 a19-1742 CHILLER IDENTIFICATION NAMEPLATE Fig.
The second type of temperature sensor is a thermistor, which is installed either in the motor windings or at the thrust bearing within the compressor. Both of these have redundant sensors such that if one fails, the other can be connected external to the machine. See Table 3 for a list of standard instrumentation sensors. The PIC III control determines refrigerant temperature in the condenser and evaporator from pressure in those vessels, read from the corresponding pressure transducers. See Fig. 13.
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.
When an alarm is detected, the ICVC default screen will freeze (stop updating) at the time of alarm. The freeze enables the operator to view the chiller conditions at the time of alarm. The STATUS tables will show the updated information. Once all alarms have been cleared (by pressing the RESET softkey), the default ICVC screen will return to normal operation. • Press PREVIOUS to scroll the cursor bar up in order to highlight a point or to view points above the current screen.
DEFAULT SCREEN LOCAL CCN RESET MENU (SOFTKEYS) Start Chiller In CCN Control Start Chiller in Local Control Clear Alarms Access Main Menu STATUS SCHEDULE SETPOINT List the Status Tables SERVICE 1 1 1 1 (ENTER A 4-DIGIT PASSWORD) (VALUES SHOWN AT FACTORY DEFAULT) List the Service Tables • MAINSTAT • VPF_STAT • STARTUP • COMPRESS • HEAT_EX • POWER • VFD_STAT • ICVC_PWD Select a Status Table PREVIOUS NEXT Select a Modification Point PREVIOUS NEXT Modify a Discrete Point START STOP ON OFF Modify an A
SERVICE TABLE NEXT PREVIOUS SELECT EXIT ALERT HISTORY ALARM HISTORY Alert History (The table holds up to 25 alerts with the most recent alert at the top of the screen.) Display Alarm History (The table holds up to 25 alarms with the most recent alarm at the top of the screen.
SERVICE MENU CONTINUED FROM PREVIOUS PAGE VFD CONFIG DATA EQUIPMENT SERVICE 4 4 4 4 (ENTER A 4-DIGIT PASSWORD) (VALUES SHOWN AT FACTORY DEFAULT) Service Tables: • OPTIONS • SETUP1 • SETUP2 • LEADLAG • RAMP_DEM • TEMP_CTL Select a Service Table PREVIOUS NEXT Service Tables: • VFD (STARTER) CONFIG PASSWORD • VFD_CONF SELECT EXIT Select a Service Table Parameter SELECT PREVIOUS NEXT EXIT Modify a Service Table Parameter INCREASE DECREASE QUIT ENABLE DISABLE QUIT ENTER (ANALOG VALUES) ENTER (DIS
FORCING OPERATIONS To Force (manually override) a Value or Status 1. From any point status screen, press NEXT PREVIOUS to highlight the desired value. TO VIEW STATUS (Fig. 18) — The status table shows the actual value of overall chiller status such as CONTROL MODE, RUN STATUS, AUTO CHILLED WATER RESET, and REMOTE RESET SENSOR. 1. On the menu screen, press STATUS to view the list of point status tables. or 2. Press SELECT to select the highlighted value. 2.
Force Indication — A forced value is indicated by “SUPVSR,” “SERVC,” or “BEST” flashing next to the point value on the STATUS table. TIME SCHEDULE OPERATION (Fig. 19) 1. On the Menu screen, press SCHEDULE . 2. Press NEXT or PREVIOUS to highlight the desired schedule. OCCPC01S — LOCAL Time Schedule OCCPC02S — ICE BUILD Time Schedule OCCPC03S — CCN Time Schedule a19-1638 Fig. 19 — Example of Time Schedule Operation Screen 7.
6. Press ENTER to save the changes and return to the previous screen. 2. There are 5 set points on this screen: BASE DEMAND LIMIT, LCW SETPOINT (leaving chilled water set point), ECW SETPOINT (entering chilled water set point), ICE BUILD SETPOINT, and TOWER FAN HIGH SETPOINT. Only one of the chilled water set points can be active at one time. The set point that is active is determined from the SERVICE menu. See the Service Operation section, page 56.
Table 4 — ICVC Display Data 6. Reference Point Names shown in these tables in all capital letters can be read by CCN and BS software. Of these capitalized names, those preceded by a dagger (†) can also be changed (that is, written to) by the CCN, BS, and the ICVC. Capitalized Reference Point Names preceded by two asterisks (**) can be changed only from the ICVC. Reference Point Names in lower case type can be viewed by CCN or BS only by viewing the whole table. 7.
Table 4 — ICVC Display Data (cont) EXAMPLE 2 — MAINTSTAT DISPLAY SCREEN To access this display from the ICVC default screen: 1. Press MENU . 2. Press STATUS ( MAINSTAT will be highlighted). 3. Press SELECT .
Table 4 — ICVC Display Data (cont) EXAMPLE 4 — STARTUP DISPLAY SCREEN To access this display from the ICVC default screen: 1. Press MENU . 2. Press STATUS . 3. Scroll down to highlight STARTUP 4. Press SELECT . .
Table 4 — ICVC Display Data (cont) EXAMPLE 6 — HEAT_EX DISPLAY SCREEN To access this display from the ICVC default screen: 1. Press MENU . 2. Press STATUS . 3. Scroll down to highlight HEAT_EX . 4. Press SELECT .
Table 4 — ICVC Display Data (cont) EXAMPLE 7 — POWER DISPLAY SCREEN To access this display from the ICVC default screen: 1. Press MENU . 2. Press STATUS . 3. Scroll down to highlight POWER . 4. Press SELECT .
Table 4 — ICVC Display Data (cont) EXAMPLE 8 — VFD_STAT DISPLAY SCREEN To access this display from the ICVC default screen: 1. Press MENU . 2. Press STATUS . 3. Scroll down to highlight VFD_STAT . 4. Press SELECT .
Table 4 — ICVC Display Data (cont) EXAMPLE 11 — CAPACITY DISPLAY SCREEN To access this display from the ICVC default screen: 1. Press MENU . 2. 3. 4. 5. 6. Press SERVICE . Scroll down to highlight CONTROL ALGORITHM STATUS . Press SELECT . Scroll down to highlight CAPACITY . Press SELECT .
Table 4 — ICVC Display Data (cont) EXAMPLE 13 — SURGPREV DISPLAY SCREEN To access this display from the ICVC default screen: 1. Press MENU . 2. 3. 4. 5. 6. Press SERVICE . Scroll down to highlight CONTROL ALGORITHM STATUS . Press SELECT . Scroll down to highlight SURGPREV . Press SELECT .
Table 4 — ICVC Display Data (cont) EXAMPLE 15 — VFD_HIST DISPLAY SCREEN To access this display from the ICVC default screen: 1. Press MENU . 2. Press SERVICE . 3. Scroll down to highlight CONTROL ALGORITHM STATUS . 4. Press SELECT . 5. Scroll down to highlight VFD_HIST . 6. Press SELECT .
Table 4 — ICVC Display Data (cont) EXAMPLE 17 — NET_OPT DISPLAY SCREEN To access this display from the ICVC default screen: 1. Press MENU . 2. 3. 4. 5. 6. Press SERVICE . Scroll down to highlight EQUIPMENT CONFIGURATION . Press SELECT . Scroll down to highlight NET_OPT .
Table 4 — ICVC Display Data (cont) EXAMPLE 19 — OPTIONS DISPLAY SCREEN To access this display from the ICVC default screen: 1. Press MENU . 2. 3. 4. 5. 6. Press SERVICE . Scroll down to highlight EQUIPMENT SERVICE . Press SELECT . Scroll down to highlight OPTIONS . Press SELECT .
Table 4 — ICVC Display Data (cont) EXAMPLE 20 — SETUP1 DISPLAY SCREEN To access this display from the ICVC default screen: 1. Press MENU . 2. 3. 4. 5. 6. Press SERVICE . Scroll down to highlight EQUIPMENT SERVICE . Press SELECT . Scroll down to highlight SETUP1 . Press SELECT .
Table 4 — ICVC Display Data (cont) EXAMPLE 22 — LEADLAG DISPLAY SCREEN To access this display from the ICVC default screen: 1. Press MENU . 2. 3. 4. 5. 6. Press SERVICE . Scroll down to highlight EQUIPMENT SERVICE . Press SELECT . Scroll down to highlight LEADLAG . Press SELECT .
PIC III System Functions Table 5 — Guide Vane Delta Modes IMPORTANT: Words not part of paragraph headings and printed in all capital letters can be viewed on the ICVC (e.g., LOCAL, CCN, RUNNING, ALARM, etc.). Words printed both in all capital letters and italics can also be viewed on the ICVC and are parameters (CONTROL MODE, TARGET GUIDE VANE POS, etc.) with associated values (e.g., modes, temperatures, pressures, percentages, on, off, enable, disable, etc.).
X X X °F 48.2 48 47.8 47.6 47.4 47.2 SET POINT = 47 46.8 46.6 46.4 X X X X X X X X X X X EXAMPLE 1 EXAMPLE 2 EXAMPLE 3 a19-1957 Fig. 21 — Transient Example of ECW Gain 41 3 2.5 2 1.5 1 0.5 0 -0.5 -1 TOTAL ERROR PROPORTIONAL BANDS and LCW DEADBAND should be adjusted satisfactorily. Increase the ECW GAIN if the ENT CHILLED WATER TEMP drifts away from the ECW SETPOINT.
