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

obligations.
Catalog No. 04-53190022-01 Printed in U.S.A. Form 19XR,XRV-CLT-9SS Pg 1 10-13 Replaces: 19XR-6SS
Start-Up, Operation, and Maintenance Instructions
SAFETY CONSIDERATIONS
Centrifugal liquid chillers are designed to provide safe
and reliable service when operated within design specifi-
cations. When operating this equipment, use good judg-
ment 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
Failure to follow these procedures will result in severe per-
sonal injury or death.
DO NOT VENT refrigerant relief valves within a building.
Outlet from rupture disc or relief valve must be vented out-
doors 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 harm-
ful 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 litera-
ture 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
Failure to follow these procedures may result in personal
injury or death.
DO NOT USE TORCH to remove any component. System
contains oil and refrigerant under pressure.
To remove a component, wear protective gloves and gog-
gles and proceed as follows:
a. Shut off electrical power to unit.
b. Recover refrigerant to relieve all pressure from sys-
tem using both high-pressure and low pressure ports.
c. Traces of vapor should be displaced with nitrogen
and the work area should be well ventilated. Refrig-
erant in contact with an open flame produces toxic
gases.
d. Cut component connection tubing with tubing cutter
and remove component from unit. Use a pan to catch
any oil that may come out of the lines and as a gage
for how much oil to add to the system.
e. Carefully unsweat remaining tubing stubs when nec-
essary. Oil can ignite when exposed to torch flame.
DO NOT USE eyebolts or eyebolt holes to rig chiller sec-
tions 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 servic-
ing. IF WORK IS INTERRUPTED, confirm that all cir-
cuits 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 refriger-
ant 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 ILLE-
GAL. 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.
(Warnings continued on next page.)
EVERGREEN

19XR,XRV
Single-Stage or Two-Stage
Semi-Hermetic Centrifugal Liquid Chillers
with PIC II Controls and HFC-134a
50/60 Hz
2
CONTENTS
Page
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . 1,2
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
ABBREVIATIONS AND EXPLANATIONS . . . . . . . . . . 5
CHILLER FAMILIARIZATION. . . . . . . . . . . . . . . . . . . . 5-9
Chiller Information Nameplate. . . . . . . . . . . . . . . . . . . . 5
System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Cooler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Motor-Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Control Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Economizer (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Factory-Mounted Starter or Variable
Frequency Drive (Optional). . . . . . . . . . . . . . . . . . . . . 7
Storage Vessel (Optional) . . . . . . . . . . . . . . . . . . . . . . . . 7
REFRIGERATION CYCLE. . . . . . . . . . . . . . . . . . . . . 10,11
MOTOR AND OIL COOLING CYCLE . . . . . . . . . . . . . 11
VFD COOLING CYCLE. . . . . . . . . . . . . . . . . . . . . . . . . . . 12
LUBRICATION CYCLE. . . . . . . . . . . . . . . . . . . . . . . . 12-14
Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Details. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Oil Reclaim System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
PRIMARY OIL RECOVERY MODE
SECONDARY OIL RECOVERY METHOD
STARTING EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . 14-17
Unit-Mounted Solid-State Starter
(Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Unit-Mounted Wye-Delta Starter
(Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Unit-Mounted VFD (Optional) . . . . . . . . . . . . . . . . . . . . 16
CONTROLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-63
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
ANALOG SIGNAL
DISCRETE SIGNAL
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
PIC II System Components . . . . . . . . . . . . . . . . . . . . . . 17
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. . . . . . . . . . . . . . . . . . . . . . 20
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. . . . . . . . . . . . . . . . . . . . . . . . . 42
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
WARNING
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 com-
pressed spring. Sudden release of the spring can cause it
and objects in its path to act as projectiles.
CAUTION
Failure to follow these procedures may result in personal
injury or damage to equipment.
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 water-
box 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.
DO NOT re-use compressor oil or any oil that has been
exposed to the atmosphere. Dispose of oil per local codes
and regulations.
DO NOT leave refrigerant system open to air any longer
than the actual time required to service the equipment. Seal
circuits being serviced and charge with dry nitrogen to pre-
vent oil contamination when timely repairs cannot be
completed.
3
CONTENTS (cont)
Page
PROPORTIONAL BANDS
DIFFUSER CONTROL
DEMAND LIMITING
CHILLER TIMERS AND STARTS COUNTER
OCCUPANCY SCHEDULE
Safety Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Pump and Fan Control . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Shunt Trip (Option). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Function Loss Trip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Default Screen Freeze. . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Ramp Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Rampdown. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Capacity Override. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
High Discharge Temperature Control. . . . . . . . . . . . 51
Compressor Bearing Temperature . . . . . . . . . . . . . . 51
Oil Sump Temperature and Pump Control . . . . . . . 51
Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Remote Start/Stop Controls . . . . . . . . . . . . . . . . . . . . . 53
Spare Safety and Spare Temperature Inputs . . . . 53
Alarm (Trip) Output Contacts. . . . . . . . . . . . . . . . . . . . 53
Refrigerant Leak Detector . . . . . . . . . . . . . . . . . . . . . . . 53
Kilowatt Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Remote Reset of Alarms . . . . . . . . . . . . . . . . . . . . . . . . 53
Condenser Pump Control . . . . . . . . . . . . . . . . . . . . . . . 53
Condenser Freeze Prevention. . . . . . . . . . . . . . . . . . . 54
Evaporator Freeze Protection . . . . . . . . . . . . . . . . . . . 54
Tower Fan Relay Low and High. . . . . . . . . . . . . . . . . . 54
Auto. Restart After Power Failure . . . . . . . . . . . . . . . 54
Fast Power Source Transfers. . . . . . . . . . . . . . . . . . . . 55
Water/Brine Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
RESET TYPE 1
RESET TYPE 2
RESET TYPE 3
Demand Limit Control Option . . . . . . . . . . . . . . . . . . . 55
Surge Prevention Constant Flow and
Variable Primary Flow (VPF) . . . . . . . . . . . . . . . . . . 55
Hot Gas Bypass (Optional) Algorithm . . . . . . . . . . . 55
Surge Protection (Fixed Speed Chiller) . . . . . . . . . . 56
Surge Prevention Algorithm with VFD. . . . . . . . . . . 56
Surge Protection (VFD Chiller) . . . . . . . . . . . . . . . . . . 57
VFD Start-Up Speed Control. . . . . . . . . . . . . . . . . . . . . 57
Head Pressure Reference Output . . . . . . . . . . . . . . . 57
Lead/Lag Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
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 . . . . . . . . . . . . . . . 61
ATTACHING TO OTHER CCN MODULES
Service Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
TO ACCESS THE SERVICE SCREENS
TO LOG OUT OF NETWORK DEVICE
TIME BROADCAST ENABLE
HOLIDAY SCHEDULING
DAYLIGHT SAVING TIME CONFIGURATION
START-UP/SHUTDOWN/RECYCLE
SEQUENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63-66
Local Start-Up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Shutdown Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Automatic Soft Stop Amps Threshold. . . . . . . . . . . 65
Page
Chilled Water Recycle Mode. . . . . . . . . . . . . . . . . . . . . 65
Safety Shutdown. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
BEFORE INITIAL START-UP . . . . . . . . . . . . . . . . . . 66-84
Job Data Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Equipment Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Using the Optional Storage Tank
and Pumpout System . . . . . . . . . . . . . . . . . . . . . . . . . 66
Remove Shipping Packaging. . . . . . . . . . . . . . . . . . . . 66
Open Oil Circuit Valves. . . . . . . . . . . . . . . . . . . . . . . . . . 66
Tighten All Gasketed Joints and
Guide Vane Shaft Packing. . . . . . . . . . . . . . . . . . . . . 66
Check Chiller Tightness. . . . . . . . . . . . . . . . . . . . . . . . . 66
Refrigerant Tracer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Leak Test Chiller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Standing Vacuum Test . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Chiller Dehydration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Inspect Water Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Check Optional Pumpout Compressor
Water Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Check Relief Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Inspect Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Carrier Comfort Network

Interface . . . . . . . . . . . . . 71
Check Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
MECHANICAL STARTER
BENSHAW, INC. RediStart MX3
SOLID-STATE STARTER
VFD STARTER
Oil Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Power Up the Controls and
Check the Oil Heater . . . . . . . . . . . . . . . . . . . . . . . . . . 72
SOFTWARE VERSION
Software Configuration . . . . . . . . . . . . . . . . . . . . . . . . . 73
Input the Design Set Points . . . . . . . . . . . . . . . . . . . . . 73
Input the Local Occupied Schedule
(OCCPC01S) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Input Service Configurations. . . . . . . . . . . . . . . . . . . . 73
PASSWORD
INPUT TIME AND DATE
CHANGE ICVC CONFIGURATION
IF NECESSARY
TO CHANGE THE PASSWORD
TO CHANGE THE ICVC DISPLAY FROM
ENGLISH TO METRIC UNITS
CHANGE LANGUAGE
MODIFY CONTROLLER IDENTIFICATION
IF NECESSARY
INPUT EQUIPMENT SERVICE PARAMETERS
IF NECESSARY
CHANGE THE BENSHAW, INC., RediStart
MX3 SOFTWARE CONFIGURATION
IF NECESSARY
VFD Field Set Up and Verification . . . . . . . . . . . . . . . 74
LABEL LOCATIONS
DRIVE PROTECTION AND OTHER INCOMING
WIRING
VFD CONTROL VERIFICATION (Non-Running)
VFD CONTROL VERIFICATION (Running)
HAND CALCULATE SURGE PREVENTION
CONFIGURATIONS
CONFIGURE DIFFUSER CONTROL IF
NECESSARY
MODIFY EQUIPMENT CONFIGURATION
IF NECESSARY
Perform a Control Test . . . . . . . . . . . . . . . . . . . . . . . . . . 80
GUIDE VANE ACTUATOR CALIBRATION
COOLER AND CONDENSER PRESSURE TRANS-
DUCER AND WATERSIDE FLOW DEVICE
CALIBRATION
4
CONTENTS (cont)
Page
OPTIONAL THERMAL DISPERSION FLOW
SWITCH CALIBRATION
Check Optional Pumpout System
Controls and Compressor. . . . . . . . . . . . . . . . . . . . . 82
High Altitude Locations . . . . . . . . . . . . . . . . . . . . . . . . . 82
Charge Refrigerant Into Chiller . . . . . . . . . . . . . . . . . . 82
CHILLER EQUALIZATION WITHOUT A
PUMPOUT UNIT
CHILLER EQUALIZATION WITH
PUMPOUT UNIT
TRIMMING REFRIGERANT CHARGE
INITIAL START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84-86
Preparation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Dry Run to Test Start-Up Sequence. . . . . . . . . . . . . . 84
Check Motor Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Check Oil Pressure and Compressor Stop. . . . . . . 85
To Prevent Accidental Start-Up. . . . . . . . . . . . . . . . . . 85
Check Chiller Operating Condition . . . . . . . . . . . . . . 85
Instruct the Customer Operator . . . . . . . . . . . . . . . . . 85
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 . . . . . . . . . . . . . . . . . 86,87
Operator Duties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Prepare the Chiller for Start-Up. . . . . . . . . . . . . . . . . . 86
To Start the Chiller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Check the Running System. . . . . . . . . . . . . . . . . . . . . . 86
To Stop the Chiller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
After Limited Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . 86
Preparation for Extended Shutdown. . . . . . . . . . . . . 86
After Extended Shutdown . . . . . . . . . . . . . . . . . . . . . . . 86
Cold Weather Operation. . . . . . . . . . . . . . . . . . . . . . . . . 86
Manual Guide Vane Operation . . . . . . . . . . . . . . . . . . . 87
Refrigeration Log. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
PUMPOUT AND REFRIGERANT TRANSFER
PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87-92
Preparation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Operating the Optional Pumpout Unit . . . . . . . . . . . 89
TO READ REFRIGERANT PRESSURES
POSITIVE PRESSURE CHILLERS WITH STORAGE
TANKS
CHILLERS WITH ISOLATION VALVES
DISTILLING THE REFRIGERANT
GENERAL MAINTENANCE . . . . . . . . . . . . . . . . . . . 92,93
Refrigerant Properties. . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Adding Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Adjusting the Refrigerant Charge. . . . . . . . . . . . . . . . 92
Refrigerant Leak Testing . . . . . . . . . . . . . . . . . . . . . . . . 92
Leak Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Test After Service, Repair, or Major Leak . . . . . . . . 92
TESTING WITH REFRIGERANT TRACER
TESTING WITHOUT REFRIGERANT TRACER
TO PRESSURIZE WITH DRY NITROGEN
Repair the Leak, Retest, and Apply
Standing Vacuum Test . . . . . . . . . . . . . . . . . . . . . . . . 92
Checking Guide Vane Linkage. . . . . . . . . . . . . . . . . . . 92
Trim Refrigerant Charge. . . . . . . . . . . . . . . . . . . . . . . . . 93
Page
WEEKLY MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . 93
Check the Lubrication System. . . . . . . . . . . . . . . . . . . 93
SCHEDULED MAINTENANCE . . . . . . . . . . . . . . . . 93-97
Service Ontime. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Inspect the Control Panel. . . . . . . . . . . . . . . . . . . . . . . . 93
Check Safety and Operating Controls
Monthly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Changing Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Oil Specification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Oil Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
TO CHANGE THE OIL
Refrigerant Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Oil Reclaim Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Inspect Refrigerant Float System. . . . . . . . . . . . . . . . 94
ECONOMIZER FLOAT SYSTEM
ECONOMIZER DAMPER VALVE
Inspect Relief Valves and Piping . . . . . . . . . . . . . . . . 95
Compressor Bearing and Gear
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Inspect the Heat Exchanger Tubes
and Flow Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
COOLER AND OPTIONAL FLOW DEVICES
CONDENSER AND OPTIONAL FLOW DEVICES
Water Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Water Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Inspect the Starting Equipment. . . . . . . . . . . . . . . . . . 96
Recalibrate Pressure Transducers. . . . . . . . . . . . . . . 96
Optional Pumpout System Maintenance. . . . . . . . . 96
OPTIONAL PUMPOUT COMPRESSOR OIL
CHARGE
OPTIONAL PUMPOUT SAFETY CONTROL
SETTINGS
Ordering Replacement Chiller Parts . . . . . . . . . . . . . 97
TROUBLESHOOTING GUIDE . . . . . . . . . . . . . . . . 97-176
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Checking Display Messages. . . . . . . . . . . . . . . . . . . . . 97
Checking Temperature Sensors . . . . . . . . . . . . . . . . . 97
RESISTANCE CHECK
VOLTAGE DROP
CHECK SENSOR ACCURACY
DUAL TEMPERATURE SENSORS
Checking Pressure Transducers. . . . . . . . . . . . . . . . 114
TRANSDUCER REPLACEMENT
COOLER AND CONDENSER PRESSURE TRANS-
DUCER AND OPTIONAL WATERSIDE FLOW
DEVICE CALIBRATION
Control Algorithms Checkout Procedure . . . . . . . 115
Control Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Control Modules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
RED LED (Labeled as STAT)
GREEN LED (Labeled as COM)
Notes on Module Operation . . . . . . . . . . . . . . . . . . . . 115
Chiller Control Module (CCM) . . . . . . . . . . . . . . . . . . 115
INPUTS
OUTPUTS
Integrated Starter Module . . . . . . . . . . . . . . . . . . . . . . 115
INPUTS
OUTPUTS
Replacing Defective Processor Modules . . . . . . . 118
INSTALLATION
Solid-State Starters . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
TESTING SILICON CONTROL RECTIFIERS IN
BENSHAW, INC. SOLID-STATE STARTERS
SCR REMOVAL/INSTALLATION
Physical Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
APPENDIX A ICVC PARAMETER INDEX . .177-183
5
CONTENTS (cont)
Page
APPENDIX B LEAD/LAG WIRING . . . . . . . . 184,185
APPENDIX C MAINTENANCE SUMMARY
AND LOG SHEETS . . . . . . . . . . . . . . . . . . . . . . . 186-188
APPENDIX D BACNET COMMUNICATION
OPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189-195
INDEX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
INITIAL START-UP CHECKLIST FOR
19XR, XRV HERMETIC CENTRIFUGAL
LIQUID CHILLER. . . . . . . . . . . . . . . . . . . . CL-1 to CL-14
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 start-
up, operation and maintenance of the unit with the control sys-
tem before performing start-up procedures. Procedures in this
manual are arranged in the sequence required for proper chiller
start-up and operation.
ABBREVIATIONS AND EXPLANATIONS
Frequently used abbreviations in this manual include:
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, tempera-
tures, percentages, pressures, on, off, etc.).
Words printed in all capital letters and in a box represent
softkeys on the ICVC control panel (e.g., , ,
, , etc.).
Factory-installed additional components are referred to as
options in this manual; factory-supplied but field-installed ad-
ditional components are referred to as accessories.
The chiller software part number of the 19XR unit is located
on the back of the ICVC.
CHILLER FAMILIARIZATION (Fig. 1-3)
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, econo-
mizer (optional) and motor starter. All connections from pres-
sure vessels have external threads to enable each component to
be pressure tested with a threaded pipe cap during factory as-
sembly.
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 dis-
sipate body electrostatic charge before working inside con-
trol 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 com-
munications. It has been tested and found to comply with
the limits for a Class A computing device pursuant to Inter-
national Standard in North America EN 61000-2/3 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.
CAUTION
WHEN FLUSHING THE WATER SYSTEMS isolate the
chiller from the water circuits to prevent damage to the heat
exchanger tubes.
CCM Chiller Control Module
CCN Carrier Comfort Network

CCW Counterclockwise
CW Clockwise
ECDW Entering Condenser Water
ECW Entering Chilled Water
EMS Energy Management System
HGBP Hot Gas Bypass
I/O Input/Output
ICVC International Chiller Visual Controller
ISM Integrated Starter Module
LCD Liquid Crystal Display
LCDW Leaving Condenser Water
LCW Leaving Chilled Water
LED Light-Emitting Diode
OLTA Overload Trip Amps
PIC II Product Integrated Controls II
RLA Rated Load Amps
SCR Silicon Controlled Rectifier
SI International System of Units
TXV Thermostatic Expansion Valve
VFD Variable Frequency Drive
ENTER EXIT
INCREASE QUIT
6
27 10 Q 19843
Week of Year
Year of Manufacture
Unique Number
Place of Manufacture
MODEL NUMBER NOMENCLATURE
SERIAL NUMBER BREAKDOWN
Fig. 1 19XR,XRV Identification
a19-1969
*Frame sizes 1 through 6 available on single-stage units only.
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.
Refer to the 19XR, 19XRV Computer Selection Program for motor size details.
7 3
Cooler Size*
10-12 (Frame 1)
15-17 (Frame 1)
20-22 (Frame 2)
30-32 (Frame 3)
35-37 (Frame 3)
40-42 (Frame 4)
45-47 (Frame 4)
50-54 (Frame 5)
5A-5C (Frame 5)
55-59 (Frame 5)
5F-5H (Frame 5)
5K-5R (Frame 5)**
5T-5Z (Frame 5)**
60-64 (Frame 6)
6K-6R (Frame 6)**
65-69 (Frame 6)
6T-6Z (Frame 6)**
70-74 (Frame 7)
7K-7R (Frame 7)**
75-79 (Frame 7)
7T-7Z (Frame 7)**
80-84 (Frame 8)
8K-8R (Frame 8)**
85-89 (Frame 8)
8T-8Z (Frame 8)**
Condenser Size*
10-12 (Frame 1)
15-17 (Frame 1)
20-22 (Frame 2)
30-32 (Frame 3)
35-37 (Frame 3)
40-42 (Frame 4)
45-47 (Frame 4)
50-54 (Frame 5)
55-59 (Frame 5)
60-64 (Frame 6)
65-69 (Frame 6)
70-74 (Frame 7)
75-79 (Frame 7)
80-84 (Frame 8)
85-89 (Frame 8)
Compressor Frame
2, 3, 4, 5 Single-Stage
E Two-Stage
Motor Code
Motor Efficiency Code
Compressor Frame 2, 3, 4, 5
H High Efficiency
S Standard Efficiency
Compressor Frame E
A,B,C,D,E A-E Gear Ratio

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
5B
6A
6B
6C

10000-3-50
11000-3-50
11000-3-60
10000-3-60
13800-3-60
Special Order Indicator
Standard
S Special Order
Description
19XR High Efciency Semi-Hermetic
Centrifugal Liquid Chiller
19XRV High Efficiency Semi-Hermetic
Centrifugal Liquid Chiller with
Unit-Mounted VFD
Impeller Diameter
DG H 64 19XR 52 51 4
Impeller Shroud
7
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 re-
move heat from water flowing through its internal tubes.
Condenser The condenser operates at a higher temper-
ature/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 sys-
tem temperature and pressure differences and moves the heat-
carrying refrigerant from the cooler to the condenser. Compres-
sor Frames 2-5 are single-stage compressors with one impeller.
Frame E compressors are two-stage compressors with two
impellers.
Control Panel The control panel is the user interface
for controlling the chiller. It regulates the chillers 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 micropro-
cessor control
displays status of motor starter
provides access to other CCN (Carrier Comfort Net-
work

) 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.
Economizer (Optional) An economizer, along
with a two-stage compressor, allows for higher lift applica-
tions. The economizer is a separate vessel in the flow path af-
ter the condenser that improves the refrigerant cycle by allow-
ing a small amount of refrigerant to flash into vapor. This
phase change decreases the temperature of the remaining liquid
refrigerant. The vapor is drawn into the second stage of the
compressor, which saves energy because the refrigerant does
not have to be compressed by both stages.
Factory-Mounted Starter or Variable Fre-
quency Drive (Optional) The starter allows for the
proper start and disconnect of electrical energy for the com-
pressor-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, factory-
installed isolation valves on the chiller may be used to isolate
the chiller charge in either the cooler or condenser. An optional
pumpout system is used to transfer refrigerant from vessel to
vessel.
8
Fig. 2 19XR,XRV Single-Stage Compressor
REAR VIEW
FRONT VIEW
LEGEND
1 Guide Vane Actuator
2 Suction Elbow
3 International Chiller Visual Control (ICVC)
4 Chiller Identification Nameplate
5 Cooler Auto Reset Relief Valves
6 Cooler Pressure Transducer
7 Condenser In/Out Temperature Thermistors
8 Cooler In/Out Temperature Thermistors
9 Refrigerant Storage Tank Connection Valve
10 Typical Flange Connection
11 Oil Drain Valve
12 Oil Level Sight Glasses
13 Refrigerant Oil Cooler (Hidden)
14 Auxiliary Power Panel
15 Motor Housing
LEGEND
16 Condenser Auto. Reset Relief Valves
17 Motor Circuit Breaker
18 Solid-State Starter Control Display
19 Unit-Mounted Starter or VFD (Optional)
Solid-State Starter Shown
20 Motor Sight Glass
21 Cooler Return-End Waterbox Cover
22 ASME Nameplate (One Hidden)
23 Typical Waterbox Drain Port
24 Condenser Return-End Waterbox Cover
25 Refrigerant Moisture/Flow Indicator
26 Refrigerant Filter/Drier
27 Liquid Line Isolation Valve (Optional)
28 Liquid Float Valve Chamber
29 Vessel Take-Apart Connector
30 Discharge Isolation Valve (Optional)
31 Condenser Pressure Transducer
32 Refrigerant Charging Valve/Pumpout
Connection
1
2
3
5
6
4
11
12
13
15
14
7
9
10
8
18 19 20
21
22
23
31
30
29 28 27 26 25 24
32
22
22
16 17
9
Fig. 3 19XR,XRV Two-Stage Compressor
REAR VIEW
FRONT VIEW
LEGEND
1 Guide Vane Actuator
2 Suction Elbow
3 Chiller Identification Nameplate
4 Condenser Auto Reset Relief Valves
5 Condenser In/Out Temperature Thermistors
6 Cooler In/Out Temperature Thermistors
7 Cooler Pressure Transducer
8 Refrigerant Storage Tank Connection Valve
9 Refrigerant Isolation Valve
10 Chiller Visual Controller/ International Chiller
Visual Control (ICVC)
11 Typical Flange Connection
12 Oil Level Sight Glasses
13 Oil Drain Charging Valve
14 Auxiliary Power Panel
15 Refrigerant Oil Cooler (Hidden)
16 Compressor Motor Housing
LEGEND
17 Damper Valve
18 Cooler Auto. Reset Relief Valves
19 Solid-State Starter Control Display (Optional)
20 Unit-Mounted Starter (Optional)
21 Motor Sight Glass
22 Cooler Return-End Waterbox Cover
23 ASME Nameplate
24 Vessel Take-Apart Connector
25 Typical Waterbox Drain Port
26 Condenser Return-End Waterbox Cover
27 Refrigerant Moisture/Flow Indicator
28 Refrigerant Filter/Drier
29 Liquid Line Isolation Valve (Optional)
30 Linear Float Valve Chamber
31 Economizer Assembly
32 Economizer Float Ball Valve Assembly (Inside)
33 Discharge Isolation Valve (Optional)
34 Condenser Pressure Transducer
35 Refrigerant Charging Valve/Pumpout
Connection
16
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
17
18
19 20
21
22
23
24
23
25
26
27 28 29
30
31
32
33
34
35
10
REFRIGERATION CYCLE
The compressor continuously draws refrigerant vapor from
the cooler at a rate set by the amount of guide vane opening. As
the compressor suction reduces the pressure in the cooler, the
remaining refrigerant boils at a fairly low temperature (typical-
ly 38 to 42 F [3 to 6 C]). The energy required for boiling is ob-
tained 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 refrig-
erant and the vapor condenses to liquid.
The liquid refrigerant passes through orifices into the
FLASC (Flash Subcooler) chamber (Fig. 4). 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 cham-
ber between the FLASC chamber and cooler. Here the Accu-
Meter float valve forms a liquid seal to keep FLASC
chamber vapor from entering the cooler. When liquid refriger-
ant 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 tempera-
ture and pressure at which the cycle began. Refrigerant from
the condenser also cools the oil and optional variable speed
drive.
The refrigeration cycle for a 19XR,XRV chiller with two-
stage compressor is similar to the one described above, with
the following exception: Liquid refrigerant from the condenser
FLASC chamber linear float valve flows into an economizer at
intermediate pressure (see Fig. 5). As liquid enters the cham-
ber, due to the lower pressure in the economizer, some liquid
flashes into a vapor and cools the remaining liquid. The sepa-
rated vapor flows to the second stage of the compressor for
greater cycle efficiency. A damper valve located on the econo-
mizer line to the compressor acts as a pressure regulating de-
vice to stabilize low load, low condensing pressure operating
conditions. The damper will back up gas flow and thereby rais-
es the economizer pressure to permit proper refrigerant flow
through the economizer valve during those conditions. The
damper also is closed during start-up conditions to allow the
second stage impeller to start unloaded.
The subcooled liquid remaining in the economizer flows
through a float valve and then into the cooler.
Fig. 4 Refrigeration Cycle 19XR,XRV Single-Stage Compressor
a19-
1550tf
11
MOTOR AND OIL COOLING CYCLE
The motor and the lubricating oil are cooled by liquid refriger-
ant taken from the bottom of the condenser vessel (Fig. 4 and
5). 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 di-
rected over the motor by a spray nozzle. The refrigerant col-
lects in the bottom of the motor casing and is then drained back
into the cooler through the motor refrigerant drain line. An ori-
fice (in the motor shell) maintains a higher pressure in the
motor shell than in the cooler. The motor is protected by a tem-
perature 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 exchang-
er (the oil cooler in Fig. 4 and 5). The expansion valve bulbs
control oil temperature to the bearings. The refrigerant leaving
the oil cooler heat exchanger returns to the chiller cooler.
COOLER
ISOLATION
VALVE
(OPTION)
CHILLED
WATER
COMPRESSOR
BACK PRESSURE
ORIFICE (INTEGRAL
TO MOTOR SHELL)
IMPELLERS
OIL COOLER
ORIFICE
OPTIONAL UNIT
MOUNTED VFD
(VARIABLE
FREQUENCY
DRIVE) HEAT
EXCHANGER
THERMOSTATIC
EXPANSION
VALVE (TXV)
FLOAT BALL VALVE
HGBP VALVE
ORIFICE
FITTING
MOISTURE/
FLOW
INDICATOR
FILTER
DRIER
REFRIGERANT
COOLING
ISOLATION
VALVE
ROTOR
TRANSMISSION
ORIFICE
FITTING
DAMPER
VALVE
REFRIGERANT
ISOLATION VALVE
HOT GAS BYPASS (OPTIONAL)
FLOAT
VALVE
CHAMBER
CONDENSER
WATER
FLASC CHAMBER
ISOLATION
VALVE
REFRIGERANT
LIQUID
REFRIGERANT
VAPOR
REFRIGERANT
LIQUID/VAPOR
MOTOR
Fig. 5 Refrigeration Cycle 19XR,XRV Two-Stage Compressor
12
VFD COOLING CYCLE
The unit-mounted variable frequency drive (VFD) typically
has PIC III controls. The only unit-mounted drive available
with PIC II controls is the 575-v input drive.
The 575-v unit-mounted variable frequency drive (VFD) is
cooled in a manner similar to the motor and oil cooling cycle
(Fig. 4 and 5).
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 op-
erational temperatures. After the oil cooler, part of the flow is
directed to the gears and the high speed shaft bearings; the re-
maining flow is directed to the motor shaft bearings. Oil drains
into the transmission oil sump to complete the cycle (Fig. 6 and
7).
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 tem-
perature is displayed on the ICVC (International Chiller Visual
Controller) default screen. During compressor operation, the
oil sump temperature ranges between 125 and 150 F (52 and
66 C).
The oil pump suction is fed from the oil reservoir. An oil
pressure relief valve maintains 18 to 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 92-97,
for details). The oil is then piped to the oil cooler heat exchang-
er. 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 In-
tegrated 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 51). This
temperature is read on the ICVC default screen.
ISOLATION
VALVE
SIGHT
GLASS
FILTER
ISOLATION
VALVE
OIL SKIMMER
LINE
FILTER EDUCTOR
OIL
PUMP
TXV BULB PRESSURE
TRANSDUCER
ISOLATION
VALVES
OIL
COOLER
OIL PUMP
MOTOR
OIL
HEATER
MOTOR
COOLING LINE
LABYRINTH
GAS LINE
FWD MOTOR
BEARING
OIL SUPPLY TO
FORWARD HIGH
SPEED BEARING
SIGHT
GLASS
FLOW
OIL
FILTER
REAR MOTOR
BEARING
STRAINER
Fig. 6 Single-Stage Lubrication System
a19-1965
13
During the chiller start-up, using version 11 PIC II controls,
the oil pump is energized and provides 40 seconds of lubrica-
tion to the bearings after pressure is verified before starting the
compressor. During shutdown, the oil pump runs for 60 sec-
onds to ensure lubrication as the compressor coasts to a stop.
The oil pump can also be energized for testing purposes by us-
ing the Controls Test.
Ramp loading can be adjusted to help to 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 controls 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 cool-
er. 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 qui-
eter than other designs.
The gerotor pump can be most easily identified by the exter-
nal location of the oil pressure regulator. The regulator is
located on the bottom of the pump pointing horizontally to the
left. See Fig. 8.
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
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 laby-
rinth 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 suc-
tion end. The impeller side face of the midspan bearing in-
cludes 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 employ-
ing the rolling element bearings can be expected to have higher
oil pressure and thrust bearing temperatures than those com-
pressors using the alternate bearing design.
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 recov-
ered by skimming it from the operating refrigerant level in the
cooler vessel.
OIL PUMP
AND MOTOR
OIL
HEATER
OIL PRESS
REGULATOR
OIL COOLER
ISOLATION
VALVES
PRESSURE
TRANSDUCER
TXV BULB
MOTOR
COOLING LINE
REAR HIGH
SPD BRG
OIL FILTER
FLOW
EDUCTORS
SIGHT GLASS
STRAINERS
FILTER
SIGHT
GLASS
OIL SKIMMER
LINE
COOLER
LABYRINTH
GAS LINE
OIL SUPPLY TO
FORWARD HIGH
SPEED BEARING
FWD MOTOR
BEARING
REAR MOTOR
BEARING
Fig. 7 Two-Stage Lubrication System
14
PRIMARY OIL RECOVERY MODE Oil is normally re-
covered 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 sec-
ondary 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 using discharge gas pres-
sure to power an eductor. 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 cen-
trifugal hermetic compressor motor, the oil pump, and various
auxiliary equipment. The starter is the main field wiring inter-
face for the contractor.
See Carrier Specification Z-415 for specific starter require-
ments, 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 me-
chanical safety requirements. Starters may be supplied as sepa-
rate, 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 start-
er. 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 break-
er 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 con-
nected to the main breaker.
All starters and freestanding VFDs must include a Carrier
control module called the Integrated Starter Module (ISM), ex-
cluding the Benshaw solid-state and wye-delta MX3 starters.
This module controls and monitors all aspects of the starter.
See the Controls section (following) for additional ISM infor-
mation. Contact Carriers Replacement Component Division
(RCD) for replacement parts.
Unit-Mounted Solid-State Starter (Optional)
The 19XR chiller may be equipped with a solid-state, reduced-
voltage starter (Fig. 9 and 10). This starters primary function is
to provide on-off control of the compressor motor. This type of
starter reduces the peak starting torque, controls the motor in-
rush 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 in-
stalled). 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 volt-
age 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 re-
quired to get the motor moving. The voltage is reduced by sili-
con 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.
1. GERATOR OIL PUMP
2. ISOLATION VALVE
3. OIL PRESSURE REGULATOR VALVE
4. OIL SUMP PRESSURE TRANSDUCER
5. OIL SUMP DRAIN
6. BEARING TEMPERATURE SENSOR TERMINAL BLOCK
7. OIL HEATER
2
1
3
5
7
6
4
Fig. 8 Gerotor Oil Pump
a19-1852
WARNING
The main circuit breaker on the front of the starter discon-
nects 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.
15
MAIN CIRCUIT
BREAKER
TERMINAL
STRIP
MX
BOARD
METERS
SWITCHES
OPTIONAL
VOLT AND AMP
METERS AND
SELECTOR
SWITCHES
METERS ME
SWITCHES
KEYPAD/
DISPLAY
Fig. 9 Benshaw Solid-State Starter, Internal View
a19-1896
SIDE SERVICE
ACCESS PANEL
AIR INTAKE
LOUVERS
OPTIONAL ANALOG 3-PHASE
VOLTMETER AND AMMETER
STARTER CONTROL
DISPLAY INTERFACE
VOLTMETER/
AMMETER
SELECTOR
SWITCHES
STARTER
ACCESS
DOOR
MOTOR
POWER
DISCONNECT
HANDLE
LOW VOLTAGE
ACCESS
DOOR
Fig. 10 Typical Starter External View (Solid-State Starter Shown)
a19-1854
16
There is a display on the front of the Benshaw, Inc., solid-
state 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 72 and 97.
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 mo-
tors (under 600 v). It reduces the starting current inrush by con-
necting each phase of the motor windings into a wye configu-
ration. This occurs during the starting period when the motor is
accelerating up to speed. Once the motor is up to speed, the
starter automatically connects the phase windings into a delta
configuration. Starter control, monitoring, and motor
protection is provided by Carriers Integrated Starter Module
(ISM) except for Benshaw MX3 wye-delta starters which do
not use an ISM.
Unit-Mounted VFD (Optional for 575 v
Only) The 19XRV unit can be equipped with a variable
frequency drive motor controller mounted on the unit. See
Fig. 11. This VFD is used with low voltage motors at 575 v on-
ly. All other unit-mounted VFDs use PIC III controls. A VFD
reduces the starting current inrush by controlling the voltage
and frequency to the compressor motor. Once the motor has ac-
celerated to start-up speed the PIC II modulates the compressor
speed and guide vane position to control chilled water tempera-
ture. The VFD is further explained in the Controls section and
Troubleshooting Guide sections, pages 17 and 97.
Typically, three separate circuit breakers are inside the start-
er. 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 pro-
vided to those services when the VFD circuit breaker is open.
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 volt-
age. Do not touch the heat sinks, power wiring, or motor
terminals while voltage is present or serious injury will
result.
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 dis-
connect power will result in personal injury.
57.17
54.54
60.00
INPUT INDUCTOR
BEHIND CAP
ASSEMBLY
12
15
14
13
6 8
7
9
1
2
3
4
5
11
10
3KVA X-FORMER
BEHIND
THE 15AMP CB
Fig. 11 PIC II Unit-Mounted 575-v Variable Frequency Drive (VFD) Internal View
LEGEND
1 Main Power Circuit Breaker (CB)
2 Electric Surge Protector
3 Control Transformer
4 Contr Power CB
5 Control Power Fuse
6 Oil Pump CB
7 Pre-Charge Resistors
8 Pre-Charge Fuses
9 Pre-Charge Contactors
10 Input line Reactor
11 Capacitor Filter Bank
12 Input Current Transformers
13 Interface Relays
14 ISM
15 VFD Power Module
17
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 dis-
cussed above, 19XR chillers may be provided with other alter-
natives 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 con-
trols remains consistent.
CONTROLS
Definitions
ANALOG SIGNAL An analog signal varies in proportion
to the monitored source. It quantifies values between operating
limits. (Example: A temperature sensor is an analog device be-
cause its resistance changes in proportion to the temperature,
generating many values.)
DISCRETE SIGNAL A discrete signal is a 2-position rep-
resentation of the value of a monitored source. (Example: A
switch produces a discrete signal indicating whether a value is
above or below a set point or boundary by generating an on/off,
high/low, or open/closed signal.)
General The 19XR hermetic centrifugal liquid chiller
contains a microprocessor-based control center that monitors
and controls all operations of the chiller (see Fig. 12). The mi-
croprocessor control system matches the cooling capacity of
the chiller to the cooling load while providing state-of-the-art
chiller protection. The system controls cooling load within the
set point plus the deadband by sensing the leaving chilled water
or brine temperature and regulating the inlet guide vane via a
mechanically linked actuator 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 va-
por flow into the compressor. An increase in guide vane open-
ing increases capacity. A decrease in guide vane opening de-
creases capacity. The microprocessor-based control center pro-
tects the chiller by monitoring the digital and analog inputs and
executing capacity overrides or safety shutdowns, if required.
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 main-
tain 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 by-
pass valve, if installed. The PIC II controls provide critical pro-
tection for the compressor motor and controls the motor starter.
The PIC II can interface with the Carrier Comfort Net-
work