(displayed in the MAINSTAT screen). LINE KILOWATTS is measured by the VFD, and the MOTOR RATED LOAD kW value (100% rated kW) is set in the VFD_CONF table. If the DEMAND LIMIT SOURCE (percent line current) exceeds the ACTIVE DEMAND LIMIT by 5% or less, increases in guide vane opening will be prevented. If the DEMAND LIMIT SOURCE (percent line current) exceeds the ACTIVE DEMAND LIMIT by more than 5%, the guide vanes will be forced to close.
If the PIC III control initiates a safety shutdown, it displays the reason for the shutdown (the fault) on the ICVC display screen along with a primary and secondary message, and blinks the alarm light on the control panel. The alarm is stored in memory and can be viewed on the ALARM HISTORY and VFD_HIST screens on the ICVC, along with a message for troubleshooting. If the safety shutdown was also initiated by a fault detected in the VFD, the conditions at the time of the fault will be stored in VFD_HIST.
Table 6 — Protective Safety Limits and Control Settings MONITORED PARAMETER Temperature Sensors Out of Range Pressure Transducers Out of Range High Compressor Discharge Temperature ALARM/ ALERT 260-271, 140,141 260-271 231 167 103 High Motor Temperature 233 102 Compressor Thrust Bearing Temperature 101 234 Low Evaporator Temperature (Freeze Protection) LIMIT .06 > Voltage Ratio > .
Table 6 — Protective Limits and Control Settings (cont) MONITORED PARAMETER ALARM/ALERT LIMIT > 5 surge events within SURGE TIME PERIOD and VFD SPEED > 90% > 5 surge events within SURGE TIME PERIOD and VFD SPEED < 90% Motor — Surge 238 Surge 236 Current Imbalance 225 Overload Trip 217 Excessive Amps 208 Acceleration Fault 203 PERCENT LOAD CURRENT > 95% and VFDSTART = TRUE for 5 to 40 sec Amps Not Sensed 202 PERCENT LOAD CURRENT < 5% for 3 seconds and VFD START=TRUE for 20 sec Starts Limit
Ramp Loading — The ramp loading control slows down the rate at which the compressor loads up. This control can prevent the compressor from loading up during the short period of time when the chiller is started and the chilled water loop has to be brought down to CONTROL POINT. This helps reduce electrical demand charges by slowly bringing the chilled water to CONTROL POINT. The total power draw during this period remains almost unchanged. There are several methods of ramp loading with the PIC III.
the certified drawings for further details on contact ratings. The contacts must have 24 vac dry contact rating. valves are strapped to the oil supply line leaving the heat exchanger, and the valves are set to maintain 110 F (43 C). NOTE: The TXVs are not adjustable. The oil sump temperature may be at a lower temperature during compressor operation.
TEMP was more than 5 F (2.7 C) above the CONDENSER FREEZE POINT, the same low temperature condition will generate Alarm State 244 and the CONDENSER WATER PUMP will be energized. In either case, the fault state will clear and the pump will turn off when the CONDENSER REFRIG TEMP is more than 5 F (2.7 C) above the CONDENSER FREEZE POINT and the entering condenser water temperature is greater than the CONDENSER FREEZE POINT.
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.
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.
the compressor, if possible, while adjusting the guide vane position until a stable operating point with improved chiller efficiency is attained. Following a start command, the PIC III controls internally set the VFD TARGET SPEED to the smaller of the VFD MAXIMUM SPEED or the VFD START SPEED.
displayed. The lead/lag maintenance screen (LL_MAINT) displays the message ‘INVALID CONFIG’ in the LEADLAG: CONFIGURATION and CURRENT MODE fields. The lead chiller responds to normal start/stop controls such as the occupancy schedule, a forced start or stop, and remote start contact inputs. After completing start-up and ramp loading, the PIC III evaluates the need for additional capacity. If additional capacity is needed, the PIC III initiates the start-up of the chiller configured at the LAG ADDRESS.
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).
ICE BUILD INITIATION — The ice build time schedule (OCCPC02S) is the means for activating the ice build option. Ice Build is enabled if: • a day of the week and a time period on the ice build time schedule are enabled. The SCHEDULE screen shows an X in the day field and ON/OFF times are designated for the day(s), • and the ICE BUILD OPTION is enabled. The following events take place (unless overridden by a higher authority CCN device). • CHILLER START/STOP is forced to START.
When the ATTACH TO NETWORK DEVICE screen is accessed, information can not be read from the ICVC on any device until one of the devices listed on that screen is attached. The ICVC erases information about the module to which it was attached to make room for information on another device. Therefore, a CCN module must be attached when this screen is entered. To attach any CCN device, highlight it using the SELECT softkey and press the ATTACH softkey. The message “UPLOADING TABLES, PLEASE WAIT” displays.
password and, from the SERVICE menu, highlight LOG OUT OF NETWORK DEVICE and press the SELECT softkey. The ICVC default screen will now be displayed. Service Operation — An overview of the tables and screens available for the SERVICE function is shown in Fig. 17. TO ACCESS THE SERVICE SCREENS — When the SERVICE screens are accessed, a password must be entered. 1. From the main MENU screen, press the SERVICE softkey. The softkeys now correspond to the numerals 1, 2, 3, 4.
the internal timers have expired. The timers include a 15-minute start-to-start timer and a 1-minute stop-to-start timer, which together serve to prevent excessive cycling and abuse of the motor. The value of these timers is displayed as START INHIBIT TIMER and can be viewed on the MAINSTAT and DEFAULT screens. Both timers must expire before the chiller will start. If the timers have not expired, the RUN STATUS parameter on the MAINSTAT screen will read TIMEOUT. 7. Press SELECT to access the holiday table.
• a recycle condition is present (see Chilled Water Recycle Mode section) • the time schedule has gone into unoccupied mode • the chiller protective limit has been reached and chiller is in alarm • the start/stop status is overridden to stop from the CCN network or the ICVC When a stop signal occurs, the shutdown sequence first stops the compressor by deactivating the VFD output to the motor.
Table 9 — Prestart Checks QUANTITY CHECKED STARTS IN 12 HOURS COMP THRUST BRG TEMP COMP MOTOR WINDING TEMP COMP DISCHARGE TEMP EVAPORATOR REFRIG TEMP OIL SUMP TEMP CONDENSER PRESSURE PERCENT LINE VOLTAGE PERCENT LINE VOLTAGE ACTUAL GUIDE VANE POS RECTIFIER TEMPERATURE INVERTER TEMPERATURE REQUIREMENT < 8 (not counting recycle restarts or auto restarts after power failure) ALERT is cleared once RESET is pressed. < [COMP THRUST BRG ALERT] –10 F (5.6 C) < [COMP MOTOR TEMP OVERRIDE] –10 F (5.
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.
a19-1625 61 Fig.
If the chiller is spring isolated, keep all springs blocked in both directions to prevent possible piping stress and damage during the transfer of refrigerant from vessel to vessel during the leak test process, or any time refrigerant is being transferred. Adjust the springs when the refrigerant is in operating condition and the water circuits are full. 3. 4.
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.
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.
and condenser must meet job requirements. Measure the pressure drop across the cooler and the condenser. Chiller Dehydration — Dehydration is recommended if the chiller has been open for a considerable period of time, if the chiller is known to contain moisture, or if there has been a complete loss of chiller holding charge or refrigerant pressure.
Input Power Wiring — All wiring should be installed in conformance with applicable local, national, and international codes. Use grommets, when hubs are not provided, to guard against wire chafing. Use the following steps to connect AC input power to the main input circuit breaker: 1. Turn off, lockout, and tag the input power to the drive. 2. Remove the input wiring panel and drill the required number of openings in the top of the drive enclosure. Take care that metal chips do not enter the enclosure. 3.
2. With the tester connected to the motor leads, take 10-second and 60-second megohm readings as follows: Tie terminals 1, 2, and 3 together and test between the group and ground. 3. Divide the 60-second resistance reading by the 10-second reading. The ratio, or polarization index, must be one or higher. Both the 10 and 60-second readings must be at least 50 megohms. If the readings are unsatisfactory, repeat the test at the motor with the power leads disconnected.
the screen to SI units as required, and change the password if desired. TO CHANGE THE PASSWORD — The password may be changed from the ICVC CONFIGURATION screen. 1. Press the MENU and SERVICE softkeys. Enter the current password and highlight ICVC CONFIGURATION. Press the SELECT softkey. Only the last 5 entries on the ICVC CONFIG screen can be changed: BUS NUMBER, ADDRESS, BAUD RATE, US IMP/ METRIC, and PASSWORD. SOFTWARE VERSION — The software part number is labeled on the backside of the ICVC module.
• Rated Line Voltage — Nominal line voltage selected for the job site. • Rated Line Amps — Line current required for the chiller to run at the design point. • Rated Line Kilowatts — Line power required for the chiller to run at the design point. • Motor Rated Load kW — Power consumed by the motor when running at the chiller design point. • Motor Rated Load Amps — Motor current required for the chiller to run at the design point. • Motor Nameplate Amps — Motor nameplate full load amps.
Maximum Load T2: 54 – 44 = 10º F (12.2 – 6.7 = 5.5º C) Maximum Load P2: 120 – 37 = 83 psid (827 – 255 = 572 kPad) To avoid unnecessary surge prevention, add about 10 psid (70 kPad) to P2 from these conditions: T2 = 10º F (5.5º C) P2 = 93 psid (642 kPad) Calculate Minimum Load — To calculate the minimum load conditions, estimate the temperature difference the cooler will have at 10% load, then estimate what the suction and condensing temperatures will be at this point.
• 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.
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.
sensing water side flow are not provided as standard. These readings can be viewed and calibrated from the COMPRESS and HEAT_EX screens on the ICVC controller. Each transducer or transducer pair can be calibrated at two points: zero (0 psig or 0 kPa) and “high end” (between 25 and 250 psig, or between 173 and 1724 kPa). It is not usually necessary to calibrate at initial start-up.
CHILLER EQUALIZATION WITHOUT A PUMPOUT UNIT If the ICVC fails to accept the high end calibration, the value will not change and the display will show “Higher Force In Effect.” This indicates that the sensor voltage is out of the acceptable range for the entered value. If this occurs with a differential pair, one possible remedy is to swap the high end (inlet) and low end (outlet) transducers. In most cases this puts the sensor voltage within the acceptable range.
Table 14A — Refrigerant (HFC-134a) Charge with Compressor End Entering Cooler Water CODE 20 21 22 30 31 32 35 36 37 40 41 42 45 46 47 50 51 52 53 54 55 56 57 58 59 5A 5B 5C 5F 5G 5H 5K 5L 5M 5P 5Q 5R 5T 5U 5V 5X 5Y 5Z 60 61 62 63 64 65 66 67 68 69 MACHINE CHARGE English Metric (SI) Refrigerant Refrigerant Weight (lb) Weight (kg) Cooler Condenser Cooler Condenser 345 225 156 102 385 225 175 102 435 225 197 102 350 260 159 118 420 260 191 118 490 260 222 118 400 310 181 141 480 310 218 141 550 310 249 141
Table 14B — Refrigerant (HFC-134a) Charge with Drive End Entering Cooler Water CODE 20 21 22 30 31 32 35 36 37 40 41 42 45 46 47 50 51 52 53 54 55 56 57 58 59 5A 5B 5C 5F 5G 5H 5K 5L 5M 5P 5Q 5R 5T 5U 5V 5X 5Y 5Z 60 61 62 63 64 65 66 67 68 69 MACHINE CHARGE English Metric (SI) Refrigerant Refrigerant Weight (lb) Weight (kg) Cooler Condenser Cooler Condenser 416 252 189 114 459 252 208 114 505 252 229 114 510 308 232 140 565 308 257 140 626 308 284 140 577 349 262 158 639 349 290 158 709 349 322 158 726 3
4. Oil is at the proper level in the reservoir sight glasses. 5. Oil reservoir temperature is above 140 F (60 C) or above refrigerant temperature plus 50 F (28 C). 6. Valves in the evaporator and condenser water circuits are open. NOTE: If the pumps are not automatic, ensure water is circulating properly. CAUTION Ensure that the condenser and chilled water pumps are operating whenever charging, transferring, or removing refrigerant from the chiller.
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.
5. 6. 7. 8. be up to 10 psid (69 kPad) higher for Frame 3 compressors equipped with rolling element bearings. The moisture indicator sight glass on the refrigerant motor cooling line should indicate refrigerant flow and a dry condition. The condenser pressure and temperature varies with the chiller design conditions. Typically the pressure will range between 60 and 135 psig (390 to 950 kPa) with a corresponding temperature range of 60 to 105 F (15 to 41 C).
TIME Press. Temp In Out GPM Pressure Water COOLER DATE Refrigerant MODEL NO. Plant In Out Temp Press. Temp Refrigerant In Out GPM Pressure Water CONDENSER SERIAL NO. In Pressure Sump Temp Oil COMPRESSOR Level Fig.
under all operating conditions and during shutdown. If oil is low, add oil as described under Optional Pumpout System Maintenance section, page 88. The pumpout unit control wiring schematic is detailed in Fig. 43. To read refrigerant pressures during pumpout or leak testing: 1. The ICVC display on the chiller control panel is suitable for determining refrigerant-side pressures and low (soft) vacuum.
CONTROL PANEL VALVE CONDITION FRAME ASSEMBLY 1a 1b 2 3 C 4 C 5 6 7 C 10 C 11 g. Turn on pumpout condenser water. h. Run the pumpout compressor in manual mode until the storage tank pressure reaches 5 psig (34 kPa), 18 in. Hg vacuum (41 kPa absolute). i. Turn off the pumpout compressor. j. Close valves 1a, 1b, 2, 5, and 6. VALVE 2 VALVE 3 VALVE 4 VALVE CONDITION COMPRESSOR OIL HEATER LEAVING WATER CONDENSER OIL FILL FITTING OIL SEPARATOR a23-1546 VALVE CONDITION Fig.
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.
b. Close pumpout and storage tank valves 2, 4, 5, and 10, and close chiller charging valve 7; open chiller isolation valve 11 and any other chiller isolation valves, if present. c. Open pumpout and storage tank valves 3 and 6; open chiller valves 1a and 1b. VALVE CONDITION 1a 1b 2 C 3 4 C 5 C 6 7 C 10 C Removing Refrigerant — If the optional pumpout sys- tem is used, the 19XRV refrigerant charge may be transferred to a pumpout storage tank or to the chiller condenser or cooler vessels.
Repair the Leak, Retest, and Apply Standing Vacuum Test — After pressurizing the chiller, test for WEEKLY MAINTENANCE Check the Lubrication System — Mark the oil level on the reservoir sight glass, and observe the level each week while the chiller is shut down. If the level goes below the lower sight glass, check the oil reclaim system for proper operation. If additional oil is required, add it through the oil drain charging valve (Fig. 2). A pump is required when adding oil against refrigerant pressure.
the valve so that new oil can be pumped into the filter housing. Fill with the same amount that was removed; then close the charging valve. 10. Remove the hose from the charging valve, open the isolation valves to the filter housing, and turn on the power to the pump and the motor. SCHEDULED MAINTENANCE Establish a regular maintenance schedule based on actual chiller requirements such as chiller load, run hours, and water quality.
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.
Troubleshooting Guide section. Oil differential pressure (OIL PUMP DELTA P on the COMPRESS screen) should be zero whenever the compressor is off. Water Treatment — Untreated or improperly treated water may result in corrosion, scaling, erosion, or algae. The services of a qualified water treatment specialist should be obtained to develop and monitor a treatment program.
RESISTANCE CHECK — Turn off the control power and, from the module, disconnect the terminal plug of the sensor in question. With a digital ohmmeter, measure sensor resistance between receptacles as designated by the wiring diagram. The resistance and corresponding temperature are listed in Table 18A or 18B. Check the resistance of both wires to ground. This resistance should be infinite.
high altitude locations must be compensated for, so the chiller temperature/pressure relationship is correct. COOLER CONDENSER PRESSURE TRANSDUCER AND OPTIONAL WATERSIDE FLOW DEVICE CALIBRATION — Calibration can be checked by comparing the pressure readings from the transducer to an accurate refrigeration gage reading. These readings can be viewed or calibrated from the HEAT_EX screen on the ICVC. The transducer can be checked and calibrated at 2 pressure points.
Terminate Lockout feature ends the Pumpdown/Lockout after the pumpdown procedure is reversed and refrigerant is added. Control Test — The Control Test feature can check all the thermistor temperature sensors, pressure transducers, pumps and their associated flow devices, the guide vane actuator, and other control outputs such as tower fans, VFD cooling solenoid, shunt trip relay, oil heaters, alarm relay, and hot gas bypass.
Table 16 — Alarm and Alert Messages (cont) D. PRE-START ALERTS: These alerts only delay start-up. When alert is corrected, the start-up will continue. No reset is necessary.
Table 16 — Alarm and Alert Messages (cont) F.
Table 16 — Alarm and Alert Messages (cont) H. OUT-OF-RANGE SENSOR ICVC FAULT STATE PRIMARY MESSAGE 260 SENSOR FAULT 261 SENSOR FAULT 262 SENSOR FAULT 263 SENSOR FAULT 264 SENSOR FAULT 265 SENSOR FAULT 266 SENSOR FAULT 267 SENSOR FAULT 268 SENSOR FAULT 269 SENSOR FAULT 270 SENSOR FAULT 271 SENSOR FAULT SECONDARY MESSAGE PRIMARY CAUSE ADDITIONAL CAUSE/REMEDY Check sensor resistance or voltage drop. Check for proper wiring. Check for disconnected or shorted wiring.
Table 16 — Alarm and Alert Messages (cont) I. CHILLER PROTECTIVE LIMIT FAULTS ICVC FAULT STATE 200 201 202 203 204 205 206 207 208 209 210 211 212 213 214 215 216 217 218 219 PRIMARY MESSAGE SECONDARY MESSAGE RECTIFIER POWER PROTECTIVE LIMIT FAULT PRIMARY CAUSE 200Rectifier Power Fault: Check VFD Status. PROTECTIVE LIMIT INVERTER POWER FAULT 201Inverter Power Fault: Check VFD Status. 202Motor Amps Not MOTOR AMPS NOT Sensed — Average Load PROTECTIVE LIMIT SENSED Current [VALUE].
Table 16 — Alarm and Alert Messaged (cont) I.
Table 16 — Alarm and Alert Messages (cont) I. CHILLER PROTECTIVE LIMIT FAULTS (cont) ICVC FAULT STATE PRIMARY MESSAGE SECONDARY MESSAGE PRIMARY CAUSE 233Comp Motor Winding Temp [VALUE] exceeded limit of [LIMIT]*. 233 HIGH MOTOR PROTECTIVE LIMIT TEMPERATURE 234 PROTECTIVE LIMIT 235 PROTECTIVE LIMIT HIGH CONDENSER PRESSURE 236 PROTECTIVE LIMIT 237 PROTECTIVE LIMIT SPARE SAFETY DEVICE 238 PROTECTIVE LIMIT EXCESSIVE COMPR SURGE 238Compressor Surge: Check condenser water temp and flow.