(CCN) if desired. It can communicate with other PIC I,

PIC II or PIC III equipped chillers and other CCN devices.
The PIC II consists of 3 modules housed inside 3 major
components. The component names and corresponding control
voltages are listed below (also see Table 1):
control panel
all extra low-voltage wiring (24 v or less)
power panel
115 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)
OIL COOLER THERMOSTATIC
EXPANSION VALVE (TXV)
OIL COOLER THERMOSTATIC
EXPANSION VALVE (TXV) BULB
OIL HEATER TERMINAL
BOX
HIGH PRESSURE
SWITCH LOCATION
COMPRESSOR DISCHARGE
TEMPERATURE SENSOR
CABLE
GUIDE VALVE
ACTUATOR CABLE
DIFFUSER PRESSURE
AND DIFFUSER ACTUATOR
CABLE (FRAME 4 & 5
COMPRESSOR ONLY)
OIL RECLAIM
SIGHT GLASS
CABLE FROM
CONTROL PANEL
COMPRESSOR OIL SUMP
TEMPERATURE CABLE
COMPRESSOR OIL SUMP
PRESSURE CABLE
BEARING TEMPERATURE
SENSOR CABLE
COMPRESSOR OIL DISCHARGE
PRESSURE CABLE
MOTOR TEMPERATURE
SENSOR CABLE
Fig. 12 19XR,XRV Compressor Controls and Sensor Locations
a19-1606
18
Table 1 Major PIC II Components and
Panel Locations
INTERNATIONAL CHILLER VISUAL CONTROLLER
(ICVC) The ICVC (International Chiller Visual Controller)
is a display/processor module that comes preprogrammed to
display all tables in the following optional character sets (lan-
guages): 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.
The ICVC may be identified by viewing the back of the
plate on which the display is mounted. (Open up the control
panel door to view.)
*This manual covers ICVC software version 11. Obtain obsolete
manuals and service bulletins for information on previous software
versions.
The ICVC has a stop button, an alarm light, four buttons for
logic inputs, and a backlight display. The backlight will auto-
matically 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 opti-
mum 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. 13. To change the contrast of the
display, access the adjustment on the back of the ICVC. See
Fig. 13.
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 acti-
vate the backlight display without implementing a softkey
function.
INTEGRATED STARTER MODULE (ISM) This mod-
ule is located in the starter cabinet. This module initiates com-
mands from the ICVC for starter functions such as starting and
stopping the compressor, condenser, chilled water pumps, tow-
er fan, spare alarm contacts, and the shunt trip. The ISM moni-
tors starter inputs such as line voltage, motor current, ground
fault, remote start contact, spare safety, condenser high pres-
sure, 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) com-
munications bus. The ISM software also defines conditions for
transition for different starter types, and it integrates I
2
t in mon-
itoring 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 de-
mand limit, chilled water reset, remote temperature reset, re-
frigerant leak sensor and motor kilowatt output.
OIL HEATER CONTACTOR (1C) This contactor is lo-
cated in the power panel (Fig. 14) and operates the heater at ei-
ther 115 or 230 v. It is controlled by the PIC II to maintain oil
temperature during chiller shutdown. Refer to the control panel
wiring schematic.
OIL PUMP CONTACTOR (2C) This contactor is located
in the power panel. It operates all 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 transform-
ers 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 15 shows a typical temperature sensor for which
sensor wells are not used, in systems having an ICVC control-
ler. 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. 16. 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 sen-
sors.
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 tem-
peratures for R-134a refrigerant. When the chiller is running, if
the computed value for EVAPORATOR REFRIG TEMP is
greater than, or within 0.6 F (0.33 C) of the LEAVING
CHILLED WATER temperature, its value is displayed as 0.6 F
(0.33 C) below LEAVING CHILLED WATER temperature.
When the chiller is running, if the computed value for CON-
DENSER REFRIG TEMP is less than, or within 1.2 F
(0.67 C) of the LEAVING COND WATER temperature, its val-
ue is displayed as 1.2 F (0.67 C) above LEAVING COND
WATER temperature.
PIC II COMPONENT PANEL LOCATION
Chiller Visual Controller (ICVC) and
Display
Control Panel
Integrated Starter Module (ISM) Starter Cabinet
Chiller Control Module (CCM) Control Panel
Oil Heater Contactor (1C) Power Panel
Oil Pump Contactor (2C) Power Panel
Hot Gas Bypass Relay (3C) (Optional) Power Panel
Control Transformers (T1, T2) Power Panel
Temperature Sensors
See Fig. 2, Fig. 12,
and Table 2
Pressure Transducers
See Fig. 2, Fig. 12,
and Table 2
CONTROLL-
ER
COLOR OF
PLATE
CEPL NO.
(Hardware)
SOFTWARE
NO.*
OTHER
MARKINGS
ICVC Metallic
CEPL
130455-03-R
CESR
131294-11
PIC II mark-
ing on back
of green cir-
cuit board
19


DIFFUSER
SCHEDULE
SETTINGS
(FRAME 5
COMPRESSOR
AND FRAME 4
WITH SPLIT RING
DIFFUSER ONLY)
CARRIER COMFORT
NETWORK (CCN)
INTERFACE
CONTROL POWER
CIRCUIT BREAKERS
(CB1,CB2)
SURGE/HGBP
PARAMETER
LABEL CHILLER CONTROL
MODULE (CCM)
CONTROL PANEL INTERNAL VIEW
CHILLER
VISUAL
CONTROLLER
(ICVC)
FRONT VIEW
CONTROL PANEL
DISPLAY
(FRONT VIEW)
Fig. 13 Control Panel
a19-1855
a19-1897
a19-1956
OIL HEATER CONDUIT CONTROL PANEL
POWER CONDUIT
OPTIONAL HOT GAS
BYPASS CONDUIT
3C HOT GAS BYPASS
RELAY (OPTIONAL)
T2-24 VAC POWER TRANSFORMER
FOR ICVC AND CCM
T1-24 VAC POWER TRANSFORMER
FOR HOT GAS BYPASS RELAY,
OIL PUMP CONTACTOR, AND
OIL HEATER CONTACTOR
T1 T2
OIL HEATER
CONTACTOR
11 12 13
21 22 23
11 12 13
21 22 23
31
65
42
51
50
43
17
C
B
A
OIL PUMP
CONTACTOR
Fig. 14 Power Panel
a19-1856
20
Table 2 Standard Instrumentation Sensors
A Refrigerant Saturation Temperature sensor (thermistor) is
located in the base of the evaporator, sensing refrigerant tem-
perature directly. Evaporator and condenser water side differ-
ential pressure transducers are not standard and are not re-
quired. The ICVC software uses the evaporator saturation re-
frigerant 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). CONDENS-
ER APPROACH is defined as CONDENSER REFRIGER-
ANT TEMP (derived from condenser pressure) minus LEAV-
ING 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.
ICVC Operation and Menus (Table 3 and
Fig. 17-23)
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. 17).
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. 18).
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 62.
MODES
LOCAL In LOCAL mode the PIC II accepts com-
mands from the ICVC only and uses the local time occu-
pancy 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.
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.
TYPE LOCATION MONITORED REMARKS
Temperature
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
Pressure
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
Angular Position
Guide Vane Actuator Potentiometer Inside of Actuator
Split Ring Diffuser Actuator (only on split ring dif-
fuser equipped machines)
Potentiometer Inside of the Actuator (Split Ring Diffuser Position is
not Displayed on the ICVC)
Pressure Switch High Condenser (Discharge) Pressure Wired into the Starter Control Circuit
Temperature Switch Oil Pump Motor Winding Temperature Wired into the Oil Pump Control Circuit
Fig. 15 Control Sensors (Temperature)
SHRINK WRAP
STRAIN RELIEF
1/8 NPT
THERMOWELL
REMOVABLE
TEMPERATURE
SENSOR
Fig. 16 Temperature Sensor Used
with Thermal Well
a23-1624
21
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 access-
ing 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 ma-
chine safety or fire alarm. See Table 4.
ALARMS AND ALERTS An alarm shuts down the com-
pressor. An alert does not shut down the compressor, but it no-
tifies 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 soft-
key), 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 suc-
cessfully completed its self test. The self test takes place auto-
matically, after power-up.
Press the softkey to view the list of menu struc-
tures: , , , and
.
The STATUS menu allows viewing and limited calibra-
tion 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. 20.
Press the softkey that corresponds to the menu structure to
be viewed: , , or
. 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 soft-
key to select that item. The softkey choices that then appear de-
pend 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.
Press to leave the selected decision or field with-
out saving any changes.
Press to leave the selected decision or field and
save changes.
Press to scroll the cursor bar down in order to
highlight a point or to view more points below the cur-
rent screen.
Press to scroll the cursor bar up in order to
highlight a point or to view points above the current
screen.
RUNNING TEMP CONTROL
LEAVING CHILLED WATER
01-01-95 11:48
28.8 HOURS
CHWIN CHWOUT EVAP REF
CDWIN CDWOUT COND REF
OILPRESS OILTEMP AMPS %
CCN LOCAL RESET MENU
55.1 44.1 40.7
85.0 95.0 98.1
21.8 132.9 93
PRIMARY STATUS
MESSAGE
COMPRESSOR
ON TIME
DATE TIME
SOFT KEYS
MENU
LINE
EACH KEY'S FUNCTION IS
DEFINED BY THE MENU DESCRIPTION
ON MENU LINE ABOVE
ALARM LIGHT
(ILLUMINATED
WHEN POWER ON)
STOP BUTTON

HOLD FOR ONE

SECOND TO STOP

BLINKS CONTINUOUSLY
ON FOR AN ALARM
BLINKS ONCE TO
CONFIRM A STOP
SECONDARY
STATUS
MESSAGE
Fig. 17 ICVC Default Screen
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
ALARM HISTORY
19XR_II SERVICE
Fig. 18 ICVC Service Screen
RESET
MENU
STATUS SCHEDULE SETPOINT
SERVICE
STATUS SCHEDULE SETPOINT
SERVICE
NEXT PREVIOUS
SELECT
QUIT
ENTER
NEXT
PREVIOUS
22
Press to view the next screen level (high-
lighted with the cursor bar), or to override (if allowable)
the highlighted point value.
Press to return to the previous screen level.
Press or to change the high-
lighted point value.
TO VIEW STATUS (Fig. 19) 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 to view the list of
point status tables.
2. Press or to highlight the desired
status table. The list of tables is:
MAINSTAT Overall chiller status
VPF_STAT Variable primary flow surge preven-
tion 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 com-
pressor
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
3. Press to view the desired point status table.
4. On the point status table, press or
until the desired point is displayed on the screen.
OVERRIDE OPERATIONS (Manual Overrides)
To Force (Manually Override) a Value or Status
1. From any point status screen, press
or to highlight the desired value.
2. Press to select the highlighted value. Then:
For Discrete Points Press or to se-
lect the desired state.
For Analog Points Press
or to select the desired value.
3. Press to register the new value.
NOTE: When forcing or changing metric values, it is neces-
sary to hold down the softkey for a few seconds in order to see
a value change, especially on kilopascal values.
SELECT
EXIT
INCREASE DECREASE
STATUS
NEXT PREVIOUS
SELECT
19XR_II MAINSTAT POINT STATUS
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
OFF
Ready
0.0 Min
NO
NORMAL
STOP
Open
0.0 F
44.0 F
44.6 F
100%
0.0%
Fig. 19 Example of Status Screen
NEXT PREVIOUS
NEXT
PREVIOUS
SELECT
START STOP
INCREASE
DECREASE
ENTER
23
CCN LOCAL RESET MENU
DEFAULT SCREEN
Start Chiller In CCN Control
Start Chiller in Local Control
Clear Alarms
STAT US SCHEDULE SETPOINT SERVICE
(SOFTKEYS)
Access Main Menu
List the
Status T ables
Display The Setpoint T able
(ENTER A 4-DIGIT P ASSWORD) (V ALUES SHOWN AT F ACTORY DEFAULT)
List the Service Ta bles
OCCPC01S LOCAL TIME SCHEDULE
OCCPC02S ICE BUILD TIME SCHEDULE
OCCPC03S CCN TIME SCHEDULE
List the Schedules
1
ALARM HISTORY
ALERT HISTORY
CONTROL T EST
CONTROL ALGORITHM STAT US
EQUIPMENT CONFIGURA TION
ISM CONFIG DA TA
EQUIPMENT SERVICE
TIME AND DA TE
AT T ACH TO NETWORK DEVICE
LOG OUT OF DEVICE
ICVC CONFIGURA TION
Base Demand Limit
LCW Setpoint
ECW Setpoint
Ice Build Setpoint
To wer Fan High Setpoint
EXIT SELECT PREVIOUS NEXT
Select a Schedule
1
2
3
4
5
6
7
8
Override
ENABLE DISABLE
EXIT SELECT PREVIOUS NEXT
Select a Time Period/Override
Modify a Schedule Time
ENTER EXI T
INCREASE DECREASE ENTER EXI T (ANALOG VA LUES)
(DISCRETE VA LUES)
Add/Eliminate a Da y
1 1 1
Select a Status T able
NEXT PREVIOUS SELECT EXIT
START
ON
STOP
OFF
RELEASE ENTER
EXIT NEXT PREVIOUS SELECT
ENTER ENABLE DISABLE QUIT
DECREASE INCREASE ENTER RELEASE
Select a Modification Point
Modify a Discrete Point
Modify an Analog Point
Modify Control Options
MAINSTAT
STARTUP
COMPRESS
HEA T_EX
POWER
ISM_ STAT
ICVCPSWD
Modify the Setpoint
DECREASE INCREASE QUIT ENTER
NEXT PREVIOUS SELECT EXIT
Select the Setpoint

NEXT PREVIOUS SELECT EXIT

SEE FIGURE 21
VPF_STAT
VDO_STAT
Fig. 20 PIC II19XR,XRV Chiller Display Menu Structure for ICVC Software Version 11
a19-2047
24
NEXT PREVIOUS SELECT EXIT
SERVICE TABLE
Display Alarm History
(The table holds up to 25 alarms
with the most recent alarm at
the top of the screen.) See note.
CCM Thermistors
CCM Pressure Transducers
Pumps
Discrete Outputs
IGV and SRD Actuator
Head Pressure Output
Diffuser Actuator
Pumpdown/Lockout
Terminate Lockout
Guide Vane Calibration
CONTINUED
ON NEXT PAGE
CONTROL ALGORITHM STATUS
CONTROL TEST
ALARM HISTORY
List the Control Tests
NEXT PREVIOUS SELECT EXIT
Select a Test
List the Control Algorithm Status Tables
CAPACITY (Capacity Control)
OVERRIDE (Override Status)
LL_MAINT (Lead Lag Status)
ISM_HIST (ISM Alarm History)
LOADSHED
CUR_ALARM (Current Alarm State)
WSMCHLRE (Water System Manager Control Status)
OCCDEFCM (Time Schedule Status)
NEXT PREVIOUS SELECT EXIT
Select a Table
NET_OPT
BRODEF
OCCDEFCS
HOLIDAYS
CONSUME
RUNTIME
(ANALOG VALUES)
(DISCRETE VALUES)
Select a Parameter
NEXT PREVIOUS SELECT EXIT
Modify a Parameter
ENTER ENABLE DISABLE QUIT
DECREASE INCREASE ENTER QUIT
NEXT PREVIOUS SELECT EXIT
Select a Table
EQUIPMENT CONFIGURATION List the Equipment Configuration Tables
CAPACITY (Capacity Control Algorithm)
OVERRIDE (Override Status)
LL_MAINT (LEADLAG Status)
WSMCHLRE (Water System Manager Control Status)
Maintenance Table Data
NEXT PREVIOUS SELECT EXIT
Data Select Table
OCCPC01S (Local Status)
OCCPC02S (CCN, ICE BUILD Status)
OCCPC03S (CCN Status)
OCCDEFM (Time Schedule Status)
SELECT (USE ENTER) TO SCROLL DOWN
(The table holds up to 25 alerts
with the most recent alert at
the top of the screen.) See Note.
Alert History
ALERT HISTORY
SURGPREV (Surge Prevention)
Fig. 21 PIC II 19XR,XRV Service Menu Structure for ICVC Software Version 11
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.
a19-2048
25
NEXT PREVIOUS SELECT EXIT
SERVICE MENU CONTINUED
FROM PREVIOUS PAGE
Select a Service Table
Select a Service Table Parameter
NEXT PREVIOUS SELECT EXIT
Modify a Service Table Parameter
(ANALOG VALUES)
(DISCRETE VALUES)
TIME AND DATE
Display Time and Date Table:
To Modify Current Time Day of Week
Current Date Holiday Today
ATTACH TO NETWORK DEVICE
ENTER DECREASE INCREASE EXIT
ENTER ENABLE DISABLE QUIT
DECREASE INCREASE ENTER QUIT
Select a Device
ATTACH NEXT PREVIOUS SELECT
Modify Device Address
EXIT INCREASE DECREASE ENTER
Use to attach ICVC to another CCN network or device
Attach to "LOCAL" to enter this machine
To upload new tables
Default Screen
MENU RESET CCN LOCAL
LOG OUT OF DEVICE
List Network Devices
Local
Device 1
Device 2
Device 3
Device 4
Device 5
Device 6
Device 7
Device 8
Attach to any Device
Service Tables:
OPTIONS
SETUP1
SETUP2
LEADLAG
RAMP_DEM
TEMP_CTL
EQUIPMENT SERVICE
ISM STARTER CONFIG DATA
Service Tables:
ISM (STARTER) CONFIG PASSWORD
ISM_CONF
(ENTER A 4-DIGIT PASSWORD)
(VALUES SHOWN AT FACTORY DEFAULT)
4 4 4 4
ICVC CONFIGURATION
EXIT INCREASE DECREASE ENTER
ICVC Configuration Table
To Modify ICVC CCN Bus and Address
Baud Rate (Do not change this)
English (U.S. IMP.) or S.I. Metric Units
Password
LID Language
To View ICVC Software Version
(last 2 digits of part number
indicate software version)
ENTER NO YES EXIT
(ANALOG VALUE)
(DISCRETE VALUE)
VDO_SRD
LEGEND
CCN Carrier Comfort Network
ICVC International Chiller Visual Controller
ISM Integrated Starter Module
PIC II Product Integrated Control II
Fig. 21 PIC II 19XR,XRV Service Menu Structure for ICVC Software Version 11 (cont)
a19-1859
26
To Remove a Force
1. On the point status table press or
to highlight the desired value.
2. Press to access the highlighted value.
3. Press to remove the override and return the
point to the PIC IIs automatic control.
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. 22)
On the Menu screen, press .
4. Press or to highlight the desired
schedule.
OCCPC01S LOCAL Time Schedule
OCCPC02S ICE BUILD Time Schedule
OCCPC03S CCN Time Schedule
5. Press to view the desired time schedule.
6. Press or to highlight the desired
period or override to change.
7. Press to access the highlighted period or over-
ride.
8. a. Press or to change the
time values. Override values are in one-hour
increments, up to 4 hours.
b. Press to select days in the day-of-week
fields. Press to eliminate days from the
period.
9. Press to register the values and to move horizon-
tally (left to right) within a period.
10. Press to leave the period or override.
11. Either return to Step 4 to select another period or over-
ride, or press again to leave the current time sched-
ule screen and save the changes.
12. The Holiday Designation (HOLIDEF table) may be
found in the Service Operation section, page 62. 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.
NEXT PREVIOUS
SELECT
RELEASE
SCHEDULE
NEXT PREVIOUS
SELECT
NEXT PREVIOUS
SELECT
Fig. 22 Example of Time Schedule
Operation Screen
INCREASE DECREASE
ENABLE
DISABLE
ENTER
EXIT
EXIT
27
TO VIEW AND CHANGE SET POINTS (Fig. 23)
1. To view the SETPOINT table, from the MENU screen
press .
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 ac-
tive 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 62. The ice build (ICE BUILD)
function is also activated and configured from the SER-
VICE menu.
3. Press or to highlight the desired
set point entry.
4. Press to modify the highlighted set point.
5. Press or to change the select-
ed set point value.
6. Press to save the changes and return to the previ-
ous screen.
SERVICE OPERATION To view the menu-driven pro-
grams available for Service Operation, see Service Operation
section, page 62. For examples of ICVC display screens, see
Table 3.
SETPOINT
19XR_II SETPOINT SELECT SETPOINT
Base Demand Limit
Control Point
LCW Setpoint
ECW Setpoint
ICE BUILD Setpoint
Tower Fan High Setpoint
100%
50.0 F
60.0 F
40.0 F
85.0 F
Fig. 23 Example of Set Point Screen
NEXT PREVIOUS
SELECT
INCREASE DECREASE
ENTER
28
Table 3 ICVC Display Data
1. The Display data shown applies to ICVC software version 11.
2. Only 12 lines of information appear on the chiller display screen
at any one time. Press the or softkey to
highlight a point or to view items below or above the current
screen. Press the softkey twice to page forward; press
the softkey twice to page back.
3. To access the information shown in Examples 10 through 25,
enter your 4-digit password after pressing the soft-
key. If no softkeys are pressed for 15 minutes, the ICVC auto-
matically 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 10 through 25.
4. Terms in the Description column of these tables are listed as
they appear on the chiller display screen.
5. The ICVC may be configured in English or Metric (SI) units
using the ICVC CONFIGURATION screen. See the Service
Operation section, page 62, for instructions on making this
change.
6. 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.
7. Reference Point Names shown in these tables in all capital let-
ters can be read by CCN and BS software. Of these capitalized
names, those preceded by a dagger () can also be changed
(that is, written to) by the CCN, BS, and the ICVC. Capitalized
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.
8. 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 indi-
cates an alert state. The asterisk (or exclamation point) indi-
cates 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 21.
9. Index of all ICVC parameters is shown in Appendix A.
10. 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
IMPORTANT: The following notes apply to all Table 3
examples.
NEXT PREVIOUS
NEXT
PREVIOUS
SERVICE
CCN Carrier Comfort Network
CHW Chilled Water
CT Current Transformer
ECW Entering Chilled Water
HGBP Hot Gas Bypass
ICVC International Chiller Visual Controller
IGV Inlet Guide Vane
ISM Integrated Starter Module
LCW Leaving Chilled Water
LRA Locked Rotor Amps
mA Milliamps
P Pressure
PIC II Product Integrated Controls II
SRD Split Ring Diffuser
SS Solid State
T Temperature
VFD Variable Frequency Drive
WSM Water System Manager
^ F Temperature Difference in Degrees Fahrenheit
29
Table 3 ICVC Display Data (cont)
EXAMPLE 1 CHILLER DISPLAY DEFAULT SCREEN
The following data is displayed in the Default screen.
NOTES:
1. The Evaporator Refrigerant Temperature displayed is the
smaller value of EVAP REFRIG LIQUID TEMP or CALC EVAP
SAT TEMP.
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 .
2. Press ( will be highlighted).
3. Press .
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 opera-
tions 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.
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 is starting back up due to a power failure and
auto-restart is enabled.
Override: The chiller is prevented from reaching full load by the con-
trols because the chiller is running close to an operational limit.
Tripout: The chiller has declared an alarm and has shut down.
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 energiz-
ing the compressor motor.
DESCRIPTION STATUS UNITS
REFERENCE POINT NAME
(ALARM HISTORY)
DISPLAY
(PRIMARY MESSAGE)
(SECONDARY MESSAGE)
(DATE AND TIME)
Compressor Ontime 0-500000.0 HOURS C_HRS
Entering Chilled Water 40-245 DEG F ECW CHW IN
Leaving Chilled Water 40-245 DEG F LCW CHW OUT
Evaporator Refrigerant Temperature (See Note 1) 40-245 DEG F ERT_EST EVAP REF
Entering Condenser Water 40-245 DEG F ECDW CDW IN
Leaving Condenser Water 40-245 DEG F LCDW CDW OUT
Condenser Refrigerant Temperature 40-245 DEG F CRT COND REF
Oil Pressure 0-420 PSI OILPD OILPRESS
Oil Sump Temp 40-245 DEG F OILT OIL TEMP
Average Line Current 0-999 % %_AMPS % AMPS
0-1 CCN
0-1 LOCAL
0-1 RESET
DESCRIPTION STATUS UNITS POINT
Control Mode NOTE 2 NOTE 2 MODE
Run Status NOTE 3 NOTE 3 STATUS
Start Inhibit Timer 0-15 min T_START
Occupied? 0/1 NO/YES OCC
System Alert/Alarm 1-3 NOTE 4 SYS_ALM
Chiller Start/Stop 0/1 STOP/START CHIL_S_S
Remote Start Contact 0/1 OPEN/CLOSE REMCON
Temperature Reset 30-30 DEG F T_RESET
Control Point (See Note 7) 10-120 DEG F LCW_STPT
Chilled Water Temp (See Note 8) 40-245 DEG F CHW_TMP
Active Demand Limit 40-100 % DEM_LIM
Average Line Current 0-999 % AMPS_%
Motor Percent Kilowatts 0-999 % KW_P
Auto Demand Limit Input 4-20 mA AUTODEM
Auto Chilled Water Reset 4-20 mA AUTORES
Remote Reset Sensor 40-245 DEG F R_RESET
Total Compressor Starts 0-99999 c_starts
Starts in 12 Hours 0-8 STARTS
Compressor Ontime 0-500000.0 HOURS c_hrs
Service Ontime 0-32767 HOURS S_HRS
Ice Build Contact 0-1 OPEN/CLOSE ICE_CON
Refrigerant Leak Sensor 0-20 mA REF_LEAK
Emergency Stop 0/1 ENABLE/EMSTOP ENABLE
Alarm Relay 0/1 NORMAL/ALARM
MENU
STATUS MAINSTAT
SELECT
30
Table 3 ICVC Display Data (cont)
EXAMPLE 3 STARTUP DISPLAY SCREEN
To access this display from the ICVC default screen:
1. Press .
2. Press .
3. Scroll down to highlight .
4. Press .
NOTE: All variables with CAPITAL LETTER point names are avail-
able for CCN read operation. Those shown with (**) shall support
write operations for the ICVC only.
EXAMPLE 4 COMPRESS DISPLAY SCREEN
To access this display from the ICVC default screen:
1. Press .
2. Press .
3. Scroll down to highlight .
4. Press .
NOTE: All variables with CAPITAL LETTER point names are avail-
able for CCN read operation. Those shown with (**) shall support
write operations for the ICVC only.
DESCRIPTION STATUS UNITS POINT
Actual Guide Vane Pos 0-100 % GV_ACT
**Chilled Water Pump 0-1 OFF/ON CHWP
Chilled Water Flow 0-1 NO/YES CHW_FLOW
**Condenser Water Pump 0-1 OFF/ON CDP
Condenser Water Flow 0-1 NO/YES CDW_FLOW
Oil Pump Relay 0-1 OFF/ON OILR
**Oil Pump Delta P 6.7-200 ^PSI OILPD
Compressor Start Relay 0-1 OFF/ON CMPR
Compressor Start Contact 0-1 OPEN/CLOSED 1CR_A
Starter Trans Relay 0-1 OFF/ON CMPTRANS
Compressor Run Contact 0-1 OPEN/CLOSED 2M_AUX
**Tower Fan Relay Low 0-1 OFF/ON TFR_LOW
**Tower Fan Relay High 0-1 OFF/ON TFR_HIGH
Starter Fault 0-1 ALARM/NORMAL STR_FLT
Spare Safety Input 0-1 ALARM/NORMAL SAFETY
Shunt Trip Relay 0-1 OFF/ON TRIPR
ISM Fault Status 0-255 ISMFLT
MENU
STATUS
STARTUP
SELECT
DESCRIPTION STATUS UNITS POINT
Actual Guide Vane Pos 0-100 % GV_POS
Guide Vane Delta -2.0-2.0 % GV_DELTA
**Target Guide Vane Pos 0-100 % GV_TRG
Oil Sump Temp 40 245 F OILT
**Oil Pump Delta P -6.7-200 PSI OILPD
Comp Discharge Temp 40 245 F CMPD
Comp Thrust Brg Temp 40 245 F MTRB
Comp Thrust Lvg OilTemp 40 245 F MTRB_OIL
Comp Thrust Brg Reset 40 245 F TB_RESET
Comp Motor Winding Temp 40 245 F MTRW
Spare Temperature 1 40 245 F SPARE_T1
Spare Temperature 2 40 245 F SPARE_T2
Oil Heater Relay 0/1 OFF/ON OILHEAT
Diffuser Actuator 0-100 % DIFF_OUT
SRD Rotating Stall 0-1 NO/YES DIFFAULT
**Target VFD Speed 0-110 % VFD_OUT
**Actual VFD Speed 0-110 % VFD_ACT
Surge Protection Counts 0-5 SPC
Active Delta Tsat 0-200 ^ F CDW_DT
Surge Line Delta Tsat 0-200 ^ F DELTA_TX
Surge Prevention Active? 0/1 NO/YES SHG_ACT
MENU
STATUS
COMPRESS
SELECT
31
Table 3 ICVC Display Data (cont)
EXAMPLE 5 HEAT_EX DISPLAY SCREEN
To access this display from the ICVC default screen:
1. Press .
2. Press .
3. Scroll down to highlight .
4. Press .
NOTE: All variables with CAPITAL LETTER point names are avail-
able for CCN read operation. Those shown with (**) shall support
write operations for the ICVC only.
EXAMPLE 6 POWER DISPLAY SCREEN
To access this display from the ICVC default screen:
1. Press .
2. Press .
3. Scroll down to highlight .
4. Press .
NOTE: All variables with CAPITAL LETTER point names are avail-
able for CCN read operation. Those shown with (**) shall support
write operations for ICVC only.
DESCRIPTION STATUS UNITS POINT
**Chilled Water Delta P -6.7-420 PSI CHWPD
Entering Chilled Water 40 245 F ECW
Leaving Chilled Water 40 245 F LCW
Chilled Water Delta T 40 245 ^ F CHW_DT
Chill Water Pulldown/Min -20-20 ^ F CHW_PULL
Calc Evap Sat Temp 40 245 F ERT
**Evaporator Pressure -6.7 420 PSI ERP
Evap Refrig Liquid Temp 40.0 245.0 F EST
Evaporator Approach 0-99 ^ F EVAP_APP
**Condenser Water Delta P -6.7-420 PSI CDWPD
Entering Condenser Water 40 245 F ECDW
Leaving Condenser Water 40 245 F LCDW
Condenser Refrig Temp 40 245 F CRT
**Condenser Pressure -6.7 420 PSI CRP
Condenser Approach 0-99 ^ F COND_APP
Hot Gas Bypass Relay 0/1 OFF/ON HGBYPASS
Surge Prevention Active? 0/1 NO/YES SHG_ACT
Actual Guide Vane Pos 0-100 % GV_POS
Active Delta Tsat 0-200 ^ F CDW_DT
Surge Line Delta Tsat 0-200 ^ F DELTA_TX
Head Pressure Reference 0-100 % HPR
MENU
STATUS
HEAT_EX
SELECT
DESCRIPTION STATUS UNITS POINT
Average Line Current 0-999 % AMPS_P
Actual Line Current 0-99999 AMPS AMP_A
Average Line Voltage 0-999 % VOLT_P
Actual Line Voltage 0-99999 VOLTS VOLT_A
Power Factor 0.0-1.0 POW_FACT
Motor Kilowatts 0-99999 kW KW
**Motor Kilowatt-Hours 0-99999 kWH KWH
Demand Kilowatts 0-99999 kWH DEM_KWH
Line Current Phase 1 0-99999 AMPS AMPS_1
Line Current Phase 2 0-99999 AMPS AMPS_2
Line Current Phase 3 0-99999 AMPS AMPS_3
Line Voltage Phase 1 0-99999 VOLTS VOLT_1
Line Voltage Phase 2 0-99999 VOLTS VOLT_2
Line Voltage Phase 3 0-99999 VOLTS VOLT_3
Ground Fault Phase 1 0-999 AMPS GF_1
Ground Fault Phase 2 0-999 AMPS GF_2
Ground Fault Phase 3 0-999 AMPS GF_3
Frequency 0-99 Hz FREQ
I2T Sum Heat-Phase 1 0-200 % SUM1HEAT
I2T Sum Heat-Phase 2 0-200 % SUM2HEAT
I2T Sum Heat-Phase 3 0-200 % SUM3HEAT
MENU
STATUS
POWER
SELECT
32
Table 3 ICVC Display Data (cont)
EXAMPLE 7 ISM_STAT DISPLAY SCREEN
To access this display from the ICVC default screen:
1. Press .
2. Press .
3. Scroll down to highlight .
4. Press .
NOTE: All variables with CAPITAL LETTER point names are avail-
able for CCN read operation.
EXAMPLE 8 ICVCPSWD DISPLAY SCREEN
To access this display from the ICVC default screen:
1. Press .
2. Press .
3. Scroll down to highlight
4. Press .
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
without a password. This access is cancelled at 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 Comfort-
WORKS