Table 16 — Alarm and Alert Messages (cont) I. CHILLER PROTECTIVE LIMIT FAULTS (cont) ICVC FAULT STATE PRIMARY MESSAGE SECONDARY MESSAGE 245 PROTECTIVE LIMIT HIGH VFD SPEED 246 PROTECTIVE LIMIT INVALID DIFFUSER CONFIG. 247 DIFFUSER POSITION PROTECTIVE LIMIT FAULT 248 PROTECTIVE LIMIT 249 SPARE TEMPERATURE PROTECTIVE LIMIT #2 250 UNUSED SPARE TEMPERATURE #1 UNUSED PRIMARY CAUSE ADDITIONAL CAUSE/REMEDY 245Actual VFD Speed exceeded limit of Target VFD Speed + 10%.
Table 16 — Alarm and Alert Messages (cont) I. CHILLER PROTECTIVE LIMIT FAULTS (cont) ICVC FAULT STATE PRIMARY MESSAGE 259 SECONDARY MESSAGE CCN OVERRIDE PROTECTIVE LIMIT STOP 282 INVALID VFD CONPROTECTIVE LIMIT FIG 282Line Frequency [VALUE] Exceeded Configuration Range. 283 INVALID VFD CONPROTECTIVE LIMIT FIG 283Compressor 100% Speed Config Ranges: 50=Hz 45-52; 60 Hz=55-62.
Table 16 — Alarm and Alert Messages (cont) J. CHILLER ALERTS (cont) ICVC FAULT STATE PRIMARY MESSAGE SECONDARY MESSAGE PRIMARY CAUSE 151High Condenser Pressure [VALUE]: Pump Energized to Reduce Pressure. ADDITIONAL CAUSE/REMEDY Check sensor wiring and accuracy. Check condenser flow and water temperature. Check for fouled tubes. This alarm is not caused by the High Pressure Switch. Chiller load is too low to keep compressor on line and there has been more than 5 starts in 4 hours.
Table 17 — Fault Code Descriptions and Corrective Actions Fault Type indicates if the fault is: 1 — Auto-resettable 2 — Non-resettable 3 — User-configurable 4 — Normal Fault VFD FAULT FAULT TYPE CODE 2 Auxiliary Input 1 3 Power Loss 1, 3 4 UnderVoltage 1, 3 5 OverVoltage 1 7 Motor Overload 1, 3 8 Invtr Base Temp 1 9 Invtr IGBT Temp 1 12 HW OverCurrent 1 13 Ground Fault 1 24 Decel Inhibit 3 25 OverSpeed Limit 1 29 Analog In Loss 1, 3 33 Auto Rstrt Tries 3 35 Current FBK Lost 4 36 S
Table 17 — Fault Code Descriptions and Corrective Actions (cont) Fault Type indicates if the fault is: 1 — Auto-resettable 2 — Non-resettable 3 — User-configurable 4 — Normal Fault VFD FAULT FAULT TYPE CODE 38 Phase U to Grnd 39 Phase V to Grnd 40 Phase W to Grnd 41 42 43 Phase UV Short Phase VW Short Phase UW Short 48 Params Defaulted 63 Shear Pin 3 64 Drive OverLoad 70 HW Fault 4 71- 75 Port 1-5 Net Loss 76 Peripheral Fault at DPI Port 6 77 78 79 80 81- 85 87 100 101 102 103 104 105 DPI E
Table 17 — Fault Code Descriptions and Corrective Actions (cont) Fault Type indicates if the fault is: 1 — Auto-resettable 2 — Non-resettable 3 — User-configurable 4 — Normal Fault VFD FAULT CODE FAULT TYPE DESCRIPTION ACTION 121 Drive rating information stored on the Incompat MCB-PB 2 power board is incompatible with the Main Control board. Replaced MCB-PB 2 Main Control board was replaced and parameters were not programmed. I/O Board Mismatch Incorrect I/O board identified.
Table 17 — Fault Code Descriptions and Corrective Actions (cont) Fault Type indicates if the fault is: 1 — Auto-resettable 2 — Non-resettable 3 — User-configurable 4 — Normal Fault VFD FAULT CODE FAULT TYPE DESCRIPTION ACTION Input Amp Imbalance Input Volt Imbalance Input phase current imbalance exceeded limits. 227 AC Line Lost Input power Lost. 228 Line Frequency 225 226 Rectifier Checksum Inverter HW Unknown 4 Rectifier HW Unknown 4 229 230 231 Input voltage imbalance exceeded limits.
Table 18A — Thermistor Temperature (F) vs. Resistance/Voltage Drop TEMPERATURE (F) –25 –24 –23 –22 –21 –20 –19 –18 –17 –16 –15 –14 –13 –12 –11 –10 –9 –8 –7 –6 –5 –4 –3 –2 –1 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 PIC III VOLTAGE DROP (V) 4.700 4.690 4.680 4.670 4.659 4.648 4.637 4.625 4.613 4.601 4.588 4.576 4.562 4.549 4.535 4.521 4.507 4.492 4.477 4.461 4.
Table 18B — Thermistor Temperature (C) vs. Resistance/Voltage Drop TEMPERATURE (C) –33 –32 –31 –30 –29 –28 –27 –26 –25 –24 –23 –22 –21 –20 –19 –18 –17 –16 –15 –14 –13 –12 –11 –10 –9 –8 –7 –6 –5 –4 –3 –2 –1 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 PIC III VOLTAGE DROP (V) 4.722 4.706 4.688 4.670 4.650 4.630 4.608 4.586 4.562 4.538 4.512 4.486 4.458 4.429 4.399 4.368 4.336 4.303 4.269 4.233 4.196 4.158 4.119 4.079 4.037 3.994 3.
CCM is accomplished through the SIO (Sensor Input/ Output) bus, which is a phone cable. The communication between the CCM and VFD is accomplished through the sensor bus, which is a 3-wire cable. 2. If a green LED is on continuously, check the communication wiring. If a green LED is off, check the red LED operation. If the red LED is normal, check the module address switches (SW1). See Fig. 48 and 49. Confirm all switches are in OFF position. All system operating intelligence resides in the ICVC.
J11 DISCRETE OUTPUTS J12 DISCRETE OUTPUTS SW1 SIO ADDRESS DIP SWITCH SET ALL TO “OFF” J1 24 VAC ANALOG OUT J8 SIO J7 SIO J6 SW2 V/I INPUT CONFIGURATION DIP SWITCH 1 MUST BE “OFF” V/I INPUTS J5 STAT COMM THERMISTORS J4 DIFF PRESSURE J3 PRESSURE a19-1724 J2 Fig. 49 — Chiller Control Module (CCM) Replacing Defective Processor Modules — The module replacement part number is printed on a small label on the rear of the ICVC module.
Board is mounted on the front of the VFD power module in a vertical orientation. release the force on SERVICE ONTIME after the desired value has been set. 9. Perform the guide vane calibration procedure (in Control Test). Check and recalibrate pressure transducer readings. Check that the CURRENT TIME and DATE in the TIME AND DATE screen are correct. DPI Communications Interface Board Status LEDs — VFD status can be determined from the status LEDs on the DPI Communications Interface Board shown in Fig. 50.
Table 20 — MS Status Indicator: State Definitions DPI RIBBON CABLE CONNECTOR STATE CAUSE The Gateway is not powered. Off NODE ADDRESS TENS DIGIT = 0 (DO NOT CHANGE) Flashing Recoverable Fault Red Condition DATA RATE = PGM (DO NOT CHANGE) Solid Red The module has failed the hardware test. The Gateway is operaFlashing tional. No I/O data is Green being transferred. The Gateway is operaSolid tional and transferring Green I/O data.
CAUTION WARNING Before rigging the compressor, disconnect all wires entering the power panel. Do not attempt to disconnect flanges while the machine is under pressure. Failure to relieve pressure can result in personal injury or damage to the unit.