controls.
DESCRIPTION STATUS UNITS POINT
ISM Fault Status 0-255 ISMFLT
Single Cycle Dropout 0-1 NORMAL/ALARM CYCLE_1
Phase Loss 0-1 NORMAL/ALARM PH_LOSS
Overvoltage 0-1 NORMAL/ALARM OV_VOLT
Undervoltage 0-1 NORMAL/ALARM UN_VOLT
Current Imbalance 0-1 NORMAL/ALARM AMP_UNB
Voltage Imbalance 0-1 NORMAL/ALARM VOLT_UNB
Overload Trip 0-1 NORMAL/ALARM OVERLOAD
Locked Rotor Trip 0-1 NORMAL/ALARM LRATRIP
Starter LRA Trip 0-1 NORMAL/ALARM SLRATRIP
Ground Fault 0-1 NORMAL/ALARM GRND_FLT
Phase Reversal 0-1 NORMAL/ALARM PH_REV
Frequency Out of Range 0-1 NORMAL/ALARM FREQFLT
ISM Power on Reset 0-1 NORMAL/ALARM ISM_POR
Phase 1 Fault 0-1 NORMAL/ALARM PHASE_1
Phase 2 Fault 0-1 NORMAL/ALARM PHASE_2
Phase 3 Fault 0-1 NORMAL/ALARM PHASE_3
1CR Start Complete 0-1 FALSE/TRUE START_OK
1M Start/Run Fault 0-1 NORMAL/ALARM 1M_FLT
2M Start/Run Fault 0-1 NORMAL/ALARM 2M_FLT
Pressure Trip Contact 0-1 NORMAL/ALARM PRS_TRIP
Starter Fault 0-1 NORMAL/ALARM STRT_FLT
Motor Amps Not Sensed 0-1 NORMAL/ALARM NO_AMPS
Starter Acceleration Fault 0-1 NORMAL/ALARM ACCELFLT
High Motor Amps 0-1 NORMAL/ALARM HIGHAMPS
1CR Stop Complete 0-1 FALSE/TRUE STOP_OK
1M/2M Stop Fault 0-1 NORMAL/ALARM 1M2MSTOP
Motor Amps When Stopped 0-1 NORMAL/ALARM AMPSTOP
Hardware Failure 0-1 NORMAL/ALARM HARDWARE
MENU
STATUS
ISM_STAT
SELECT
DESCRIPTION STATUS UNITS POINT
Disable Service Password 0-1 DSABLE/ENABLE PSWD_DIS
**Remote Reset Option (See Note 3) 0-1 DSABLE/ENABLE RESETOPT
Reset Alarm? 0-1 NO/YES REMRESET
CCN Mode? 1 YES REM_CCN
MENU
STATUS
ICVC
SELECT
33
Table 3 ICVC Display Data (cont)
EXAMPLE 9 SETPOINT DISPLAY SCREEN
To access this display from the ICVC default screen:
1. Press .
2. Press .
3. Press .
NOTE: All variables are available for CCN read operation; forcing shall not be supported on setpoint screens.
EXAMPLE 10 CAPACITY DISPLAY SCREEN
To access this display from the ICVC default screen:
1. Press .
2. Press .
3. Scroll down to highlight .
4. Press .
5. Scroll down to highlight .
6. Press .
NOTE: All variables with CAPITAL LETTER point names are available for CCN read operation; forcing shall not be supported on maintenance
screen.
EXAMPLE 11 OVERRIDE DISPLAY SCREEN
To access this display from the ICVC default screen:
1. Press .
2. Press .
3. Scroll down to highlight .
4. Press .
5. Scroll down to highlight .
6. Press .
NOTE: All variables with CAPITAL LETTER point names are available for CCN read operation; forcing shall not be supported on maintenance
screens.
DESCRIPTION STATUS UNITS POINT DEFAULT
Base Demand Limit 40-100 % DLM 100
Control Point
LCW Setpoint 10-120 DEG F lcw_sp 50.0
ECW Setpoint 15-120 DEG F ecw_sp 60.0
Ice Build Setpoint 15-60 DEG F ice_sp 40.0
Tower Fan High Setpoint 55-105 DEG F TFH_SP 75
DESCRIPTION STATUS UNITS POINT
Entering Chilled Water 40-245 DEG F ECW
Leaving Chilled Water 40-245 DEG F LCW
Capacity Control
Control Point 10-120 DEG F ctrlpt
Control Point Error 99-99 ^F cperr
ECW Delta T 99-99 ^F ecwdt
ECW Reset 99-99 ^F ecwres
LCW Reset 99-99 ^F lcwres
Total Error + Resets 99-99 ^F error
Guide Vane Delta 2.0-2.0 % gvd
Target Guide Vane Pos 0-100 % GV_TRG
Actual Guide Vane Pos 0-100 % GV_POS
Target VFD Speed 0-100 % VFD_OUT
Actual VFD Speed 0-110 % VFD_ACT
VFD Gain 0.1-1.5 VFD_CTRL
VFD Load Factor 0.0-1.0 VFD_FACT
Demand Limit Inhibit 0.2-2.0 % DEM_INH
Amps/kW Ramp 40-100 % DMDLIM
DESCRIPTION STATUS UNITS POINT
Comp Motor Winding Temp 40-245 DEG F MTRW
Comp Motor Temp Override 150-200 DEG F MT_OVER
Condenser Pressure 0-420 PSI CRP
Cond Press Override 90-180 PSI CP_OVER
Calc Evap Sat Temp 40-245 DEG F ERT
Evap Sat Override Temp 2-45 DEG F ERT_OVER
Comp Discharge Temp 40-245 DEG F CMPD
Comp Discharge Alert 125-200 DEG F CD_ALERT
Comp Thrust Lvg Oil Temp 40-245 DEG F MTRB_OIL
Comp Thrust Brg Reset 40-245 DEG F TB_RESET
Comp Thrust Brg Temp 155-175 DEG F MTRB
Comp Thrust Brg Alert 165-185 DEG F TB_ALERT
Comp Thrust Brg Trip 175-185 DEG F TB_TRIP
Actual Superheat 20-99 ^F SUPRHEAT
Superheat Required 6-99 ^F SUPR_REQ
Condenser Refrig Temp 40-245 DEG F CRT
MENU
SETPOINT
SELECT
MENU
SERVICE
CONTROL ALGORITHM STATUS
SELECT
CAPACITY
SELECT
MENU
SERVICE
CONTROL ALGORITHM STATUS
SELECT
OVERRIDE
SELECT
34
Table 3 ICVC Display Data (cont)
EXAMPLE 12 LL_MAINT DISPLAY SCREEN
To access this display from the ICVC default screen:
1. Press .
2. Press .
3. Scroll down to highlight .
4. Press .
5. Scroll down to highlight
6. Press .
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
5. Stop, Start, Retain
6. All variables with CAPITAL LETTER point names are available
for CCN read operation; forcing shall not be supported on main-
tenance screens.
DESCRIPTION STATUS UNITS POINT
LeadLag Control
LEADLAG: Configuration NOTE 1 leadlag
Current Mode NOTE 2 llmode
Load Balance Option 0/1 DSABLE/ENABLE loadbal
LAG START Time 2-60 MIN lagstart
LAG STOP Time 2-60 MIN lagstop
Prestart Fault Time 2-30 MIN preflt
Pulldown Time 2-30 MIN pulldown
Pulldown: Delta T / Min x.xx ^F pull_dt
Satisfied? 0/1 NO/YES pull_sat
LEAD CHILLER in Control 0/1 NO/YES leadctrl
LAG CHILLER: Mode NOTE 3 lagmode
Run Status NOTE 4 lagstat
Start/Stop NOTE 5 lag_s_s
Recovery Start Request 0/1 NO/YES lag_rec
STANDBY CHILLER: Mode NOTE 3 stdmode
Run Status NOTE 4 stdstat
Start/Stop NOTE 5 std_s_s
Recovery Start Request 0/1 NO/YES std_rec
Spare Temperature 1 40-245 DEG F SPARE_T1
Spare Temperature 2 40-245 DEG F SPARE_T2
MENU
SERVICE
CONTROL ALGORITHM STATUS
SELECT
LL_MAINT.
SELECT
35
Table 3 ICVC Display Data (cont)
EXAMPLE 13 SURGPREV DISPLAY SCREEN
To access this display from the ICVC default screen:
1. Press .
2. Press .
3. Scroll down to highlight .
4. Press .
5. Scroll down to highlight .
6. Press .
NOTE: All variables with CAPITAL LETTER point names are available for CCN read operation; forcing shall not be supported on maintenance
screens.
EXAMPLE 14 ISM_HIST DISPLAY SCREEN
To access this display from the ICVC default screen:
1. Press .
2. Press .
3. Scroll down to highlight .
4. Press .
5. Scroll down to highlight .
6. Press .
NOTE: All variables with CAPITAL LETTER point names are available for CCN read operation; forcing shall not be supported on maintenance
screens.
DESCRIPTION STATUS UNITS POINT
Active Region 0-2 ACT_REG
Surge Prevention Active? 0/1 No/Yes SHG_ACT
Actual Guide Vane Pos 0-100 % GV_POS
Active Delta Tsat 0-150 ^F DTS_A
Surge Line Delta Tsat 0-150 ^F DTS_C
Chilled Water Delta T 40-245 ^F CHWDT
HGBP On Delta T 0.5-10.0 ^F HGBP_ON
HGBP Off Delta T 1.5-20.0 ^F HGBP_OFF
Guide Vane Delta 2.0-2.0 % GV_DELTA
Target Guide Vane Pos 0-100 % GV_OUT
Target VFD Speed 0-100 % VFD_TRG
Speed Change in Effect 0-5 SPD_CHG
VFD Speed Factor 0.000-1.000 VFD_SPD
Surge Counts 0-99 SC
Surge Protection Counts 0-4 SPC
Ramp Loading Active 0/1 No/Yes RAMP_ACT
VFD Rampdown Active 0/1 No/Yes VFD_RAMP
HGBP/VFD Active 0-2 HGBP_VFD
VFD Load Factor 0.00-1.20 VFD_RAT
Hot Gas Bypass Relay 0/1 Off/On HGBYPASS
Surge Limit/HGBP Option 0-2 HGBP_OPT
Override Inhibit Active 0/1 No/Yes VANE_INH
Override Decrease Active 0/1 No/Yes VANE_DEC
DESCRIPTION STATUS UNITS POINT
ISM FAULT HISTORY
Values At Last Fault:
Line Current Phase 1 0-99999 AMPS AMPS_H1
Line Current Phase 2 0-99999 AMPS AMPS_H2
Line Current Phase 3 0-99999 AMPS AMPS_H3
Line Voltage Phase 1 0-99999 VOLTS VOLTS_H1
Line Voltage Phase 2 0-99999 VOLTS VOLTS_H2
Line Voltage Phase 3 0-99999 VOLTS VOLTS_H3
Ground Fault Phase 1 0-999 AMPS GRFT_H31
Ground Fault Phase 2 0-999 AMPS GRFT_H23
Ground Fault Phase 3 0-999 AMPS GRFT_H12
I2T Sum Heat-Phase 1 0-200 % SUM1HT_H
I2T Sum Heat-Phase 2 0-200 % SUM2HT_H
I2T Sum Heat-Phase 3 0-200 % SUM3HT_H
Phase 1 Faulted? 0/1 NO/YES PHASE_H1
Phase 2 Faulted? 0/1 NO/YES PHASE_H2
Phase 3 Faulted? 0/1 NO/YES PHASE_H3
Line Frequency 0-99 Hz FREQ_H
ISM Fault Status 0-9999 ISMFLT_H
MENU
SERVICE
CONTROL ALGORITHM STATUS
SELECT
SURGPREV
SELECT
MENU
SERVICE
CONTROL ALGORITHM STATUS
SELECT
ISM_HIST
SELECT
36
Table 3 ICVC Display Data (cont)
EXAMPLE 15 WSMCHRLE DISPLAY SCREEN
To access this display from the ICVC default screen:
1. Press .
2. Press .
3. Scroll down to highlight .
4. Press .
5. Scroll down to highlight .
6. Press .
NOTE: All variables with CAPITAL LETTER point names are available for CCN read operation; forcing shall not be supported on maintenance
screens.
EXAMPLE 16 NET_OPT DISPLAY SCREEN
To access this display from the ICVC default screen:
1. Press .
2. Press .
3. Scroll down to highlight .
4. Press .
5. Scroll down to highlight .
6. Press .
NOTE: No variables are available for CCN read or write operation.
DESCRIPTION STATUS UNITS POINT
WSM Active? 0/1 NO/YES WSMSTAT
Chilled Water Temp 0.0-99.9 DEG F CHWTEMP
Equipment Status 0/1 OFF/ON CHWRST
Commanded State XXXXXXXX TEXT CHLRENA
CHW setpt Reset Value 0.0-25.0 DEG F CHWRVAL
Current CHW Set Point 0.0-99.9 DEG F CHWSTPT
DESCRIPTION STATUS UNITS POINT DEFAULT
Loadshed Function
Group Number 0-99 ldsgrp 0
Demand Limit Decrease 0-60 % ldsdlta 20
Maximum Loadshed Time 0-120 MIN maxshed 60
CCN Occupancy Config:
Schedule Number 3-99 occ_num 3
Broadcast Option 0-1 DSABLE/ENABLE occbrcst DSABLE
Alarm Configuration
Re-Alarm Time 0-1440 MIN retime 30
Alarm Routing xxxxxxxx routing 10000000
MENU
SERVICE
CONTROL ALGORITHM STATUS
SELECT
WSMCHRLE
SELECT
MENU
SERVICE
EQUIPMENT CONFIGURATION
SELECT
NET_OPT
SELECT
37
Table 3 ICVC Display Data (cont)
EXAMPLE 17 ISM_CONF DISPLAY SCREEN
To access this display from the ICVC default screen:
1. Press .
2. Press .
3. Scroll down to highlight .
4. Press .
5. Enter password (4444 Factory Default).
6. Scroll down to highlight .
7. Press .
DESCRIPTION STATUS UNITS POINT DEFAULT
Starter Type 0-3 starter 1
(0 = Full, 1 = Red, 2 = SS/VFD, 3 = VFD)
Motor Rated Line Voltage 200-13200 VOLTS rlv 460
Volt Transformer Ratio:1 1-115 vt_rat 1
Overvoltage Threshold 105-115 % overvolt 115
Undervoltage Threshold 85-95 % undrvolt 85
Over/Under Volt Time 1-10 SEC ovuntime 5
Voltage % Imbalance 1-10 % v_unbal 10
Voltage Imbalance Time 1-10 SEC vu_time 5
Motor Rated Load Amps 10-5000 AMPS rla 200
Motor Locked Rotor Trip 100-60000 AMPS mot_lra 1000
Locked Rotor Start Delay 1-10 cycles lrs_del 5
Starter LRA Rating 100-60000 AMPS str_lra 2000
Motor Current CT Ratio:1 10-1000 ct_ratio 100
Current % Imbalance 5-40 % c_unbal 15
Current Imbalance Time 1-10 SEC cu_time 5
Grnd Fault CTs? 0/1 NO/YES gf_cts YES
Ground Fault CT Ratio:1 150 gfct_rat 150
Ground Fault Current 1-25 AMPS gf_amps 15
Ground Fault Start Delay 1-20 cycles gf_sdel 10
Ground Fault Persistence 1-10 cycles gf_pdel 5
Single Cycle Dropout 0/1 DSABLE/ENABLE 1cyc_en DSABLE
Frequency = 60 Hz? (No = 50) 0/1 NO/YES linefreq YES
Line Frequency Faulting 0/1 DSABLE/ENABLE freq_en DSABLE
MENU
SERVICE
ISM (STARTER) CONFIG DATA
SELECT
ISM_CONF
SELECT
38
Table 3 ICVC Display Data (cont)
EXAMPLE 18 OPTIONS DISPLAY SCREEN
To access this display from the ICVC default screen:
1. Press .
2. Press .
3. Scroll down to highlight .
4. Press .
5. Scroll down to highlight .
6. Press .
NOTE: No variables are available for CCN read or write operation.
EXAMPLE 19 VDO_SRD DISPLAY SCREEN
To access this display from the ICVC default screen:
1. Press .
2. Press .
3. Scroll down to highlight .
4. Press .
5. Scroll down to highlight .
6. Press .
NOTE: No variables are available for CCN read or write operation.
DESCRIPTION STATUS UNITS POINT DEFAULT
Auto Restart Option 0/1 DSABLE/ENABLE ASTART DSABLE
Guide Vane Closure 4-25 % GV_CLOSE 4
Remote Contacts Option 0/1 DSABLE/ENABLE MODES DSABLE
Soft Stop Amps Threshold 40-100 % STRTSTOP 100
Surge / Hot Gas Bypass
Surge Limit/HGBP Option 0, 1, 2 srg_hgbp 0
Select: Surge=0, HGBP=1
Low Load HGBP=2
Minimum Load Point
Surge/HGBP Delta Tsmin 0.0-150.0 ^ F DTsatmin 45
Surge/HGBP IGVmin 0.0-110.0 % GV_MIN 5.0
Full Load Point
Surge/HGBP Delta Tsmax 0.0-150.0 ^ F DTsatmax 70
Surge/HGBP IGVmax 0.0-110.0 % GV_MAX 5.0
Surge Line Shape Factor -1.000 - 0.000 shapefac -0.040
Surge Line Speed Factor 0.00-3.00 VFD_POW 1.85
Surge Line High Offset 0.1-3.0 SP_HIGH 1.0
Surge/HGBP Deadband 0.5-3 ^ F hgb_db 1
HGBP On Delta T 0.5-10.0 ^ F Hgb_ton 2.0
HGBP Off Delta T 0.5-10.0 ^ F Hgb_toff 4.0
Surge Protection
Surge Delta % Amps 5-40 % surge_a 20
Surge Time Period 7-10 MIN surge_t 8
Surge Delay Time 0-120 SEC SURG_DEL 0
Ice Build Control
Ice Build Option 0/1 DSABLE/ENABLE Ibopt DSABLE
Ice Build Termination 0-2 Ibterm 0
0=Temp, 1=Contact, 2=Both
Ice Build Recycle 0/1 DSABLE/ENABLE Ibrecyc DSABLE
Refrigerant Leak Option 0/1 DSABLE/ENABLE LEAK_EN DSABLE
Refrigerant Leak Alarm mA 4-20 MA LEAK_MA 20
Head Pressure Reference
Delta P at 0% (4 Ma) 20-85 PSI HPDP0 25
Delta P at 100% (20 mA) 20-85 PSI HPDP100 50
Minimum Output 0-100 % HPDPMIN% 0
DESCRIPTION STATUS UNITS POINT DEFAULT
Diffuser Control
Diffuser Option 0/1 DIFF_OPT 0
Diffuser Full Span mA 15-22 mA DIFF_MA 18.0
Guide Vane 25% Load (2) 0-83 % GV1_25 6.4
Guide Vane 50% Load (2) 0-83 % GV1_50 22.9
Guide Vane 75% Load (2) 0-83 % GV1_75 41.3
SRD 25% Load (1) 0-100 % SRD1_25 73.5
SRD 50% Load (1) 0-100 % SRD1_50 35.1
SRD 75% Load (1) 0-100 % SRD1_75 19.5
Lift @ 25% Load (1) 0-100 ^F LF1_25 52.4
Lift @ 100% Load (1) 0-100 ^F LF1_100 67.5
Lift @ 25% Load (2) 0-100 ^F LF2_25 27.2
SRD IGV Offset Select 1-5 OFF_SEL 3
Low Lift Profile Select 1-5 PRO_SEL 3
MENU
SERVICE
EQUIPMENT SERVICE
SELECT
OPTIONS
SELECT
MENU
SERVICE
EQUIPMENT SERVICE
SELECT
VDO_SRD
SELECT
39
Table 3 ICVC Display Data (cont)
EXAMPLE 20 SETUP1 DISPLAY SCREEN
To access this display from the ICVC default screen:
1. Press .
2. Press .
3. Scroll down to highlight .
4. Press .
5. Scroll down to highlight .
6. Press
*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.
DESCRIPTION STATUS UNITS POINT DEFAULT
Comp Motor Temp Override 150-200 DEG F MT_OVER 200
Cond Press Override 90-165 PSI CP_OVER 125
Comp Discharge Alert 125-200 DEG F CD_ALERT 200
Comp Thrust Brg Alert 10-20 ^F TB_ALERT 10
Comp Thrust Brg Trip 160-185 DEG F TB_TRIP 185
Thrust Brg Reset Factor 1.0-3.0 TB_POWER 1.4
Chilled Medium 0/1 WATER/BRINE MEDIUM WATER
Chilled Water Deadband 0.5-2.0 ^F CWDB 1.0
Evap Refrig Trippoint 0.0-40.0 DEG F ERT_TRIP 33
Refrig Override Delta T 2.0-5.0 ^F REF_OVER 3
Evap Approach Alert 0.5-15 ^F EVAP_AL 5
Cond Approach Alert 0.5-15 ^F COND_AL 6
Condenser Freeze Point -20 - 35 DEG F CDFREEZE 34
Flow Delta P Display 0/1 DSABLE/ENABLE FLOWDISP DSABLE
Evap Flow Delta P Cutout 0.5 - 50.0 ^PSI EVAP_CUT 5.0
Cond Flow Delta P Cutout 0.5 - 50.0 ^PSI COND_CUT 5.0
Cond Hi Flow Alarm Opt* 0/1 DSABLE/ENABLE COND_ALM DSABLE
Cond Hi Flow Del P Limit 0.5-50.0 PSI COND_VAL 50.0
Water Flow Verify Time 0.5-5 MIN WFLOW_T 5
Oil Press Verify Time 15-300 SEC OILPR_T 40
Recycle Control
Restart Delta T 2.0-10.0 ^F rcycr_dt 5
Shutdown Delta T 0.5-4.0 ^F rcycs_dt 1
Spare Alert/Alarm Enable
Disable=0, Lo=1/3,Hi=2/4
Spare Temp #1 Enable 0-4 sp1_en 0
Spare Temp #1 Limit -40-245 DEG F sp1_lim 245
Spare Temp #2 Enable 0-4 sp2_en 0
Spare Temp #2 Limit -40-245 DEG F sp2_lim 245
MENU
SERVICE
EQUIPMENT SERVICE
SELECT
SETUP1
SELECT
40
Table 3 ICVC Display Data (cont)
EXAMPLE 21 SETUP2 DISPLAY SCREEN
To access this display from the ICVC default screen:
1. Press .
2. Press .
3. Scroll down to highlight .
4. Press .
5. Scroll down to highlight .
6. Press .
NOTE: No variables are available for CCN read or write operation; forcing shall not be supported on service screens.
EXAMPLE 22 LEADLAG DISPLAY SCREEN
To access this display from the ICVC default screen:
1. Press .
2. Press .
3. Scroll down to highlight .
4. Press .
5. Scroll down to highlight .
6. Press .
NOTE: No variables are available for CCN read or write operation.
DESCRIPTION STATUS UNITS POINT DEFAULT
Capacity Control
Proportional Inc Band 2-10 gv_inc 6.5
Proportional Dec Band 2-10 gv_dec 6.0
Proportional ECW Gain 1-3 gv_ecw 2.0
Guide Vane Travel Limit 30-100 % GV_CTRL 80
VFD Speed Control
VFD Option 0/1 DSABLE/ENABLE vfd_opt DSABLE
VFD Gain 0.1-1.5 vfd_gain 0.75
VFD Increase Step 1-5 % vfd_step 2
VFD Minimum Speed 65-100 % vfd_min 70
VFD Maximum Speed 90-110 % vfd_max 100
VFD Start Speed 65-100 % vfd_str 100
VFD Surge Line Gain 2.0-3.5 vfd_slg 2.0
VFD Current Limit 0-99999 amps VFDLIM_T 250
DESCRIPTION STATUS UNITS POINT DEFAULT
Lead Lag Control
LEAD/LAG: Configuration 0-3 leadlag 0
DSABLE=0, Lead=1
LAG=2, STANDBY=3
Load Balance Option 0/1 DSABLE/ENABLE load/bal DSABLE
Common Sensor Option 0/1 DSABLE/ENABLE commsens DSABLE
LAG % Capacity 25-75 % lag_per 50
LAG Address 1-236 lag_add 92
LAG START Timer 2-60 MIN lagstart 10
LAG STOP Timer 2-60 MIN lagstop 10
PRESTART FAULT Timer 2-30 MIN preft 5
PULLDOWN Timer 1-30 MIN pulltime 2
STANDBY Chiller Option 0/1 DSABLE/ENABLE stnd_opt DSABLE
STANDBY % Capacity 25-75 % stnd_per 50
STANDBY Address 1-236 stnd_add 93
MENU
SERVICE
EQUIPMENT SERVICE
SELECT
SETUP2
SELECT
MENU
SERVICE
EQUIPMENT SERVICE
SELECT
LEADLAG
SELECT
41
Table 3 ICVC Display Data (cont)
EXAMPLE 23 RAMP_DEM DISPLAY SCREEN
To access this display from the ICVC default screen:
1. Press .
2. Press .
3. Scroll down to highlight .
4. Press .
5. Scroll down to highlight .
6. Press .
NOTE: No variables are available for CCN read or write operation.
EXAMPLE 24 TEMP_CTL DISPLAY SCREEN
To access this display from the ICVC default screen:
1. Press .
2. Press .
3. Scroll down to highlight .
4. Press .
5. Scroll down to highlight .
6. Press .
EXAMPLE 25 ICVC CONFIGURATION TABLE
To access this display from the ICVC default screen:
1. Press .
2. Press .
3. Scroll down to highlight .
4. Press .
NOTE: Default values are shown for configurable items.
DESCRIPTION STATUS UNITS POINT DEFAULT
Pulldown Ramp Type: 0/1 ramp_opt 1
Select: Temp=0, Load=1
Demand Limit and kW Ramp
Demand Limit Source 0/1 dem_src 0
Select: Amps=0, kW=1
Amps or kW Ramp% Min 5-20 %/MIN kw_ramp 10
Demand Limit Prop Band 3-15 % dem_prop 10
Demand Limit At 20 mA 40-100 % dem_20ma 40
20 mA Demand Limit Opt 0/1 DSABLE/ENABLE dem_sel DSABLE
Motor Rated Kilowatts 50-9999 kW motor_kw 145
Demand Watts Interval 5-60 MIN dw_int 15
DESCRIPTION STATUS UNITS POINT DEFAULT
Control Point
ECW Control Option 0/1 DSABLE/ENABLE ecw_opt DSABLE
Temp Pulldown Deg/Min 2-10 ^F tmp_ramp 3
Temperature Reset
RESET TYPE 1
Degrees Reset At 20 mA 30- 30 ^F deg_20ma 10
RESET TYPE 2
Remote Temp > No Reset 40-245 DEG F res_rt1 85
Remote Temp > Full Reset 40-245 DEG F res_rt2 65
Degrees Reset 30-30 ^F deg_rt 10
RESET TYPE 3
CHW Delta T > No Reset 0-15 ^F restd_1 10
CHW Delta T > Full Reset 0-15 ^F restd_2 0
Degrees Reset 30-30 ^F deg_chw 5
Select/Enable Reset Type 0-3 res_sel 0
DESCRIPTION STATUS DEFAULT
Device Name 19XRPIC2
Description 19XR Centrifugal Chiller
Software Part Number CESR-131294-xx
Model Number text string
Serial Number text string
Reference Number VER xx
Bus Number 0 0
Address 1 1
Baud Rate 9600 9600
US Imp/Metric US Imp US Imp
Password 1111 1111
LID Language ENGLISH ENGLISH
MENU
SERVICE
EQUIPMENT SERVICE
SELECT
RAMP_DEM
SELECT
MENU
SERVICE
EQUIPMENT SERVICE
SELECT
TEMP_CTL
SELECT
MENU
SERVICE
ICVC CONFIGURATION
SELECT
42
PIC II System Functions Refer to ICVC Opera-
tion and Menus section on page 20.
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., and ). See Table 3 for exam-
ples of the type of information that can appear on the ICVC
screens. Figures 17-23 give an overview of ICVC operations
and menus.
ALARMS AND ALERTS An alarm shuts down the com-
pressor. An alert does not shut down the compressor, but it no-
tifies 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 de-
fault 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 asso-
ciated 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 suc-
cessfully completed its self test. The self test takes place auto-
matically, 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 calibra-
tion 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
setpoints.
The SERVICE menu can be used to view or modify
information on the Alarm History, Alert History, Control
Test, Control Algorithm Status, Equipment Configura-
tion, 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. 20
and 21.
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 ma-
chine safety or fire alarm. See Table 4.
FLOW DETECTION Flow detection for the evaporator
and condenser is (a) a required condition for start-up, and (b)
used in the freeze protection safety.
Flow and no flow conditions are detected from a combina-
tion of several measurements. The usage of water side differen-
tial pressure measurements is not standard.
Positive determination of flow on the evaporator side is
made if the following conditions are true: (1) the EVAPORA-
TOR REFRIGERANT LIQUID TEMP reads equal to or high-
er than 1 F (0.6 C) above the EVAPORATOR REFRIGER-
ANT 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) CON-
DENSER PRESSURE is less than the configured CONDENS-
ER PRESSURE OVERRIDE threshold by more than 5 psig
(34.5 kPa). In addition, if the water side differential pressure
measurement option is enabled, the water side pressure differ-
entials (cooler and condenser) must exceed their respective
configured cutout thresholds.
Table 4 CCN Force Priority Hierarchy
NOTE: Not all apply to chillers.
ENTER EXIT
LEVEL NAME DESCRIPTION
1 FIRE Fire Alarm
2 SAFETY Machine Safety
3 SERVCE Service Tool Access
4 SUPVSR Supervisor or LID/ICVC
5 MONITR Offsite Building Supervisor or ComfortWorks
6 MINOFF Minimum on/off time
7 CONTROL Typically 3
rd
party access via interface
8 BEST BEST control from FIDs and comfort controllers
9 TEMP Temperature Override (thermostat type function)
10 LOAD Loadshed for demand limit/shedding load
43
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 AP-
PROACH 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 deter-
mined, and subsequently conditions change such that neither
conditions for Flow nor No Flow are all satisfied, the determi-
nation 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 transduc-
ers may be connected to the CCM at terminals J3 13-24 in
place of the standard resistors and jumpers to determine water-
side pressure differentials as in the standard ICVC configura-
tion. (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 CUT-
OUT) 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-of-
flow alarm (alarm state 229 or 230) will be declared. If the
measured differential exceeds the FLOW DELTA P cutout val-
ue, 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 ter-
minals 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 per-
form a zero point calibration (with the flow switch open).
CAPACITY CONTROL Generally the chiller adjusts ca-
pacity 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 SET-
POINT), and CONTROL POINT is equal to this SETPOINT
plus any active chilled water reset value. A reset value may
originate from any of the three chilled water/brine reset options
configured in the ICVC SERVICE/EQUIPMENT SERVICE/
TEMP_CTL screen (see page 55) or from a CCN device. The
default reset value is 0 F so that if no reset function is config-
ured the CONTROL POINT will equal the SETPOINT. CON-
TROL POINT may be viewed or manually overridden from the
MAINSTAT screen.
Minor adjustments to the rate of capacity adjustment can be
made by changing PROPORTIONAL INC (Increase) BAND,
PROPORTIONAL DEC (Decrease) BAND, and PROPOR-
TIONAL ECW (Entering Chilled Water), GAIN in the SER-
VICE/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 section on page 44.
Parameters used in the capacity control determination are
displayed in the SERVICE/CONTROL ALGORITHM STA-
TUS/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 maxi-
mum is 80%. Note the guide vane position at design condi-
tions. 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 actu-
al 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 51), proportional bands
and gain (see page 44), and VFD speed (see below). Parame-
ters affecting guide vane action are displayed in the CAPACI-
TY screen of the SERVICE/CONTROL ALGORITHM STA-
TUS menu.
FIXED SPEED APPLICATIONS For fixed speed appli-
cations, 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. Ta-
ble 5 indicates which output is modulated first. When the first
output reaches its limit (e.g., ACTUAL GUIDE VANE POSI-
TION 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.
44
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 over-
current feature which is similar to Demand Limit Control. The
ICVC computes a projected value for motor current (VFD out-
put 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 CUR-
RENT LIMIT, and that value may be further adjusted as de-
scribed under the VFD Control Verification section. (See
page 76.)
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 de-
crease as well. This action ceases when the VFD LOAD FAC-
TOR subsequently drops below 1.0. VFD LOAD FACTOR is
displayed in the CONTROL ALGORITHM STATUS / CA-
PACITY screen.
NOTE: Increasing motor speed reduces motor amp draw. This
is the current between the VFD and the motor, NOT line cur-
rent. Generally for the case of LINE VOLTAGE equaling motor
voltage (460 volts), VFD output (motor) current is a few per-
cent 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.
Table 5 Guide Vane Delta Modes
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
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 config-
ured 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 fluctua-
tions 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 1F, which is 0.5 F above
and below the CONTROL POINT. The CONTROL POINT set-
ting 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 con-
trol how far the guide vanes will move in response to a specific
change in leaving water temperature. Increasing the propor-
tional 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 tem-
perature will increase or decrease slowly enough that the tem-
perature moves away from the control point by an unaccept-
able 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 in-
creasing and decreasing capacity. The PROPORTIONIONAL
INCREASE BAND should be set as described above. The PRO-
PORTIONIONAL DECREASE BAND should be set at a typi-
cally 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.
GUIDE VANE
DELTA
NORMAL
CONTROL
MODE
SURGE
PREVENTION
MODE
IGV
POSITION
VFD
SPEED
IGV
POSITION
VFD
SPEED
From +0.2 to
+2.0
Increase
1st
Increase
when IGV
= max
Increase
only if VFD
speed =
max and if
hot gas
bypass is
present
and open
Increase
1st
From 0.2 to
2.0
Decrease
when VFD
speed =
min
Decrease
1st
Decrease
Speed
decrease
not
allowed
45
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 CON-
TROL and before tuning the ECW GAIN, the LCW PROPOR-
TIONAL 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 feed-
back 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 En-
tering 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. 24)
Error = the contribution of the ECW control to the total er-
ror 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. 24 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 tem-
perature drops below the set point.
Example 3 The third section of Fig. 24 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 On all units with Frame 5 com-
pressors and those Frame 4 compressors with the variable (split
ring) diffuser option, the PIC II adjusts the diffuser actuator po-
sition based on the ACTUAL GUIDE VANE POSITION, then
adjusts from that position using Carrier's Variable Diffuser Op-
timization (VDO) algorithm. Configurations for VDO are pro-
duced by the Carrier's chiller selection program and are entered
into the VDO_SRD screen. The starting point diffuser sched-
ule 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. Figure 25 shows the starting point relationship
between diffuser related parameters for a typical build. 0% out-
put 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).
Diffuser control output is enabled whenever the DIFFUSER
OPTION is enabled, whether the machine is running or not.
The diffuser position adjusts from the specific relationship to
the guide vane position, and is adjusted based on several fac-
tors: guide vane position, compressor lift, rotating stall and
surge conditions. 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 opera-
tion; the diffuser and the guide vane operate independently. Us-
ing the Controls Test, the diffuser can be incremented from ful-
ly open to completely closed. A 0% output is fully open; the
setting is completely closed when the value equals that of the
Diffuser 25% Load Point value. The configurations for VDO
Diffuser Control are found on a label on the back of the control
panel. See Fig. 13. If you do not have the correct settings for
VDO Diffuser Control contact a Carrier Engineering Repre-
sentative.
The diffuser actuator should NOT be configured to a per-
cent that is greater than the factory set Diffuser 25% Load Point
value as the diffuser will be at a mechanical stop for its fully
closed position.
A diffuser pressure transducer is installed on compressors
with a split ring diffuser. The CCM monitors pressure fluctua-
tions at the inlet to the inner diffuser ring. Excessive pressure
fluctuations may indicate that the impeller is experiencing pres-
sure pulsations known as rotating stall. A Diffuser Position
Fault (Alarm 247) is declared if pressure fluctuations exceed
acceptable limits.
IMPORTANT: Do not alter the factory settings for VDO
Diffuser Control without consulting with Carrier Engineer-
ing. Incorrect settings could cause the machine to repeat-
edly shut down on rotating stall alarm or surge.
-1
-0. 5
0
0. 5
1
1. 5
2
2. 5
3
46. 4
46. 6
46. 8
SET POINT = 47
47. 2
47. 4
47. 6
47. 8
48
48. 2
T
O
T
A
L

E
R
R
O
R

F
EXAMPLE 1
ECW(F)
ECW-10 sec
Error, Gain = 1
Error, Gain = 3
EXAMPLE 2 EXAMPLE 3
X
X
X
X
X
X
X
X
X
X
X
X
X
X