Table 23A — 19XR Heat Exchanger Data — Drive End Entering Cooler Water (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
Table 23B — 19XR Heat Exchanger Data — Compressor End Entering Cooler Water ENGLISH CODE 20 21 22 30 31 32 35 36 37 40 41 42 45 46 47 50 51 52 53 54 55 56 57 58 59 5A 5B 5C 5F 5G 5H 5K 5L 5M 5P 5Q 5R 5T 5U 5V 5X 5Y 5Z 60 61 62 63 64 65 66 67 68 69 Dry Rigging Weight (lb)* Cooler Only Condenser Only 3407 3555 3711 4071 4253 4445 4343 4551 4769 4908 5078 5226 5363 5559 5730 5713 5940 6083 6141 6192 6257 6517 6682 6751 6811 5124 5177 5243 5577 5640 5716 4993 5090 5165 5041 5131 5214 5425 5534 5620 5484 558
Table 23B — 19XR Heat Exchanger Data — Compressor End Entering Cooler Water (cont) ENGLISH CODE 6K 6L 6M 6P 6Q 6R 6T 6U 6V 6X 6Y 6Z 70 71 72 73 74 75 76 77 78 79 7K 7L 7M 7P 7Q 7R 7T 7U 7V 7X 7Y 7Z 80 81 82 83 84 85 86 87 88 89 8K 8L 8M 8P 8Q 8R 8T 8U 8V 8X 8Y 8Z Dry Rigging Weight (lb)* Cooler Only Condenser Only 5716 5804 5894 5768 5852 5938 6230 6330 6433 6293 6388 6487 9942 10330 10632 10715 10790 10840 11289 11638 11738 11828 8728 8959 9161 8792 9023 9229 9431 9698 9932 9510 9777 10016 12664 12998
Table 24 — 19XRV Additional Data for Marine Waterboxes* HEAT EXCHANGER FRAME, PASS FRAME 2, 1 AND 3 PASS FRAME 2, 2 PASS FRAME 3, 1 AND 3 PASS FRAME 3, 2 PASS FRAME 4, 1 AND 3 PASS FRAME 4, 2 PASS FRAME 5, 1 AND 3 PASS FRAME 5, 2 PASS FRAME 6, 1 AND 3 PASS FRAME 6, 2 PASS FRAME 7, 1 AND 3 PASS FRAME 7, 2 PASS FRAME 8, 1 AND 3 PASS FRAME 8, 2 PASS FRAME 2, 1 AND 3 PASS FRAME 2, 2 PASS FRAME 3, 1 AND 3 PASS FRAME 3, 2 PASS FRAME 4, 1 AND 3 PASS FRAME 4, 2 PASS FRAME 5, 1 AND 3 PASS FRAME 5, 2 PASS FRAME 6, 1
Table 26A — 19XRV Compressor and Motor Weights* — Compressor Frame Size 2† ENGLISH SI 60 Hz 50 Hz 60 Hz 50 Hz End Bell End Bell MOTOR Compressor Compressor Cover Cover CODE Stator Rotor Stator Rotor Stator Rotor Stator Rotor Weight** Weight** Weight†† Weight Weight†† Weight Weight Weight†† Weight Weight†† Weight Weight (lb) (kg) (lb) (kg) (lb) (lb) (lb) (lb) (kg) (kg) (kg) (kg) STANDARD-EFFICIENCY MOTORS / LOW VOLTAGE (200-575v) BDS 2300 900 190 915 205 185 1043 408 86 415 93 84 BES 2300
Table 26B — 19XRV Compressor and Motor Weights* — Compressor Frame Size 3† (cont) ENGLISH SI 60 Hz 50 Hz 60 Hz 50 Hz End Bell End Bell MOTOR Compressor Compressor Cover Cover CODE Stator Rotor Stator Rotor Stator Rotor Stator Rotor Weight** Weight** Weight†† Weight Weight†† Weight Weight Weight†† Weight Weight†† Weight Weight (lb) (kg) (lb) (kg) (lb) (lb) (lb) (lb) (kg) (kg) (kg) (kg) STANDARD-EFFICIENCY MOTORS / LOW VOLTAGE (200-575v) CBS 2816 1146 219 1188 236 274 1277 520 99 539 107 124
Table 26B — 19XRV Compressor and Motor Weights* — Compressor Frame Size 3† (cont) ENGLISH 60 Hz SI 50 Hz 60 Hz 50 Hz End Bell End Bell MOTOR Compressor Compressor Cover Cover CODE Stator Rotor Stator Rotor Stator Rotor Stator Rotor Weight** Weight** Weight†† Weight Weight†† Weight Weight Weight†† Weight Weight†† Weight Weight (lb) (kg) (lb) (kg) (lb) (lb) (lb) (lb) (kg) (kg) (kg) (kg) HIGH-EFFICIENCY MOTORS / MEDIUM VOLTAGE (2400-4160v) CBH 2816 1114 242 1156 255 274 1277 505 110 524 116 124
Table 26C — 19XRV Compressor and Motor Weights* — Compressor Frame Size 4† ENGLISH SI 60 Hz 50 Hz 60 Hz MOTOR Compressor CODE Stator Rotor Stator Rotor Weight** Weight†† Weight Weight†† Weight (lb) (lb) (lb) (lb) (lb) 50 Hz End Bell Compressor Cover Stator Rotor Stator Rotor Weight** Weight Weight†† Weight Weight†† Weight (kg) (lb) (kg) (kg) (kg) (kg) End Bell Cover Weight (kg) STANDARD-EFFICIENCY MOTORS / LOW VOLTAGE (200-575v) DBS 3425 / 4211 1570 324 1725 347 236 1554 / 1910 712 147 782
Table 26C — 19XRV Compressor and Motor Weights* — Compressor Frame Size 4† (cont) ENGLISH SI 60 Hz 50 Hz 60 Hz 50 Hz End Bell End Bell MOTOR Compressor Compressor Cover Cover CODE Stator Rotor Stator Rotor Stator Rotor Stator Rotor Weight** Weight** Weight†† Weight Weight†† Weight Weight Weight†† Weight Weight†† Weight Weight (lb) (kg) (lb) (kg) (lb) (lb) (lb) (lb) (kg) (kg) (kg) (kg) HIGH-EFFICIENCY MOTORS / LOW VOLTAGE (200-575v) LBH 3425 / 4211 1873 364 1939 389 318 1554 / 1910 850 165 880
Table 26D — 19XRV Compressor and Motor Weights* — Compressor Frame Size 5† (cont) ENGLISH SI 60 Hz 50 Hz 60 Hz 50 Hz End Bell End Bell MOTOR Compressor Compressor Cover Cover CODE Stator Rotor Stator Rotor Stator Rotor Stator Rotor Weight** Weight** Weight†† Weight Weight†† Weight Weight Weight†† Weight Weight†† Weight Weight (lb) (kg) (lb) (kg) (lb) (lb) (lb) (lb) (kg) (kg) (kg) (kg) STANDARD-EFFICIENCY MOTORS / LOW VOLTAGE (200-575v) EHS 7285 2843 741 2943 775 414 3304 1290 336 1335 352 1
Table 26D — 19XRV Compressor and Motor Weights* — Compressor Frame Size 5† (cont) ENGLISH SI 60 Hz 50 Hz 60 Hz 50 Hz End Bell End Bell MOTOR Compressor Compressor Cover Cover CODE Stator Rotor Stator Rotor Stator Rotor Stator Rotor Weight** Weight** Weight†† Weight Weight†† Weight Weight Weight†† Weight Weight†† Weight Weight (lb) (kg) (lb) (kg) (lb) (lb) (lb) (lb) (kg) (kg) (kg) (kg) HIGH-EFFICIENCY MOTORS / LOW VOLTAGE (200-575v) MBH 7285 2795 645 2856 665 414 3304 1268 293 1295 302 188
Table 27A — 19XRV Waterbox Cover Weights — English (lb) FRAMES 2 and 3 — COOLER Frame 2 WATERBOX DESCRIPTION Frame 3 Standard Nozzles Flanged Standard Nozzles Flanged NIH, 1 Pass Cover, 150 psig 320 350 320 350 NIH, 2 Pass Cover, 150 psig 320 350 320 350 NIH, 3 Pass Cover, 150 psig 310 340 310 340 NIH Plain End Cover, 150 psig 300 300 300 300 MWB End Cover, 150 psig 300 300 300 300 MWB Return Cover, 150 psig 243 243 243 243 NIH, 1 Pass Cover, 300 psig 411 486 411 486
Table 27A — 19XRV Waterbox Cover Weights — English (lb) (cont) FRAMES 4, 5, and 6 — COOLER Frame 4 WATERBOX DESCRIPTION Standard Nozzles NIH, 1 Pass Cover, 150 psig NIH, 2 Pass Cover, 150 psig Frame 5 Flanged Standard Nozzles 148 185 202 256 NIH, 3 Pass Cover, 150 psig 473 NIH Plain End Cover, 150 psig Frame 6 Flanged Standard Nozzles Flanged 168 229 187 223 224 298 257 330 489 629 655 817 843 138 138 154 154 172 172 MWB End Cover, 150 psig 317 317 393 393 503 MWB Ret
Table 27A — 19XRV Waterbox Cover Weights — English (lb) (cont) FRAMES 7 and 8 — COOLER FRAME 7 WATERBOX DESCRIPTION FRAME 8 Standard Nozzles Flanged Standard Nozzles Flanged NIH, 1 Pass Cover, 150 psig 329 441 417 494 NIH, 2 Pass Cover, 150 psig 426 541 531 685 NIH, 3 Pass Cover, 150 psig 1625 1202 1239 1568 NIH Plain End Cover, 150 psig 315 315 404 404 MWB End Cover, 150 psig 789 789 1339 1339 MWB Return Cover, 150 psig 315 315 404 404 NIH, 1 Pass Cover, 300 psig 1636
Table 27B — 19XRV Waterbox Cover Weights — SI (kg) FRAMES 2 and 3 — COOLER FRAME 2 WATERBOX DESCRIPTION FRAME 3 Standard Nozzles Flanged Standard Nozzles Flanged NIH, 1 Pass Cover, 1034 kPa 145 159 145 159 NIH, 2 Pass Cover, 1034 kPa 145 159 145 159 NIH, 3 Pass Cover, 1034 kPa 141 154 141 154 NIH Plain End Cover, 1034 kPa 136 136 136 136 MWB End Cover, 1034 kPa 136 136 136 136 MWB Return Cover, 1034 kPa 110 110 110 110 NIH, 1 Pass Cover, 2068 kPa 186 220 186 220 NIH,
Table 27B — 19XR Waterbox Cover Weights — SI (kg) (cont) FRAMES 4, 5, and 6 — COOLER Frame 4 WATERBOX DESCRIPTION Standard Nozzles Frame 5 Flanged Standard Nozzles Frame 6 Flanged Standard Nozzles Flanged NIH, 1 Pass Cover, 1034 kPa 67 84 76 104 85 101 NIH, 2 Pass Cover, 1034 kPa 92 116 102 135 117 150 NIH, 3 Pass Cover, 1034 kPa 215 222 285 297 371 382 63 63 70 70 78 78 144 144 178 178 228 228 NIH Plain End Cover, 1034 kPa MWB End Cover, 1034 kPa MWB Return Cover, 10
Table 27B — 19XR Waterbox Cover Weights — SI (kg) (cont) FRAMES 7 and 8 — COOLER Frame 7 WATERBOX DESCRIPTION Frame 8 Standard Nozzles Flanged Standard Nozzles Flanged NIH, 1 Pass Cover, 1034 kPa 149 200 189 224 NIH, 2 Pass Cover, 1034 kPa 193 245 241 311 NIH, 3 Pass Cover, 1034 kPa 545 562 711 737 NIH Plain End Cover, 1034 kPa 143 143 183 183 MWB End Cover, 1034 kPa 358 358 607 607 MWB Return Cover, 1034 kPa 143 143 183 183 NIH, 1 Pass Cover, 2068 kPa 742 817 1027 11
Table 28 — 19XRV Component Weights FRAME 2 FRAME 3 FRAME 4 FRAME 5 COMPRESSOR* COMPRESSOR* COMPRESSOR* COMPRESSOR* COMPONENT lb kg lb kg Suction Elbow 116 lb 53 185 84 239 108 407 185 Discharge Elbow 100 45 125 57 157 71 325 147 34 15 34 15 34 15 34 15 11 Control Panel† Optional Cooler Inlet Isolation Valve kg lb kg 8 4 13 6 20 9 24 26 12 46 21 74 34 108 Std Tier VFD — 380, 400, and 460-v (335, 445 A) 650 295 650 295 — — — — Std Tier VFD — 380, 400
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 .