Fig. 24 Transient Example of ECW Gain

a19-1957
46
DEMAND LIMITING The PIC II controls provide a fea-
ture 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 33, 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 58).
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 de-
mand limiting based on PERCENT LINE KILOWATTS (dis-
played in the MAINSTAT screen). MOTOR PERCENT KILO-
WATTS 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, in-
creases in guide vane opening will be prevented. If the DE-
MAND LIMIT SOURCE (percent line current) exceeds the
ACTIVE DEMAND LIMIT by more than 5%, the guide vanes
will be forced to close. Also, as the DEMAND LIMIT
SOURCE approaches the ACTIVE DEMAND LIMIT from a
lower value, allowable capacity increases become increasingly
more limited, beginning when the DEMAND LIMIT
SOURCE is within the DEMAND LIMIT PROP BAND (con-
figurable in the RAMP_DEM table).
Demand Limit Control Option The demand limit control
option (20 mA DEMAND LIMIT OPT) is externally con-
trolled 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 (regard-
less of the value of BASE DEMAND LIMIT), and 20 mA will
set ACTIVE DEMAND LIMIT to the value configured as
20MA DEMAND LIMIT OPT in the RAMP_DEM table.
Wire the auto demand limit 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. 26.
A DEMAND KILOWATTS monitoring feature is also avail-
able. 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 COM-
PRESSOR 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 oppor-
tunity, before the first start-up with the new controller, is pro-
vided to set COMPRESSOR ONTIME and TOTAL
COMPRESSOR STARTS to the last readings retained with the
prior controller. The SERVICE ONTIME timer can register up
to 32,767 hours before it rolls over to zero.
The chiller also maintains a start-to-start timer and a stop-
to-start timer. These timers limit how soon the chiller can be
started. START INHIBIT TIMER is displayed on the MAIN-
STAT screen. See the Start-Up/Shutdown/Recycle Sequence
section, page 63, for more information on this topic.
OCCUPANCY SCHEDULE The chiller schedule, de-
scribed in the Time Schedule Operation section (page 26), de-
termines when the chiller can run. Each schedule consists of
from 1 to 8 occupied or unoccupied time periods, set by the op-
erator. The chiller can be started and run during an occupied
time period (when OCCUPIED? is set to YES on the
MAINSTAT display screen). It cannot be started or run during
an unoccupied time period (when OCCUPIED? is set to NO
on the MAINSTAT display screen). These time periods can be
set for each day of the week and for holidays. The day begins
with 0000 hours and ends with 2400 hours. The default setting
for OCCUPIED? is YES, unless an unoccupied time period is
in effect.
These schedules can be set up to follow a buildings occu-
pancy schedule, or the chiller can be set so to run 100% of the
time, if the operator wishes. The schedules also can be by-
passed by forcing the CHILLER START/STOP parameter on
the MAINSTAT screen to START. For more information on
forced starts, see Local Start-Up, page 63.
25 % Load Point
50 % 0 % 75 %
50 % Load Point
rotating stall
less likely
surge more likely
75 % Load Point
surge less likely
2 mA
(0%)
4 mA
(0.2%)
100%
Open
100%
Closed
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GUIDE VANE POSITION (% OPEN)
* DIFFUSER FULL SPAN MA.
25 % 100 %
approx.
20 mA
Fig. 25 Diffuser Control
a19-1861
Fig. 26 Auto Demand Limit Wiring (1 to 5 vdc)
a19-1885
47
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 26.
Figure 22 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 Occu-
pancy 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 Occu-
pancy 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 16. SCHED-
ULE 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. 21.
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 TEM-
PERATURE). The high discharge temperature safety mea-
sures only sensible temperature.
Faults or protective devices within the optional VFD can
shut down the chiller.
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 chill-
ers 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 97.
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 accom-
plished 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 Instruc-
tions and certified drawings). If primary control of water
pumps and tower fans is provided by customer-installed devic-
es, a parallel means for the Carrier controls to independently
operate the pumps 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-mount-
ed 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 cir-
cuit breaker. The shunt trip is activated by ISM logic, based on
values entered in the ISM_CONF table, under any of the fol-
lowing 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, Ben-
shaw solid-state starters include several such protective cir-
cuits. The shunt trip is also activated if EVAPORATOR PRES-
SURE drops below 0 psig (0 kPa). The Shunt Trip feature can
be tested using the Control Test feature.
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.
CAUTION
If compressor motor overload occurs, check the motor for
grounded or open phases before attempting a restart.
48
Table 6 Protective Safety Limits and Control Settings
MONITORED PARAMETER STATE LIMIT COMMENTS
Temperature Sensors Out of
Range
260-270,
272,140,
141
Temperature <-40 deg F or >245 deg F for
3 seconds
Preset Alarm
Pressure Transducers Out of
Range
260-270
.06>Voltage Ratio>.98 for 3 seconds, Valid Range
is > -6.7 PSI and < 420 PSI
Preset Alarm, Voltage Ratio=Input Voltage/
Voltage Reference (5 Volts)
Compressor Discharge
Temperature
231
COMP DISCHARGE TEMP > 220 deg F
(104.4 deg C)
Preset Alarm,
149
COMP DISCHARGE TEMP > COMP DISCHARGE
ALERT
Configure COMP DISCHARGE ALERT in
SETUP1 screen
103
COMP DISCHARGE TEMP > COMP DISCHARGE
ALERT - 10 deg F(5.6 deg C)
Prestart Alert, Configure COMP DIS-
CHARGE ALERT in SETUP1 screen
Motor Winding Temperature
233
COMP MOTOR WINDING TEMP > 220 deg F
(104 deg C)
Preset Alarm, Configure COMP MOTOR
TEMP OVERRIDE in SETUP1 screen
102
COMP MOTOR WINDING TEMP > COMP
MOTOR TEMP OVERRIDE - 10 deg F (5.6 deg C)
Prestart Alert, Configure COMP MOTOR
TEMP OVERRIDE in SETUP1 screen
Compressor Thrust Bearing
Temperature
101
COMP THRUST BRG TEMP > COMP THRUST
BRG ALERT - 10 deg F (5.6 deg C)
Prestart Alert, Configure COMP THRUST
BRG ALERT in SETUP1 screen
150
COMP THRUST BRG TEMP > COMP THRUST
BRG ALERT
Configure COMP THRUST BRG ALERT in
SETUP1 screen (rolling element bearings
have higher normal operating temperature
but within limit)
234
COMP THRUST BRG TEMP > COMP THRUST
BRG TRIP
Configure COMP THRUST BEARING
RESET FACTOR (default = 1.4). Trip point
varied by THRUST BEARING RESET. See
PIC II Functions > COMPRESSOR BEAR-
ING TEMPERATURE.
Low Refrigerant Temperature
(Freeze Protection)
243
Chiller in RECYCLE SHUTDOWN and [CALC
EVAP SAT TEMP or EVAP REFRIG LIQUID TEMP]
< EVAP REFRIG TRIPPOINT + 1 deg F
Preset Alarm, configure EVAP REFRIG
TRIPPOINT in SETUP1 screen
232
Water chilling: EVAP REFRIG TEMP < 33 deg F
Brine Chilling: EVAP REFRIG TEMP<0-40 deg F
(configurable) and EVAP APPROACH > EVAP
APPROACH ALERT
Preset Alarm, Configure EVAP
APPROACH ALERT, EVAP REFRIG TRIP
POINT and CHILLED MEDIUM in SETUP1
screen
104
Water Chilling: CALC EVAP SAT TEMP or EVAP
REFRIG LIQUID TEMP < 33 deg F + REFRIG
OVERRIDE DELTA T
Brine Chilling: CALC EVAP SAT TEMP or EVAP
REFRIG LIQUID TEMP < EVAP REFRIG TRIP-
POINT
Prestart Alert, Configure REFRIG OVER-
RIDE DELTA T, EVAP REFRIG TRIP-
POINT and CHILLED MEDIUM in SETUP1
screen
Transducer Voltage Fault 239 Voltage Reference < 4.5 VDC or > 5.5 VDC Preset Alarm
High Condenser Pressure -
Control
235 CONDENSER PRESSURE > 165 PSI
Preset Alarm, Configure COND PRESS
OVERRIDE in SETUP1 screen
High Condenser Pressure -
Prestart
106
CONDENSER PRESSURE > COND PRESS
OVERRIDE - 20 PSI or CONDENSER PRESSURE
> 145 PSI
Prestart Alert, Configure COND PRESS
OVERRIDE in SETUP1 screen. Causes
condenser pump to start and remain on
through startup.
Low Discharge Superheat 240
DISCHARGE SUPERHEAT < SUPERHEAT
REQUIRED - 3 deg F(1.7 deg C) for 60 seconds.
SUPERHEAT REQUIRED is calculated for current
conditions.
Preset Alarm, DISCHARGE SUPERHEAT
= COMP DISCHARGE TEMP - CON-
DENSER REFRIG TEMP
Condenser High Pressure Switch
Circuit
207
High Pressure Switch Circuit Open and START =
YES and CONDENSER PRESSURE > 160 PSI
Preset Alarm, High Pressure Switch resets
at 110 +/-7 PSIG
224
High Pressure Switch Circuit Open, START = YES
and CONDENSER PRESSURE < 160 PSI
Preset Alarm, High Pressure Switch resets
at 110 +/-7 PSIG
235 CONDENSER PRESSURE >165 PRESET ALARM
Low Condenser Pressure (Freeze
Protection)
244
Energizes condenser pump relay if Chiller in
PUMPDOWN mode and CONDENSER REFRIG
TEMP < CONDENSER FREEZE POINT
De-energizes condenser pump relay when [CON-
DENSER REFRIG TEMP > CONDENSER
FREEZE POINT + 5 deg F (2.8 deg C)] and
[ENTERING COND LIQUID > CONDENSER
FREEZE POINT]
Preset Alarm, Configure CONDENSER
FREEZE POINT in SETUP1 screen.
154
Energizes condenser pump relay if CONDENSER
REFRIG TEMP < CONDENSER FREEZE POINT.
De-energizes condenser pump relay when [CON-
DENSER REFRIG TEMP > CONDENSER
FREEZE POINT + 5 deg F (2.8 deg C)] and
[ENTERING COND LIQUID > CONDENSER
FREEZE POINT]
Preset Alarm, Configure CONDENSER
FREEZE POINT in SETUP1 screen.
Oil - Low Pressure 228
[OIL PRESSURE DELTA P < 18 PSID and START
= TRUE] or [ OIL PRESSURE DELTA P < 15 PSID
and startup complete after OIL PRESS VERIFY
TIME elapsed]
Preset Alarm, Configure OIL PRESS VER-
IFY TIME in SETUP1 screen
49
Table 6 Protective Safety Limits and Control Settings (cont)
MONITORED PARAMETER STATE LIMIT COMMENTS
Low Pressure 142
OIL PRESSURE DELTA P < 18 PSID and startup
complete
Preset Alert
Oil - Pressure Sensor Fault 227
OIL PRESSURE DELTA P > 4 PSI immediately
before oil pump turned on
Preset Alarm
Oil - Low Temperature 105
OIL SUMP TEMP < 150 deg F and [OIL SUMP
TEMP < CALC EVAP SAT TEMP + 50 deg F(27.8
deg C)]
Prestart Alert
Line Voltage - High
211/145
Line voltage > 150 % MOTOR RATED LINE VOLT-
AGE for 1 second
Preset Alarm / Alert if Autorestart is
enabled
211/145
Line voltage > 115 % MOTOR RATED LINE VOLT-
AGE for 10 seconds
211/145
Line voltage > OVERVOLTAGE THRESHOLD for
OVER/UNDER VOLTAGE TIME
Configure OVERVOLTAGE THRESHOLD
and OVER/UNDER VOLT TIME in
ISM_CONF screen
108
AVERAGE LINE VOLTAGE > OVERVOLTAGE
THRESHOLD
Configure OVERVOLTAGE THRESHOLD
in ISM_CONF screen
Line Voltage - Low
212/146
AVERAGE LINE VOLTAGE < 75% MOTOR RATED
LINE VOLTAGE for 1 second OR AVERAGE LINE
VOLTAGE < 80% MOTOR RATED LINE VOLTAGE
for 5 seconds OR AVERAGE LINE VOLTAGE <
85% MOTOR RATED LINE VOLTAGE for 10 sec-
onds OR AVERAGE LINE VOLTAGE < UNDER-
VOLTAGE THRESHOLD for > OVER/UNDER
VOLTAGE TIME
Preset Alarm/Alert Configure UNDER-
VOLTAGE THRESHOLD and OVER/
UNDER VOLT TIME in ISM_CONF screen
107
PERCENT LINE VOLTAGE < UNDERVOLTAGE
THRESHOLD
Prestart Alert, Configure UNDERVOLTAGE
THRESHOLD in ISM_CONF screen
Line Voltage - imbalance 216
Line Voltage Imbalance > VOLTAGE % IMBAL-
ANCE for > VOLTAGE IMBALANCE TIME
Configure VOLTAGE % IMBALANCE and
VOLTAGE IMBALANCE TIME in
ISM_CONF screen
Line Current -Single Cycle
Dropout
210/144 Line Voltage on 2 Phases < 50% for 1 Cycle
Preset Alarm/Prestart Alert, Configure
SINGLE CYCLE DROPOUT in ISM_CONF
screen
Current Imbalance 215
Line Current Imbalance > CURRENT % IMBAL-
ANCE for > CURRENT IMBALANCE TIME
Configure CURRENT % IMBALANCE and
CURRENT IMBALANCE TIME in
ISM_CONF screen
Power - Line Frequency Out of
Range
222
LINE FREQUENCY [<56 Hz or > 64 Hz] (60 Hz),
LINE FREQUENCY [<46 Hz or > 54 Hz] (50 HZ)
Preset Alarm
Phase Loss
209/143
Any LINE VOLTAGE PHASE < 50% MOTOR
RATED LINE VOLTAGE
Condition must persist for 2 seconds
209/143
Minimum LINE CURRENT PHASE < 1/16 Maxi-
mum LINE CURRENT PHASE and Maximum LINE
CURRENT PHASE > 5% MOTOR RATED LOAD
AMPS
Condition must persist for 1 seconds
ISM Power on Reset 213/147
Loss of control power (brownout < 97 volts) to ISM
for excessive time period
Preset Alarm
ICVC Power on Reset 214/148
Loss of control power (<18 volts) to ICVC for exces-
sive time period
Preset Alarm
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 Aux. contacts open with 1CR = ON + 3 sec. Preset Alarm
2M Aux. contact fault 201
Aux. contacts open with 1CR/Transition = ON + 3
Sec
Preset Alarm
Starter Fault 206 Starter Fault = Open w/1CR = ON Preset Alarm, Check starter safety circuit
Compressor Surge 238
> 4 surge protection counts within SURGE TIME
PERIOD and VFD SPEED > 90%
Preset Alarm, Configure SURGE DELTA%
AMPS and SURGE TIME PERIOD in
OPTIONS screen
Surge 236
> 4 surge protection counts within SURGE TIME
PERIOD and VFD SPEED < 90%
Preset Alarm, Configure SURGE DELTA%
AMPS and SURGE TIME PERIOD in
OPTIONS screen
50
Table 6 Protective Safety Limits and Control Settings (cont)
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 de-
fault 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
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 HISTO-
RY screen for additional help in determining the reasons for the
alarms. Once all existing alarms are cleared (by pressing
the softkey), the default ICVC display returns to nor-
mal operation.
MONITORED PARAMETER STATE LIMIT COMMENTS
Overload Trip 217
Any LOAD CURRENT PHASE > 108% for Exces-
sive Time Period
Preset Alarm, Force ACTIVE DEMAND
LIMIT in MAINSTAT screen
Locked Rotor Trip 218 Motor Locked Rotor Amps exceeded Preset Alarm
Excessive Amps 208 PERCENT LOAD CURRENT > 110% for 30 sec. Preset Alarm
Acceleration Fault (full voltage) 203
PERCENT LOAD CURRENT >100% at 10 sec
after 1CR closes (across the line)
Preset Alarm, PERCENT LOAD CUR-
RENT = AVERAGE LOAD CURRENT/
MOTOR RATED LOAD AMPS
Acceleration Fault (reduced
voltage)
203
PERCENT LOAD CURRENT >150% at 20 sec
after 1CR closes (reduced voltage)
Preset Alarm, PERCENT LOAD CUR-
RENT = AVERAGE LOAD CURRENT/
MOTOR RATED LOAD AMPS
203
PERCENT LOAD CURRENT >100% at 45 sec
after 1CR closes (reduced voltage)
Preset Alarm, PERCENT LOAD CUR-
RENT = AVERAGE LOAD CURRENT/
MOTOR RATED LOAD AMPS
Amps not Sensed 202
PERCENT LOAD CURRENT < 15% w/1M/2M
closed
Preset Alarm, PERCENT LOAD CUR-
RENT = AVERAGE LOAD CURRENT/
MOTOR RATED LOAD AMPS
Amps when Stopped 205 Amp signal > 10% w/1M/2M open preset alarm
Failure to Stop
204 1M/2M contacts fail to open Shunt trip, if equipped
205
MOTOR AMPS WHEN STOPPED ( Amps > 10%
w/ 1CR OFF )
Shunt trip, if equipped
Starts Limit Exceeded 100 More than 8 starts in 12 hours Preset Prestart Alert
Low Chilled Water Flow 229
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
Optional Alarm With ICVC DSABLE
FLOW DELTA P DISPLAY in SETUP1
screen Optional Alarm, All limits configu-
rable in SETUP1 screen
Low Cond Water Flow 230
CONDENSER LIQUID DELTA P < COND FLOW
DELTA P CUTOUT OR CONDENSER APPROACH
> CONDENSER APPROACH ALERT OR CON-
DENSER PRESSURE > COND PRESS OVER-
RIDE + 5
Optional Alarm With ICVC DSABLE
FLOW DELTA P DISPLAY in SETUP1
screen
High Approach - Evaporator 162
EVAPORATOR APPROACH > EVAP APPROACH
ALERT and startup complete
Configure EVAP APPROACH ALERT in
SETUP1 screen
Condenser 163
CONDENSER APPROACH > COND APPROACH
ALERT and startup complete
Configure COND APPROACH ALERT in
SETUP1 screen
VFD - High VFD Speed 245
ACTUAL VFD SPEED > VFD SPEED OUTPUT +
10%
Preset Alarm, Must be outside +10%
threshold for 30 sec.
Starter Transition - 2M Start/Run
Fault
201
ISM 2M aux contact not closed after 20 sec from
start
Reduced voltage starters only
Ground Fault 220
GROUND FAULT CURRENT > GROUND FAULT
AMPS
Configure GROUND FAULT AMPS in
ISM_CONF screen
Optional Limits - Spare
Temperature
158/159
SPARE TEMPERATURE > or < SPARE TEMP
LIMIT
Optional Alarm/Alert, Confirure SPARE
TEMP ENABLE and SPARE TEMP LIMIT
in SETUP1 screen
Guide Vane Position 253
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
Preset Alarm
High Condenser Water Flow 254
CONDENSER WATER DELTA P > CONDENSER
HIGH FLOW DELTA P LIMIT for more than
2 minutes.
Optional Alarm. Configure COND HI
FLOW DEL P LIMIT in SETUP1 screen
Variable Diffuser Operation 247
Detects discharge pulses caused by incorrect dif-
fuser position.
Preset Alarm. Transducer measures
pulses, no on-screen pressure reading. No
calibration needed.
RESET
51
Ramp Loading The ramp loading control slows down
the rate at which the compressor loads up. This control can pre-
vent 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 de-
creases. This rate is configured by the operator on the
TEMP_CTL screen. The lowest temperature ramp load-
ing 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 regard-
less 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 com-
pressor motor current or compressor motor load increas-
es. The LOAD PULLDOWN rate is configured by the
operator on the RAMP_DEM screen in amps or kilo-
watts. 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 Requi-
sition 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 start-up 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 tem-
perature is within the control point dead band and any condi-
tion is reached that would require the VFD speed to hold or in-
crease. The chiller is then out of Rampdown and running in
normal capacity control.
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 pre-
vented from opening further, and the status line on the
ICVC indicates the reason for the override. Normal ca-
pacity control operation is restored when the value cross-
es back over the First Stage Set Point, leaving the Over-
ride Region. See Table 7.
2. When the value of interest is in the Override Region and
further crosses the Second Stage Set Point, the guide
vanes are closed until the value meets the Override Ter-
mination Condition. The PIC II controls resume normal
capacity control operation after the override termination
condition has been satisfied. (In the case of high dis-
charge 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 by-
pass valve will open instead of holding the vanes. See the
Surge Prevention section, page 55.
If the chiller is VFD-equipped, the guide vanes will be al-
lowed to open during surge prevention if the VFD is at 100%
speed or forced and the chiller is in Ramp Loading or in Ramp-
down. 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 tempera-
ture 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 incre-
ment 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 nor-
mally be left at that value unless other wise advised by Carrier
Service Engineering.
Oil Sump Temperature and Pump Con-
trol 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 start-
up continues.
The oil heater relay is energized whenever the chiller com-
pressor is off and the oil sump temperature is less than 140 F
(60.0 C) or the oil sump 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).
52
Table 7 Capacity Overrides
OVERRIDE
CONDITION
(Configurable
Override
Paramter)
FIRST STAGE SET POINT
(Capacity Inhibit)
SECOND STAGE SET POINT
(Forced Capacity Decrease)
OVERRIDE
TERMINATION
View/Modify on
ICVC Screen
Override Default
Value
Configurable Range Value Value
High Condenser
Pressure (COND
PRESS
OVERRIDE)
SETUP1
CONDENSER
PRESSURE > 125
PSIG (862 kPa)
90 to 165 PSIG
(621 to 1138 kPa)
CONDENSER PRESSURE >
COND PRESS OVERRIDE + 2.4
PSIG (16.5 kPA)
CONDENSER PRES-
SURE < CON-
DENSER PRESS
OVERRIDE - 1 PSI
(6.9 kPa)
High Motor
Temperature
(COMP MOTOR
TEMP
OVERRIDE)
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)
COMP MOTOR WINDING TEMP
> COMP MOTOR TEMP OVER-
RIDE + 10 F (5.6 C)
COMPR MOTOR
WINDING TEMP <
COMP MOTOR TEMP
OVERRIDE - 2 F
(1.1 C)
Low Evaporator
Temperature
(REFRIG
OVERRIDE
DELTA T)
SETUP1
CALC EVAP SAT
TEMP < EVAP
REFRIG TRIP-
POINT + 3 F(1.7 C)
2 to 5 F
(1.1 to 2.8 C)
CALC EVAP SAT TEMP < EVAP
SAT OVERRIDE TEMP - 1 F
(0.6 C) NOTE: EVAP SAT OVER-
RIDE TEMP = EVAP REFRIG
TRIPPOINT + REFRIG OVER-
RIDE DELTA T
CALC EVAP SAT
TEMP > EVAP SAT
OVERRIDE TEMP +
2 F (1.1 C)
High
Compressor Lift
(Surge
Prevention)
(Tsmin, IGVmin,
Tsmax, IGVmax,
Shapefac)
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
ActiveTsat < Surge-
Line Tsat + Dead-
band Setting
Manual Guide
Vane Target
(TARGET GUIDE
VANE POS)
COMPRESS Automatic 0 to 100% None
Press RELEASE soft-
key after selecting
TARGET GUIDE
VANE POS
Manual Speed
Control
(TARGET VFD
SPEED)
COMPRESS Automatic
VFD MINIMUM SPEED
to 100%
Forced TARGET VFD SPEED
cannot override either a capacity
inhibit or a capacity decrease
command generated by the PIC II
Press RELEASE soft-
key after selecting
TARGET VFD SPEED
Motor Load
(ACTIVE
DEMAND LIMIT)
MAINSTAT
AVERAGE LINE
CURRENT or
MOTOR PERCENT
KILOWATTS > 100%
40 to 100%
AVERAGE LINE CURRENT or
MOTOR PERCENT KILOWATTS
> ACTIVE DEMAND LIMIT + 5%
AVERAGE LINE CUR-
RENT or MOTOR
PERCENT KILO-
WATTS < ACTIVE
DEMAND LIMIT
Low Discharge
Superheat
OVERRIDE
ACTUAL SUPER-
HEAT < SUPER-
HEAT REQUIRED
for conditions
None
ACTUAL SUPERHEAT <
SUPERHEAT REQUIRED - 0.5 F
(0.3 C)
ACTUAL SUPER-
HEAT > SUPERHEAT
REQUIRED + 1 F
(0.56 C)
53
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 be-
ing heated (for 30 seconds at the end of every 30 minutes).
The oil pump will not operate if the EVAPORATOR PRES-
SURE is less than 5 psig (34.5 kPa).
Oil Cooler The oil must be cooled when the compres-
sor is running. This is accomplished through a small, plate-type
heat exchanger (also called the oil cooler) located behind the
oil pump. The heat exchanger uses liquid condenser refrigerant
as the cooling liquid. Refrigerant thermostatic expansion
valves (TXVs) regulate refrigerant flow to control the oil tem-
perature entering the bearings. The bulbs for the expansion
valves are strapped to the oil supply line leaving the heat ex-
changer, and the valves are set to maintain 110 F (43 C).
NOTE: The TXVs are not adjustable. The oil sump tempera-
ture may be at a lower temperature during compressor
operations.
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 pro-
grammed 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 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 ter-
minal 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.
Spare Safety and Spare Temperature
Inputs Normally closed (NC) discrete inputs for addi-
tional field-supplied safeties may be wired to the spare protec-
tive limits input channel in place of the factory-installed jump-
er. (Wire multiple inputs in series.) The opening of any contact
will result in a safety shutdown and a display on the ICVC. Re-
fer 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 TEM-
PERATURE #2) at terminals J4 25-26 and J4 27-28, respec-
tively. 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 run-
ning 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 Ap-
pendix B.
Alarm (Trip) Output Contacts One set of alarm
contacts is provided in the starter. The contact ratings are pro-
vided 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
refrigerant leak detector. Enabling REFRIGERANT LEAK OP-
TION (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 config-
ured for 1 to 5 vdc by setting switch 1 at the OFF position. The
output of the refrigerant leak detector is displayed as REFRIG-
ERANT 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.
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 sys-
tem to monitor the chillers 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 (repre-
senting 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 RAT-
ED KILOWATTS from the job data sheet.
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 soft-
ware from building automation systems (BAS) or energy man-
agement 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 oper-
ating 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 Mes-
sages, page 97. After the alarm has been reset the PIC II control
will increment the Starts in 12 Hours counter by one upon re-
start. 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).
Condenser Pump Control The chiller will moni-
tor the condenser pressure (CONDENSER PRESSURE) and
may turn on the condenser pump if the condenser pressure be-
comes too high while the compressor is shut down. The con-
denser pressure override (COND PRESS OVERRIDE) parame-
ter 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 condens-
er refrigerant temperature (CONDENSER REFRIG TEMP) is
within 3 F (1.7 C) of the entering condenser water tempera-
ture (ENTERING CONDENSER WATER).
RESET
54
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 pump-
down 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 CON-
DENSER 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 CON-
DENSER FREEZE POINT, the same low temperature condi-
tion 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 non-
recycle shutdown.
Evaporator Freeze Protection When the EVAP-
ORATOR REFRIG TEMP is less than the EVAP REFRIG
TRIPPOINT plus the REFRIG OVERRIDE DELTA T (configu-
rable 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 deener-
gize as the pressure differential between cooler and condenser
vessels changes. This prevents low condenser water tempera-
ture 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 con-
denser 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 condens-
er pump is off or the EVAP REFRIGERANT TEMP is less than
the EVAP SAT OVERRIDE TEMP for ENTERING CON-
DENSER 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 con-
denser water pump is running and the difference between
EVAPORATOR PRESSURE and CONDENSER PRESSURE is
more than 30 psid (206.8 kPad) and ENTERING COND
WATER 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 PRES-
SURE and CONDENSER PRESSURE is less than 28 Psid
(193 kPa), and ENTERING CONDENSER WATER tempera-
ture is less than TOWER FAN HIGH SETPOINT minus 3 F
(5.4 C).
Auto Restart After Power Failure ICVC Soft-
ware Version 11 The Auto Restart feature is enabled/
disabled in the OPTIONS screen.
NOTE: This section assumes that a chiller without Uninter-
ruptible Power supply has been installed.
The following faults will reset when Auto Restart is en-
abled: single cycle dropout (if enabled), line current imbalance,
high line voltage, low line voltage, and ISM power-on reset
(Alerts 143-148). With this feature enabled, these faults are
treated as alerts instead of alarms, so start-up proceeds as soon
as the condition has been 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 incre-
mented.
This feature allows the controls to make an express restart
as long as the controls have been without power for 20 minutes
or less. If the power is off for less than 20 minutes, the timing
of the restart is now in an express mode. When enabled, at the
time of power up, if the chiller had been operating at the time
of shutdown, the controls will immediately energize the
CHILLED WATER PUMP output, wait 1 second, energize the
CONDENSER WATER PUMP output, then wait 1 second to
start to verify water flow. When flow is verified, and the
chilled water temperature is calling for cooling, the guide vane
is now checked for closure. If the unit is configured for VFD,
then the guide vanes have no closure requirement. If there is
no VFD configured, the vanes must be less than or equal to the
GUIDE VANE CLOSURE limit set in the OPTIONS table.
After guide vanes are checked and in position, the oil pump
is started and when the oil pressure is confirmed the controls
wait 4 seconds to maintain pressure. At this point the compres-
sor is commanded to start.
If the power had been off for longer than 20 minutes, the
timing of the restart will be standard timing for auto restart af-
ter power failure. When power is restored (after the longer
than 20-minute power failure) and if the compressor had been
running, the oil pump will energize for one minute before ener-
gizing 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 time clock 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 30 seconds at the end of every
30-minute period until the chiller is started.
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.
55
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 trans-
fer is an open transition type, and time to transfer is less than 5
seconds, the chiller should be stopped before the transfer oc-
curs 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 re-
start the chiller. The contacts must be wired to the to the Re-
mote 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 automati-
cally restart the chiller.
Water/Brine Reset For this application, it is recom-
mended the Single Cycle Drop Out in the ISM Configuration
be enabled. Chilled water capacity control is based on achiev-
ing and maintaining a CONTROL POINT temperature, which
is the sum of the LCW SET POINT or ECW SETPOINT (from
the SETPOINT screen) and a Water/Brine Reset value, if any.
CONTROL POINT is limited to a minimum of 35 F (+1.7 C)
for water, or 10 F (12.2 C) for brine. Three types of chilled
water or brine reset are available and can be viewed or modi-
fied 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, in-
put 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 appropri-
ately configured. Reset Type 1 permits up to 30 F (16.7 C)
of reset to the chilled water set point. Inputs are wired to termi-
nals 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 tempera-
ture difference (the difference between entering and leaving
chilled water) at which no temperature reset occurs (CHW
DELTA T > NO RESET). This chilled water temperature dif-
ference is usually the full design load temperature difference.
Next, enter the difference in chilled water temperature at which
the full amount of reset occurs (CHW DELTA T > FULL RE-
SET). Finally, enter the amount of reset (DEGREES RESET).
Reset Type 3 can now be activated.
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% de-
mand 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 pow-
ered 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
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.
Surge Prevention Constant Flow and Vari-
able Primary Flow (VPF) A surge condition occurs
when the lift becomes so high that the gas flow across the im-
peller 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 con-
denser 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 particu-
lar impeller wheel can perform varies with the gas flow across
the impeller and the size of the wheel.
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 Preven-
tion there is no difference in field configuration between con-
stant and variable flow water systems.
The controls calculate the conditions at which the compres-
sor 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.
Hot Gas Bypass (Optional) Algorithm If a
hot gas bypass solenoid valve is present and the HGBP OP-
TION in the OPTIONS table is set to 1 or 2, this operator con-
figurable 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 (VFD Option Disabled) The algo-
rithm determines if corrective action is necessary by checking
the chiller operating point against an operator configured
56
threshold. The threshold is calculated from a combination of
GUIDE VANE POSITION and the difference between CON-
DENSER PRESSURE and EVAPORATOR PRESSURE.
The operator configured data points are the MINIMUM and
MAXIMUM SATURATED TEMPERATURE DIFFER-
ENCE (Surge/HGP Delta Tsmin and Surge/HGBP DeltaTs-
max), the MAXIMUM AND MINIMUM GUIDE VANE PO-
SITIONS (Surge/HGBP IGVmax and Surge/HGBP IGVmin)
printed on a label fixed to the bottom of interior face of the con-
trol 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 ACTU-
AL GUIDE VANE POSITION falls to the right side of the plot-
ted 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 condi-
tions, instructions to adjust the Surge / Hot Gas Bypass config-
urations are found on page 78.
HGBP OPTION = 1 (VFD Option Enabled) The HGBP
is only energized if a SURGE PROTECTION COUNT is regis-
tered, 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 in-
crease when the VFD TARGET SPEED is equal to VFD MAX-
IMUM SPEED or if the VFD TARGET SPEED is FORCED to
a fixed value.
HGBP OPTION = 2 This option energizes the HOT GAS
BYPASS RELAY solely based on the ACTIVE DELTA T (actu-
al temperature difference between the LEAVING CHILLED
WATER and ENTERING CHILLED WATER). Evaluation of
the ACTIVE DELTA T begins at the completion of ramp load-
ing. The hot gas bypass valve is energized if the ACTIVE DEL-
TA T is less than the HGBP ON DELTA T. The hot gas bypass
relay will be turned off when the ACTIVE DELTA T is greater
than or equal to the sum of HGBP ON DELTA T plus HGBP
OFF DELTA T See Fig. 27.
The HGBP ON DELTA T must be set to a value larger
than the minimum delta T to which the chiller can un-
load.
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 am-
perage 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.
If a surge occurs, the guide vane position will be reduced by
10%. The guide vanes will be prevented from increasing posi-
tion until either the Surge Time Period expires causing the
SURGE PROTECTION COUNT to return to zero or the En-
tering 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 posi-
tion 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 IN-
CREASE 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 DE-
CREASE softkey to adjust the time duration. The default set-
ting 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.
Surge Prevention Algorithm with VFD This is
an operator configurable feature that can determine if lift con-
ditions 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 com-
pressor lift capability at the reduced speed. If the actual operat-
ing 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 AC-
TUAL VFD SPEED. Increasing VFD SURGE LINE GAIN re-
duces the size of the SURGE PREVENTION on area.
When the controls enter SURGE PREVENTION mode the
first response is to increase ACTUAL VFD SPEED and in-
crease 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 preven-
tion region, the controls will energize the HOT GAS BYPASS
RELAY and if the SURGE LIMIT/HGBP OPTION is config-
ured for Hot Gas Bypass).
If load decreases while the chiller is in SURGE PREVEN-
TION 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
HGBP
On
HGBP Off As ACTIVE
DELTA T Decreases
HGBP On As ACTIVE
DELTA T Increases
P
T
HGBP ON
DELTA T
HGBP OFF
DELTA T
HGBP
Off
LEGEND
P = (Condenser Pressure) (Cooler Pressure)
T = (ECW) (LCW)
Fig. 27 19XR Hot Gas Bypass/Surge
Prevention (Option 2)
ECW Entering Chilled Water
HGBP Hot Gas Bypass
LCW Leaving Chilled Water
a19-1864
57
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, investi-
gate 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 even-
tually cause chiller damage. When enabled, the Surge Preven-
tion 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.
When in Surge Prevention mode, with a command to in-
crease capacity, the VFD speed will increase until maximum
VFD speed is reached. At VFD MAXIMUM SPEED, when Ca-
pacity still needs to increase, the IGVs open. When in Surge
Prevention mode and with a command to decrease capacity
only the IGVs will close, the VFD speed will not decrease.
Surge Protection (VFD Chiller) The PIC II mon-
itors surge, which results in a fluctuation on the compressor
motor amperage. Each time the fluctuation in amperage ex-
ceeds an operator-specified limit (SURGE DELTA % AMPS)
plus a load correction factor, both SURGE COUNTS are incre-
mented 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 PROTEC-
TION COUNTS are also incremented by one. If more than 4
SURGE PROTECTION COUNTS occur within an operator-
specified time (SURGE TIME PERIOD) and the ACTUAL
VFD SPEED is greater than 90% then the PIC 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 MAXI-
MUM SPEED then the TARGET VFD SPEED will be in-
creased 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 por-
tion 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 DE-
CREASE 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.
VFD Start-Up Speed Control Immediately accel-
erating to a high VFD speed improves the ability of the com-
pressor to compensate for some start-up environments that ex-
ceed 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 po-
sition until a stable operating point with improved chiller effi-
ciency 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
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 DEAD-
BAND surrounding the Setpoint. RAMP LOADING AC-
TIVE 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 pre-
vention algorithms at the conclusion of the rampdown process.
Head Pressure Reference Output (See
Fig. 28) The PIC II control outputs a 4 to 20 mA signal
for the configurable Delta P (CONDENSER PRESSURE mi-
nus EVAPORATOR PRESSURE) reference curve shown in
Fig. 28. An output is available on the ISM module [Terminal
J8-3 (+), J8-4 () labeled spare]. The DELTA P AT 100% (chill-
er 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 con-
figurable in the EQUIPMENT SERVICE-OPTIONS table.
When configuring this output ensure that minimum require-
ments 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 engineer-
ing agent to integrate this analog output with any external sys-
tem 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 ele-
ments or signal conditioning), although it may be.
MINIMUM
REFERENCE
OUTPUT
DELTA P
AT 100%
DELTA P
AT 0%
DELTA P
0 mA 2 mA
4 mA
(0%)
20 mA
(100%)
4 T0 20 mA OUTPUT
Fig. 28 Head Pressure Reference Output
(Minimum Set Above 4 mA)
58
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.
Lead/Lag Control The lead/lag control system auto-
matically starts and stops a lag or second chiller in a 2-chiller
water system. A third chiller can be added to the lead/lag
system as a standby chiller to start up in case the lead or lag
chiller in the system has shut down during an alarm condition
and additional cooling is required. Refer to Fig. 20 and 21 for
menu, table, and screen selection information.
NOTE: The lead/lag function can be configured on the LEAD-
LAG screen, which is accessed from the SERVICE menu and
EQUIPMENT SERVICE table. See Table 3, Example 22.
Lead/lag status during chiller operation can be viewed on the
LL_MAINT display screen, which is accessed from the SER-
VICE menu and CONTROL ALGORITHM STATUS table.
See Table 3, Example 12.
Lead/Lag System Requirements:
all chillers in the system must have software capable of
performing the lead/lag function
water pumps MUST be energized from the PIC 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 INSTALLA-
TION Refer to 19XR,XRV Lead Lag Schematics, Appen-
dix 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 OP-
TION 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 sen-
sors 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 ap-
plication the COMMON SENSOR OPTION should only be en-
abled 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 applica-
tion 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 TEM-
PERATURE when chillers are piped in parallel, the water flow
through the shutdown chiller(s) should be isolated so that no
water bypass around the operating chiller occurs. However, if
water bypass around the operating chiller is unavoidable, a
common point sensor in the mixed LEAVING CHILLED WA-
TER piping should be provided and enabled for the Lead
chiller.
CHILLER COMMUNICATION WIRING Refer to the
chillers 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 op-
tion 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 LEAD-
LAG screen is set to 1.
A chiller is designated the lag chiller when its
LEADLAG: CONFIGURATION value is set to 2.
A chiller is designated as a standby chiller when its
LEADLAG: CONFIGURATION value is set to 3.
A value of 0 disables the lead/lag designation of a
chiller.This setting should also be used when normal
operation without regard to lead/lag rules is desired (in
LOCAL or CCN mode).
When configuring the LAG ADDRESS value on the
LEADLAG screen of chiller A enter the address of the chill-
er on the system which will serve as lag when/if chiller A is
configured as lead. For example, if the user is configuring chill-
er 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 chill-
ers. Note that only the lag and standby chiller addresses speci-
fied 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 func-
tion is disabled and an alert (!) message displays. For example,
if the LAG ADDRESS matches the lead chillers 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: CONFIGU-
RATION and CURRENT MODE fields. See Table below.
LEAD/LAG
CONFIGURATION
INVALID
CONDITIONS
1 (Lead)
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
2 (Lag)
Local Addres (Lead) = Lag Address
Standby Chiller Option = Enable AND Local
Address (Lag) = Standby Address
59
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 load-
ing, the PIC II evaluates the need for additional capacity. If ad-
ditional 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 ca-
pacity has been reduced enough for the lead chiller to sustain
the system alone. If the capacity is reduced enough for the lead
chiller to sustain the CONTROL POINT temperatures alone,
then the operating lag chiller is stopped.
If the lead chiller is stopped in CCN mode for any reason
other than an alarm (*) condition, the lag and standby chillers
are also stopped. If the configured lead chiller stops for an
alarm condition, the configured lag chiller takes the lead
chillers 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 TIM-
ER (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 PRE-
START FAULT TIMER elapses, the lag chiller stops, and the
standby chiller is requested to start, if configured and ready.
Standby Chiller Configuration and Operation A chiller is
designated as a standby chiller when its LEADLAG: CONFIG-
URATION 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 oper-
ate 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 MAIN-
STAT 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 wa-
ter sensor, depending on which options are configured
and enabled.
6. Lead chiller temperature pulldown rate (TEMP PULL-
DOWN 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 PULL-
DOWN 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 pa-
rameter 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 chill-
er applications with large chilled liquid loop volumes must ac-
commodate intermittent slugs of warm ENTERING
CHILLED WATER for short time periods. This type of tran-
sient condition can result when a control valve rapidly opens to
allow flow through a previously isolated branch or zone within
the chilled liquid system. A PULLDOWN TIMER can be con-
figured to delay starting the lag chiller so it does not excessive-
ly 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 be-
fore 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 tempera-
ture 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 temper-
ature 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 succes-
sive 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 un-
able 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 re-
maining 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 PULL-
DOWN TIME lapses to 0.0 min.
If PULLDOWN: SATISFIED changes to YES as the
PULLDOWN TIME is counting down to zero, the PULL-
DOWN 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 re-
set 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 WA-
TER DEADBAND.
Lag Chiller Shutdown Requirements The following condi-
tions 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
60
capacity, which is defined as 115 LAG % CAPACITY.
The LAG % CAPACITY parameter is on the LEADLAG
screen, which is accessed from the EQUIPMENT SER-
VICE 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 tem-
perature (see the SETUP1 screen).
3. The configured LAG STOP TIMER entry has elapsed.
The LAG STOP TIMER starts when the lead chiller
chilled water temperature is less than the chilled water
CONTROL POINT plus 1/2 of the CHILLED WATER
DEADBAND and the lead chiller compressor motor load
(MOTOR PERCENT KILOWATT or AVERAGE LINE
CURRENT on the MAINSTAT screen) is less than the
lead chiller percent capacity.
NOTE: The use of AVERAGE LINE CURRENT or PER-
CENT MOTOR KILOWATTS in the Lag chiller shutdown
decision is based on the DEMAND LIMIT SOURCE configu-
ration 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 commu-
nicating to the lag and standby chillers. After 30 seconds, the
lag chiller becomes the acting lead chiller and starts and stops
the standby chiller, if necessary.
If the lag chiller goes into alarm when 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 softkey to clear the alarm.
The chiller is placed in CCN mode. The lead chiller communi-
cates and monitors the RUN STATUS of the lag and standby
chillers. If both the lag and standby chillers are running, the
lead chiller does not attempt to start and does not assume the
role of lead chiller until either the lag or standby chiller shuts
down. If only one chiller is running, the lead chiller waits for a
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 condi-
tions 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 PULL-
DOWN DEG/MIN) of the chilled water temperature is
less than 0.5 F (0.27 C) per minute.
5. The standby chiller is not running as a lag chiller.
6. The configured LAG START TIMER configured in the lag
(acting lead) chiller has elapsed. The LAG START TIMER
is started when the lag (acting lead) chillers ramp loading
is completed.
LOAD BALANCING When the LOAD BALANCE OP-
TION (see LEADLAG screen) is enabled, the lead chiller sets
the ACTIVE DEMAND LIMIT in the lag chiller to the lead
chillers compressor motor load value MOTOR PERCENT
KILOWATTS or AVERAGE LINE CURRENT on the MAIN-
STAT screen). This value has limits of 40% to 100%. In addi-
tion, the CONTROL POINT for the lag chiller will be modified
to a value of 3 F (1.67 C) less than the lead chillers CON-
TROL 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 con-
figuration. The lead chiller does not have a delay. The lag chill-
er 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
delay sequence occurs whether the chiller is in CCN or LO-
CAL mode and is intended to stagger the compressor motor
starts. Preventing the motors from starting simultaneously
helps reduce the inrush demands on the building power system.
Ice Build Control The selectable ice build mode per-
mits 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 satis-
fied) 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 18.
The ICE BUILD SETPOINT can be configured from the
SETPOINT display, which is accessed from the PIC II
main menu. See Table 3, Example 9.
The ice build schedule can be viewed or modified from
the SCHEDULE table. From this table, select the ice
build schedule (OCCPC02S) screen. See Fig. 22 and the
section on Time Schedule Operation, page 26, 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 OP-
TIONS screen, allow the chiller operator to recycle or termi-
nate 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 opera-
tor sets the ICE BUILD TERMINATION parameter to 0
on the OPTIONS screen.
the REMOTE CONTACT inputs from an ice level indi-
cator 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.
RESET
61
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 SET-
POINT.
Any force (Auto) is removed from the ACTIVE
DEMAND LIMIT.
NOTE: A parameters value can be forced, that is, the value
can be manually changed at the ICVC by an operator, changed
from another CCN device, or changed by other algorithms in
the PIC II control system.
NOTE: The Ice Build steps do not occur if the chiller is config-
ured 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 follow-
ing 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 deter-
mines whether or not the chiller will go into an ice build RE-
CYCLE 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 satisfy-
ing one of the above conditions. Once ice build is termi-
nated 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 tem-
perature of the LEAVING CHILLED WATER later increases
above the ICE BUILD SETPOINT plus half the RECYCLE
RESTART DELTA T value, the compressor restarts, control-
ling 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 CON-
TROL OPTION and any temperature reset option shall be ig-
nored, 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 opera-
tion terminates, based on temperature, if the ICE BUILD
TERMINATION parameter is set to 0 (TEMP), the EN-
TERING CHILLED WATER temperature is less than the
ICE BUILD SETPOINT, and the ICE BUILD RECYCLE
is set to DSABLE. If the ICE BUILD RECYCLE OP-
TION is set to ENABLE, a recycle shutdown occurs and
recycle start-up depends on the LEAVING CHILLED
WATER temperature being greater than the water/brine
CONTROL POINT plus the RESTART DELTA T
temperature.
3. Remote Contacts/Ice Level Input Ice build operation
terminates when the ICE BUILD TERMINATION param-
eter 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 sched-
ule (OCCPC02S) is set for ice build operation. The re-
mote 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) dur-
ing 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 sched-
ules 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 opera-
tion. 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.
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 29 shows the ATTACH TO NETWORK DEVICE
screen. The LOCAL parameter is always the ICVC module ad-
dress of the chiller on which it is mounted. Whenever the con-
troller identification of the ICVC changes, the change is re-
flected automatically in the BUS and ADDRESS columns for
the local device. See Fig. 21. Default address for local device is
BUS 0 ADDRESS 1.
62
When the ATTACH TO NETWORK DEVICE screen is ac-
cessed, information can not be read from the ICVC on any de-
vice (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
information on another device. Therefore, a CCN module must
be attached when this screen is entered.
To attach any CCN device, highlight it using the
softkey and press the softkey. The message UP-
LOADING 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 AT-
TACH 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 upload-
ing process takes 1 to 2 minutes. Before leaving the ATTACH
TO NETWORK DEVICE screen, select the local device. Oth-
erwise, the ICVC will be unable to display information on the
local chiller.
ATTACHING TO OTHER CCN MODULES If the chill-
er 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 oth-
er unit is in CCN control), if desired, from this particular ICVC
module.
If the module number is not valid, the COMMUNICA-
TION FAILURE message will show and a new address num-
ber 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 de-
scriptor on the upper left hand corner of the ICVC screen. See
Fig. 19.
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 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 softkey to attach to
the LOCAL device and view the chiller operation.
Service Operation An overview of the tables and
screens available for the SERVICE function is shown in
Fig. 21.
TO ACCESS THE SERVICE SCREENS When the SER-
VICE screens are accessed, a password must be entered.
1. From the main MENU screen, press the
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
If this occurs, return to Step 1 and try to access the SER-
VICE screens again. If the password is correct, the soft-
key labels change to:
NOTE: The SERVICE screen password can be changed
by entering the ICVC CONFIGURATION screen under
SERVICE menu. The password is located at the bottom
of the menu.
The ICVC screen displays the following list of available
SERVICE screens:
Alarm History
Alert History
Control Test
Control Algorithm Status
Equipment Configuration
ISM (Starter) Config Data
Equipment Service
Time and Date
Attach to Network Device
Log Out of Device
ICVC Configuration
See Fig. 21 for additional screens and tables available from
the SERVICE screens listed above. Use the softkey to
return to the main MENU screen.
NOTE: To prevent unauthorized 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 and softkeys. Enter the
password and, from the SERVICE menu, highlight LOG OUT
OF NETWORK DEVICE and press the softkey.
The ICVC default screen will now be displayed.
TIME BROADCAST ENABLE The first displayed line,
Time Broadcast Enable, in the SERVICE/EQUIPMENT
CONFIGURATION/BRODEF screen, is used to designate the
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 holi-
Fig. 29 Example of Attach to Network
Device Screen
SELECT
ATTACH
ATTACH
ATTACH
SERVICE
EXIT
MENU SERVICE
SELECT
63
days as configured in the local chillers 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 chill-
ers) on the network.
HOLIDAY SCHEDULING (Fig. 30) 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. 30, 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 col-
umn) 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.
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 CONFIGURA-
TION 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 de-
vice. The controller that is configured as the broadcaster is the
device responsible for transmitting holiday, time, and daylight-
savings dates throughout the network.
To access the BRODEF screen, see the SERVICE menu
structure, Fig. 21.
To view or change the holiday periods for up to 18 different
holidays, perform the following operation:
1. At the Menu screen, press to access the Ser-
vice menu.
2. If not logged on, follow the instructions for Attach to Net-
work Device or To Log Out. Once logged on,
press until Equipment Configuration is high-
lighted.
3. Once Equipment Configuration is highlighted,
press to access.
4. Press until HOLIDAYS is highlighted. This is
the Holiday Definition table.
5. Press to enter the Data Table Select screen.
This screen lists 18 holiday tables.
6. Press to highlight the holiday table that is to be
viewed or changed. Each table is one holiday period,
starting on a specific date, and lasting up to 99 days.
7. Press to access the holiday table. The Configu-
ration Select table now shows the holiday start month and
day, and how many days the holiday period will last.
8. Press or to highlight the month,
day, or duration.
9. Press to modify the month, day, or duration.
10. Press or to change the select-
ed value.
11. Press to save the changes.
12. Press to return to the previous menu.
DAYLIGHT SAVING TIME CONFIGURATION The
BRODEF table also defines Daylight Saving Time changes.
This feature is by default enabled, and the settings should be re-
viewed 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.
Table 8 Daylight Saving Time Values
START-UP/SHUTDOWN/
RECYCLE SEQUENCE (Fig. 31)
Local Start-Up The timing of a normal start-up will
change when auto-restart after power failure is enabled and the
unit has been without power less than 20 minutes. See the
Auto Restart After Power Failure section. Local start-up (or a
manual start-up) is initiated by pressing the 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-to-start inhibit timers have expired. These timers
SERVICE
NEXT
SELECT
NEXT
SELECT
NEXT
SELECT
NEXT PREVIOUS
ITEM DEFINITION
Month
1 = January, 2 = February, ,
12 = December.
Day of Week 1 = Monday,, 7 = Sunday
Week
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
Time of day in 24-hour format
when the time advance or set
back will occur.
Advance/Back
Advance occurs first in the
year, setting the time ahead by
the specified number of minutes
on the selected date. Back
sets the time back by the speci-
fied amount (later in the year).
Fig. 30 Example of Holiday Period Screen
SELECT
INCREASE DECREASE
ENTER
EXIT
LOCAL
64
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 26), Occupancy
Schedule (page 46), and To Prevent Accidental Start-Up
(page 85), and Fig. 22.
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 and
softkeys. Scroll to highlight MAINSTAT. Press the
softkey. Scroll to highlight CHILLER START/STOP. Press
the 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 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
and softkeys. Scroll down and select the current
schedule. Select OVERRIDE, and set the desired override
time.
Another condition for start-up must be met for chillers that
have the REMOTE CONTACTS OPTION on the EQUIP-
MENT SERVICE screen set to ENABLE. For these chillers,
the REMOTE START CONTACT parameter on the MAIN-
STAT screen must be CLOSED. From the ICVC default
screen, press the and softkeys. Scroll to
highlight MAINSTAT and press the softkey. Scroll
down the MAINSTAT screen to highlight REMOTE START
CONTACT and press the softkey. Then, press
the softkey. To end the override, select REMOTE
CONTACTS INPUT and press the 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 parame-
ter on the MAINSTAT screen line now reads PRESTART. If a
test is not successful, the start-up is delayed or aborted. If the
tests are successful, the chilled water/brine pump relay energiz-
es, 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 con-
trol board). In place of the cooler and condenser water pressure
inputs on the CCM is a 4300-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 ener-
gizes. 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.
Failure to verify any of the requirements up to this point will
result in the PIC II aborting the start and displaying the applica-
ble 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.
MENU STATUS
SELECT
START
RELEASE
MENU
SCHEDULE
MENU STATUS
SELECT
SELECT
CLOSE
RELEASE
A START INITIATED: Pre-start checks are made; evaporator pump
started.*
B Condenser water pump started (5 seconds after A).
C Water flows verified (30 seconds to 5 minutes maximum after B).
Chilled water temperatures checked against control point. Guide
vanes checked for closure. Oil pump started; tower fan control
enabled.
D Oil pressure verified (15 seconds minimum, 300 seconds maximum
after C).
E Compressor motor starts; compressor ontime and service ontime
start, 15-minute inhibit timer starts (10 seconds after D), total com-
pressor starts advances by one, and the number of starts over a
12-hour period advances by one.
F SHUTDOWN INITIATED Compressor motor stops; compressor
ontime and service ontime stop, and 1-minute inhibit timer starts.
G Oil pump and evaporator pumps deenergized (60 seconds after F).
Condenser pump and tower fan control may continue to operate if
condenser pressure is high. Evaporator pump may continue if in
RECYCLE mode.
O/A Restart permitted (both inhibit timers expired: minimum of 15 minutes
after E; minimum of 1 minute after F).
Fig. 31 Control Timing Sequence
(for Normal Start-Up)
* Auto Restart After Power Failure Timing sequence will be faster.
65
Table 9 Prestart Checks
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, COM-
PRESSOR DEENERGIZED is displayed, and the compres-
sor 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 tem-
perature is greater than or equal to 115 F (46.1 C) and the
CONDENSER REFRIG TEMP is greater than the CONDENS-
ER 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 CON-
DENSER PRESSURE is less than the COND PRESS
OVERRIDE threshold minus 3.5 psi (24.1 kPa) and the
CONDENSER REFRIG TEMP is less than or equal to the
ENTERING CONDENSER WATER temperature plus
3 F (1.6 C).
If the chiller shuts down due to low refrigerant tempera-
ture, 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).
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 sig-
nal 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 or 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, COM-
PRESSOR UNLOADING displays on the ICVC.
The soft stop amps threshold function can be terminated and
the compressor motor deenergized immediately by depressing
the STOP button twice.
Chilled Water Recycle Mode The chiller may
cycle off and wait until the load increases to restart when the
compressor is running in a lightly loaded condition. This cy-
cling 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 (config-
ured 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 de-
faults to 5 F (3 C). This value can be viewed or modified on
QUANTITY CHECKED REQUIREMENT ALERT STATE IF FALSE
STARTS IN 12 HOURS
< 8 (not counting recycle restarts or auto restarts after power failure)
ALERT is cleared once RESET is pressed.
100
COMP THRUST BRG TEMP < [COMP THRUST BRG ALERT] 10 F (5.6 C) 101
COMP MOTOR WINDING TEMP < [COMP MOTOR TEMP OVERRIDE] 10 F (5.6 C) 102
COMP DISCHARGE TEMP < [COMP DISCHARGE ALERT] 10 F (5.6 C) 103
EVAP REFRIG LIQUID TEMP < [EVAP REFRIG TRIPPOINT] + [REFRIG OVERRIDE DELTA T] 104
OIL SUMP TEMP < 150 F (65.5 C) or <[EVAPORATOR REFRIG TEMP] + 50 F (27.8 C) 105
CONDENSER PRESSURE
< [COND PRESS OVERRIDE] 20 PSI (138 kPa) and
< 145 psi (1000 kPa)
106
PERCENT LINE VOLTAGE < [Undervoltage Threshold] 107
PERCENT LINE VOLTAGE > [Overvoltage Threshold] 108
ACTUAL GUIDE VANE POS Controls test guide vane calibration must be performed 109
INCREASE DECREASE
66
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 ex-
tremely 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.
Safety Shutdown A safety shutdown is identical to a
manual shutdown with the exception that, during a safety shut-
down, 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 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 or softkeys to re-
start the chiller.
BEFORE INITIAL START-UP
Job Data Required
list of applicable design temperatures and pressures
(product data submittal)
chiller certified prints
starting equipment details and wiring diagrams
diagrams and instructions for special controls or options
19XR Installation Instructions
Equipment Required
mechanics 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. 32)
500-v insulation tester (megohmmeter) for compressor
motors with nameplate voltage of 600 v or less, or a
5000-v insulation tester for compressor motor rated
above 600 v
Using the Optional Storage Tank and Pump-
out System Refer to Positive Pressure Chillers with
Storage Tanks section, page 89 for pumpout system prepara-
tion, refrigerant transfer, and chiller evacuation.
Remove Shipping Packaging Remove any pack-
aging 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.
Open Oil Circuit Valves Check to ensure the oil fil-
ter isolation valves (Fig. 6 and 7) 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
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.
Check Chiller Tightness Figure 33 outlines the
proper sequence and procedures for leak testing.
The 19XR chillers are shipped with the refrigerant con-
tained in the condenser shell and the oil charge in the compres-
sor. The cooler is shipped with a 15 psig (103 kPa) refrigerant
charge. Units may be ordered with the refrigerant shipped sepa-
rately, 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 pressur-
ized. 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 trans-
ferred. Adjust the springs when the refrigerant is in operating
condition and the water circuits are full.
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.
RESET
CCN LOCAL
Fig. 32 Typical Wet-Bulb Type
Vacuum Indicator
67
Table 10 Bolt Torque Requirements, Foot Pounds
Leak Test Chiller Due to regulations regarding refrig-
erant 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 satu-
rated pressure for the surrounding temperature.
Follow pumpout procedures in the Transfer Refrig-
erant from Pumpout Storage Tank to Chiller sec-
tion, Steps 1a-e, page 90.
c. Leak test chiller as outlined in Steps 3 - 9.
2. If the pressure readings are abnormal for the chiller con-
dition:
a. Prepare to leak test chillers shipped with refriger-
ant (Step 2h).
b. Check for large leaks by connecting a nitrogen bottle
and raising the pressure to 30 psig (207 kPa). Soap
test all joints. If the test pressure holds for 30 minutes,
prepare the test for small leaks (Steps 2g - h).
c. Plainly mark any leaks that are found.
d. Release the pressure in the system.
e. Repair all leaks.
f. Retest the joints that were repaired.
g. After successfully completing the test for large
leaks, remove as much nitrogen, air, and moisture
as possible, given the fact that small leaks may be
present in the system. This can be accomplished by
following the dehydration procedure, outlined in
the Chiller Dehydration section, page 70.
h. Slowly raise the system pressure to a maximum of
160 psig (1103 kPa) but no less than 35 psig
(241 kPa) for HFC-134a by adding refrigerant.
Proceed with the test for small leaks (Steps 3-9).
3. Check the chiller carefully with an electronic leak detec-
tor or soap bubble solution.
4. Leak Determination If an electronic leak detector indi-
cates a leak, use a soap bubble solution, if possible, to
confirm. Total all leak rates for the entire chiller. Leakage
at rates greater than 0.1% of the total charge per year must
be repaired. Note the total chiller leak rate on the start-up
report.
5. 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.
BOLT SIZE
(in.)
SAE 2, A307 GR A
HEX HEAD
NO MARKS
LOW CARBON STEEL
SAE 5, SA449
SOCKET HEAD OR HEX
WITH 3 RADIAL LINES
MEDIUM CARBON STEEL
SAE 8, SA354 GR BD
HEX HEAD
WITH 6 RADIAL LINES
MEDIUM CARBON STEEL
Minimum Maximum Minimum Maximum Minimum Maximum
1
/
4
4 6 6 9 9 13
5
/
16
8 11 13 18 20 28
3
/
8
13 19 22 31 32 46
7
/
16
21 30 35 50 53 75
1
/
2
32 45 53 75 80 115
9
/
16
46 65 75 110 115 165
5
/
8
65 95 105 150 160 225
3
/
4
105 150 175 250 260 370
7
/
8
140 200 265 380 415 590
1 210 300 410 580 625 893
1
1
/
8
330 475 545 780 985 1,410
1
1
/
4
460 660 770 1,100 1,380 1,960
1
3
/
8
620 885 1,020 1,460 1,840 2,630
1
1
/
2
740 1060 1,220 1,750 2,200 3,150
1
5
/
8
1010 1450 1,670 2,390 3,020 4,310
1
3
/
4
1320 1890 2,180 3,110 3,930 5,610
1
7
/
8
1630 2340 2,930 4,190 5,280 7,550
2 1900 2720 3,150 4,500 5,670 8,100
2
1
/
4
2180 3120 4,550 6,500 8,200 11,710
2
1
/
2
3070 4380 5,000 7,140 11,350 16,210
2
3
/
4
5120 7320 8,460 12,090 15,710 22,440
3 6620 9460 11,040 15,770 19,900 28,440
WARNING
Do not use air or oxygen as a means of pressurizing the
chiller. Mixtures of HFC-134a and air can undergo
combustion.
WARNING
Never charge liquid refrigerant into the chiller if the pres-
sure in the chiller is less than 35 psig (241 kPa) for HFC-
134a. Charge as a gas only, with the cooler and condenser
pumps running, until this pressure is reached, using
PUMPDOWN LOCKOUT and TERMINATE LOCK-
OUT mode on the PIC II. Flashing of liquid refrigerant at
low pressures can cause tube freeze-up and considerable
damage.
68
F
i
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.

3
3

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X
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69
Table 11A HFC-134a Pressure
Temperature (F)
Table 11B HFC-134a Pressure
Temperature (C)
TEMPERATURE,
F
PRESSURE
(psig)
0 6.50
2 7.52
4 8.60
6 9.66
8 10.79
10 11.96
12 13.17
14 14.42
16 15.72
18 17.06
20 18.45
22 19.88
24 21.37
26 22.90
28 24.48
30 26.11
32 27.80
34 29.53
36 31.32
38 33.17
40 35.08
42 37.04
44 39.06
46 41.14
48 43.28
50 45.48
52 47.74
54 50.07
56 52.47
58 54.93
60 57.46
62 60.06
64 62.73
66 65.47
68 68.29
70 71.18
72 74.14
74 77.18
76 80.30
78 83.49
80 86.17
82 90.13
84 93.57
86 97.09
88 100.70
90 104.40
92 108.18
94 112.06
96 116.02
98 120.08
100 124.23
102 128.47
104 132.81
106 137.25
108 141.79
110 146.43
112 151.17
114 156.01
116 160.96
118 166.01
120 171.17
122 176.45
124 181.83
126 187.32
128 192.93
130 198.66
132 204.50
134 210.47
136 216.55
138 222.76
140 229.09
TEMPERATURE,
C
PRESSURE
(kPa)
18.0 44.8
16.7 51.9
15.6 59.3
14.4 66.6
13.3 74.4
12.2 82.5
11.1 90.8
10.0 99.4
8.9 108.0
7.8 118.0
6.7 127.0
5.6 137.0
4.4 147.0
3.3 158.0
2.2 169.0
1.1 180.0
0.0 192.0
1.1 204.0
2.2 216.0
3.3 229.0
4.4 242.0
5.0 248.0
5.6 255.0
6.1 261.0
6.7 269.0
7.2 276.0
7.8 284.0
8.3 290.0
8.9 298.0
9.4 305.0
10.0 314.0
11.1 329.0
12.2 345.0
13.3 362.0
14.4 379.0
15.6 396.0
16.7 414.0
17.8 433.0
18.9 451.0
20.0 471.0
21.1 491.0
22.2 511.0
23.3 532.0
24.4 554.0
25.6 576.0
26.7 598.0
27.8 621.0
28.9 645.0
30.0 669.0
31.1 694.0
32.2 720.0
33.3 746.0
34.4 773.0
35.6 800.0
36.7 828.0
37.8 857.0
38.9 886.0
40.0 916.0
41.1 946.0
42.2 978.0
43.3 1010.0
44.4 1042.0
45.6 1076.0
46.7 1110.0
47.8 1145.0
48.9 1180.0
50.0 1217.0
51.1 1254.0
52.2 1292.0
53.3 1330.0
54.4 1370.0
55.6 1410.0
56.7 1451.0
57.8 1493.0
58.9 1536.0
60.0 1580.0
70
6. If no leak is found after a retest:
a. Transfer the refrigerant to the pumpout storage
tank and perform a standing vacuum test as out-
lined 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.
7. If a leak is found after a retest, pump the refrigerant back
into the pumpout storage tank or, if isolation valves are
present, pump the refrigerant into the non-leaking vessel.
See the Transfer Refrigerant from Pumpout Storage
Tank to Chiller section on page 90.
8. Transfer the refrigerant until the chiller pressure is at
18 in. Hg (40 kPa absolute).
9. Repair the leak and repeat the procedure, beginning from
Step 2h, to ensure a leak-tight repair. (If the chiller is
opened to the atmosphere for an extended period, evacu-
ate it before repeating the leak test.)
Standing Vacuum Test When performing the
standing vacuum test or chiller dehydration, use a manometer
or a wet bulb indicator. Dial gages cannot indicate the small
amount of acceptable leakage during a short period of time.
1. Attach an absolute pressure manometer or wet bulb indi-
cator 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 incre-
ments 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.
Dehydration can be done at room temperatures. Using a
cold trap (Fig. 34) 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 m
3
/s]
or larger is recommended) to the refrigerant charging
valve (Fig. 2 and 3). 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 vacu-
um indicator to measure the vacuum. Open the shutoff
valve to the vacuum indicator only when taking a read-
ing. Leave the valve open for 3 minutes to allow the indi-
cator vacuum to equalize with the chiller vacuum.
3. If the entire chiller is to be dehydrated, open all isolation
valves (if present).
4. With the chiller ambient temperature at 60 F (15.6 C) or
higher, operate the vacuum pump until the manometer
reads 29.8 in. Hg vac, ref 30 in. bar (0.1 psia)
(100.61 kPa) or a vacuum indicator reads 35 F (1.7 C).
Operate the pump an additional 2 hours.
Do not apply a greater vacuum than 29.82 in. Hg vac
(757.4 mm Hg) or go below 33 F (.56 C) on the wet bulb
vacuum indicator. At this temperature and pressure, iso-
lated pockets of moisture can turn into ice. The slow rate
of evaporation (sublimation) of ice at these low tempera-
tures 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 re-
peat dehydration.
8. Once dehydration is complete, the evacuation process can
continue. Evacuate the vessel or chiller with the vacuum
pump set to at least 18 in. hg vac, ref 30-in. bar (41 kPa).
Inspect Water Piping Refer to piping diagrams pro-
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 pres-
sure drop across the cooler and the condenser.
CAUTION
Do not start or megohm-test the compressor motor or oil
pump motor, even for a rotation check, if the chiller is
under dehydration vacuum. Insulation breakdown and
severe damage may result.
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.
Fig. 34 Dehydration Cold Trap
71
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.
Inspect Wiring
1. Examine the wiring for conformance to the job wiring di-
agrams and all applicable electrical codes.
2. On low-voltage compressors (600 v or less) connect a
voltmeter across the power wires to the compressor start-
er 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 com-
pare 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 customers contractor has verified proper op-
eration 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 compres-
sor 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.) Factory-
mounted starters do not require a megohm test.
a. Open the starter main disconnect switch and follow
lockout/tagout rules.
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.
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 unsat-
isfactory, 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 contac-
tors. Clean and inspect the contactors if this has occurred.
Carrier Comfort Network

Interface The Car-

rier 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 sys-
tem 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 instal-
lation manual.
NOTE: Conductors and drain wire must be 20 AWG (Ameri-
can 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.
CAUTION
Water must be within design limits, clean, and treated to
ensure proper chiller performance and to reduce the poten-
tial of tube damage due to corrosion, scaling, or erosion.
Carrier assumes no responsibility for chiller damage result-
ing from untreated or improperly treated water.
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. Insula-
tion breakdown and serious damage may result.
CAUTION
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.
MANUFACTURER CABLE NO.
Alpha 2413 or 5463
American A22503
Belden 8772
Columbia 02525
72
When connecting the CCN communication bus to a system
element, a color code system for the entire network is recom-
mended to simplify installation and checkout. The following
color code is recommended:
Check Starter
Use the instruction and service manual supplied by the start-
er manufacturer to verify the starter has been installed correct-
ly, to set up and calibrate the starter, and for complete trouble-
shooting information.
MECHANICAL STARTER
1. Check all field wiring connections for tightness, clear-
ance 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
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 start-
er 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 ter-
minals 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.
Oil Charge The oil charge for the 19XR compressor de-
pends 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)
Frame E 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 and 3). If oil is added, it must meet
Carriers specification for centrifugal compressor use as de-
scribed in the Oil Specification section. Charge the oil through
the oil charging valve located near the bottom of the transmis-
sion housing (Fig. 2 and 3). The oil must be pumped from the
oil container through the charging valve due to higher refriger-
ant 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.
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 cir-
cuit. 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 la-
beled on the backside of the ICVC module. The software ver-
sion also appears on the ICVC CONFIGURATION screen as
the last two digits of the software part number.
SIGNAL
TYPE
CCN BUS
CONDUCTOR
INSULATION
COLOR
CCN TERMINAL
CONNECTION
ICVC PLUG
J1 PIN NO.
+ Red RED (+) 1
Ground White WHITE (G) 2
Black BLACK () 3
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.
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.
WARNING
This equipment is at line voltage when AC power is con-
nected. 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.
73
Software Configuration
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-14, 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 SER-
VICE (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 customers re-
quirements. 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 26.
The CCN Occupied Schedule (OCCPC03S) should be con-
figured if a CCN system is being installed or if a secondary
time schedule is needed.
NOTE: The default CCN Occupied Schedule OCCPC03S is
configured to be occupied.
Input Service Configurations The following con-
figurations require the ICVC screen to be in the SERVICE por-
tion of the menu.
password
input time and date
ICVC configuration
service parameters
equipment configuration
automated control test
PASSWORD When accessing the SERVICE tables, a pass-
word must be entered. All ICVCs are initially set for a pass-
word 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 CONFIGU-
RATION screen. From there, view or modify the ICVC CCN
address, change to English or SI units, and change the pass-
word. 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 and softkeys. Enter the
current password and highlight ICVC CONFIGURA-
TION. Press the 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 softkey to scroll to PASSWORD. The
first digit of the password is highlighted on the screen.
3. To change the digit, press the
or softkey. When the desired digit is seen,
press the softkey.
4. The next digit is highlighted. Change it, and the third and
fourth digits in the same way the first was changed.
5. After the last digit is changed, the ICVC goes to the BUS
NUMBER parameter. Press the softkey to leave
that screen and return to the SERVICE menu.
TO CHANGE THE ICVC DISPLAY FROM ENGLISH TO
METRIC UNITS By default, the ICVC displays informa-
tion in English units. To change to metric units, access the
ICVC CONFIGURATION screen.
1. Press the and softkeys. Enter the
password and highlight ICVC CONFIGURATION. Press
the softkey.
2. Use the softkey to scroll to US IMP/METRIC.
3. Press the softkey that corresponds to the units desired for
display on the ICVC (e.g., US or METRIC).
CHANGE LANGUAGE By default, the ICVC displays
information in English. To change to another Language, access
the ICVC CONFIGURATION screen:
1. Press the and softkeys. Enter the
password and highlight ICVC CONFIGURATION. Press
the softkey.
2. Use the softkey to scroll to LID LANGUAGE.
3. Press the INCREASE or DECREASE softkey until the
desired language is displayed. Press to confirm
desired language.
MODIFY CONTROLLER IDENTIFICATION IF NECES-
SARY 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 NEC-
ESSARY 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 SOFT-
WARE CONFIGURATION IF NECESSARY Benshaw
starter configurations are checked and modified from the
menus in the Benshaw Redistart MX3 Default Display. See
Fig. 35 and Table 13 for default display and menu items. To ac-
cess the menus to perform checks and modifications, the Ben-
shaw starter must be powered up and its self-test must have
been successfully completed. The self-test takes place automat-
ically after power-up. Current and Ramp Time configurations
WARNING
Do not operate the chiller before the control configurations
have been checked and a Control Test has been satisfacto-
rily completed. Protection by safety controls cannot be
assumed until all control configurations have been
confirmed.
CAUTION
Be sure to remember the password. Retain a copy for
future reference. Without the password, access to the SER-
VICE menu will not be possible unless the ICVC_PSWD
menu on the STATUS screen is accessed by a Carrier
representative.
MENU SERVICE
SELECT
ENTER
INCREASE
DECREASE
ENTER
EXIT
MENU SERVICE
SELECT
ENTER
MENU SERVICE
SELECT
ENTER
ENTER
74
are entered in the CFN menu. CT Ratio configuration is en-
tered in the FUN menu. See Table 13 for menu structure and
Table 14 for settings.
1. Press the softkey until the desired menu is select-
ed on the display.
2. Press the softkey to access the displayed menu
items (Table 14).
3. Use the or arrow keys to scroll between menu items
until the desired item is reached on the display.
4. Press the 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 progres-
sively increase the rate of change. The value will stop
changing when either the factory set minimum or maxi-
mum value is reached. To make fine adjustments press
and release the arrow key.
6. When the correct value has been selected, press
the key to store the new configuration. At this
point, there are two options. The key will return
the display to the main display. The or arrow keys
will move the display to the next menu item. When fin-
ished press the 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.
VFD Field Setup and Verification
Table 12 Job Site Parameters
*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 sensi-
tivity. Decreasing time or persistence increases sensitivity to the fault
condition.
MENU
ENTER

ENTER


ENTER
MENU

MENU
IMPORTANT: The VFD controller has been factory con-
figured for use and communications to the International
Chiller Visual Controller (ICVC). Some parameters are
specific to the chiller configuration and will need to be ver-
ified prior to operation. Speed control and starting the drive
have been disabled at the VFD keypad. All command func-
tions must be initiated from the ICVC.
Fig. 35 Benshaw RediStart
MICRO Default Display
a19-1958
PARAMETER TABLE
Starter Type
ISM_CONF Select 0 for full voltage, 1 for
reduced voltage, or 2 for solid state or 3 for vari-
able frequency drive.
Motor Rated Line
Voltage
ISM_CONF Motor rated voltage from chiller
information nameplate.
Volt Transformer
Ratio
ISM_CONF Enter ratio (reduced to a ratio to
1) of power transformer wired to terminal J3 of
ISM. If no transformer is used enter 1.
Motor Rated
Load Amps
ISM_CONF Per chiller nameplate data. RL
AMPS on compressor nameplate.
Motor Locked
Rotor Trip
ISM_CONF Per chiller identification name-
plate.
Starter LRA
Rating
ISM_CONF Enter value from nameplate in
starter cabinet MAXIMUM FUSE. This value
shall always be 9999 for Benshaw RediStart
MX3 wye-delta and solid-state starters.
Motor Current
CT Ratio
ISM_CONF Enter ratio (reduced to a ratio to
1) of current transformers wired to terminal J4 of
ISM. This value shall always be 100 for Ben-
shaw RediStart MX3 wye-delta and solid-state
starters.
Current% Imbalance
ISM_CONF Current imbalance trip threshold.
Enter up to 100% for starter type 3 (VFD).
Ground Fault
Current
Transformers
ISM_CONF Enter 0 if no ground fault CTs are
wired to terminal J5 of ISM. Enter 1 if ground
fault CTs are used.
Ground Fault
CT Ratio
ISM_CONF Enter ratio (reduced to a ratio to
1) of ground fault CT.
Single Cycle
Dropout
ISM_CONF ENABLE if motor protection
required from drop in line voltage within one
cycle.
Line Frequency
ISM_CONF Enter YES for 60 Hz or NO for
50 Hz.
Line Frequency
Faulting
ISM_CONF ENABLE if motor
protection required for drop in line
frequency.
Surge Limit/Hot Gas
Bypass Option
OPTIONS Enter 1 or 2 if HGBP is installed.
Enter 0 otherwise.
PARAMETER TABLE
Minimum Load
Points (Tsmin, IGVmin)
OPTIONS Per Chiller Requisition (Tsmin,
IGVmin) if available or per job data See mod-
ify load points section. Refer to table located in
the control panel.
Full (Maximum) Load
Points (Tsmax, IGVmax)
OPTIONS Per Chiller Requisition (Tsmax,
IGVmax) if available or per job data See mod-
ify load points section. Refer to table located in
the control panel.
Surge Line Shape Factor
(shapefac)
OPTIONS Per Chiller Requisition (shapefac).
Refer to table located in the control panel.
Chilled Medium SETUP1 Enter water or brine.
Evaporator
Refrigerant
Trippoint
SETUP1 Usually 3 F (1.7 C) below design
refrigerant temperature.
Evaporator Flow
Delta P Cutout
SETUP1 Per Chiller Requisition if available or
enter 50% of design pressure drop to 0.5 psi
(3.4 kPa).*
Condenser Flow
Delta P Cutout
SETUP1 Per Chiller Requisition if available or
enter 50% of design pressure drop to 0.5 psi
(3.4 kPa).*
High Condenser Water
Delta P
SETUP1 Enter the maximum allowable value
for condenser water pressure drop.
VFD Option
SETUP2 ENABLE if a VFD is supplied for the
chiller.
VFD Current List
SETUP2 Enter the value fo the full load output
amps of the VFD.
Diffuser Option
(Compressors with Split
Ring Diffusers)
VDO_SRD ENABLE for 4 and 5 size com-
pressor with split ring diffusers. See model num-
ber nomenclature.
Diffuser Full Span mA
(Compressors with Split
Ring Diffusers)
SETUP2 VDO_SRD Enter diffuser actuator
full span mA rating for 4 and 5 size compressor.
Value is located on label on side of diffuser actu-
ator motor.
Motor Rated
Kilowatts
RAMP_DEM Enter value from chiller requisi-
tion form (product data submittal) if DEMAND
LIMIT SOURCE is set to kW.
75
Table 13 Benshaw RediStart MX3 Menu Structure
Table 14 Benshaw RediStart MX3 Menu Items*
*These values are not displayed in the ISM_CONF table.
Current Transformer Ratio
See the Initial Start-Up Checklist section for VFD Job Spe-
cific Configuration table. For job specific parameters see inside
of the VFD enclosure door. Refer to the VFD Configuration ta-
ble for the entire list of parameters.
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. 36.)
VFD Parameter (Unit-Mounted VFD Only) Located
on the inside of the VFD door.
VFD Enclosure Nameplate (Unit-Mounted VFD Only)
Located on the right side of the VFD as viewed from
its front. (See Fig. 36.)
ISM MENU CFN MENU FUN MENU FL MENU E MENU
Shows parameters entered on
the ISM_CONF screen on the
ICVC
Initial Current as % RLA Meter #1 display Fault Log (9 faults) Event Log (99 events)
Max. Current As% LRA Meter #2 display
Ramp Time (seconds) CT Ratio
Time & Date Format
Time
Date
Passcode
DESCRIPTION BENSHAW PARAMETER RANGE UNITS DEFAULT
INITIAL CURRENT CFN01 50-300 % 125
MAX. CURR AS % LRA CFN02 30-70 % 55
RAMP TIME CFN03 5-30 SEC 15
CT RATIO FUN03 2640-5760
Starter Frame Size
(Amps)
Motor RLA Range
(Amps)
CT Ratio
200 Amps 95-135 Amps 864:1
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
480 Amps 341-480 Amps 3900:1
600 Amps 481-580 Amps 3900:1
600 Amps 581-600 Amps 3900:1
740 Amps 601-740 Amps 3900:1
1250 Amps 741-855 Amps 5760:1
1250 Amps 856-1250 Amps 5760:1
CAUTION
Changing parameters may adversely affect chiller
operation.
SAFETY CODE CERTIFICATION
COMPRESSOR MOTOR DATA
R-
REFRIGERATION MACHINE
CARRIER CHARLOTTE
9701 OLD STATESVILLE ROAD
CHARLOTTE, NORTH CAROLINA 28269
MADE IN USA
PRODUCTION YEAR: 20XX
19XR05009801
A United Technologies Company
TM
THIS UNIT IS DESIGNED,CONSTRUCTED,
AND TESTED IN CONFORMANCE WITH
ANSI/ASHRAE 15 (LATEST REVISION),
SPECIFICATION Z-415.
IN ACCORDANCE WITH CARRIER
AND OVERLOAD PROTECTION MUST BE
THE COMPRESSOR MOTOR CONTROLLER
REFRIGERATION.
SAFETY CODE FOR MECHANICAL
TEST PRESSURE
DESIGN PRESSURE
CLR.WATER PRESSURE
COND.WATER PRESSURE
PSI
PSI
PSI
PSI
KPA
KPA
KPA
KPA
C A Z T R E H / E S A H P / S T L O V
RL AMPS
OLT AMPS
LR AMPS Y-
LR AMPS D-
MAX FUSE/CIRCUIT BKR
MIN. CIRCUIT AMPACITY
LBS.
CHARGED
KGS. REFRIGERANT
MODEL NUMBER SERIAL NO.
MACHINE
COMP'R
COOLER
CONDENSER
ECON
STOR TANK
RATED iKW
RATED TONS
Fig. 36 Machine Electrical Data Nameplates
VFD ENCLOSURE
NAMEPLATE
CHILLER ID NAMEPLATE CONSTANT SPEED CHILLER
a19-1881
a19-1882
a19-1883
CHILLER ID NAMEPLATE
VFD-EQUIPPED CHILLER
76
DRIVE PROTECTION AND OTHER INCOMING
WIRING
1. Verify that the branch disconnects or other local discon-
nects are open and properly tagged out.
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 Commis-
sion) 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.
6. Verify the conduit for the power wiring in securely con-
nected 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 chill-
er controller or the VFD are in separate conduit.
VFD Cooling System Leak Inspection
1. Check for leaks on the refrigerant cooling flange connec-
tions to the VFD enclosure.
2. Check for leaks on all tubing internal to the VFD enclo-
sure, the tubing flair connection to the VFD module and
the TXV valve.
Power Up Verification
1. Inspect control wiring inside the VFD and verify the in-
tegrity 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.
The VFD is configured to attempt an automatic reset of mi-
nor 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.
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 .
2. Press .
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:
6. Press to the softkey to save changes when exiting
the ISM_CONF screeen.
7. Press the softkey to and exit the ISM Configura-
tion Screen.
VFD Enable Configuration To access the parameters:
1. Press .
2. Press .
3. Select EQUIPMENT SERVICE.
4. Scroll down and select SETUP2.
5. Verify the following parameters:
Configure Surge Parameters
1. Press .
2. Press .
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.
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 .
2. Press .
ENTER
SERVICE
DESCRIPTION SETTING
STARTER TYPE
(3 = VFD)
3
MOTOR RATED
LINE VOLTAGE
VOLTAGE from "Load Side" section of
the VFD enclosure nameplate.
MOTOR RATED
LOAD AMPS
CHILLER FL AMPS from "Line Side"
section of the VFD enclosure
nameplate
MOTOR LOCKED
ROTOR TRIP
MOTOR LRA from "Load Side" sec-
tion of the VFD enclosure nameplate
STARTER LRA RATING 600 for VFD
part #19XVR0414XXX
750 for VFD
part #19XVR0500XXX
900 for VFD
part #19XVR0643XXX
MOTOR CURRENT
CT RATIO:1
163 (500A and 643A VFDs)
120 (414A VFDs)
3 GRND FAULT CT?
(1=NO)
NO
FREQUENCY-60HZ
(YES=60)
YES for 60 Hz selection
NO for 50 Hz selection
VFD OPTION ENABLED
VFD CURRENT LIMIT MOTOR FLA from "Load Side" section
of the VFD enclosure nameplate
DESCRIPTION SETTINGS
SURGE/HGBP
DELTA TSMIN
Surge parameter label
SURGE/HGBP
IGVMIN
Surge parameter label
SURGE/HGBP
DELTA TSMAX
Surge parameter label
SURGE/HGBP
IGVMAX
Surge parameter label
SURGE LINE
SHAPE FACTOR
Surge parameter label
SAVE
EXIT
MENU
SERVICE
MENU
SERVICE
MENU
STATUS
77
3. Press .
4. Press .
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 ex-
cept the Password LED.
NOTE: The value shown in the VFD display is the fre-
quency at which the VFD is being commanded to
operate. This value is called the VFD Speed reference.
2. Verify that the actual speed signal feedback to the chiller
controller is 0% by accessing the ACTUAL VFD SPEED
in the ICVC COMPRESS screen.
3. Verify ACTUAL VFD SPEED is 0% to 1% on the ICVC.
Set TARGET VFD SPEED to 100%.
1. Press .
2. Press .
3. Press .
4. Press .
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 TAR-
GET VFD SPEED frequency within 1 Hz.
2. Release the TARGET VFD SPEED so that it can operate
in automatic mode. (Refer to Override Operations Sec-
tion on page 22.)
VFD CONTROL VERIFICATION (Running)
Preparation
1. Disconnect power to the VFD. Verify that the branch dis-
connects 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. 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% un-
der 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 in-
put phases.
4. Calculate the line side error ratio using the following
equation:
* 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 CUR-
RENT CT RATIO in the ISM_CONF screen. This
screen can only be accessed when the chiller is not run-
ning.
Change CT Ratio
1. New MOTOR CURRENT CT RATIO = Present MO-
TOR CURRENT CT RATIO multiplied by (1+ Line Side
Error Ratio).
To access the ISM_CONF screen:
2. Press .
3. Press .
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 softkey to save changes.
10. Press the 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 chill-
er 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.
Next, access the VFD LOAD FACTOR on the Capacity
Control screen. Calculate the Load Side Error Ratio using
the equation below:
3. If the load side error ratio is greater than 0.02, adjust the
VFD LOAD FACTOR by changing the VFD CUR-
RENT 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 TAR-
GET VFD SPEED control.
Press .
Press .
Press .
(Refer to Override Operations section on page 22.)
COMPRESS
SELECT
MENU
STATUS
COMPRESS
SELECT
Error Ratio =
Amp Meter current ACTUAL LINE CURRENT*
Amp Meter current
Load Side
Current Ratio
=
VFD Actual Load Amps (from VFD)
VFD CURRENT LIMIT (in SETUP2)
Load Side
Error Ratio
=
VFD LOAD FACTOR Load Side Current Ratio
Load Side Current Ratio
ENTER
SERVICE
SAVE
EXIT
MENU
STATUS
COMPRESS
78
HAND CALCULATE SURGE PREVENTION CONFIGU-
RATIONS 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 P maximum and P minimum using 2 point
method in the preceding section. If the original selection con-
figuration points are available, use P1 and P4 from that se-
lection as P maximum and P minimum. If the original selec-
tion configuration was for a 2 point surge line, use P1 and
P2.
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 suc-
tion temp to pressure using an R-134a pressure/temperature
chart.
Min. Cond. Pressure = (suction pressure) + (P 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 suc-
tion temperature)
Calculate Surge/ HGBP Delta Tsmax
Max. Cond. Pressure = (suction pressure) + (P 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 suc-
tion temperature)
VPF Surge Prevention Configurations are defined as fol-
lows:
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.)
Surge Line Speed Factor determines how much the surge
line moves to accommodate lower compressor speed. As
compressor speed drops the T values on the surge pre-
vention 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 T 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 2 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 2 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 2 F.
2. Increase SURGE/HGBP DELTA TSMAX in steps of
2 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. Like-
wise, DELTA TSMAX rarely requires more than a 2 degree
increase.
If surge is encountered then the surge line is probably too
optimistic or high. Note following parameters from ICVC at
surge:
EVAPORATOR REFRIGERANT TEMP
EVAPORATOR PRESSURE
CONDENSER REFRIG TEMP
CONDENSER PRESSURE
ACTUAL GUIDE VANE POSITION
AVERAGE LINE CURRENT
79
If ACTUAL GUIDE VANE POSITION is less than 30%,
go to Step 1. If ACTUAL GUIDE VANE POSITION is greater
than 60%, then go to Step 3.
1. Do not change SURGE LINE SHAPE FACTOR from
the value selected by Chiller Builder (ECAT). Decrease
SURGE/HGBP DELTA TSMIN in 1 F steps up to 5
times. Monitor chiller for surge.
2. If ACTUAL GUIDE VANE POSITION is still less than
30 and step 1 failed, then increase the value of SURGE
LINE SHAPE FACTOR in steps of 0.01 up to 2 times.
For example, if surge is encountered when shape factor is
0.06, increase the SURGE LINE SHAPE FACTOR to
0.05. If this does not solve the problem, go to step 5,
even if ACTUAL GUIDE VANE POSITION is less than
30%.
3. Do not change SURGE LINE SHAPE FACTOR from
the value selected by Chiller Builder (ECAT). Decrease
SURGE/HGBP DELTA TSMAX by 1 F Steps up to 5
times. Monitor chiller for surge.
4. If ACTUAL GUIDE VANE POSITION is greater than
60% and Step 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 ACTU-
AL GUIDE VANE POSITION is greater than 60%.
5. If ACTUAL GUIDE VANE POSITION is greater than
30% but less than 60% or if Step 2 failed (with ACTUAL
GUIDE VANE POSITION less than 30) or if Step 4
failed (with ACTUAL GUIDE VANE POSITION great-
er than 60), then perform this step. Do not change
SURGE LINE SHAPE FACTOR from the value speci-
fied 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 NECES-
SARY If the compressor is equipped with a variable
diffuser, (size 4 or 5 compressor) access the VDO_SRD
screen. Scroll to DIFFUSER CONTROL and press the
softkey. Compare the diffuser and guide vane val-
ues (GUIDE VANE 25% LOAD PT, GUIDE VANE 50%
0
5
10
15
20
25
30
35
40
0 10 20 30 40 50 60 70 80 90 100 110
Tsmin=30
Tsmin=40
Tsmin=50
GV_POS
D
e
l
t
a

T
s
a
t
Fig. 37 Effect of SURGE/HGBP DELTA TSMIN
on Surge Prevention
a19-1959
0
5
10
15
20
25
30
35
40
45
0 10 20 30 40 50 60 70 80 90 100 110
Tsmax=60
Tsmax=70
Tsmax=80
GV_POS
D
e
l
t
a

T
s
a
t
Fig. 38 Effect of SURGE/HGBP DELTA TSMAX
on Surge Prevention
a19-1960
0.00
5.00
10.00
15.00
20.00
25.00
30.00
35.00
40.00
45.00
50.00
55.00
60.00
0 10 20 30 40 50 60 70 80 90 100 110
Shape factor
= -0.020
Shape factor
= -0.040
Shape factor
= -0.050
GV_POS
D
e
l
t
a

T
s
a
t
Fig. 39 Effect of SURGE LINE SHAPE FACTOR
on Surge Prevention
a19-1961
0.00
5.00
10.00
15.00
20.00
25.00
30.00
35.00
40.00
0 10 20 30 40 50 60 70 80 90 100 110
Speed Factor
=1.60
Speed Factor
=1.85
Speed Factor
=2.00
GV_POS
D
e
l
t
a

T
s
a
t
Fig. 40 Effect of SURGE LINE SPEED FACTOR
on Surge Prevention
a19-1962
ENABLE
80
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. 13.
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 NECES-
SARY The EQUIPMENT SERVICE table has screens to
select, view, or modify parameters. Carriers 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 42) for description of
these functions.
Owner-Modified CCN Tables The following EQUIP-
MENT CONFIGURATION screens are described for refer-
ence 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 holi-
day paragraphs in the Controls section for more details.
BRODEF The BRODEF screen defines the start and end of
daylight savings time. By default this feature is enabled. Enter
the dates for the start and end of daylight savings if required
for your location. Note that for Day of Week, 1 represents
Monday. Start Week and Stop Week refer to the instance of the
selected Day of Week during the selected month and year. To
disable the feature, change START ADVANCE and STOP
BACK times to 0 (minutes). In the BRODEF table the user
may also identify a chiller as the time broadcaster for a CCN
network. There should be only one device on a CCN network
which is designated as the Time Broadcaster.
ALARM ROUTING This is in the table SERVICE>
EQUIPMENT CONFIGURATION>NET_OPT under the
heading Alarm Configuration. ALARM ROUTING consists
of an 8-bit binary number. Only bits 1, 2, and 4 (counting
from the left, first) are used. The others do not matter. The bits
can be set by any device which can access and change configu-
ration 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 pro-
cessed by a front end device, such as a Comfort-
WORKS

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 mod-
ule) or ServiceLink modules.
The RE-ALARM time is a time period after which, if a preex-
isting 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 RUN-
TIME screens contain parameters used with a CCN system.
See the applicable CCN manual for more information on these
screens. These tables can only be defined from a CCN Build-
ing Supervisor.
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 com-
pressor can be put in OFF mode by pressing the STOP push-
button on the ICVC. Each test asks the operator to confirm the
operation is occurring and whether or not to continue. If an er-
ror 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.
1 1 0 1 0 0 0 0
Alarm Printer Interface Module
Autodial Gateway
Local Building Supervisors(s)
or ComfortWORKS
unused
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:
NOTE: If your CCN does not contain ComfortWORKS controls or
a Building Supervisor, Autodial Gateway, or APIM to serve as an
alarm acknowledger, set all digits in this decision to 0 in order to
prevent unnecessary activity on the CCN Communication Bus.
Allowable Entries 00000000 to 11111111
0 = Disabled, 1 = Enabled
Default Value 10000000
Fig. 41 Alarm Control and Alarm Routing
a19-1627
81
Table 15 Control Test Menu Functions
LEGEND
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.
GUIDE VANE ACTUATOR CALIBRATION This auto-
mated procedure is performed at the factory prior to new chiller
shipment. During this test, the CCM outputs a discrete 24-v sig-
nal 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 control-
ler software is downloaded. A prestart alert message will re-
mind 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 con-
figured at maximum opening). The system will store voltages
corresponding to 0% and 100%, then indicate the the calibra-
tion 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 softkey is
pressed, the test stops, and the CONTROL TEST menu dis-
plays. 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 TRANS-
DUCER AND WATERSIDE FLOW DEVICE CALIBRA-
TION (waterside device optional with CCM inputs
available) Calibration can be checked by comparing the
pressure readings from the transducer to an accurate refrigera-
tion 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 calibra-
tion 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 transduc-
ers can be calibrated for zero without removing the trans-
ducer 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 de-
vice, view the particular reading (CHILLED WATER
DELTA P and CONDENSER WATER DELTA P on the
HEAT_EX screen and OIL PUMP DELTA P on the
COMPRESS screen). It should read 0 psi (0 kPa). If the
reading is not 0 psi (0 kPa), but within 5 psi (35 kPa),
the value may be set to zero by pressing the
softkey while the appropriate transducer parameter is
highlighted on the ICVC screen. Then press the
softkey. The value will now go to zero. No high end cali-
bration is necessary for OIL PUMP DELTA P or flow
devices.
TESTS TO BE
PERFORMED
DEVICES TESTED
1. CCM Thermistors Entering Chilled Water
Leaving Chilled Water
Entering Condenser Water
Leaving Condenser Water
Evap Refrig Liquid Temp
Comp Discharge Temp
Comp Thrust Brg Temp
Oil Sump Temp
Comp Motor Winding Temp
Spare Temperature 1
Spare Temperature 2
Remote Reset Sensor
2. CCM Pressure
Transducers
Evaporator Pressure
Condenser Pressure
Oil Pump Delta P
SRD Delta P
SRD Rotating Stall
Chiled Water Delta P
Condenser Water Delta P
Transducer Voltage Ref
3. Pumps Oil Pump Confirm Delta P
Chilled Water Confirm flow and Delta
P
Condenser Water Confirm flow and
Delta P
4. Discrete Outputs Oil Heater Relay
Hot Gas Bypass Relay
Tower Fan Relay Low
Tower Fan Relay High
Alarm Relay
Shunt Trip Relay
5. IGV and SRD
Actuator
Open/Close
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.
6. Head Pressure
Output
Increase/Decrease 4-20 mA output
7. Diffuser Actuator Open/Close (independent of guide
vanes)
8. Pumpdown Lockout When using pumpdown/lockout,
observe freeze up precautions when
removing charge:
Instructs operator which valves to close
and when.
Starts chilled water and condenser water
pumps and confirms flows.
Monitors
Evaporator pressure
Condenser pressure
Evaporator temperature during
pumpout procedures
Turns pumps off after pumpdown.
Locks out compressor.
9. Terminate Lockout Starts pumps and monitors flows.
Instructs operator which valves to
open and when.
Monitors
Evaporator pressure
Condenser pressure
Evaporator temperature during
charging process
Terminates compressor lockout.
10. Guide Vane
Calibration
Automatic, displays guide vane position
signal voltage. This test is required before
first start-up with new actuator, new con-
troller, or new software.
Calibrates guide vane input on CCM.
CCM Chiller Control Module
IGV Inlet Guide Vane
SRD Spilt Ring Diffuser
EXIT
SELECT
ENTER
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 J2-
5. 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 regu-
lated 250 psig (1724 kPa) maximum pressure (usually
from a nitrogen cylinder). The high pressure point can be
calibrated by accessing the appropriate transducer param-
eter on the HEAT_EX screen, highlighting the parameter,
pressing the softkey, and then using
the or softkeys to adjust the
value to the exact pressure on the refrigerant gage. Press
the 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.
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 adjust-
ment 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 val-
ue 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.
Increase the sensitivity of the flow switch by turning the ad-
justment 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 thermo-
stat, 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 com-
pressor 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 87 and
96, for details on the transfer of refrigerant, oil specifications,
etc.
High Altitude Locations Because the chiller is ini-
tially calibrated at sea level, it is necessary to recalibrate the
pressure transducers if the chiller has been moved to a high alti-
tude location. See the calibration procedure in the Trouble-
shooting Guide section.
Charge Refrigerant into Chiller
The standard 19XR chiller is shipped with the refrigerant
already charged in the vessels. However, the 19XR may be or-
dered 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
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.
SELECT
INCREASE DECREASE
ENTER
Fig. 42 CCM Inputs for Optional
Waterside Delta P Transducers
a19-1866
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
Always operate the condenser and chilled water pumps
during charging operations to prevent freeze-ups.
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 (con-
nected between the pumpout valves on top of the cooler
and condenser) should be used as the equalization valve.
IMPORTANT: Turn on the chilled water and con-
denser water pumps to prevent freezing.
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 isola-
tion valve may now be opened. Refer to Fig. 43 and 44
for the location of the valves.