C1 C2 THRUST THRUST B C1 B a19-1637 a19-1636 VIEW A2 LOW SPEED SHAFT THRUST DISK VIEW A1 LOW SPEED SHAFT THRUST DISK G SEE NOTE 5 E H O F1 F2 THRUST P I J IMPELLER SHIMMING TO BE DETERMINED AT ASSEMBLY L K SEE VIEW C a19-1639 VIEW B — HIGH SPEED SHAFT (FRAME 2, 4, OR 5) Fig.
+0.0007 -0.0007 0.0050 0.0020 0.025 0.005 +0.0007 -0.0007 THRUST 0.0011 0.0013 INTERFERENCE 0.0011 0.0013 INTERFERENCE a19-1640 0.0012 0.0004 VIEW B — HIGH SPEED SHAFT (FRAME 3) N M VIEW C — HIGH SPEED SHAFT RING SEAL Fig.
a19-1642 a19-1643 MOTOR LEAD INSTALLATION LABELS 19XRV COMPRESSOR ASSEMBLY TORQUES COMPRESSOR Code FRAME 2 201-299, 2ZZ DESCRIPTION Fixed Diffuser ITEM 1 2 3 4 Oil Heater Retaining Nut — ft-lb (N·m) Bull Gear Retaining Bolt — ft-lb (N·m) Demister Bolts — ft-lb (N·m) Impeller bolt Torque — ft-lb (N·m) N/A 80-90 (108-122) 15-19 (20-26) 32-48 (43-65) FRAME 3 321-389, 3ZZ With Rolling Element Bearings 18-22 (25-30) 80-90 (108-122) 15-19 (20-26) 55-60 (75-81) FRAME 4 421-487 FRAME 4 4B1-4W7 FRAME 5
(SHIELD) AUTO DEMAND LIMIT (OPTIONAL) EXT 4-20mA (1-5vdc) AUTO CHILLED WATER RESET (OPTIONAL) EXT 4-20mA (1-5vdc) (RED) (BLK) (CLR) (CLR) (BLK) (SHIELD) 4-20mAkw OUTPUT 6 + - + + - + - 2 3 5 4 3 2 J5 1 (BLK) 2 EVAP LVG WATER TEMP (RED) 3 (BLK) 4 COND ENT WATER TEMP (RED) 5 (BLK) 6 COND LVG WATER TEMP (RED) 7 (BLK) 8 (CLR) 9 (BLK) 10 4 7 10K J7 1 J8 SWITCH POSITION O N 1 2 3 SEE NOTE SW "ON" = EXT 4-20mA SW "OFF" = EXT 1-5Vdc SW2 (WHT) 1 "OFF" 2 "ON" (BL
(GRN) 1 TO TB-G ** 21 COMP'R OIL HEATER 11 11 230V 1C 22 (BLK) 23 (WHT) 6 (WHT) 13 (WHT) (RED) (BLK) (WHT) (WHT) 1C OPEN HGBP ACTUATOR 1C 13 COM (WHT) 12 (BLK) 1C COM 3 5 1C (BLK) 12 115V 2 4 CLOSE (BLK) (BLK) 3C 6 (WHT) 1C 5 230V WIRING MODIFICATION COMP'R OIL HEATER (BLU) (BLK) 3C (BLK) (BLU) 4 2 (WHT) (WHT) HOT GAS BYPASS (BLK) (BLK) (FR #7 & 8 HT EXCH) 115V CONTROL ONLY (BLK) (RED) (RED) 51 (ORN) 50 (BRN) 43 (BLK) (BLK) 17 (BLK) (CLR) C
A (RED) (RED) (BLK) (CLR) TO CCM J7-2* TO CCM J7-1* (SHIELD) B (BLK) C 17 (BLK) (CLR) (BLK) 43 (BRN) TO CCM J7-3* TO VFD (BLK) 50 (ORN) (BLK) COMPR OIL PUMP MOTOR (1-1/2 HP) M COMM 115V 230V COMPR DISCH HIGH PRESS (WHT) RED BLK 51 (YEL) TO CB2* (RED) (BLK) (YEL) YEL (RED) (WHT) 13 12 11 TO CCM J12-2* (BLK) TO GVA L1 2C 2C 2C (WHT) 23 22 21 TO GVA L2 VOLTAGE PER JOB REQMT a19-2009 (BLK) TO CB2* (BLK) (WHT) (BRN) (RED) TO CCM J12-5* 13 12
a19-1733 137 Fig.
a19-1997 138 UPC Fig.
a19-2015 139 312 Fig.
a19-1736 140 Fig.
a19-1999 141 UPC 2 Fig.
a19-2016 312 142 Fig.
120A 118 116 114 143 K1A 20A 600V TS1 T1 T2 T3 A2 L1 L2 L3 A1 153 14 13 154 PRECHARGE CONTACTORS 132 PRECHARGE RESISTORS 10 , 600W 137A,B 2 139 R4 128 FU7 127 136 4x 140J 2V FU4 FU5 FU6 150A 600V 138 119A 117 115 IND1 INPUT INDUCTOR MAIN CIRCUIT BREAKER CB1 GND 129 20A 600V 1uF 113 46uF ea 100k , 50W FILTER CAP ASSY a19-2017 312 1 4 R R5 131 FU8 130A 7 1 L1 155 A1 A2 T3 T2 L3 L2 14 T1 8 2 S L1 13 5 L2 9 3 T K1B 156 6 L3 1
312 1 uF R1 R2 R3 144 T1 T2 T3 A2 L1 L2 L3 A1 231F 14 13 K1A 225E PRECHARGE CONTACTORS 227D PRECHARGE RESISTORS 20 2 1 TS1 20A 600V 2 227A R4 203 200 229 228 1 207 2 FU7 2V 4x 140J FU4 FU5 FU6 300A 2 500V INPUT INDUCTOR IND1 CB1 MAIN CIRCUIT BREAKER GND INPUT FIELD WIRING REF.
a19-2001 145 Fig.
TB2 TB3 − LF2 VFD FRAME 4 TB1 − LF2 VFD FRAME 3 GATE KILL † * OIL PUMP INTERLOCK OIL PUMP INTERLOCK TB1 − LF2 VFD FRAME 4 ** POWER PANEL * a19-2010 * Located on A12 card, other terminals on field terminal strip. † Located on A33 card, other terminals on field terminal strip. ** Located on A22 card, other terminals on field terminal strip. Fig.
a19-1714 Fig.
LEGEND FOR FIG.
NOTES FOR FIG. 60 I General 1.0 Variable Frequency Drive (VFD) shall be designed and manufactured in accordance with Carrier engineering requirement Z-420. 1.1 All field-supplied conductors and devices must be compliant, and be installed in compliance with all applicable codes and job specifications. 1.2 The routing of field-installed conduit and conductors and the location of field-installed devices must not interfere with equipment access or the reading, adjusting or servicing of any component. 1.
POWER PANEL OIL PUMP INTERLOCK OIL PUMP INTERLOCK TB4-1 SEE NOTE 3.6 a19-1950 Fig.
a19-1951 Fig.
LEGEND FOR FIG.
NOTES FOR FIG. 61 I General 1.0 Variable Frequency Drive (VFD) shall be designed and manufactured in accordance with Carrier engineering requirement Z-420. 1.1 All field-supplied conductors and devices must be compliant, and be installed in compliance with all applicable codes and job specifications. 1.2 The routing of field-installed conduit and conductors and the location of field-installed devices must not interfere with equipment access or the reading, adjusting or servicing of any component. 1.