CHILLER EQUALIZATION WITH PUMPOUT UNIT
The following steps describe how to equalize refrigerant pres-
sure on an isolated 19XR chiller using the pumpout unit.
1. Access the terminate lockout function on the CONTROL
TEST screen.
2.
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 isola-
tion valve, cooler isolation valve, optional hot gas bypass
isolation valve, and the refrigerant isolation valve can be
opened. Close valves 1a and 1b, and all pumpout unit
valves.
The full refrigerant charge on the 19XR will vary with chill-
er 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
the Heat Exchanger Data tables in the Physical Data section of
this book, pages 119 to 176.
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 HFC-
134a. After the chiller is beyond this pressure the refrigerant
should be charged as a liquid until all the recommended refrig-
erant 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.
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.
IMPORTANT: Turn on the chilled water and con-
denser water pumps to prevent freezing.
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.
CAUTION
Always operate the condenser and chilled water pumps
whenever charging, transferring, or removing refrigerant
from the chiller.
STORAGE
TANK LIQUID
VALVE
OIL
SEPARATOR
PUMPOUT
CONDENSER
WATER SUPPLY
AND RETURN
PUMPOUT
CONDENSER
STORAGE TANK
VAPOR VALVE
2 3
4 5
PRESSURE
RELIEF SAFETY
VALVE
PUMPOUT
COMPRESSOR
TEE FOR
CHARGING
REFRIGERANT
CHARGING VALVE
COOLER
REFRIGERANT
ISOLATION
VALVE
LIQUID LINE
SERVICE
VALVE
CHILLER
CONDENSER
VESSEL
CHILLER
COOLER
VESSEL
10
6
7
11
1a
1b
SERVICE VALVE ON
PUMPOUT UNIT
=
SERVICE VALVE ON
CHILLER (FIELD
SUPPLIED)
=
=
MAINTAIN AT LEAST 2 FT (610mm) CLEARANCE AROUND
STORAGE TANK FOR SERVICE AND OPERATION WORK.
REFRIGERANT
CHARGING VALVE
Fig. 43 Typical Optional Pumpout System Piping Schematic with Storage Tank
a19-1721
84
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 tem-
perature 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.
The 19XR chiller refrigerant charges for each cooler and
condenser code are listed in the Heat Exchanger Data tables in
the Physical Data section of this book, pages 119 to 176. Total
refrigerant charge is the sum of the cooler and condenser
charge.
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.
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 mes-
sage in the upper left-hand corner reads, Manually
Stopped, Press the or softkey to start. If
the chiller controls do not go into a start mode (Unoccu-
pied Mode is displayed) go to the SCHEDULE screen
and override the schedule or change the occupied time.
Press the softkey to begin the start-up
sequences.
3. View the STARTUP display screen and verify the chilled
water and condenser water pumps have energized.
OIL
SEPARATOR
PUMPOUT
CONDENSER
WATER SUPPLY
AND RETURN
PUMPOUT
CONDENSER
2 3
4 5
PRESSURE
RELIEF SAFETY
VALVE
PUMPOUT
COMPRESSOR
COOLER
REFRIGERANT
ISOLATION
VALVE
REFRIGERANT
CHARGING
VALVE
CHILLER
CONDENSER
VESSEL
CHILLER
COOLER
VESSEL
7
11
1a
1b
SERVICE VALVE ON
PUMPOUT UNIT
=
SERVICE VALVE ON
CHILLER
=
LIQUID LINE
SERVICE
VALVE
REFRIGERANT
CHARGING
VALVE
Fig. 44 Typical Optional Pumpout System Piping Schematic without Storage Tank
a19-1722
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.
CCN LOCAL
LOCAL
85
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.
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 en-
closure, move the VFD Test/Run switch into the RUN
position. Close the VFD enclosure and engage the main
VFD disconnect.
Check Motor Rotation
1. Disengage the main VFD disconnect. Open the VFD en-
closure 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 enclo-
sure door.
3. Finally, close the main disconnect on the front of the VFD
enclosure.
4. The ISM mounted in the VFD enclosure checks for prop-
er 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 softkey. The PIC II control per-
forms start-up checks.
7. When the starter is energized and the motor begins to
turn, check for clockwise motor rotation (Fig. 45).
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.
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 or softkeys, high-
light the CHILLER START/STOP parameter. Override the cur-
rent START value by pressing the softkey. Press
the softkey followed by the softkey. The
word SUPVSR! displays on the ICVC indicating the override
is in place.
To restart the chiller the STOP override setting must be re-
moved. Access the MAINSTAT screen and using
or softkeys highlight CHILLER START/STOP.
The 3 softkeys that appear represent 3 choices:
forces the chiller ON
forces the chiller OFF
puts the chiller under remote or schedule
control.
To return the chiller to normal control, press
the softkey followed by the softkey. For
more information, see Local Start-Up, page 63.
The default ICVC screen message line indicates which
command is in effect.
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 op-
erator(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, re-
frigerant charging valve, temperature sensor locations, pressure
transducer locations, Schrader fittings, waterboxes and tubes,
and vents and drains.
OPTIONAL PUMPOUT STORAGE TANK AND PUMP-
OUT SYSTEM Transfer valves and pumpout system, refrig-
erant charging and pumpdown procedure, and relief devices.
MOTOR COMPRESSOR ASSEMBLY Guide vane actu-
ator, transmission, motor cooling system, oil cooling system,
temperature and pressure sensors, oil sight glasses, integral oil
pump, isolatable oil filter, extra oil and motor temperature sen-
sors, 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 ex-
tended shutdowns, importance of a log sheet, importance of
water treatment and tube cleaning, and importance of maintain-
ing a leak-free chiller.
SAFETY DEVICES AND PROCEDURES Electrical dis-
connects, relief device inspection, and handling refrigerant.
CHECK OPERATOR KNOWLEDGE Start, stop, and
shutdown procedures, safety and operating controls, refrigerant
and oil charging, and job safety.
IMPORTANT: Do not check motor rotation during coast-
down. Rotation may have reversed during equalization of
vessel pressures.
LOCAL
Fig. 45 Correct Motor Rotation
NEXT PREVIOUS
SELECT
STOP ENTER
NEXT
PREVIOUS
START
STOP
RELEASE
RELEASE ENTER
86
REVIEW THE START-UP OPERATION, AND MAINTE-
NANCE MANUAL.
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 re-
frigerant 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 84.
To Start the Chiller
1. Start the water pumps, if they are not automatic.
2. On the ICVC default screen, press the or
softkey to start the system. If the chiller is in the OCCU-
PIED mode and the start timers have expired, the start se-
quence will start. Follow the procedure described in the
Start-Up/Shutdown/Recycle Sequence section, page 63.
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 tem-
perature. 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 mo-
tor 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 tempera-
ture 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
demand charge for the short period of high demand oper-
ation. Pulldown rate can be based on load rate or temper-
ature rate and is accessed on the EQUIPMENT SER-
VICE screen, RAMP_DEM table (Table 3, Example 23).
9. The economizer (if installed) has two sight glasses that
look into the float chamber. When the chiller is operating,
the top sight glass is empty and the bottom sight glass is
full.
To Stop the Chiller
1. The occupancy schedule starts and stops the chiller auto-
matically once the time schedule is configured.
2. By pressing the STOP button for one second, the alarm
light blinks once to confirm the button has been pressed.
The compressor will then follow the normal shutdown
sequence as described in the Shutdown Sequence, Start-
Up/Shutdown/Recycle Sequence section, page 63. The
chiller will not restart until the or softkey
is pressed. The chiller is now in the OFF control mode.
If the chiller is stopped by an alarm condition, do not re-
start the chiller until the problem is diagnosed and cor-
rected.
After Limited Shutdown No special preparations
should be necessary. Follow the regular preliminary checks and
starting procedures.
Preparation for Extended Shutdown The refrig-
erant should be transferred into the pumpout storage tank (if
supplied; see Pumpout and Refrigerant Transfer Procedures) to
reduce chiller pressure and the possibility of leaks. Maintain a
holding charge of 5 to 10 lb (2.27 to 4.5 kg) of refrigerant or ni-
trogen to prevent air from leaking into the chiller.
If freezing temperatures are likely to occur in the chiller ar-
ea, drain the chilled water, condenser water, and the pumpout
condenser water circuits to avoid freeze-up. Keep the waterbox
drains open. It is recommended not to store the refrigerant in
the unit if below freezing temperatures are anticipated. A nitro-
gen holding charge is recommended in this case.
Leave the oil charge in the chiller with the oil heater and
controls energized to maintain the minimum oil reservoir
temperature.
After Extended Shutdown Ensure the water sys-
tem drains 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 fit-
tings 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 66.
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 compres-
sor oil level appears abnormally high, the oil may have ab-
sorbed refrigerant. Ensure that the oil temperature is above
140 F (60 C) or above the CALC EVAP SAT TEMP plus 50 F
(27 C).
Cold Weather Operation When the entering con-
denser water temperature drops very low, the operator should
automatically cycle the cooling tower fans off to keep the tem-
LOCAL CCN
IMPORTANT: Do not attempt to stop the chiller by opening
an isolating knife switch. High intensity arcing may occur.
CCN LOCAL
87
perature 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 J9-
12 on ISM).
Manual Guide Vane Operation It is possible to
manually operate the guide vanes in order to check control
operation or to control the guide vanes in an emergency. Manu-
al 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 con-
trol the position, use the or soft-
key 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
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, capac-
ity 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 Con-
trols section.
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 per-
formance. It is also an aid when scheduling routine mainte-
nance and diagnosing chiller problems.
Keep a record of the chiller pressures, temperatures, and liq-
uid levels on a sheet similar to the one in Fig. 46. Automatic re-
cording 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.
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 ser-
vice work to either the chiller compressor vessel or chiller con-
denser vessel by using the optional pumpout system. If a
pumpout storage tank is supplied, the refrigerant can be iso-
lated in the storage tank. The following procedures describe
how to transfer refrigerant from vessel to vessel and perform
chiller evacuation.
INCREASE DECREASE
RELEASE
CAUTION
The power to the pumpout compressor oil heater must be
on whenever any valve connecting the pumpout compres-
sor 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 re-
frigerant 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.
88
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89

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 96. 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 and 3) 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.
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
Do not mix refrigerants from chillers that use different
compressor oils. Compressor damage can result.
CAUTION
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
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.
COMPRESSOR
OIL
SEPARATOR
CONDENSER
LEAVING
WATER
ENTERING
WATER
VALVE
5
VALVE
4
VALVE
2
CONTROL
PANEL
FRAME
ASSEMBLY
OIL
HEATER
VALVE
3
OIL FILL
FITTING
Fig. 47 Pumpout Unit
a23-1546
2 OL
2 OL
2 OL
MTR-1
L1
L2
PUMP OUT
COMPRESSOR
CRANKCASE HEATER
240-600v
27-40 WATT
GND
H1 H4
X1 X2
X2
HIGH PRESSURE
SAFETY
NC OPEN > 185psig
CONTROL POWER
TRANSFORMER
XFMR-1
69 VA
C
C
C
8
7
HTR-1
F
U
1

0
.
2
5
A

F
U
2

0
.
2
5
A

F
U
3

0
.
5
A

1 2
2
2
3
4
SS-1
OFF
AUTO ON
LOW PRESSURE CONTROL
NC OPEN < 7 psia (-15.7 in. HG)
CLOSE > 9 psia (-11.6 in. HG)
5 C
X2
6
FIELD
POWER
SUPPLY
L1
L2
L3
LEGEND
C Contactor
FU Fuse
GND Ground
HTR Heater
MTR Motor
NC Normally Closed
OL Overload
SS Selector Switch
Fig. 48 Pumpout Unit Wiring Schematic
a23-1615
90
Transfer Refrigerant from Pumpout Storage Tank to Chiller
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.
d. Gradually crack open valve 5 to increase chiller
pressure to 35 psig (241 kPa). Slowly feed refriger-
ant to prevent freeze-up.
e. Open valve 5 fully after the chiller pressure rises
above the freezing point of the refrigerant. Let the
storage tank and chiller pressure equalize. Open
refrigerant charging valve 7 and storage tank
charging valve 10 to let liquid refrigerant drain into
the chiller.
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.
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.
k. Turn off pumpout condenser water.
Transfer the Refrigerant from Chiller to Pumpout Storage
Tank
1. Equalize refrigerant pressure.
a. Valve positions:
b. Slowly open valve 5 and refrigerant charging
valves 7 and 10 to allow liquid refrigerant to drain
by gravity into the storage tank.
2. Transfer the remaining liquid.
a. Turn off pumpout condenser water. Place valves in
the following positions:
b. Run the pumpout compressor in automatic mode
until vacuum switch is satisfied and compressor
stops. Close valves 7 and 10.
c. Turn off the pumpout compressor.
3. Remove any remaining refrigerant.
a. Turn on chiller water pumps.
b. Turn on pumpout condenser water.
c. Place valves in the following positions:
d. Run the pumpout compressor until the chiller pres-
sure reaches 35 psig (241 kPa); then, shut off the
pumpout compressor. Warm chiller condenser
water will boil off any entrapped liquid refrigerant
and chiller pressure will rise.
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 abso-
lute). This can be done in On or Automatic mode.
f. Close valves 1a, 1b, 3, 4, and 6.
g. Turn off the pumpout condenser water.
4. Establish vacuum for service. To conserve refrigerant,
operate the pumpout compressor as described in Step 3e
until the chiller pressure is reduced to 18 in. Hg
vacuum (41 kPa absolute).
This operation can be done in Automatic or On mode.
In Automatic mode, the compressor will stop automati-
cally at approximately 15 in. Hg vacuum (51 kPa
absolute).
CHILLERS WITH ISOLATION VALVES The valves re-
ferred to in the following instructions are shown in Fig. 43 and
44. Valve 7 remains closed.
Transfer All Refrigerant to Chiller Condenser Vessel
1. Push refrigerant into chiller condenser vessel.
a. Turn on the chiller water pumps and monitor the
chiller pressure.
b. Valve positions:
WARNING
During transfer of refrigerant into and out of the
19XR,XRV storage tank, carefully monitor the storage
tank level gage. Do not fill the tank more than 90% of
capacity to allow for refrigerant expansion. Overfilling
may result in damage to the tank and personal injury.
VALVE 1a 1b 2 3 4 5 6 7 10 11
CONDITION C C C C C
VALVE 1a 1b 2 3 4 5 6 7 10 11
CONDITION C C
VALVE 1a 1b 2 3 4 5 6 7 10 11
CONDITION C C C C
VALVE 1a 1b 2 3 4 5 6 7 10 11
CONDITION C C C C C C C C C
VALVE 1a 1b 2 3 4 5 6 7 10 11
CONDITION C C C C C
VALVE 1a 1b 2 3 4 5 6 7 10 11
CONDITION C C
VALVE 1a 1b 2 3 4 5 6 7 10 11
CONDITION C C
VALVE 1a 1b 2 3 4 5 6 7 10 11
CONDITION C C C C
VALVE 1a 1b 2 3 4 5 6 7 10 11
CONDITION C C C C
VALVE 1a 1b 2 3 4 5 6 7 10 11
CONDITION C C C C C C C C C
VALVE 1a 1b 2 3 4 5 11
CONDITION C C
91
c. Equalize the refrigerant in the chiller cooler and
condenser.
d. Turn off chiller water pumps and pumpout con-
denser water supply.
e. Turn on pumpout compressor to push liquid out of
the chiller cooler vessel.
f. When all liquid has been pushed into the chiller
condenser vessel, close the cooler refrigerant isola-
tion valve (11).
g. Turn on the chiller water pumps.
h. Turn off the pumpout compressor.
2. Evacuate gas from chiller cooler vessel.
a. Close liquid line service valves 2 and 5; open
valves 3 and 4.
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).
d. Close valve 1a.
e. Turn off pumpout compressor.
f. Close valves 1b, 3, and 4.
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:
c. Equalize the refrigerant in the chiller cooler and
condenser.
d. Turn off chiller water pumps and pumpout con-
denser water.
e. Turn on pumpout compressor to push refrigerant
out of the chiller condenser.
f. When all liquid is out of the chiller condenser,
close valve 11 and any other liquid isolation valves
on the chiller.
g. Turn off the pumpout 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.
c. Turn on pumpout condenser water.
d. Run the pumpout compressor until the chiller con-
denser reaches 18 in. Hg vacuum (41 kPa absolute)
in Manual or Automatic mode. Monitor pressure at
the chiller control panel and refrigerant gages.
e. Close valve 1b.
f. Turn off pumpout compressor.
g. Close valves 1a, 2, and 5.
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.
4. Crack open valve 5, gradually increasing pressure in the
evacuated chiller vessel to 35 psig (241 kPa). Feed refrig-
erant slowly to prevent tube freeze-up.
5. Leak test to ensure chiller vessel integrity.
6. Open valve 5 fully.
7. Close valves 1a, 1b, 3, and 5.
8. Open chiller isolation valve 11 and any other isolation
valves, if present.
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.
d. Gradually crack open valve 5 to increase chiller
pressure to 35 psig (241 kPa). Slowly feed refriger-
ant to prevent freeze-up.
e. Open valve 5 fully after the chiller pressure rises
above the freezing point of the refrigerant. Let the
storage tank and chiller pressure equalize.
VALVE 1a 1b 2 3 4 5 11
CONDITION C C C
VALVE 1a 1b 2 3 4 5 11
CONDITION C C C C C C C
VALVE 1a 1b 2 3 4 5 11
CONDITION C C
VALVE 1a 1b 2 3 4 5 11
CONDITION C C C
VALVE 1a 1b 2 3 4 5 11
CONDITION C C C C C C C
VALVE 1a 1b 2 3 4 5 11
CONDITION C C C C
VALVE 1a 1b 2 3 4 5 11
CONDITION C C C
VALVE 1a 1b 2 3 4 5 11
CONDITION C C C C C C
VALVE 1a 1b 2 3 4 5 6 7 10 11
CONDITION C C C C C
92
3. Transfer remaining refrigerant.
a. Close valve 3.
b. Open valve 2.
c. Turn on pumpout condenser water.
d. Run the pumpout compressor until the storage tank
pressure reaches 5 psig (34 kPa), 18 in. Hg vacuum
(41 kPa absolute) in Manual or Automatic mode.
e. Turn off the pumpout compressor.
f. Close valves 1a, 1b, 2, 5, and 6.
g. Turn off pumpout condenser water.
4. Drain the contaminants from the bottom of the storage
tank into a container. Dispose of contaminants safely.
GENERAL MAINTENANCE
Refrigerant Properties The standard refrigerant for
the 19XR chiller is HFC-134a. At normal atmospheric pres-
sure, HFC-134a will boil at 14 F (25 C) and must, therefore,
be kept in pressurized containers or storage tanks. The refriger-
ant is practically odorless when mixed with air and is noncom-
bustible at atmospheric pressure. Read the Material Safety
Data Sheet and the latest ASHRAE Safety Guide for Mechani-
cal Refrigeration to learn more about safe handling of this
refrigerant.
Adding Refrigerant Follow the procedures de-
scribed in Trim Refrigerant Charge section, page 93.
Adjusting the Refrigerant Charge If the addi-
tion or removal of refrigerant is required to improve chiller per-
formance, follow the procedures given under the Trim Refrig-
erant Charge section, page 93.
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 elec-
tronic 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
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.
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.
TESTING WITH REFRIGERANT TRACER Use an en-
vironmentally acceptable refrigerant as a tracer for leak test
procedures. Use dry nitrogen to raise the machine pressure to
leak testing levels.
TESTING WITHOUT REFRIGERANT TRACER An-
other 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 cop-
per tube if it is no longer required.
Repair the Leak, Retest, and Apply Standing
Vacuum Test After pressurizing the chiller, test for
leaks with an electronic halide leak detector, soap bubble solu-
tion, or an ultrasonic leak detector. Bring the chiller back to at-
mospheric pressure, repair any leaks found, and retest.
After retesting and finding no leaks, apply a standing vacu-
um test. Then dehydrate the chiller. Refer to the Standing Vacu-
um Test and Chiller Dehydration section (page 70) in the Be-
fore Initial Start-Up section.
Checking Guide Vane Linkage When the chiller
is off, the guide vanes are closed and the actuator mechanism is
in the position shown in Fig. 49. Slack in the guide vane actua-
tors 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 actuators holddown bolts.
3. Pull the guide vane actuator away from the suction hous-
ing along the slotted holes in the actuator bracket.
VALVE 1a 1b 2 3 4 5 6 7 10 11
CONDITION C C C C
VALVE 1a 1b 2 3 4 5 6 7 10 11
CONDITION C C C C C C C C C
DANGER
HFC-134a will dissolve oil and some nonmetallic materi-
als, dry the skin, and, in heavy concentrations, may dis-
place enough oxygen to cause asphyxiation. When
handling this refrigerant, protect the hands and eyes and
avoid breathing fumes.
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 refrig-
erant may flash into a gas and cause possible freeze-up
when the chiller pressure is below 30 psig (207 kPa) for
HFC-134a.
WARNING
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.
93
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 re-
move refrigerant slowly until the difference between the leav-
ing chilled water temperature and the cooler refrigerant tem-
perature 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 90.
WEEKLY MAINTENANCE
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 re-
quired, add it through the oil drain charging valve (Fig. 2 and
3). 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)
Frame E 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 94. Any additional oil that is added should be logged
by noting the amount and date. Any oil that is added due to oil
loss that is not related to service will eventually return to the
sump. It must be removed when the level is high.
An oil heater is controlled by the PIC II to maintain oil tem-
perature (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 re-
sistance.
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.
SCHEDULED MAINTENANCE
Establish a regular maintenance schedule based on your ac-
tual chiller requirements such as chiller load, run hours, and
water quality. The time intervals listed in this section are of-
fered as guides to service only.
Service Ontime The ICVC will display a SERVICE
ONTIME value on the MAINSTAT screen. This value should
be reset to zero by the service person or the operator each time
major service work is completed so that the time between ser-
vice can be viewed and tracked.
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 mal-
functions, refer to the Troubleshooting Guide section for con-
trol checks and adjustments.
CHAIN
GUARD
DRIVE
CHAIN
GUIDE VANE
ACTUATOR
SPROCKET
SET
SCREWS
GUIDE VANE
ACTUATOR
SUCTION
HOUSING
GUIDE VANE
ACTUATOR
SHAFT
ACTUATOR
BRACKET
HOLDDOWN
BOLTS (3)
GUIDE VANE
SHAFT
GUIDE VANE
SPROCKET
O
P
E
N
CL
O
S
E
Fig. 49 Guide Vane Actuator Linkage
a19-1731
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.
94
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 filters higher internal pressure to ambient
by connecting an oil charging hose to the Schrader valve
on the oil filter housing. Collect the oil-refrigerant mix-
ture 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).
9. Evacuate the filter housing by placing a vacuum pump on
the charging valve. Follow the normal evacuation proce-
dures. Shut the charging valve when done and reconnect
the valve so that new oil can be pumped into the filter
housing. Fill with the same amount that was removed;
then close the charging valve.
10. Remove the hose from the charging valve, open the isola-
tion valves to the filter housing, and turn on the power to
the pump and the motor.
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.
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 and 3). 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 sec-
tion, 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 condi-
tions, the oil level should be full in the lower sight glass.
If the oil level is above
1
/
2
full in the upper sight glass, re-
move the excess oil. The oil level should now be equal to
the amount shown in Step 2.
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 fil-
ter isolation valves (Fig. 2 and 3) and slowly opening the flare
fittings with a wrench and back-up wrench to relieve the pres-
sure. A moisture indicator sight glass is located beyond this fil-
ter to indicate the volume and moisture in the refrigerant. If the
moisture indicator indicates moisture, locate the source of wa-
ter 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. Re-
place the filter once every 5 years or when the machine is
opened for service. This filter does not contain desiccant for
moisture removal, so changing the filter will not change the
moisture indicator status. 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 evacuat-
ed from the cooler.
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 accompa-
nied 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 to-
ward the bubbler tube for proper operation.
CAUTION
The oil filter housing is at a high pressure. Relieve this
pressure slowly. Failure to do so could result in serious per-
sonal injury.
95
ECONOMIZER FLOAT SYSTEM (Two-Stage Compres-
sors) For two-stage compressors, the economizer has a low
side ball type float system. The float refrigerant level can be
observed through the two sight glasses located on the float cov-
er under the condenser. See Fig. 51 for float detail. Inspect the
float every five years. Clean the chamber and the float valve as-
sembly. Be sure that the float moves freely and the ball bear-
ings that the float moves on are clean.
ECONOMIZER DAMPER VALVE (Two-Stage Compres-
sors) The damper valve should be inspected every 5 years
or when the condenser is opened for service. With the refriger-
ant transferred, remove the spring housing from the valve
(Fig. 52). The valve spring will exert 50 lb force upward.
Check the valve and linkage for free travel and loose parts.
Clean the assembly thoroughly. Replace the valve packing and
the housing O-ring if necessary.
Inspect Relief Valves and Piping The relief valves
on this chiller protect the system against the potentially danger-
ous effects of overpressure. To ensure against damage to the
equipment and possible injury to personnel, these devices must
be kept in peak operating condition.
As a minimum, the following maintenance is required.
1. At least once a year, disconnect the vent piping at the
valve outlet and carefully inspect the valve body and
mechanism for any evidence of internal corrosion or rust,
dirt, scale, leakage, etc.
2. If corrosion or foreign material is found, do not attempt to
repair or recondition. Replace the valve.
3. If the chiller is installed in a corrosive atmosphere or the
relief valves are vented into a corrosive atmosphere, in-
spect the relief valves at more frequent intervals.
Compressor Bearing and Gear Maintenance
The key to good bearing and gear maintenance is proper lubri-
cation. Use the proper grade of oil, maintained at recom-
mended level, temperature, and pressure. Inspect the
lubrication system regularly and thoroughly. Annual oil analy-
ses and vibration measurements 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 compres-
sor teardown is required. Only a trained service technician
should remove and examine the bearings. The frequency of ex-
amination 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, 5
1
2
3
4
5
6
7
8
LEGEND
Fig. 50 19XR/XRV Float Valve Design
1 Refrigerant Inlet from FLASC Chamber
2 Linear Float Assembly
3 Float Screen
4 Bubbler Line
5 Float Cover
6 Bubbler Line Connection
7 Refrigerant Outlet to Cooler
8 Gasket
a23-1632
2
3
1
LEGEND
Fig. 51 Economizer Float System
(Two-Stage Compressor Chiller)
1 Float Ball
2 Refrigerant Exit
3 Bearings
SPRING
HOUSING
CONNECTION
TO COOLER
O-RING
ECONOMIZER
SIDE
COMPRESSOR
SIDE
VALVE
PACKING
Fig. 52 Economizer Damper Valve
(Two-Stage Compressor Chiller)
96
and E compressor high speed shaft only) cannot be field in-
spected; excessive vibration is the primary sign of wear or
damage. If either symptom appears, contact an experienced
and responsible service organization for assistance.
Inspect the Heat Exchanger Tubes and Flow
Devices
COOLER AND OPTIONAL FLOW DEVICES Inspect
and clean the cooler tubes at the end of the first operating sea-
son. Because these tubes have internal ridges, a rotary-type
tube cleaning system is needed to fully clean the tubes. Inspect
the tubes condition to determine the scheduled frequency for
future cleaning and to determine whether water treatment in the
chilled water/brine circuit is adequate. Inspect the entering and
leaving chilled water temperature sensors and flow devices for
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 refrig-
erant temperature against the leaving condenser water tempera-
ture. If this reading is more than what the design difference is
supposed to be, the condenser tubes may be dirty or water flow
may be incorrect. Because HFC-134a is a high-pressure refrig-
erant, air usually does not enter the chiller.
During the tube cleaning process, use brushes specially de-
signed 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 preven-
tion or removal. Consult a water treatment specialist for proper
treatment.
Water Leaks The refrigerant moisture indicator on the
refrigerant motor cooling line (Fig. 2 and 3) indicates whether
there is water leakage during chiller operation. Water leaks
should be repaired immediately.
Water Treatment Untreated or improperly treated wa-
ter may result in corrosion, scaling, erosion, or algae. The ser-
vices of a qualified water treatment specialist should be ob-
tained to develop and monitor a treatment program.
Inspect the Starting Equipment Before working
on any starter, shut off the chiller, open and tag all disconnects
supplying power to the starter.

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 re-
tighten. Recheck annually thereafter.
Recalibrate Pressure Transducers Once a
year, the pressure transducers should be checked against a pres-
sure gage reading. Check all eight transducers: the 2 oil differ-
ential pressure transducers, the condenser pressure transducer,
the cooler pressure transducer, and the optional waterside pres-
sure 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 re-
frigeration 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 Trouble-
shooting Guide section. Oil differential pressure (OIL PUMP
DELTA P on the COMPRESS screen) should be zero whenev-
er the compressor is off.
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)
CAUTION
The chiller must be dehydrated after repair of water leaks
or damage may result. See Chiller Dehydration section,
page 70.
CAUTION
Water must be within design flow limits, clean, and treated
to ensure proper chiller performance and reduce the poten-
tial of tube damage due to corrosion, scaling, erosion, and
algae. Carrier assumes no responsibility for chiller damage
resulting from untreated or improperly treated water.
CAUTION
The motor leads must be disconnected from the VFD
before an insulation test is performed. The voltage gener-
ated from the tester can damage the VFD or drive
components.
WARNING
Before working on any VFD, shut off the chiller, open and
tag all disconnects supplying power to the VFD. After dis-
connecting 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 volt-
meter. 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 discon-
nects before servicing the VFD.
WARNING
Never open isolating knife switches while equipment is
operating. Electrical arcing can cause serious injury.
CAUTION
Loose power connections can cause voltage spikes, over-
heating, malfunctioning, or failures.
97
Oil should be visible in the pumpout compressor sight glass
both during operation and at shutdown. Always check the oil
level before operating the pumpout compressor. Before adding
changing oil, relieve the refrigerant pressure through the access
valves.
Relieve refrigerant pressure and add oil to the pumpout unit
as follows:
1. Close service valves 2 and 4.
2. Run the pumpout compressor in Automatic mode for one
minute or until the vacuum switch is satisfied and com-
pressor 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. 53) 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.
TROUBLESHOOTING GUIDE
Overview The PIC II has many features to help the op-
erator and technician troubleshoot a 19XR chiller.
The ICVC shows the chillers actual operating condi-
tions and can be viewed while the unit is running.
The ICVC default screen freezes when an alarm occurs.
The freeze enables the operator to view the chiller condi-
tions at the time of alarm. The STATUS screens continue
to show current information. Once all alarms have been
cleared (by correcting the problems and pressing
the softkey), the ICVC default screen returns to
normal operation.
The CONTROL ALGORITHM STATUS screens (which
include the CAPACITY, OVERRIDE, SURGPREV,
LL_MAINT, ISM_HIST, LOADSHED, CUR_ALARM,
WSMDEFME, and OCCDEFCM screens) display infor-
mation 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
pump, water pumps, tower control, and other on/off out-
puts while the compressor is stopped. It also has the abil-
ity to lock off the compressor and turn on water pumps
for pumpout operation. The ICVC shows the tempera-
tures and pressures required during these operations.
From other SERVICE tables, the operator/technician can
access configured items, such as chilled water resets,
override set points, etc.
If an operating fault is detected, an alarm message is gen-
erated and displayed on the ICVC default screen. A more
detailed message along with a diagnostic message
is also stored into the ALARM HISTORY table.
Review the ALERT HISTORY table to view other less
critical events which may have occurred. Compare tim-
ing 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. 17). These
messages will indicate where the fault is occurring. These mes-
sages 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 SER-
VICE 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 16. If the alarm light starts to flash
while accessing a menu screen, press the softkey to re-
turn to the default screen to read the alarm message. The STA-
TUS screen can also be accessed to determine where an alarm
exists.
A C to the right of a parameters value means that there is
a communications fault on that channel.
Checking Temperature Sensors All tempera-
ture sensors are thermistor-type sensors. This means that the re-
sistance of the sensor varies with temperature. All sensors have
the same resistance characteristics. If the controls are on, deter-
mine sensor temperature by measuring voltage drop; if the con-
trols are powered off, determine sensor temperature by measur-
ing resistance. Compare the readings to the values listed in
Tables 17A and 17B.
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 17A and 17B. 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 con-
trol is energized. Table 17A or 17B lists the relationship be-
tween 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.
CONTACTOR
TERMINAL
STRIP
FUSES
TRANSFORMER
SWITCH
Fig. 53 Pumpout Control Box (Interior)
a19-1569
RESET 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.
EXIT
continued on page 114.
98
Table 16 ICVC Primary and Secondary Messages and
Custom Alarm/Alert Messages with Troubleshooting Guides
A. MANUAL STOP
B. READY TO START
C. IN RECYCLE SHUTDOWN
LEGEND FOR TABLE 16 (A through K)
PRIMARY MESSAGE SECONDARY MESSAGE PROBABLE CAUSE/REMEDY
MANUALLY STOPPED PRESS CCN OR LOCAL TO START PIC II in OFF mode, press CCN or LOCAL softkey to start unit.
TERMINATE PUMPDOWN MODE
TO SELECT CCN OR LOCAL Enter the CONTROL TEST table and select TERMINATE LOCKOUT
to unlock compressor.
SHUTDOWN IN PROGRESS COMPRESSOR UNLOADING Chiller unloading before shutdown due to soft/stop feature.
SHUTDOWN IN PROGRESS
COMPRESSOR DEENERGIZED Chiller compressor is being commanded to stop. Water pumps are
deenergized within one minute.
ICE BUILD OPERATION COMPLETE Chiller shutdown from Ice Build operation.
SHUTDOWN IN PROGRESS RECYCLE RESTART PENDING Low Load Shutdown
PRIMARY MESSAGE SECONDARY MESSAGE PROBABLE CAUSE/REMEDY
READY TO START IN XX MIN
UNOCCUPIED MODE Time schedule for PIC II is unoccupied. Chillers will start only
when occupied. Check OCCPCnnS and HOLIDAYS screens.
READY TO START IN XX MIN
REMOTE CONTACTS OPEN Remote contacts are open. Close contacts on ISM J2-5 and
J2-6 to start.
READY TO START IN XX MIN
STOP COMMAND IN EFFECT Chiller START/STOP on MAINSTAT manually forced to STOP.
Release SUPERVISOR Force or send Start Force to start.
READY TO START IN XX MIN OCCUPIED MODE Chiller timer counting down. Unit ready to start.
READY TO START IN XX MIN
REMOTE CONTACTS CLOSED Chiller timer counting down. Unit will proceed to start. Remote
contact Enabled and Closed. The chiller will stop when the
remote contacts are opened.
READY TO START IN XX MIN
START COMMAND IN EFFECT Chiller START/STOP on MAINSTAT manually forced to
START. Release SUPERVISOR force to start under normal
control.
READY TO START IN XX MIN RECYCLE RESTART PENDING Chiller is in recycle mode.
READY TO START
UNOCCUPIED 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.
READY TO START
REMOTE CONTACTS OPEN Remote contacts have stopped the chiller. Close contacts on
ISM J2-5 and J2-6 to start.
READY TO START
STOP COMMAND IN EFFECT Chiller START/STOP on MAINSTAT manually forced to STOP.
Release SUPERVISOR force to start.
READY TO START OCCUPIED MODE Chiller timer countdown is complete. Unit will proceed to start.
READY TO START REMOTE CONTACTS CLOSED Chiller timer count down complete. Unit will proceed to start.
READY TO START
START COMMAND IN EFFECT Chiller START/STOP on MAINSTAT has been manually forced
to START. Chiller will start regardless of time schedule or
remote contact status.
STARTUP INHIBITED LOADSHED IN EFFECT CCN loadshed module commanding chiller to stop.
PRIMARY MESSAGE SECONDARY MESSAGE PROBABLE CAUSE/REMEDY
RECYCLE RESTART PENDING
OCCUPIED MODE Unit in recycle mode, chilled water temperature is not sufficiently
above Setpoint to start.
RECYCLE RESTART PENDING
REMOTE CONTACT CLOSED Unit in recycle mode, chilled water temperature is not sufficiently
above Setpoint to start.
RECYCLE RESTART PENDING
START COMMAND IN EFFECT Chiller START/STOP on MAINSTAT manually forced to START, chilled
water temperature is not sufficiently above Setpoint to start.
RECYCLE RESTART PENDING
ICE BUILD MODE Chiller in ICE BUILD mode. Chilled water temperature is satisfied for
ICE BUILD conditions.
CCM Chiller Control Module
CHW Chilled Water
ICVC International Chiller Visual Control
ISM Integrated Starter Module
PIC II Product Integrated Controls II
VFD Variable Frequency Drive
99
Table 16 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.
*[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.
FAULT
STATE
PRIMARY
MESSAGE
SECONDARY
MESSAGE
PRIMARY CAUSE ADDITIONAL CAUSE/REMEDY
100
PRESTART
ALERT
STARTS LIMIT
EXCEEDED
100->Excessive compressor starts (8
in 12 hours)
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.)
101
PRESTART
ALERT
HIGH BEARING TEM-
PERATURE
"101->Comp Thrust Bearing Temp
[VALUE] exceeded limit of [LIMIT]*.
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.
102
PRESTART
ALERT
HIGH MOTOR TEMPER-
ATURE
102->Comp Motor Winding Temp
[VALUE] exceeded limit of [LIMIT]*.
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 oper-
ation, or restrictions, check refrigerant filter/drier.
Check for excessive starts within a short time span.
Check COMP MOTOR TEMP OVERRIDE setting in SETUP1
screen.
103
PRESTART
ALERT
HIGH DISCHARGE
TEMP
103->Comp Discharge Temp
[VALUE] exceeded limit of [LIMIT]*.
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.
104
PRESTART
ALERT
LOW REFRIGERANT
TEMP
104->Evaporator Refrig Temp
[VALUE] exceeded limit of [LIMIT]*.
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.
105
PRESTART
ALERT
LOW OIL TEMPERA-
TURE
105->Oil Sump Temp [VALUE]
exceeded limit of [LIMIT]*.
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.
106
PRESTART
ALERT
HIGH CONDENSER
PRESSURE
106->Condenser Pressure [VALUE]
exceeded limit of [LIMIT]*.
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.
107
PRESTART
ALERT
LOW LINE VOLTAGE 107Average Line Voltage [VALUE]
exceeded limit of [LIMIT]*.
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.
108
PRESTART
ALERT
HIGH LINE VOLTAGE 108->Average Line Voltage [VALUE]
exceeded limit of [LIMIT]*.
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.
109
PRESS STOP,
PERFORM
GUIDE VANE
CALIBRATION
109Actual Guide Vane Pos Calibra-
tion Required Before Startup
Press STOP button on ICVC and perform Guide Vane Cali-
bration in CONTROLS TEST screen. Check guide vane actu-
ator feedback potentiometer and wiring to CCM J4-9 and J4-
10.
100
Table 16 ICVC Primary and Secondary Messages and
Custom Alarm/Alert Messages with Troubleshooting Guides (cont)
E. START-UP IN PROGRESS
F. NORMAL RUN
PRIMARY MESSAGE SECONDARY MESSAGE CAUSE/REMEDY
STARTUP IN PROGRESS OCCUPIED MODE Chiller is starting. Time schedule is Occupied (OCCUPIED? = YES)
STARTUP IN PROGRESS
REMOTE CONTACT CLOSED Chiller is starting. REMOTE CONTACTS OPTION is set to ENABLE. Remote
start contact input on ISM terminals J2-5 and J2-6 is closed.
STARTUP IN PROGRESS
START COMMAND IN EFFECT Chiller is starting. Chiller START/STOP in MAINSTAT is manually forced to
START.
AUTORESTART IN
PROGRESS
OCCUPIED MODE Chiller is starting after power failure. Time schedule is Occupied (OCCU-
PIED? = YES).
AUTORESTART IN
PROGRESS
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.
AUTORESTART IN
PROGRESS
START COMMAND IN EFFECT Chiller is starting after power failure. Chiller START/STOP on MAINSTAT
screen is manually forced to START.
PRIMARY MESSAGE SECONDARY MESSAGE CAUSE/REMEDY
RUNNING RESET ACTIVE
BY 4-20 mA SIGNAL 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
RUNNING RESET ACTIVE
REMOTE TEMP SENSOR Auto chilled water reset active based on external input. ENABLE RESET TYPE
=2. A non-zero temperature reset based on the Remote Temperature Reset sen-
sor signal on CCM J4-13 and J4-14 is being added to the SETPOINT to determine
the CONTROL POINT. See TEMP_CTL screen
RUNNING RESET ACTIVE
CHW TEMP DIFFERENCE Auto chilled water reset active based on cooler chilled water temperature differ-
ence. ENABLE RESET TYPE =3. A non-zero temperature reset based on the dif-
ference between the ENTERING CHILLED WATER and LEAVING CHILLED
WATER is being added to the SETPOINT to determine the CONTROL POINT.
See TEMP_CTL screen.
RUNNING TEMP CONTROL
LEAVING CHILLED WATER Default method of temperature control. ECW CONTROL OPTION = DSABLE.
Chiller capacity is being controlled so the LEAVING CHILLED WATER tempera-
ture is being maintained within 1/2 of the CHILLED WATER DEADBAND on either
side of the CONTROL POINT. See TEMP_CTL screen
RUNNING TEMP CONTROL
ENTERING CHILLED WATER 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.
RUNNING TEMP CONTROL
TEMPERATURE RAMP
LOADING
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.
RUNNING DEMAND LIMITED
BY DEMAND RAMP LOAD-
ING
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.
RUNNING DEMAND LIMITED
BY LOCAL DEMAND SET-
POINT
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.
RUNNING DEMAND LIMITED
BY 4-20 mA SIGNAL 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.
RUNNING DEMAND LIMITED
BY CCN SIGNAL Actual demand has exceeded ACTIVE DEMAND LIMIT. Chiller CONTROL MODE
= CCN. Value of ACTIVE DEMAND LIMIT is being forced by a CCN device. AVER-
AGE LINE CURRENT or MOTOR PERCENT KILOWATTS is greater than ACTIVE
DEMAND LIMIT.
RUNNING DEMAND LIMITED
BY LOADSHED/REDLINE Actual demand has exceeded ACTIVE DEMAND LIMIT. Chiller CONTROL MODE
= CCN. Value of ACTIVE DEMAND LIMIT was set equal to AVERAGE LINE CUR-
RENT or MOTOR PERCENT KILOWATTS at the time a Redline command was
received by the loadshed POC. AVERAGE LINE CURRENT of MOTOR PER-
CENT KILOWATTS is greater than ACTIVE DEMAND LIMIT. See LOADSHED
screen.
RUNNING TEMP CONTROL
HOT GAS BYPASS 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.
RUNNING DEMAND LIMITED
BY LOCAL SIGNAL ACTIVE DEMAND LIMIT has been manually forced on MAINSTAT screen. Chiller
CONTROL MODE = LOCAL.
RUNNING TEMP CONTROL
ICE BUILD MODE ICE BUILD OPTION is set to ENABLE and chiller is running under Ice Build tem-
perature control. OCCPC02S Ice Build Schedule is OCCUPIED.
RUNNING TEMP CONTROL
IN VFD RAMPDOWN VFD OPTION is ENABLED. VFD Rampdown goes into effect following the com-
pletion of start-up Ramp Loading and when the water temperature is within or
below the CHILLED WATER DEADBAND.
RUNNING TEMP CONTROL
HGBP IS ADDING LOAD SURGE LIMIT/HGBP OPTION = 2. CHILLED WATER DELTA T is less than HGBP
ON DELTA T. See OPTIONS and SURGPREV screens.
101
Table 16 ICVC Primary and Secondary Messages and
Custom Alarm/Alert Messages with Troubleshooting Guides (cont)
G. NORMAL RUN WITH OVERRIDES
*[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.
ICVC
FAULT
STATE
PRIMARY MESSAGE SECONDARY MESSAGE PRIMARY CAUSE
ADDITIONAL
CAUSE/REMEDY
120
RUN CAPACITY
LIMITED
HIGH CONDENSER
PRESSURE
120->Condenser Pressure
[VALUE] exceeded limit of
[LIMIT]*.
Check condenser water pump operation.
Check for high condenser water temperatures
or low flow rate.
Check cooling tower bypass valves and con-
denser water strainers. Verify that chiller isola-
tion valves are open.
Check COND PRESS OVERRIDE setting in
SETUP1 screen.
121
RUN CAPACITY
LIMITED
HIGH MOTOR TEMPERA-
TURE
121->Comp Motor Winding
Temp [VALUE] exceeded limit
of [LIMIT]*.
Check for closed valves or restrictions in motor
cooling lines.
Check for closed refrigerant isolation valves.
Check COMP MOTOR TEMP OVERRIDE set-
ting in SETUP1.
Check refrigerant filter drier.
122
RUN CAPACITY
LIMITED
LOW EVAP REFRIG TEMP 122->Evaporator Refrig Temp
[VALUE] exceeded limit of
[LIMIT]*.
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 tempera-
ture.
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.
123
RUN CAPACITY
LIMITED
HIGH COMPRESSOR LIFT 123->Surge Prevention Over-
ride: Lift Too High For Com-
pressor
Check for high condenser water temperature
or low evaporator refrigerant temperature.
Check for high EVAPORATOR APPROACH or
CONDENSER APPROACH.
Check SURGE/HOT GAS BYPASS parame-
ters in OPTIONS screen.
124
RUN CAPACITY
LIMITED
MANUAL GUIDE VANE
TARGET
124->Run Capacity Limited:
Manual Guide Vane Target.
TARGET GUIDE VANE POSITION has been
forced in the COMPRESS screen. Select and
RELEASE force to return to normal (auto-
matic) operation.
125
RUN CAPACITY
LIMITED
LOW DISCHARGE
SUPERHEAT
No Alert message 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.
102
Table 16 ICVC Primary and Secondary Messages and
Custom Alarm/Alert Messages with Troubleshooting Guides (cont)
H. OUT-OF-RANGE SENSOR ALARMS
STATE PRIMARY MESSAGE SECONDARY MESSAGE PRIMARY CAUSE
ADDITIONAL
CAUSE/REMEDY
260 SENSOR FAULT
LEAVING CHILLED WATER 260->Sensor Fault: Check Leav-
ing Chilled Water Sensor
Check sensor resistance or voltage drop
against Table 17A or 17B.
Check for proper wiring between LEAVING
CHILLED WATER Temperature Sensor and
CCM J4-3 and J4-4. Check for disconnected,
grounded, or shorted wiring.
261 SENSOR FAULT
ENTERING CHILLED WATER 261->Sensor Fault: Check Enter-
ing Chilled Water Sensor
Check sensor resistance or voltage drop
against Table 17A or 17B.
Check for proper wiring between ENTERING
CHILLED WATER Temperature Sensor and
CCM J4-1 and J4-2. Check for disconnected,
grounded, or shorted wiring.
262 SENSOR FAULT
CONDENSER PRESSURE 262->Sensor Fault: Check Con-
denser Pressure Sensor
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.
263 SENSOR FAULT
EVAPORATOR PRESSURE 263->Sensor Fault: Check Evapo-
rator Pressure Sensor
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.
264 SENSOR FAULT
COMPRESSOR BEARING TEMP 264->Sensor Fault: Check Comp
Thrust Brg Temp Sensor
Check sensor resistance or voltage drop
against Table 17A or 17B.
Check for proper wiring between COMP
THRUST BRG TEMP Sensor and CCM J4-19
and J4-20. Check for disconnected, grounded,
or shorted wiring.
265 SENSOR FAULT
COMPRESSOR MOTOR TEMP 265->Sensor Fault: Check Comp
Motor Winding Temp Sensor
Check sensor resistance or voltage drop
against Table 17A or 17B.
Check for proper wiring between COMP
MOTOR WINDING TEMP Sensor and CCM J4-
23 and J4-24. Check for disconnected,
grounded, or shorted wiring.
266 SENSOR FAULT
COMP DISCHARGE TEMP 266->Sensor Fault: Check Comp
Discharge Temp Sensor
Check sensor resistance or voltage drop
against Table 17A or 17B.
Check for proper wiring between COMP DIS-
CHARGE TEMP Sensor and CCM J4-17 and
J4-18. Check for disconnected, grounded, or
shorted wiring.
267 SENSOR FAULT
OIL SUMP TEMP 267->Sensor Fault: Check Oil
Sump Temp Sensor
Check sensor resistance or voltage drop
against Table 17A or 17B.
Check for proper wiring between OIL SUMP
TEMP and CCM J4-21 and J4-22. Check for
disconnected, grounded, or shorted wiring.
268 SENSOR FAULT
COMP OIL PRESS DIFF 268->Sensor Fault: Check Oil
Pump Delta P Sensor
Check Oil Sump Pressure and Oil Pump Dis-
charge Pressure sensor wiring and accuracy.
Confirm that 5 V reference signal is available
between CCM J3-1 and J3-3 and J3-4 and J3-
6. Check for disconnected, grounded, or
shorted OIL PUMP DELTA P wiring.
269 SENSOR FAULT
CHILLED WATER FLOW 269->Sensor Fault: Check Chilled
Water Delta P Sensor
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.
270 SENSOR FAULT
COND WATER FLOW 270->Sensor Fault: Check Cond
Water Delta P Sensor
Check CONDENSER WATER DELTA P trans-
ducer 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.
271 SENSOR FAULT
VFD SPEED OUT OF RANGE 271->Sensor Fault: Check Actual
VFD Speed
Check 0 - 5 V DC input from VFD to ISM termi-
nals 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.
272 SENSOR FAULT
EVAP REFRIG LIQUID TEMP 272->Sensor Fault: Check Evap
Refrig Liquid Temp Sensor
Check sensor resistance or voltage drop
against Table 17A or 17B.
Check for proper wiring between EVAP
REFRIG LIQUID TEMP Sensor and CCM J4-11
and J4-12. Check for disconnected, grounded,
or shorted wiring.
103
Table 16 ICVC Primary and Secondary Messages and
Custom Alarm/Alert Messages with Troubleshooting Guides (cont)
I. CHILLER PROTECTIVE LIMIT FAULTS (cont)
*[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.
ICVC
FAULT
STATE
PRIMARY MESSAGE SECONDARY MESSAGE PRIMARY CAUSE
ADDITIONAL
CAUSE/REMEDY
227 PROTECTIVE LIMIT
OIL PRESS SENSOR FAULT 227->Oil Pump Delta P [VALUE]
exceeded limit of [LIMIT]*
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 Pres-
sure 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.
228 PROTECTIVE LIMIT
LOW OIL PRESSURE 228->Oil Pump Delta P [VALUE]
exceeded limit of [LIMIT]*
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 trans-
ducers. Check Oil Sump Pressure and Oil Pump
Discharge Pressure transducer wiring leading to
CCM J3-1 through J3-6. Confirm that 5.0 V refer-
ence 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.
229 PROTECTIVE LIMIT
LOW CHILLED WATER FLOW 229->Low Chilled Water Flow; Check
Delta P Config and Calibration
Perform Chilled Water pump test in CONTROLS
TEST screen. Check EVAP REFRIG LIQUID
TEMP and LEAVING CHILLED WATER tempera-
ture 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 refer-
ence voltage between CCM J3-13 and J3-15 and
J3-16 and J3-18. Activate Pumpdown Mode in
CONTROLS TEST screen before removing refrig-
erant charge.
230 PROTECTIVE LIMIT
LOW CONDENSER WATER
FLOW
230->Low Condenser Water Flow;
Check Delta P Config and Calibration
Perform Condenser Water pump test in CON-
TROLS TEST screen. Check CONDENSER
PRESSURE transducer and LEAVING CON-
DENSER WATER temperature sensor accuracy
and wiring.
Check condenser water valves and strainers.
Check COND PRESS OVERRIDE, COND
APPROACH ALERT, COND FLOW DELTA P CUT-
OUT, 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.
231 PROTECTIVE LIMIT
HIGH DISCHARGE TEMP 231->Comp Discharge Temp [VALUE]
exceeded Limit of [LIMIT]*
Check for closed compressor discharge isolation
valve. Check if chiller was operating in surge con-
ditions. Check COMP DISCHARGE TEMP sen-
sor 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 dif-
fuser actuator operation. Check for COMP DIS-
CHARGE TEMP > 220 deg F. Check for fouled
tubes, plugged water strainers, or noncondensi-
bles in the condenser.
232 PROTECTIVE LIMIT
LOW REFRIGERANT TEMP 232->Evaporator Refrig Temp [VALUE]
exceeded limit of [LIMIT]*.
Check for proper refrigerant charge.
Check float valve operation. Check for closed con-
denser 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 con-
denser 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.
104
Table 16 ICVC Primary and Secondary Messages and
Custom Alarm/Alert Messages with Troubleshooting Guides (cont)
I. CHILLER PROTECTIVE LIMIT FAULTS (cont)
*[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.
ICVC
FAULT
STATE
PRIMARY MESSAGE SECONDARY MESSAGE PRIMARY CAUSE
ADDITIONAL
CAUSE/REMEDY
233 PROTECTIVE LIMIT
HIGH MOTOR TEMPERATURE 233->Comp Motor Winding Temp
[VALUE] exceeded limit of [LIMIT]*.
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.
234 PROTECTIVE LIMIT
HIGH BEARING TEMPERATURE 234->Comp Thrust Brg Temp [VALUE]
exceeded limit of [LIMIT]*.
Check oil heater for proper operation, confirm that
oil heater is de-energized when compressor is run-
ning. Check for low oil level, partially closed oil line
isolation valves, or clogged oil filter. Check oil
cooler refrigerant thermal expansion valves, con-
firm 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 switch-
ing to spare COMP THRUST BRNG TEMP sen-
sor. This fault can result from excessive operation
at low load with low water flow to the evaporator or
condenser. Very high discharge and volute tem-
peratures 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.
235 PROTECTIVE LIMIT
HIGH CONDENSER PRESSURE 235->Condenser Pressure [VALUE]
exceeded limit of [LIMIT]*.
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.
236 PROTECTIVE LIMIT
COMPRESS SURGE/LOW
SPEED
236->Compressor Surge: Check con-
denser water temp and flow
Surge prevention alarm declared before ACTUAL
VFD SPEED reached 90%. Check for high CON-
DENSER 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.
237 PROTECTIVE LIMIT
SPARE SAFETY DEVICE 237->Spare Safety Device Spare safety input has tripped or factory installed
jumper is not present on ISM J2-1 and J2-2.
238 PROTECTIVE LIMIT
EXCESSIVE COMPR SURGE 238->Compressor Surge: Check con-
denser water temp and flow
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 con-
denser 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.
239 PROTECTIVE LIMIT
TRANSDUCER VOLTAGE FAULT 239->Transducer Voltage Ref [VALUE]
exceeded limit of [LIMIT]*.
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. Con-
firm TRANSDUCER VOLTAGE REF by measuring
voltage across a CCM Pressure Transducer (e.g.
CCM J2-1 to J2-3). Check TRANSDUCER VOLT-
AGE REF after temporarily disconnecting chiller
from CCN and disconnecting field wiring from
CCM terminal blocks J5 and J8. This fault is nor-
mally 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.
105
Table 16 ICVC Primary and Secondary Messages and
Custom Alarm/Alert Messages with Troubleshooting Guides (cont)
I. CHILLER PROTECTIVE LIMIT FAULTS (cont)
*[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 mes-
sages may mean the value is above or below a threshold.
ICVC
FAULT
STATE
PRIMARY MESSAGE SECONDARY MESSAGE PRIMARY CAUSE
ADDITIONAL
CAUSE/REMEDY
240 PROTECTIVE LIMIT
LOW DISCHARGE SUPERHEAT 240->Check for Oil in Refrigerant or
Overcharge of Refrigerant.
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 car-
ryover into the compressor. The refrigerant level in
the evaporator may be too low resulting in ineffec-
tive oil reclaim at low loads. If the chiller is over-
charged, the oil reclaim may be recovering below
the oil rich mixture on the top of the cooler refriger-
ant 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 DIS-
CHARGE TEMP sensor to CCM J4-17 and J4-18.
241
LOSS OF
COMMUNICATION
WITH STARTER MODULE 241->Loss of Communication With
Starter.
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.
242
LOSS OF
COMMUNICATION
WITH CCM MODULE 242->Loss of Communication With
CCM.
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.
243
POTENTIAL FREEZE-
UP
EVAP PRESS/TEMP TOO LOW 243->Evaporator Refrig Temp [VALUE]
exceeded limit of [LIMIT]*.
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 tempera-
ture. 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 sen-
sor. Check for evaporator waterbox division plate
gasket bypass. Check for fouled tubes.
244
POTENTIAL FREEZE-
UP
COND PRESS/TEMP TOO LOW 244->Condenser Refrig Temp [VALUE]
exceeded limit of [LIMIT]*.
Chiller is in Pumpdown/Lockout and the CON-
DENSER REFRIG TEMP is less than the CON-
DENSER 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 Tempera-
ture sensors and wiring to CCM J4. Check refriger-
ant charge.
245 PROTECTIVE LIMIT
HIGH VFD SPEED 245->Actual VFD Speed exceeded limit
of Target VFD Speed + 10%.
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.
246 PROTECTIVE LIMIT
INVALID DIFFUSER CONFIG 246->Diffuser Control Invalid Configura-
tion: Check SETUP2 Entries
Check 23%, 50%, and 75% Guide Vane and Dif-
fuser Load Point entries in SETUP2 screen
against Diffuser Schedule Settings Label on the
back of the Control Panel cover.
247 PROTECTIVE LIMIT
DIFFUSER POSITION FAULT 247->Diffuser Position Fault: Check
Guide Vane and Diffuser Actuators
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 wir-
ing. 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.
106
Table 16 ICVC Primary and Secondary Messages and
Custom Alarm/Alert Messages with Troubleshooting Guides (cont)
I. CHILLER PROTECTIVE LIMIT FAULTS (cont)
*[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 mes-
sages may mean the value is above or below a threshold.
J. CHILLER ALERTS
*[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 mes-
sages may mean the value is above or below a threshold.
ICVC
FAULT
STATE
PRIMARY MESSAGE SECONDARY MESSAGE PRIMARY CAUSE
ADDITIONAL
CAUSE/REMEDY
248 PROTECTIVE LIMIT
SPARE TEMPERATURE #1 248->Spare Temperature #1 [VALUE]
exceeded limit of [LIMIT]*.
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 TEM-
PERATURE #1 wiring to CCM J4-25 and J4-26.
249 PROTECTIVE LIMIT
SPARE TEMPERATURE #2 249->Spare Temperature #2 [VALUE]
exceeded limit of [LIMIT]*.
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 TEM-
PERATURE #2 wiring to CCM J4-27 and J4-28.
250 PROTECTIVE LIMIT
REFRIGERANT LEAK SENSOR 250->Refrigerant Leak Sensor [VALUE]
exceeded limit of [LIMIT]*
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.
251 PROTECTIVE LIMIT
ISM CONFIG CONFLICT 251->ISM Config Conflict; Verify and
Save ISM Config Data to Reset
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 CAN-
CEL. Next, re-enter the ISM_CONF screen a sec-
ond 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 set-
tings in both the ICVC and ISM.
252 Not Used Not Used 252->Not Used
253 PROTECTIVE LIMIT
GUIDE VANE CALIBRATION 253->Guide Vane Fault [VALUE]. Check
Calibration
Alarm before start indicates guide vane opening
has not closed to less than 4%. Alarm while run-
ning 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 CON-
TROL 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 feed-
back potentiometer.
254 PROTECTIVE LIMIT
HIGH COND WATER FLOW 254->High Flow: Condenser Water Delta
P Limit (VALUE) exceeded limit of
[LIMIT]*
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 Pres-
sure 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 dis-
connected, grounded, or shorted wiring. If con-
denser 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.
STATE PRIMARY
MESSAGE
SECONDARY
MESSAGE
PRIMARY CAUSE ADDITIONAL
CAUSE/REMEDY
140 SENSOR ALERT
LEAVING COND
WATER TEMP
140->Sensor Fault: Check Leav-
ing Cond Water Sensor
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 sen-
sor leads.
141 SENSOR ALERT
ENTERING
COND WATER
TEMP
141->Sensor Fault: Check Enter-
ing Cond Water Sensor
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 sen-
sor leads.
142
LOW OIL
PRESSURE
ALERT
CHECK OIL FIL-
TER
142->Low Oil Pressure Alert.
Check Oil Filter
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.
107
Table 16 ICVC Primary and Secondary Messages and
Custom Alarm/Alert Messages with Troubleshooting Guides (cont)
J. CHILLER ALERTS (cont)
*[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.
STATE PRIMARY
MESSAGE
SECONDARY
MESSAGE
PRIMARY CAUSE ADDITIONAL
CAUSE/REMEDY
143
AUTORESTART
PENDING
LINE PHASE
LOSS
143->Line Current Loss; Check
ISM Fault History to Identify Phase
Any LINE VOLTAGE < 50% MOTOR RATED LINE VOLTAGE or there is
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 trans-
former 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 poten-
tial transformers and VOLT TRANSFORMER RATIO in ISM_CONF
screen.
144
AUTORESTART
PENDING
LINE VOLTAGE
DROPOUT
144->Single Cycle Line Voltage
Dropout
Temporary loss of voltage. SINGLE CYCLE DROPOUT and AUTORE-
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
AUTORESTART
PENDING
HIGH LINE VOLT-
AGE
145>High Average Line voltage
[VALUE]
High LINE VOLTAGE for an excessive amount of time. Check LINE
VOLTAGE in ISM_HIST screen. AUTORESTART OPTION is Enabled,
chiller is automatically restarting. Check MOTOR RATED LINE VOLT-
AGE and OVERVOLTAGE THRESHOLD in ISM_CONF screen. Check
phase to phase and phase to ground line power. Consult power com-
pany. Medium voltage applications only: Check voltage potential trans-
formers and VOLT TRANSFORMER RATIO in ISM_CONF screen.
Check wiring to ISM J3-VL1, J3-VL2 and J3-VL3.
146
AUTORESTART
PENDING
LOW LINE VOLT-
AGE
146->Low Average Line voltage
[VALUE]
Low LINE VOLTAGE for an excessive amount of time. AUTORESTART
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 poten-
tial transformers and VOLT TRANSFORMER RATIO in ISM_CONF
screen. Check wiring to ISM J3-VL1, J3-VL2 and J3-VL3.
147
AUTORESTART
PENDING
STARTER MOD-
ULE RESET
147->Starter Module Power-On
Reset When Running
AUTORESTART OPTION in OPTIONS screen is enabled and there was
a temporary loss of 115 V ISM control voltage supply. Chiller will auto-
matically restart when power is restored within acceptable limits. Check
ISM_HIST screen. Check wiring leading to ISM terminals J1-LL1 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.
148
AUTORESTART
PENDING
POWER LOSS 148->Control Power-Loss When
Running
AUTO RESTART OPTION in OPTIONS screen is Enabled and there was
a temporary loss of 24 VAC power to the ICVC. The chiller will automati-
cally 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 SENSOR ALERT
HIGH DIS-
CHARGE TEMP
149->Comp Discharge Temp
[VALUE] Exceeded Limit of
[LIMIT]*
Check for proper inlet guide vane and optional diffuser actuator opera-
tion. Check COMP DISCHARGE ALERT threshold. Check for proper
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 actua-
tor operation. Check for fouled tubes, plugged water strainers, or non-
condensibles in the chiller.
150 SENSOR ALERT
HIGH BEARING
TEMPERATURE
150->Comp Thrust Brg Temp
[VALUE] exceeded limit of [LIMIT]*
Check oil heater for proper operation, confirm that oil heater is de-ener-
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
CONDENSER
PRESSURE
ALERT
PUMP RELAY
ENERGIZED
151->High Condenser Pressure
[VALUE]: Pump Energized to
Reduce Pressure.
Check for high Condenser Water temperatures, low water flow, fouled
tubes. Check CONDENSER PRESSURE OVERRIDE threshold. Check
for division plate/gasket bypass or plugged condenser water strainers.
Check for noncondensables in condenser. Check CONDENSER PRES-
SURE transducer wiring and accuracy to CCM J2-4 through J2-6. This
Alert is not caused by the High Pressure Switch.
152 RECYCLE ALERT
EXCESSIVE
RECYCLE
STARTS
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
no message:
ALERT only
no message;
ALERT only
153->Lead/Lag Disabled: Dupli-
cate Chiller Address; Check Con-
figuration
Illegal chiller address configuration in LEADLAG screen. Lead chiller, lag
chiller, and optional standby chiller must all be on the same bus but they
must all be assigned a different address in the ICVC CONFIGURATION
screen.
108
Table 16 ICVC Primary and Secondary Messages and
Custom Alarm/Alert Messages with Troubleshooting Guides (cont)
J. CHILLER ALERTS (cont)
*[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.
STATE PRIMARY
MESSAGE
SECONDARY
MESSAGE
PRIMARY CAUSE ADDITIONAL
CAUSE/REMEDY
154
POTENTIAL
FREEZE-UP
COND PRESS/
TEMP TOO LOW
154->Condenser freeze up preven-
tion
The chiller is not in Pumpdown Mode and the CONDENSER REFRIG
TEMP is less than the CONDENSER FREEZE POINT. The CON-
DENSER 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 PRES-
SURE transducer and wiring to CCM J2-4 through J2-6. Check Con-
denser 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 F in cooler so
equalization temperature in chiller approached 32 F.
155
OPTION SENSOR
FAULT
REMOTE RESET
SENSOR
155->Sensor Fault/Option Dis-
abled: Remote Reset Sensor
Type 2 Temperature Reset is Enabled and Remote Temperature Reset
sensor is out of range. Check ENABLE RESET TYPE and TEMPERA-
TURE RESET settings in TEMP_CNTL screen. Check Remote Temper-
ature Reset sensor resistance or voltage drop.
Check for proper wiring to CCM J4-13 and J4-14.
156
OPTION SENSOR
FAULT
AUTO CHILLED
WATER RESET
156->Sensor Fault/Option Dis-
abled: Auto Chilled Water Reset
Type 1 Temperature Reset is Enabled and 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. Con-
firm that wiring to CCM J5-3 and J5-4 is not grounded.
157
OPTION SENSOR
FAULT
AUTO DEMAND
LIMIT INPUT
157->Sensor Fault/Option Dis-
abled: Auto Demand Limit Input
20mA DEMAND LIMIT OPT is Enabled, Ice Build is not Active, and Auto
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.
158 SENSOR ALERT
SPARE TEMPER-
ATURE #1
158->Spare Temperature #1
[VALUE] exceeded limit of [LIMIT].*
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.
159 SENSOR ALERT
SPARE TEMPER-
ATURE #2
159->Spare Temperature #2
[VALUE] exceeded limit of [LIMIT].*
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.
160 Not Used Not Used 160->Not Used
161
LOSS OF
COMMUNICATION
WITH WSM 161->WSM Cool Source - Loss of
Communication
Check settings in WSMDEFME screen. Check CCN communications link
with WSM (Water System Manager) Module. Check Supervisory Part of
WSM.
162 SENSOR ALERT
EVAPORATOR
APPROACH
162->Evaporator Approach
[VALUE] Exceeded Limit of
[LIMIT}*
Check EVAP APPROACH ALERT setting in SETUP1 screen. Check
Evaporator Water Flow. Check EVAP REFRIG LIQUID TEMP and LEAV-
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 Iso-
lation 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.
163
SENSOR ALERT
CONDENSER
APPROACH
163->Condenser Approach
[VALUE] Exceeded Limit of
[LIMIT]*
Check COND APPROACH ALERT setting in SETUP1 screen. Check
Condenser Water Flow. Check CONDENSER PRESSURE transducer
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-conden-
sibles 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.
164
VFD SPEED
ALERT
LOW VFD
SPEED
164->Actual VFD Speed exceeded
limit of Target VFD Speed -10%
ACTUAL VFD SPEED in COMPRESS screen must be at least 90% of
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 configura-
tion parameters, jumpers, and dip switch settings.
165
MACHINE ALERT
HIGH COND
WATER FLOW
165->High Flow: Condenser Water
Delta P [VALUE] Exceeded Limit of
[LIMIT]*
COND HI FLOW ALARM OPT is disabled and CONDENSER WATER
DELTA P has exceeded configured limit. Check FLOW DELTA P DIS-
PLAY and COND HI FLOW DEL P LIMIT in SETUP1 screen. Check
optional condenser water pressure transducer wiring and accuracy. Con-
firm 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 wir-
ing. If pressure transducers are not installed, check for presence of resis-
tors and jumpers CCM terminals J3-19 through J3-24. See Chiller
Controls Schematic if flow switches are used.
109
Table 16 ICVC Primary and Secondary Messages and
Custom Alarm/Alert Messages with Troubleshooting Guides (cont)
K. ISM ALARMS
*[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.
ICVC
FAULT
STATE
PRIMARY MESSAGE SECONDARY MESSAGE PRIMARY CAUSE
ADDITIONAL
CAUSE/REMEDY
200 PROTECTIVE LIMIT
1M CONTACT FAULT 200->1M Aux Contact Fault; Check 1M
Contactor and Aux
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. Wye-
Delta Starters: Check for failed or incomplete tran-
sition. Check S-2M mechanical interlock operation.
201 PROTECTIVE LIMIT
2M CONTACT FAULT 201->2M Aux Contact Fault; Check 2M
Contactor and Aux
2M aux contact closure was delayed after 1M has
closed. Confirm starter 2M aux contact closes fol-
lowing 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.
202 PROTECTIVE LIMIT
MOTOR AMPS NOT SENSED 202->Motor Amps Not Sensed Aver-
age Line Current [VALUE]
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 ter-
minals. Check if main circuit breaker has tripped.
Check ISM_HIST screen
203 FAILURE TO START
EXCESS ACCELERATION TIME 203->Motor Acceleration Fault - Average
Line Current [VALUE]
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.
204 FAILURE TO STOP
1M/2M CONTACT FAULT 204->1M/2M Aux Contact Stop Fault;
Check 1M/2M Contactors and Aux
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.
205 FAILURE TO STOP
MOTOR AMPS WHEN
STOPPED
205->Motor Amps When Stopped -
Average Line Current [VALUE]
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-ener-
gizes 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.
206 PROTECTIVE LIMIT
STARTER FAULT 206->Starter Fault Cutout; Check
Optional Starter Contacts
The ISM has received a start command and the
starter has declared a Fault. The dry contacts con-
nected 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 transi-
tion.
207 PROTECTIVE LIMIT
HIGH CONDENSER PRESSURE 207->High Cond Pressure Cutout.
[VALUE] exceeded limit of [LIMIT]*
Check Compressor Discharge High Pressure
switch wiring and accuracy. Check for high con-
denser 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 com-
mand. 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 con-
tact and High Pressure Switch. Check the 24V cir-
cuit leading from power panel terminals 17 and 43
leading to the High Pressure Relay coil and base.
208 PROTECTIVE LIMIT
EXCESSIVE MOTOR AMPS 208->Average Line Current [VALUE]
exceeded limit of [LIMIT]*.
AVERAGE LINE CURRENT > 110% for an exces-
sive 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.
110
Table 16 ICVC Primary and Secondary Messages and
Custom Alarm/Alert Messages with Troubleshooting Guides (cont)
K. ISM ALARMS (cont)
*[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.
ICVC
FAULT
STATE
PRIMARY MESSAGE SECONDARY MESSAGE PRIMARY CAUSE
ADDITIONAL
CAUSE/REMEDY
209 PROTECTIVE LIMIT
LINE PHASE LOSS 209->Line Phase Loss; Check ISM Fault
History to Identify Phase
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.
210 PROTECTIVE LIMIT
LINE VOLTAGE DROPOUT 210->Single Cycle Line Voltage Dropout 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.
211 PROTECTIVE LIMIT
HIGH LINE VOLTAGE 211->High Average Line Voltage
[VALUE]
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.
212 PROTECTIVE LIMIT
LOW LINE VOLTAGE 212->Low Average Line Voltage
[VALUE]
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 connec-
tions to ISM terminal block J3. Consult power com-
pany. Medium voltage applications only: Check
voltage potential transformers and VOLT TRANS-
FORMER RATIO in ISM_CONF screen. Check
wiring to ISM J3-VL1, J3-VL2 and J3-VL3.
213 PROTECTIVE LIMIT
STARTER MODULE RESET 213->Starter Module Power-On Reset
When Running
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 J1-
LL1 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.
214 PROTECTIVE LIMIT
POWER LOSS 214->Control Power - Loss When Run-
ning
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 J1-
5 . Check CB1 circuit breaker in the control panel.
Check phase to phase and phase to ground distri-
bution bus voltage. Monitor chiller utility power for
disruptions. Consult power company.
215 PROTECTIVE LIMIT
LINE CURRENT IMBALANCE 215->Line Current Imbalance;Check
ISM Fault History to Identify Phase
Current imbalance > CURRENT % IMBALANCE
for greater than the CURRENT IMBALANCE
TIME. Check settings in ISM_CONF screen.
Check ISM_HIST screen. Check current trans-
former 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 imbal-
ance may improve if power or motor leads are
rotated in the same phase sequence.
216 PROTECTIVE LIMIT
LINE VOLTAGE IMBALANCE 216->Line Voltage Imbalance; Check
ISM Fault History to Identify Phase.
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 lead-
ing 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.
111
Table 16 ICVC Primary and Secondary Messages and
Custom Alarm/Alert Messages with Troubleshooting Guides (cont)
K. ISM ALARMS (cont)
*[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 mes-
sages may mean the value is above or below a threshold.
ICVC
FAULT
STATE
PRIMARY MESSAGE SECONDARY MESSAGE PRIMARY CAUSE
ADDITIONAL
CAUSE/REMEDY
217 PROTECTIVE LIMIT
MOTOR OVERLOAD TRIP 217->Motor Overload Trip; Check ISM
Configurations
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.
218 PROTECTIVE LIMIT
MOTOR LOCKED ROTOR TRIP 218->Motor Locked Rotor Amps
Exceeded;Check Motor and ISM Config
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 distur-
bances.
219 PROTECTIVE LIMIT
STARTER LOCK ROTOR TRIP 219->Starter Locked Rotor Amps Rating
Exceeded
Any LINE CURRENT > STARTER LRA RATING.
Check STARTER LRA RATING and MOTOR CUR-
RENT CT RATIO in ISM_CONF screen. Check
ISM_HIST screen. Check starter label data. Check
motor wiring and motor winding resistance.
220 PROTECTIVE LIMIT
GROUND FAULT 220->Ground Fault Trip; Check Motor
and Current Transformers
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 cor-
rect and that the correct motor leads have been
routed through the ground fault current transform-
ers 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.
221 PROTECTIVE LIMIT
PHASE REVERSAL TRIP 221-> Phase Reversal Trip; Check
Power Supply
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.
222 PROTECTIVE LIMIT
LINE FREQUENCY TRIP 222->Line Frequency - [VALUE]
exceeded limit of [LIMIT]*; Check Power
Supply.
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 fre-
quency. If operating from a generator, check gen-
erator size and speed.
223 PROTECTIVE LIMIT
STARTER MODULE FAILURE 223->Starter Module Hardware Failure 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. Con-
firm that excessive voltage has not been improp-
erly applied to any of the ISM terminals before
installing replacement ISM.
224 PROTECTIVE LIMIT
1CR START CIRCUIT FAULT 224->Check 115v Wiring to 1CR (ISM)
and to 1M Coil
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.
112
Table 17A Thermistor Temperature (F) vs. Resistance/Voltage Drop
TEMPERATURE
(F)
PIC II
VOLTAGE
DROP (V)
RESISTANCE
(Ohms)
25 4.700 97,706
24 4.690 94,549
23 4.680 91,474
22 4.670 88,480
21 4.659 85,568
20 4.648 82,737
19 4.637 79,988
18 4.625 77,320
17 4.613 74,734
16 4.601 72,229
15 4.588 69,806
14 4.576 67,465
13 4.562 65,205
12 4.549 63,027
11 4.535 60,930
10 4.521 58,915
9 4.507 56,981
8 4.492 55,129
7 4.477 53,358
6 4.461 51,669
5 4.446 50,062
4 4.429 48,536
3 4.413 47,007
2 4.396 45,528
1 4.379 44,098
0 4.361 42,715
1 4.344 41,380
2 4.325 40,089
3 4.307 38,843
4 4.288 37,639
5 4.269 36,476
6 4.249 35,354
7 4.229 34,270
8 4.209 33,224
9 4.188 32,214
10 4.167 31,239
11 4.145 30,298
12 4.123 29,389
13 4.101 28,511
14 4.079 27,663
15 4.056 26,844
16 4.033 26,052
17 4.009 25,285
18 3.985 24,544
19 3.960 23,826
20 3.936 23,130
21 3.911 22,455
22 3.886 21,800
23 3.861 21,163
24 3.835 20,556
25 3.808 19,967
26 3.782 19,396
27 3.755 18,843
28 3.727 18,307
29 3.700 17,787
30 3.672 17,284
31 3.644 16,797
32 3.617 16,325
33 3.588 15,868
34 3.559 15,426
35 3.530 14,997
36 3.501 14,582
37 3.471 14,181
38 3.442 13,791
39 3.412 13,415
40 3.382 13,050
41 3.353 12,696
42 3.322 12,353
43 3.291 12,021
44 3.260 11,699
45 3.229 11,386
46 3.198 11,082
47 3.167 10,787
48 3.135 10,500
49 3.104 10,221
50 3.074 9,949
51 3.042 9,689
52 3.010 9,436
53 2.978 9,190
54 2.946 8,951
55 2.914 8,719
56 2.882 8,494
57 2.850 8,275
58 2.819 8,062
59 2.788 7,855
60 2.756 7,655
61 2.724 7,460
62 2.692 7,271
63 2.660 7,088
64 2.628 6,909
65 2.596 6,736
TEMPERATURE
(F)
PIC II
VOLTAGE
DROP (V)
RESISTANCE
(Ohms)
66 2.565 6,568
67 2.533 6,405
68 2.503 6,246
69 2.472 6,092
70 2.440 5,942
71 2.409 5,796
72 2.378 5,655
73 2.347 5,517
74 2.317 5,382
75 2.287 5,252
76 2.256 5,124
77 2.227 5,000
78 2.197 4,880
79 2.167 4,764
80 2.137 4,650
81 2.108 4,539
82 2.079 4,432
83 2.050 4,327
84 2.021 4,225
85 1.993 4,125
86 1.965 4,028
87 1.937 3,934
88 1.909 3,843
89 1.881 3,753
90 1.854 3,667
91 1.827 3,582
92 1.800 3,500
93 1.773 3,420
94 1.747 3,342
95 1.721 3,266
96 1.695 3,192
97 1.670 3,120
98 1.644 3,049
99 1.619 2,981
100 1.595 2,914
101 1.570 2,849
102 1.546 2,786
103 1.523 2,724
104 1.499 2,663
105 1.476 2,605
106 1.453 2,547
107 1.430 2,492
108 1.408 2,437
109 1.386 2,384
110 1.364 2,332
111 1.343 2,282
112 1.321 2,232
113 1.300 2,184
114 1.279 2,137
115 1.259 2,092
116 1.239 2,047
117 1.219 2,003
118 1.200 1,961
119 1.180 1,920
120 1.161 1,879
121 1.143 1,840
122 1.124 1,801
123 1.106 1,764
124 1.088 1,727
125 1.070 1,691
126 1.053 1,656
127 1.036 1,622
128 1.019 1,589
129 1.002 1,556
130 0.986 1,524
131 0.969 1,493
132 0.953 1,463
133 0.938 1,433
134 0.922 1,404
135 0.907 1,376
136 0.893 1,348
137 0.878 1,321
138 0.864 1,295
139 0.849 1,269
140 0.835 1,244
141 0.821 1,219
142 0.808 1,195
143 0.795 1,172
144 0.782 1,149
145 0.769 1,126
146 0.756 1,104
147 0.744 1,083
148 0.731 1,062
149 0.719 1,041
150 0.707 1,021
151 0.696 1,002
152 0.684 983
153 0.673 964
154 0.662 945
155 0.651 928
156 0.640 910
TEMPERATURE
(F)
PIC II
VOLTAGE
DROP (V)
RESISTANCE
(Ohms)
157 0.630 893
158 0.619 876
159 0.609 859
160 0.599 843
161 0.589 827
162 0.579 812
163 0.570 797
164 0.561 782
165 0.551 768
166 0.542 753
167 0.533 740
168 0.524 726
169 0.516 713
170 0.508 700
171 0.499 687
172 0.491 675
173 0.484 663
174 0.476 651
175 0.468 639
176 0.460 628
177 0.453 616
178 0.445 605
179 0.438 595
180 0.431 584
181 0.424 574
182 0.418 564
183 0.411 554
184 0.404 544
185 0.398 535
186 0.392 526
187 0.385 516
188 0.379 508
189 0.373 499
190 0.367 490
191 0.361 482
192 0.356 474
193 0.350 466
194 0.344 458
195 0.339 450
196 0.333 442
197 0.328 435
198 0.323 428
199 0.318 421
200 0.313 414
201 0.308 407
202 0.304 400
203 0.299 393
204 0.294 387
205 0.290 381
206 0.285 374
207 0.281 368
208 0.277 362
209 0.272 356
210 0.268 351
211 0.264 345
212 0.260 339
213 0.256 334
214 0.252 329
215 0.248 323
216 0.245 318
217 0.241 313
218 0.237 308
219 0.234 303
220 0.230 299
221 0.227 294
222 0.224 289
223 0.220 285
224 0.217 280
225 0.214 276
226 0.211 272
227 0.208 267
228 0.205 263
229 0.203 259
230 0.198 255
231 0.195 251
232 0.192 248
233 0.190 244
234 0.187 240
235 0.184 236
236 0.182 233
237 0.179 229
238 0.176 226
239 0.174 223
240 0.172 219
241 0.169 216
242 0.167 213
243 0.164 210
244 0.162 207
245 0.160 204
246 0.158 201
247 0.155 198
248 0.153 195
113
Table 17B Thermistor Temperature (C) vs. Resistance/Voltage Drop
TEMPERATURE
(C)
PIC II
VOLTAGE
DROP (V)
RESISTANCE
(Ohms)
33 4.722 105 616
32 4.706 99 640
31 4.688 93 928
30 4.670 88 480
29 4.650 83 297
28 4.630 78 377
27 4.608 73 722
26 4.586 69 332
25 4.562 65 205
24 4.538 61 343
23 4.512 57 745
22 4.486 54 411
21 4.458 51 341
20 4.429 48 536
19 4.399 45 819
18 4.368 43 263
17 4.336 40 858
16 4.303 38 598
15 4.269 36 476
14 4.233 34 484
13 4.196 32 613
12 4.158 30 858
11 4.119 29 211
10 4.079 27 663
9 4.037 26 208
8 3.994 24 838
7 3.951 23 545
6 3.906 22 323
5 3.861 21 163
4 3.814 20 083
3 3.765 19 062
2 3.716 18 097
1 3.667 17 185
0 3.617 16 325
1 3.565 15 513
2 3.512 14 747
3 3.459 14 023
4 3.406 13 341
5 3.353 12 696
6 3.298 12 087
7 3.242 11 510
8 3.185 10 963
9 3.129 10 444
10 3.074 9 949
11 3.016 9 486
12 2.959 9 046
13 2.901 8 628
14 2.844 8 232
15 2.788 7 855
16 2.730 7 499
17 2.672 7 160
18 2.615 6 839
19 2.559 6 535
20 2.503 6 246
21 2.447 5 972
22 2.391 5 711
23 2.335 5 463
24 2.280 5 226
25 2.227 5 000
26 2.173 4 787
27 2.120 4 583
28 2.067 4 389
29 2.015 4 204
30 1.965 4 028
31 1.914 3 861
32 1.865 3 701
33 1.816 3 549
34 1.768 3 404
35 1.721 3 266
36 1.675 3 134
37 1.629 3 008
38 1.585 2 888
39 1.542 2 773
40 1.499 2 663
41 1.457 2 559
42 1.417 2 459
43 1.377 2 363
TEMPERATURE
(C)
PIC III
VOLTAGE
DROP (V)
RESISTANCE
(Ohms)
44 1.338 2 272
45 1.300 2 184
46 1.263 2 101
47 1.227 2 021
48 1.192 1 944
49 1.158 1 871
50 1.124 1 801
51 1.091 1 734
52 1.060 1 670
53 1.029 1 609
54 0.999 1 550
55 0.969 1 493
56 0.941 1 439
57 0.913 1 387
58 0.887 1 337
59 0.861 1 290
60 0.835 1 244
61 0.811 1 200
62 0.787 1 158
63 0.764 1 117
64 0.741 1 079
65 0.719 1 041
66 0.698 1 006
67 0.677 971
68 0.657 938
69 0.638 906
70 0.619 876
71 0.601 846
72 0.583 818
73 0.566 791
74 0.549 765
75 0.533 740
76 0.518 715
77 0.503 692
78 0.488 670
79 0.474 648
80 0.460 628
81 0.447 608
82 0.434 588
83 0.422 570
84 0.410 552
85 0.398 535
86 0.387 518
87 0.376 502
88 0.365 487
89 0.355 472
90 0.344 458
91 0.335 444
92 0.325 431
93 0.316 418
94 0.308 405
95 0.299 393
96 0.291 382
97 0.283 371
98 0.275 360
99 0.267 349
100 0.260 339
101 0.253 330
102 0.246 320
103 0.239 311
104 0.233 302
105 0.227 294
106 0.221 286
107 0.215 278
108 0.210 270
109 0.205 262
110 0.198 255
111 0.193 248
112 0.188 242
113 0.183 235
114 0.178 229
115 0.174 223
116 0.170 217
117 0.165 211
118 0.161 205
119 0.157 200
120 0.153 195
114
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).
See Fig. 2 and 3 for sensor locations. The sensors are im-
mersed directly in the refrigerant or water circuits. When in-
stalling 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 pro-
vides additional protection against a loss of water flow.
DUAL TEMPERATURE SENSORS For servicing con-
venience, 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 sec-
ond sensor, move the wire from the number 1 position to the
number 3 position.
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 loca-
tions, 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 oc-
curs. 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 VOLT-
AGE 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 re-
move refrigerant from the vessel when replacing the transduc-
ers. Disconnect the transducer wiring. Do not pull on the trans-
ducer 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.
COOLER AND CONDENSER PRESSURE TRANS-
DUCER AND OPTIONAL WATERSIDE FLOW DEVICE
CALIBRATION Calibration can be checked by comparing
the pressure readings from the transducer to an accurate refrig-
eration gage reading. These readings can be viewed or cali-
brated 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 transduc-
er in place.
NOTE: If the cooler or condenser vessels are at
0 psig (0 kPa) or are open to atmospheric pressure, the
transducers can be calibrated for zero without remov-
ing the transducer from the vessel.
3. Access the HEAT_EX 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
softkey while the appropriate transducer parameter is
highlighted on the ICVC screen. Then press the
softkey. The value will now go to zero. No high end
calibration is necessary for OIL PRESSURE DELTA P or
flow devices.
If the transducer value is not within the calibration
range, the transducer returns to the original reading. If
the pressure is within the allowed range (noted above),
check the voltage ratio of the transducer. To obtain the
voltage ratio, divide the voltage (dc) input from the
transducer by the TRANSDUCER VOLTAGE REF
supply voltage signal (displayed in CONTROL TEST
menu in the PRESSURE TRANSDUCERS screen) or
measure across the positive (+ red) and negative
( black) leads of the transducer. For example, the
condenser transducer voltage reference is measured
at CCM terminals J2-4 and J2-6, the condenser trans-
ducer voltage input. The input to reference voltage
ratio must be between 0.80 and 0.11 for the software to
allow calibration. Pressurize the transducer until the
ratio is within range. Then attempt calibration again.
4. A high pressure point can also be calibrated between 25
and 250 psig (172.4 and 1723.7 kPa) by attaching a regu-
lated 250 psig (1724 kPa) pressure (usually from a
nitrogen cylinder). The high pressure point can be
calibrated by accessing the appropriate transducer param-
eter on the HEAT_EX screen, highlighting the parameter,
pressing the softkey, and then using the
or softkeys to adjust the
value to the exact pressure on the refrigerant gage. Press
the 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 in-
stalled and re-calibrated. If calibration problems are encoun-
tered on the OIL PRESSURE DELTA P channel, sometimes
swapping the compressor oil discharge pressure transducer and
the oil sump pressure transducer will offset an adverse trans-
ducer tolerance stack up and allow the calibration to proceed.
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.
SELECT
ENTER
SELECT
INCREASE DECREASE
ENTER
115
Control Algorithms Checkout Procedure One
of the tables on the ICVC SERVICE menu is CONTROL AL-
GORITHM 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 de-
termine how the control temperature is calculated and guide
vane positioned and for observing the reactions from load
changes, control point overrides, hot gas bypass, surge preven-
tion, etc. The tables are:
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. Dur-
ing pumpdown operations, the pumps are energized to prevent
freeze-up and the vessel pressures and temperatures are dis-
played. The Pumpdown/Lockout feature prevents compressor
start-up when there is no refrigerant in the chiller or if the ves-
sels are isolated. The Terminate Lockout feature ends the
Pumpdown/Lockout after the pumpdown procedure is reversed
and refrigerant is added.
Control Modules
The ICVC and CCM modules perform continuous diagnos-
tic evaluations of the hardware to determine its condition.
Proper operation of all modules is indicated by LEDs (light-
emitting diodes) located on the circuit board of the ICVC and
CCM.
There is one green 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
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 dis-
covered and the module must be replaced
If there is no input power, check the fuses and circuit break-
er. 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 con-
troller and the network modules and should blink continuously.
Notes on Module Operation
1. The chiller operator monitors and modifies configura-
tions in the microprocessor by using the 4 softkeys and
the ICVC. Communications between the 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 communica-
tion wiring. If a green LED is off, check the red LED op-
eration. If the red LED is normal, check the module ad-
dress switches (SW1) (Fig. 54 and 55). Confirm all
switches are in OFF position.
All system operating intelligence resides in the ICVC.
Outputs are controlled by the CCM as well.
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.
Chiller Control Module (CCM) (Fig. 55)
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 out-
put. Refer to the chiller wiring diagram for your specific appli-
cation for the correct terminal numbers.
Integrated Starter Module (Fig. 56)
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 indi-
vidual 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.
CAPACITY Capacity
Control
This table shows all values used
to calculate the chilled water/brine
control point.
OVERRIDE Override
Status
Details of all chilled water control
override values.
SURG_PREV Surge/
HGBP
Status
The surge and hot gas bypass
control algorithm status is viewed
from this screen. All
values dealing with this control
are displayed.
HEAT_EX Heat
Exchanger
Points
Status
All sensor inputs and calculated
values related to the heat
Exchangers. Also some of the
surge control points are shown.
LL_MAINT LEAD/LAG
Status
Indicates LEAD/LAG operation
status.
OCCDEFCM Time
Schedules
Status
The Local and CCN occupied
schedules are displayed here to
help the operator quickly deter-
mine whether the schedule is in
the occupied mode or not.
WSMDEFME Water
System
Manager
Status
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 sys-
tem.
ISM_HIST ISM Alarm
History
Displays ISM values at last fault.
LOADSHED Loadshed
Status
Displays Loadshed (Demand
Limit) status.
CUR_ALARM Current
Alarm Status
Displays current chiller alarms.
SURGPREV Surge Pre-
vention Sta-
tus
Displays all information used or
supplied by the surge prevention
algorithm.
CAUTION
Turn controller power off before servicing controls. This
ensures safety and prevents damage to the controller.
116
CCN INTERFACE
CONNECTION
SW1 BACK OF CVC
MODULE PART NUMBER
SOFTWARE PART NUMBER
J7 SIO J1 POWER/
CCN
J8 SERVICE
ICVC
Fig. 54 Rear of ICVC (International Chiller Visual Controller)
a19-1868
117
STAT COMM THERMISTORS
J4
DIFF PRESSURE
J3
PRESSURE
J2
SW2 (V/I
CONFIGURATION
DIP SWITCH)
V/I INPUTS
J5
SIO
J7
ANALOG OUT
J8
J11
DISCRETE
OUTPUTS
J12
DISCRETE
OUTPUTS
J1
24 VAC
SIO
J6
SW1 (S10 ADDRESS
DIP SWITCH)
SET ALL TO OFF
Fig. 55 Chiller Control Module (CCM)
a19-1869
118
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 73.
INSTALLATION
1. Verify the existing ICVC module is defective by using the
procedure described in the Troubleshooting Guide sec-
tion, page 97, and the Control Modules section, page 115.
Do not select the ATTACH TO NETWORK DEVICE ta-
ble 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 sec-
tion. If the module to be replaced is functional, configura-
tions may also be copied manually. The data sheets on
pages CL-3 through CL-12 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 avail-
able, the module configuration should have already been
uploaded into memory. When the new module is in-
stalled, 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 net-
work device.
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 con-
figuration values. (Refer to pages CL-3 through CL-12.)
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 ON-
TIME. 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 96 and 97). Check that the CURRENT
TIME and DATE in the TIME AND DATE screen are
correct.
Solid-State Starters Troubleshooting information per-
taining 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.
115 VAC
LL1 LL2 1A
CONTACT INPUTS
SPAR ICE REM STRT 1M 2M
SFTY BLD STRT FLT AUX AUX
FUSE LINE VOLTAGES
L1 L2 L3 IL1
LINE CURRENTS
GROUND
FAULTS
IL2 IL3 1/4 2/5 3/6
VFD
HZ
INTEGRATED STARTER MODULE
I
N
T
E
R
G
R
A
T
E
D