— — — — — 4 LEGEND Carrier Comfort Network® (CCN) Interface Circuit Breakers Control Panel Internal View Chiller Control Module (CCM) CCN Conduit Knockout Factory Wiring Field Wiring 5 5 3 1 WHT 2 1 RED BLK RED BLK WHT 19XRV CHILLERS 4 3 2 5 1 Fig. 62 — CCN Communication Wiring for Multiple Chillers (Typical) NOTE: Field supplied terminal strip must be located in control panel.
APPENDIX A — 19XRV LIQUIFLO™ 2 ICVC PARAMETER INDEX PARAMETER 0% Actual Guide Vane Position 100% Actual Guide Vane Position 1st Current Alarm State 20mA Demand Limit Opt 2nd Current Alarm State 3rd Current Alarm State 4th Current Alarm State 5th Current Alarm State Active Delta P Active Delta T Active Delta Tsat Active Delta Tsat Active Demand Limit Active Region Actual Guide Vane Pos Actual Guide Vane Pos Actual Guide Vane Pos Actual Guide Vane Pos Actual Guide Vane Position Actual Guide Vane Position Actu
APPENDIX A — 19XRV LIQUIFLO™ 2 ICVC PARAMETER INDEX (cont) PARAMETER Chilled Water Delta T Chilled Water Delta T Chilled Water Flow Chilled Water Flow Chilled Water Pump Chilled Water Pump Chilled Water Temp Chilled Water Temp Chiller Fault State Chiller Start/Stop CHW Delta T->Full Reset CHW Delta T->No Reset CHW Setpt Reset Value Commanded State Common Sensor Option Comp Discharge Alert Comp Discharge Alert Comp Discharge Temp Comp Discharge Temp Comp Discharge Temp Comp Motor Frequency
APPENDIX A — 19XRV LIQUIFLO™ 2 ICVC PARAMETER INDEX (cont) PARAMETER Condenser Water Delta P Condenser Water Delta P Condenser Water Delta P Condenser Water Flow Condenser Water Flow Condenser Water Pump Condenser Water Pump CONSUME Control Mode Control Point Control Point Control Point Control Point Control Point Error CONTROL TEST Current CHW Setpoint Current Date Current Mode Current Time Date Day of Week Daylight Savings DC Bus Voltage DC Bus Voltage DC Bus Voltage Reference DC Bus Voltage Reference Dec
APPENDIX A — 19XRV LIQUIFLO™ 2 ICVC PARAMETER INDEX (cont) PARAMETER MENU SOFTKEY SERVICE STATUS SERVICE Entering Chilled Water Entering Chilled Water Entering Cond Water Entering Condenser Water Entering Condenser Water STATUS Equipment Status SERVICE Evap Approach Alert SERVICE Evap Flow Delta P Cutout SERVICE Evap Ref Override Temp SERVICE Evap Refrig Liquid Temp STATUS Evap Refrig Trippoint SERVICE Evap Saturation Temp SERVICE Evap Saturation Temp STATUS Evaporator Approach STATUS Evaporator Pressure
APPENDIX A — 19XRV LIQUIFLO™ 2 ICVC PARAMETER INDEX (cont) PARAMETER ICVC CONFIGURATION IGV & SRD Actuator Incompatibility Fault Increase Ramp Time Inverter Overcurrent Inverter Overload Inverter Overtemp Inverter Power Fault Inverter PWM Frequency Inverter Temp Override Inverter Temp Override Inverter Temperature Inverter Temperature Inverter Temperature LAG % Capacity LAG Address LAG CHILLER: Mode LAG Start Time LAG START Timer LAG Stop Time LAG STOP Timer LCW Reset LCW Setpoint LEAD CHILLER in Control Le
APPENDIX A — 19XRV LIQUIFLO™ 2 ICVC PARAMETER INDEX (cont) PARAMETER Line Volt Imbalance Time Line Voltage Imbalance Line Voltage Imbalance Line Voltage Imbalance Line Voltage % Imbalance Line Voltage Ph1 (RS) Line Voltage Ph1 (RS) Line Voltage Ph2 (ST) Line Voltage Ph2 (ST) Line Voltage Ph3 (TR) Line Voltage Ph3 (TR) Load Balance Option Load Balance Option Load Current Ph1 (U) Load Current Ph1 (U) Load Current Ph2 (V) Load Current Ph2 (V) Load Current Ph3 (W) Load Current Ph3 (W) Loadshed Loadshed Function
APPENDIX A — 19XRV LIQUIFLO™ 2 ICVC PARAMETER INDEX (cont) PARAMETER Oil Pressure Oil Pressure Acceptable? Oil Pump Delta P Oil Pump Delta P Oil Pump Delta P Oil Pump Delta P Oil Pump Relay Oil Pump Relay Oil Sump Temp Oil Sump Temp Oil Sump Temp Oil Sump Temp Override Decrease Active Override Inhibit Active Password (VFD CONFIG DATA) Password (SERVICE) Percent Line Current Percent Line Current Percent Line Current Percent Line Kilowatts Percent Line Kilowatts Percent Line Voltage Percent Load Current Perce
APPENDIX A — 19XRV LIQUIFLO™ 2 ICVC PARAMETER INDEX (cont) PARAMETER Remote Reset Option Remote Reset Sensor Remote Reset Sensor Remote Start Contact Remote Temp->Full Reset Remote Temp->No Reset RESET Reset Alarm? RESET TYPE 1 RESET TYPE 2 RESET TYPE 3 Restart Delta T Run Status Run Status RUNTIME Schedule Number SECONDARY MESSAGE Serial Number Service Ontime Shunt Trip Relay Shunt Trip Relay Test Shutdown Delta T Single Cycle Dropout Single Cycle Dropout Skip Frequency 1 Skip Frequency 2 Skip Frequency 3
APPENDIX A — 19XRV LIQUIFLO™ 2 ICVC PARAMETER INDEX (cont) PARAMETER Stop Fault Stop Month Stop Time Stop Week Superheat Required Surge Counts Surge Delta % Amps Surge / HGBP Deadband Surge / HGBP Delta Ts max Surge / HGBP Delta Ts max Surge / HGBP Delta Ts min Surge / HGBP Delta Ts min Surge / HGBP IGV max Surge / HGBP IGV max Surge / HGBP IGV min Surge / HGBP IGV min Surge / Hot Gas Bypass Surge Limit/HGBP Option Surge Limit/HGBP Option Surge Line Delta Tsat Surge Line High Offset Surge Li
APPENDIX A — 19XRV LIQUIFLO™ 2 ICVC PARAMETER INDEX (cont) PARAMETER Tower Fan Relay High Test Tower Fan Relay Low Tower Fan Relay Low Test Transducer Voltage Ref US Imp / Metric Values at Last Fault: VFD Checksum Error VFD Cold Plate Temp VFD Cold Plate Temp VFD Comm Fault VFD CONFIG PASSWORD VFD Coolant Flow VFD Coolant Flow VFD Coolant Solenoid Test VFD Dewpoint VFD ENCL Temp Correction VFD Enclosure Temp VFD Enclosure Temp VFD Fault VFD Fault Code VFD Fault Code VFD FAULT HISTORY VFD Gain VFD Gateway Ve
19XR Lead Lag Schematic Series Cooler Flow APPENDIX B — LEAD/LAG WIRING a19-1655 165
19XR Lead Lag Schematic Parallel Cooler Flow APPENDIX B — LEAD/LAG WIRING (cont) a19-1717 166
APPENDIX C — MAINTENANCE SUMMARY AND LOG SHEETS 19XRV Maintenance Interval Requirements WEEKLY Compressor Check Oil Level. Controls Review ICVC Alarm/Alert History. Cooler None. Starter None. Condenser None. Oil Reclaim None. MONTHLY Compressor None. Controls Cooler None. Starter Perform an Automated Controls test. None. Condenser None. Oil Reclaim None. FIRST YEAR Compressor Cooler Condenser Change oil filter. Send oil sample out for analysis.
APPENDIX C — MAINTENANCE SUMMARY AND LOG SHEETS 19XRV Weekly Maintenance Log Plant ___________________________Machine Serial No. ________________________________ Machine Model No. ________________Refrigerant Type __________________________________ DATE OIL LEVEL CHECK ALARMS / FAULTS OPERATOR INITIALS REMARKS NOTE: Equipment failures caused by lack of adherence to the Maintenance Interval Requirements are not covered under warranty.
APPENDIX C — MAINTENANCE SUMMARY AND LOG SHEETS 19XRV Maintenance Log Month Date Operator UNIT SECTION Compressor Cooler 169 Condenser Controls Starter Oil Reclaim 1 / ACTION Change Oil Charge Change Oil Filter Send Oil Sample Out for Analysis Leak Test Inspect Compressor Rotors Bearing Inspection Inspect Inlet Bearing Oil Orifice Inspect & Clean Cooler Tubes Inspect Relief Valves Leak Test Record Water Pressure Differential (PSI) Inspect Water Pumps Eddy Current Test Leak Test Inspect and Clean Cond
APPENDIX C — MAINTENANCE SUMMARY AND LOG SHEETS 19XRV Seasonal Shutdown Log Month Date Operator UNIT SECTION Cooler Condenser Controls 1 / 2 / / 3 / ACTION Isolate and Drain Waterbox Remove Waterbox Cover from One End Use Compressed Air to Clean Tubes Isolate and Drain Waterbox Remove Waterbox Cover from One End Use Compressed Air to Clean Tubes Do Not Disconnect Control Power NOTE: Equipment failures caused by lack of adherence to the Maintenance Interval Requirements are not covered under warranty.
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.
APPENDIX D — OPTIONAL BACNET COMMUNICATIONS WIRING (cont) CONFIGURING THE BAS PORT FOR BACNET MS/ TP — Use the same baud rate and communication settings for all controllers on the network segment. The UPC Open controller is fixed at 8 data bits, No Parity, and 1 Stop bit for this protocol's communications. If the UPC Open controller has been wired for power, pull the screw terminal connector from the controller's power termiA48nals labeled Gnd and HOT.
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.
APPENDIX D — OPTIONAL BACNET COMMUNICATIONS WIRING (cont) Table D — Open System Wiring Specifications and Recommended Vendors WIRING SPECIFICATIONS Wire Type RECOMMENDED VENDORS AND PART NUMBERS Connect Air Contractors Belden RMCORP International Wire and Cable Description 22 AWG, single twisted shielded pair, low capacitance, CL2P, TC foam FEP, plenum rated. See MS/TP Installation Guide for specifications.
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.
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.
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 Bi
INDEX Abbreviations and explanations 4, 5 Adding refrigerant 84 Adjusting the refrigerant charge 84 After extended shutdown 79 After limited shutdown 79 Alarm (trip) output contacts 47 Attach to network device control 55 Automatic soft stop amps threshold 58 Auto.
INITIAL START-UP CHECKLIST FOR 19XRV HERMETIC CENTRIFUGAL LIQUID CHILLER (Remove and use for job file.) MACHINE INFORMATION: NAME JOB NO. ADDRESS MODEL CITY STATE ZIP S/N DESIGN CONDITIONS: TONS (kW) BRINE FLOW RATE TEMPERATURE IN TEMPERATURE PRESSURE OUT DROP PASS SUCTION TEMPERATURE COOLER CONDENSER ****** CHILLER LINE SIDE: OIL PUMP: REFRIGERANT: CONDENSER TEMPERATURE ****** Volts Volts FLA RLA Type: CARRIER OBLIGATIONS: OLTA OLTA Charge Assemble... . . . . . . . . . . . . . . . .
10-Second Readings: “PHASE TO PHASE” T1-T2 T1-T3 T2-T3 ____ ____ ____ “PHASE TO GROUND” T1-G T2-G T3-G ____ ____ ____ 60-Second Readings: ____ ____ ____ ____ ____ ____ Polarization Ratio: ____ ____ ____ ____ ____ ____ MEGGER MOTOR CONTROLS: SAFETY, OPERATING, ETC. Perform Controls Test (Yes/No) PIC III CAUTION COMPRESSOR MOTOR AND CONTROL PANEL MUST BE PROPERLY AND INDIVIDUALLY Yes CONNECTED BACK TO THE EARTH GROUND IN THE VFD (IN ACCORDANCE WITH CERTIFIED DRAWINGS).
19XRV PIC III SETPOINT TABLE CONFIGURATION SHEET DESCRIPTION Base Demand Limit LCW Setpoint ECW Setpoint Ice Build Setpoint Tower Fan High Setpoint RANGE 40 to 100 10 to 120 (-12.2 to 48.9) 15 to 120 (-9.4 to 48.9) 15 to 60 (-9.4 to 15.6) 55 to 105 (13 to 41) Upload all control configuration tables via service tool? UNITS % DEFAULT 100 DEG F (C) 50.0 (10) DEG F (C) 60.0 (15.6) DEG F (C) 40.0 (4.
Day Flag M T W T F S S H Occupied Time Unoccupied Time Period 1: Period 2: Period 3: Period 4: Period 5: Period 6: Period 7: Period 8: NOTE: Default setting is OCCUPIED 24 hours/day. ICE BUILD 19XRV PIC III TIME SCHEDULE CONFIGURATION SHEET OCCPC02S Day Flag M T W T F S S H Occupied Time Unoccupied Time Period 1: Period 2: Period 3: Period 4: Period 5: Period 6: Period 7: Period 8: NOTE: Default setting is UNOCCUPIED 24 hours/day.
19XRV PIC III VFD_CONF TABLE CONFIGURATION SHEET DESCRIPTION Motor Nameplate Voltage Compressor 100% Speed Line Freq=60 Hz? (No=50) * Rated Line Voltage * Rated Line Amps * Rated Line Kilowatts * Motor Rated Load KW * Motor Rated Load Amps Motor Nameplate Amps Motor Nameplate RPM Motor Nameplate KW Inverter PWM Frequency (0=4 k Hz, 1=2 k Hz) Skip Frequency 1 Skip Frequency 2 Skip Frequency 3 Skip Frequency Band Line Voltage % Imbalance Line Volt Imbalance Time Line Current % Imbalance Line Current Imbal Tim
DESCRIPTION Auto Restart Option Remote Contacts Option Soft Stop Amps Threshold Surge / Hot Gas Bypass Surge Limit/HGBP Option Select: Surge=0, HGBP=1 Low Load HGBP=2 Minimum Load Point Surge/HGBP Delta Tsmin Surge/HGBP IGVmin Full Load Point Surge/HGBP Delta Tsmax Surge/HGBP IGVmax Surge Line Shape Factor Surge Line Speed Factor Surge Line High Offset Surge/HGBP Deadband RANGE 0/1 0/1 40 to 100 UNITS DSABLE/ENABLE DSABLE/ENABLE % 0/1/2 DEFAULT DSABLE DSABLE 100 0 0.0 to 150.0 (0.0 to 83.3) 0.
19XRV PIC III SETUP1 TABLE CONFIGURATION SHEET DESCRIPTION Comp Motor Temp Override Cond Press Override Rectifier Temp Override Inverter Temp Override Comp Discharge Alert Comp Thrust Brg Alert Comp Thrust Brg Trip Thrust Brg Reset Factor Chilled Medium Chilled Water Deadband Evap Refrig Trippoint Refrig Override Delta T Evap Approach Alert Cond Approach Alert Condenser Freeze Point Flow Delta P Display Evap Flow Delta P Cutout Cond Flow Delta P Cutout Cond Hi Flow Delta P Limit Cond Hi Flow Alarm O
DESCRIPTION Capacity Control Proportional Inc Band Proportional DEC Band Proportional ECW Gain STATUS UNITS DEFAULT 2 to 10 2 to 10 1 to 3 Guide Vane Travel Limit 30 to 100 % 80 Diffuser Control Diffuser Option Guide Vane 25% Load Pt Diffuser 25% Load Point Guide Vane 50% Load Pt Diffuser 50% Load Point Guide Vane 75% Load Pt Diffuser 75% Load Point Diffuser Full Span mA 0/1 0 to 78 0 to 100 0 to 78 0 to 100 0 to 78 0 to 100 15 to 22 DSABLE/ENABLE % % % % % % mA DSABLE 25 0 50 0 75 0 18 VFD Spe
19XRV PIC III LEADLAG TABLE CONFIGURATION SHEET DESCRIPTION Lead Lag Control LEAD/LAG: Configuration DSABLE=0, LEAD=1, LAG=2, STANDBY=3 Load Balance Option Common Sensor Option LAG% Capacity LAG Address LAG START Timer LAG STOP Timer PRESTART FAULT Timer PULLDOWN Timer STANDBY Chiller Option STANDBY% Capacity STANDBY Address RANGE UNITS 0 to 3 0/1 0/1 25 to 75 1 to 236 2 to 60 2 to 60 2 to 30 1 to 30 0/1 25 to 75 1 to 236 DEFAULT 0 DSABLE/ENABLE DSABLE/ENABLE % MIN MIN MIN MIN DSABLE/ENABLE % CL-9
DESCRIPTION Pulldown Ramp Type: Select: Temp=0, Load=1 Demand Limit and kW Ramp Demand Limit Source Select: Amps=0, kW=1 Amps or kW Load Ramp% Min Demand Limit Prop Band Demand Limit At 20 mA 20 mA Demand Limit Opt VFD Overload Decrease VFD Overload Delta Demand Watts Interval RANGE UNITS DEFAULT 0/1 1 0/1 0 5 to 20 3 to 15 40 to 100 0/1 25 to 50 3 to 15 5 to 60 % % DSABLE/ENABLE % % MIN VALUE 10 10 40 DSABLE 30 5 15 19XRV PIC III TEMP_CTL TABLE CONFIGURATION SHEET DESCRIPTION Control Point EC
BROADCAST (BRODEF) CONFIGURATION SHEET DESCRIPTION Time Broadcast Enable Daylight Savings Start Month Start Day of Week Start Week Start Time Start Advance Stop Month Stop Day of Week Stop Week Stop Time Stop Back RANGE DSABLE/ENABLE 1 to 12 1 to 7 1 to 5 00:00 to 24:00 0 to 360 1 to 12 1 to 7 1 to 5 00:00 to 24:00 0 to 360 UNITS HH:MM MIN MIN CL-11 DEFAULT DSABLE 4 7 1 02:00 0 10 7 5 02:00 0 VALUE
PRIMARY MESSAGE: DATE: SECONDARY MESSAGE: COMPRESSOR ONTIME: TIME: CHW IN CHW OUT EVAP REF CDW IN CDW OUT COND REF OILPRESS OIL TEMP AMPS %IN COMMUNICATION MESSAGE CCN LOCAL RESET MENU Copyright 2011 Carrier Corporation Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. Catalog No. 04-53190015-01 Printed in U.S.A.