S
T
A
R
T
E
R

M
O
D
U
L
E
1A
J1 1
1 + C + C + C + C + C + C
J2
J3-1 J3-2 J3-3
J4
1 + - + - + -
J5
1 + G + G + G + G
1
J6
S T A T C O M
-
J 7
- G +
1
G + G +
J 8
1
J 9
1
C O M M
C B A
4 - 2 0 M A O U T
S P A R E V F D
T R I P
A L A R M
H I
F A N
L O
F A N
C O N D
P U M P
E V A P
P U M P
S H U N T
T R I P
D I S C R E T E C O N T R O L C O N T A C T S
T R A N S 1 C R
R
W
A
R
N
I
N
G
H
I
G
H

V
O
L
T
A
G
E
D
I
S
C
O
N
N
E
C
T

P
O
W
E
R

B
E
F
O
R
E

S
E
R
V
I
C
I
N
G
I
S
M

1
9
X
R
0
4
0
1
2
2
0
1

9
9
2
5
C
E
P
L
1
3
0
2
5
9
0
1

P
C
B
0
5
C
E
P
P
1
3
0
1
7
3
-
0
3
-
0
4
-
0
1
0
0
0
0
1
3
2
8
W
A
R
N
I
N
G
H
I
G
H

V
O
L
T
A
G
E
D
I
S
C
O
N
N
E
C
T

P
O
W
E
R

B
E
F
O
R
E

S
E
R
V
I
C
I
N
G
Fig. 56 Integrated Starter Module (ISM)
CAUTION
Electrical shock can cause personal injury. Disconnect all
electrical power before servicing.
119
Attempt to solve the problem by using the following prelim-
inary checks before consulting the troubleshooting tables found
in the Benshaw manual.
With power off:
Inspect for physical damage and signs of arcing, over-
heating, 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 nor-
mally. If after completing Steps 4 - 11 resistance measure-
ments 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 re-
sistance measurements are being influenced by the motor
windings.
4. Remove power from the starter unit.
5. Using an ohmmeter, perform the following resistance
measurements and record the results:
If all measured values are greater than 5000 ohms, pro-
ceed to Step 10. If any values are less than 5000 ohms,
one or more of the SCRs in that pair is shorted.
6. Remove both SCRs in the pair (See SCR Removal/
Installation).
7. 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.
8. Replace the defective SCR(s).
9. Retest the pair for resistance values indicated above.
10. 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.
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 re-
placement SCR. This allows for improved heat dissipa-
tion and electrical conductivity.
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. 57.
5. Tighten the bolts equally in
1
/
8
turn increments until the
indicator washer(s), which are under the nut(s) in the cen-
ter of the loader bar becomes loose indicating that the
clamp is tight. See Fig. 57. On the loader bars with two
indicator washers, it may be necessary to tighten or loos-
en 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.
Physical Data Tables 18A-25 and Fig. 58-70 provide
additional information on component weights, compressor fits
and clearances, physical and electrical data, and wiring sche-
matics for the operators convenience during troubleshooting.
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.
MEASURE
BETWEEN
SCR PAIRS
BEING
CHECKED
RECORDED
VALUE
T1 and T6 3 and 6
T2 and T4 2 and 5
T3 and T5 1 and 4
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.
LOADER BAR
INDICATOR
WASHER (S)
BOLTS
Fig. 57 SCR Installation
a19-
1884
120
Table 18A 19XR,XRV Heat Exchanger Weights Drive End Entering Cooler Water
*Rigging weights are for standard tubes of standard wall thickness (0.025-in.
[0.635 mm] wall).
Heat exchanger frame sizes 1 through 6 available on single-stage chillers
only.
NOTES:
1. Cooler includes the control panel (ICVC), suction elbow, and
1
/
2
the distri-
bution 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.
5. For E compressor, add 1054 lb (478 kg) steel weight and 283 lb (128 kg)
refrigerant weight for economizer assembly.
Code
English Metric (SI)
Dry Rigging Weight
(lb)*
Machine Charge
Dry Rigging Weight
(kg)*
Machine Charge
Cooler
Only
Condenser
Only
Refrigerant
Weight (lb)
Water Weight
(lb)
Cooler
Only
Condenser
Only
Refrigerant
Weight (kg)
Water Weight
(kg)
Cooler Condenser Cooler Condenser Cooler Condenser Cooler Condenser
10 2707 2704 328 226 283 348 1229 1228 149 103 128 158
11 2777 2772 357 226 309 374 1261 1258 162 103 140 170
12 2848 2857 387 226 335 407 1293 1297 176 103 152 185
15 2968 2984 405 275 327 402 1346 1355 184 125 148 183
16 3054 3068 441 275 359 435 1387 1393 200 125 163 197
17 3141 3173 477 275 391 475 1426 1441 217 125 178 216
20 3407 3373 416 252 402 398 1547 1531 189 114 183 181
21 3555 3540 459 252 456 462 1614 1607 208 114 207 210
22 3711 3704 505 252 514 526 1685 1682 229 114 233 239
30 4071 3694 510 308 464 464 1848 1677 232 140 211 211
31 4253 3899 565 308 531 543 1931 1770 257 140 241 247
32 4445 4100 626 308 601 621 2018 1861 284 140 273 282
35 4343 4606 577 349 511 513 1972 2091 262 158 232 233
36 4551 4840 639 349 587 603 2066 2197 290 158 266 274
37 4769 5069 709 349 667 692 2165 2301 322 158 303 314
40 4908 5039 726 338 863 915 2228 2288 330 153 392 415
41 5078 5232 783 338 930 995 2305 2375 355 153 422 452
42 5226 5424 840 338 990 1074 2373 2462 381 153 449 488
45 5363 5602 821 383 938 998 2435 2543 373 174 426 453
46 5559 5824 874 383 1014 1088 2524 2644 397 174 460 494
47 5730 6044 949 383 1083 1179 2601 2744 431 174 492 535
50 5713 6090 897 446 1101 1225 2594 2765 407 202 500 556
51 5940 6283 974 446 1192 1304 2697 2852 442 202 541 592
52 6083 6464 1021 446 1248 1379 2762 2935 464 202 567 626
53 6141 6529 1010 446 1277 1409 2788 2964 459 202 580 640
54 6192 6591 987 446 1302 1439 2811 2992 448 202 591 653
55 6257 6785 1014 504 1201 1339 2841 3080 460 229 545 608
56 6517 7007 1101 504 1304 1429 2959 3181 500 229 592 649
57 6682 7215 1154 504 1369 1514 3034 3276 524 229 622 687
58 6751 7291 1143 504 1401 1550 3065 3310 519 229 636 704
59 6811 7363 1116 504 1430 1583 3092 3343 507 229 649 719
5A 5124 491 1023 2326 223 464
5B 5177 510 1050 2350 232 477
5C 5243 532 1079 2380 242 490
5F 5577 553 1113 2532 251 505
5G 5640 575 1143 2561 261 519
5H 5716 600 1176 2595 272 534
5K 4993 673 1067 2267 306 484
5L 5090 706 1118 2311 321 508
5M 5165 742 1162 2345 337 528
5P 5041 641 1111 2289 291 504
5Q 5131 678 1155 2329 308 524
5R 5214 709 1206 2367 322 548
5T 5425 768 1162 2463 349 528
5U 5534 801 1220 2512 364 554
5V 5620 843 1270 2551 383 577
5X 5484 730 1212 2490 331 550
5Y 5584 769 1262 2535 349 573
5Z 5678 805 1320 2578 365 599
60 6719 6764 1091 479 1400 1521 3050 3071 495 217 636 691
61 6895 6949 1150 479 1470 1597 3130 3155 522 217 667 725
62 7038 7130 1202 479 1527 1671 3195 3237 546 217 693 759
63 7103 7199 1202 479 1559 1704 3225 3268 546 217 708 774
64 7161 7264 1178 479 1587 1735 3251 3298 535 217 720 788
65 7392 6782 1241 542 1530 1667 3356 3079 563 246 695 757
66 7594 7894 1309 542 1610 1753 3448 3584 594 246 731 796
67 7759 8102 1369 542 1674 1838 3523 3678 622 246 760 834
68 7836 8182 1359 542 1711 1875 3558 3715 617 246 777 851
69 7905 8258 1332 542 1743 1911 3589 3749 605 246 791 868
121
Table 18A 19XR,XRV Heat Exchanger Weights Drive End Entering Cooler Water (cont)
*Rigging weights are for standard tubes of standard wall thickness (0.025-in.
[0.635 mm] wall).
Heat exchanger frame sizes 1 through 6 available on single-stage chillers
only.
NOTES:
1. Cooler includes the control panel (ICVC), suction elbow, and
1
/
2
the distri-
bution 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.
5. For E compressor, add 1054 lb (478 kg) steel weight and 283 lb (128 kg)
refrigerant weight for economizer assembly.
Code
English Metric (SI)
Dry Rigging Weight
(lb)*
Machine Charge
Dry Rigging Weight
(kg)*
Machine Charge
Cooler
Only
Condenser
Only
Refrigerant
Weight (lb)
Water Weight
(lb)
Cooler
Only
Condenser
Only
Refrigerant
Weight (kg)
Water Weight
(kg)
Cooler Condenser Cooler Condenser Cooler Condenser Cooler Condenser
6K 5716 760 1291 2595 345 586
6L 5804 797 1341 2635 362 609
6M 5894 828 1399 2676 376 635
6P 5768 725 1338 2619 329 607
6Q 5852 764 1385 2657 347 629
6R 5938 798 1439 2696 362 653
6T 6230 863 1405 2828 392 638
6U 6330 905 1462 2874 411 664
6V 6433 941 1528 2921 427 694
6X 6293 823 1459 2857 374 662
6Y 6388 868 1512 2900 394 686
6Z 6487 906 1574 2945 411 715
70 9942 10786 1409 840 2008 2225 4514 4897 640 381 912 1010
71 10330 11211 1539 840 2164 2389 4690 5090 699 381 982 1085
72 10632 11622 1646 840 2286 2548 4827 5276 747 381 1038 1157
73 10715 11737 1622 840 2328 2604 4865 5329 736 381 1057 1182
74 10790 11775 1584 840 2366 2622 4899 5346 719 381 1074 1190
75 10840 11859 1599 950 2183 2431 4921 5384 726 431 991 1104
76 11289 12345 1747 950 2361 2619 5125 5605 793 431 1072 1189
77 11638 12814 1869 950 2501 2801 5284 5818 849 431 1135 1272
78 11738 12949 1849 950 2548 2864 5329 5879 839 431 1157 1300
79 11828 12994 1806 950 2592 2885 5370 5899 820 431 1177 1310
7K 8728 1047 1948 3963 475 884
7L 8959 1132 2094 4067 514 951
7M 9161 1214 2229 4159 551 1012
7P 8792 1002 2010 3992 455 913
7Q 9023 1087 2156 4096 493 979
7R 9229 1167 2295 4190 530 1042
7T 9431 1194 2115 4282 542 960
7U 9698 1292 2282 4403 587 1036
7V 9932 1403 2436 4509 637 1106
7X 9510 1142 2185 4318 518 992
7Y 9777 1240 2352 4439 563 1068
7Z 10016 1347 2511 4547 612 1140
80 12664 12753 1700 836 2726 2977 5749 5790 772 380 1238 1352
81 12998 13149 1812 836 2863 3143 5901 5970 823 380 1300 1427
82 13347 13545 1928 836 3005 3309 6060 6149 875 380 1364 1502
83 13437 13872 1877 836 3053 3476 6100 6298 852 380 1386 1578
84 13523 14217 1840 836 3099 3651 6139 6455 835 380 1407 1658
85 13804 14008 1927 945 2951 3238 6267 6360 875 429 1340 1470
86 14191 14465 2054 945 3108 3428 6443 6567 933 429 1411 1556
87 14597 14923 2186 945 3271 3618 6627 6775 992 429 1485 1643
88 14705 15311 2142 945 3325 3608 6676 6951 972 429 1510 1638
89 14808 15721 2099 945 3378 4009 6723 7137 953 429 1534 1820
8K 11153 1385 2760 5063 629 1253
8L 11400 1484 2926 5176 674 1328
8M 11650 1589 3088 5289 721 1402
8P 11219 1334 2830 5093 606 1285
8Q 11470 1430 2999 5207 649 1362
8R 11719 1535 3161 5320 697 1435
8T 12069 1580 2991 5479 717 1358
8U 12357 1694 3180 5610 769 1444
8V 12645 1814 3365 5741 824 1528
8X 12152 1522 3070 5517 691 1394
8Y 12444 1632 3264 5650 741 1482
8Z 12733 1752 3448 5781 795 1565
122
Table 18B 19XR,XRV Heat Exchanger Weights Compressor End Entering Cooler Water
*Rigging weights are for standard tubes of standard wall thickness (0.025-in.
[0.635 mm] wall).
Heat exchanger frame sizes 1 through 6 available on single-stage chillers
only.
NOTES:
1. Cooler includes the control panel (ICVC), suction elbow, and
1
/
2
the distri-
bution 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.
5. For E compressor, add 1054 lb (478 kg) steel weight and 283 lb (128 kg)
refrigerant weight for economizer assembly.
Code
English Metric (SI)
Dry Rigging Weight
(lb)*
Machine Charge
Dry Rigging Weight
(kg)*
Machine Charge
Cooler
Only
Condenser
Only
Refrigerant
Weight (lb)
Water Weight
(lb)
Cooler
Only
Condenser
Only
Refrigerant
Weight (kg)
Water Weight
(kg)
Cooler Condenser Cooler Condenser Cooler Condenser Cooler Condenser
10 2707 2704 290 200 283 348 1228 1227 132 91 128 158
11 2777 2772 310 200 309 374 1260 1257 141 91 140 170
12 2848 2857 330 200 335 407 1292 1296 150 91 152 185
15 2968 2984 320 250 327 402 1346 1354 145 113 148 182
16 3054 3068 340 250 359 435 1385 1392 154 113 163 197
17 3141 3173 370 250 391 475 1425 1439 168 113 177 215
20 3407 3373 345 225 402 398 1545 1530 156 102 182 181
21 3555 3540 385 225 456 462 1613 1606 175 102 207 210
22 3711 3704 435 225 514 526 1683 1680 197 102 233 239
30 4071 3694 350 260 464 464 1847 1676 159 118 210 210
31 4253 3899 420 260 531 543 1929 1769 191 118 241 246
32 4445 4100 490 260 601 621 2016 1860 222 118 273 282
35 4343 4606 400 310 511 513 1970 2089 181 141 232 233
36 4551 4840 480 310 587 603 2064 2195 218 141 266 274
37 4769 5069 550 310 667 692 2163 2299 249 141 303 314
40 4908 5039 560 338 863 915 2226 2286 254 153 391 415
41 5078 5232 630 338 930 995 2303 2373 286 153 422 451
42 5226 5424 690 338 990 1074 2370 2460 313 153 449 487
45 5363 5602 640 383 938 998 2433 2541 290 174 425 453
46 5559 5824 720 383 1014 1088 2522 2642 327 174 460 494
47 5730 6044 790 383 1083 1179 2599 2742 358 174 491 535
50 5713 6090 750 446 1101 1225 2591 2762 340 202 499 556
51 5940 6283 840 446 1192 1304 2694 2850 381 202 541 591
52 6083 6464 900 446 1248 1379 2759 2932 408 202 566 626
53 6141 6529 900 446 1277 1409 2788 2964 408 202 580 640
54 6192 6591 900 446 1302 1439 2811 2992 408 202 591 653
55 6257 6785 870 509 1201 1339 2838 3078 395 231 545 607
56 6517 7007 940 509 1304 1429 2956 3178 426 231 591 648
57 6682 7215 980 509 1369 1514 3031 3273 445 231 621 687
58 6751 7291 980 509 1401 1550 3065 3310 445 231 636 704
59 6811 7363 980 509 1430 1583 3092 3343 445 231 649 719
5A 5124 500 1023 2324 227 464
5B 5177 520 1050 2348 236 476
5C 5243 550 1079 2378 249 489
5F 5577 550 1113 2530 249 505
5G 5640 570 1143 2558 259 518
5H 5716 600 1176 2593 272 533
5K 4993 673 1067 2267 306 484
5L 5090 706 1118 2311 321 508
5M 5165 742 1162 2345 337 528
5P 5041 641 1111 2289 291 504
5Q 5131 678 1155 2329 308 524
5R 5214 709 1206 2367 322 548
5T 5425 768 1162 2463 349 528
5U 5534 801 1220 2512 364 554
5V 5620 843 1270 2551 383 577
5X 5484 730 1212 2490 331 550
5Y 5584 769 1262 2535 349 573
5Z 5678 805 1320 2578 365 599
60 6719 6764 940 479 1400 1521 3048 3068 426 217 635 690
61 6895 6949 980 479 1470 1597 3128 3152 445 217 667 724
62 7038 7130 1020 479 1527 1671 3192 3234 463 217 693 758
63 7103 7199 1020 479 1559 1704 3225 3268 463 217 708 773
64 7161 7264 1020 479 1587 1735 3251 3298 463 217 720 788
65 7392 7682 1020 542 1530 1667 3353 3484 463 246 694 756
66 7594 7894 1060 542 1610 1753 3445 3581 481 246 730 795
67 7759 8102 1090 542 1674 1838 3519 3675 494 246 759 834
68 7836 8182 1090 542 1711 1875 3558 3715 494 246 777 851
69 7905 8258 1090 542 1743 1911 3589 3749 494 246 791 868
123
Table 18B 19XR,XRV Heat Exchanger Weights Compressor End Entering Cooler Water (cont)
*Rigging weights are for standard tubes of standard wall thickness (0.025-in.
[0.635 mm] wall).
Heat exchanger frame sizes 1 through 6 available on single-stage chillers
only.
NOTES:
1. Cooler includes the control panel (ICVC), suction elbow, and
1
/
2
the distri-
bution 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.
5. For E compressor, add 1054 lb (478 kg) steel weight and 283 lb (128 kg)
refrigerant weight for economizer assembly.
Code
English Metric (SI)
Dry Rigging Weight
(lb)*
Machine Charge
Dry Rigging Weight
(kg)*
Machine Charge
Cooler
Only
Condenser
Only
Refrigerant
Weight (lb)
Water Weight
(lb)
Cooler
Only
Condenser
Only
Refrigerant
Weight (kg)
Water Weight
(kg)
Cooler Condenser Cooler Condenser Cooler Condenser Cooler Condenser
6K 5716 760 1291 2595 345 586
6L 5804 797 1341 2635 362 609
6M 5894 828 1399 2676 376 635
6P 5768 725 1338 2619 329 607
6Q 5852 764 1385 2657 347 629
6R 5938 798 1439 2696 362 653
6T 6230 863 1405 2828 392 638
6U 6330 905 1462 2874 411 664
6V 6433 941 1528 2921 427 694
6X 6293 823 1459 2857 374 662
6Y 6388 868 1512 2900 394 686
6Z 6487 906 1574 2945 411 715
70 9942 10786 1220 840 2008 2225 4510 4893 553 381 911 1009
71 10330 11211 1340 840 2164 2389 4686 5085 608 381 982 1084
72 10632 11622 1440 840 2286 2548 4823 5278 653 381 1037 1156
73 10715 11737 1440 840 2328 2604 4865 5329 654 381 1057 1182
74 10790 11775 1440 840 2366 2622 4899 5346 654 381 1074 1190
75 10840 11859 1365 950 2183 2431 4917 5379 619 431 990 1103
76 11289 12345 1505 950 2361 2619 5121 5600 683 431 1071 1188
77 11638 12814 1625 950 2501 2801 5279 5812 737 431 1134 1271
78 11738 12949 1625 950 2548 2864 5329 5879 738 431 1157 1300
79 11828 12994 1625 950 2592 2885 5370 5899 738 431 1177 1310
7K 8728 1047 1948 3963 475 884
7L 8959 1132 2094 4067 514 951
7M 9161 1214 2229 4159 551 1012
7P 8792 1002 2010 3992 455 913
7Q 9023 1087 2156 4096 493 979
7R 9229 1167 2295 4190 530 1042
7T 9431 1194 2115 4282 542 960
7U 9698 1292 2282 4403 587 1036
7V 9932 1403 2436 4509 637 1106
7X 9510 1142 2185 4318 518 992
7Y 9777 1240 2352 4439 563 1068
7Z 10016 1347 2511 4547 612 1140
80 12664 12753 1500 836 2726 2977 5744 5785 680 379 1236 1350
81 12998 13149 1620 836 2863 3143 5896 5964 735 379 1299 1426
82 13347 13545 1730 836 3005 3309 6054 6144 785 379 1363 1501
83 13437 13872 1730 836 3053 3476 6100 6298 785 379 1386 1578
84 13523 14217 1730 836 3099 3651 6139 6455 785 379 1407 1658
85 13804 14008 1690 945 2951 3238 6261 6354 767 429 1339 1469
86 14191 14465 1820 945 3108 3428 6437 6561 826 429 1410 1555
87 14597 14923 1940 945 3271 3618 6621 6769 880 429 1484 1641
88 14705 15311 1940 945 3325 3808 6676 6951 881 429 1510 1729
89 14808 15721 1940 945 3378 4009 6723 7137 881 429 1534 1820
8K 11153 1385 2760 5063 629 1253
8L 11400 1484 2926 5176 674 1328
8M 11650 1589 3088 5289 721 1402
8P 11219 1334 2830 5093 606 1285
8Q 11470 1430 2999 5207 649 1362
8R 11719 1535 3161 5320 697 1435
8T 12069 1580 2991 5479 717 1358
8U 12357 1694 3180 5610 769 1444
8V 12645 1814 3365 5741 824 1528
8X 12152 1522 3070 5517 691 1394
8Y 12444 1632 3264 5650 741 1482
8Z 12733 1752 3448 5781 795 1565
124
Table 19 19XR,XRV Additional Data for Marine Waterboxes*
*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).
HEAT EXCHANGER
FRAME, PASS
ENGLISH SI
psig
Rigging Weight (lb) Water Volume (gal)
kPa
Rigging Weight (kg) Water Volume (L)
Cooler Condenser Cooler Condenser Cooler Condenser Cooler Condenser
FRAME 2, 1 AND 3 PASS
150
730 84
1034
331 318
FRAME 2, 2 PASS 365 365 42 42 166 166 159 159
FRAME 3, 1 AND 3 PASS 730 84 331 318
FRAME 3, 2 PASS 365 365 42 42 166 166 159 159
FRAME 4, 1 AND 3 PASS 1888 109 856 412
FRAME 4, 2 PASS 944 989 54 54 428 449 205 205
FRAME 5, 1 AND 3 PASS 2445 122 1109 462
FRAME 5, 2 PASS 1223 1195 61 60 555 542 231 226
FRAME 6, 1 AND 3 PASS 2860 139 1297 524
FRAME 6, 2 PASS 1430 1443 69 69 649 655 262 262
FRAME 7, 1 AND 3 PASS 3970 309 1801 1170
FRAME 7, 2 PASS 1720 1561 155 123 780 708 585 465
FRAME 8, 1 AND 3 PASS 5048 364 2290 1376
FRAME 8, 2 PASS 2182 1751 182 141 990 794 688 532
FRAME 2, 1 AND 3 PASS
300
860 84
2068
390 318
FRAME 2, 2 PASS 430 430 42 42 195 195 159 159
FRAME 3, 1 AND 3 PASS 860 84 390 318
FRAME 3, 2 PASS 430 430 42 42 195 195 159 159
FRAME 4, 1 AND 3 PASS 2162 109 981 412
FRAME 4, 2 PASS 1552 1641 47 47 704 744 178 178
FRAME 5, 1 AND 3 PASS 2655 122 1204 462
FRAME 5, 2 PASS 1965 1909 53 50 891 866 199 190
FRAME 6, 1 AND 3 PASS 3330 139 1510 524
FRAME 6, 2 PASS 2425 2451 58 58 1100 1112 218 218
FRAME 7, 1 AND 3 PASS 5294 309 2401 1170
FRAME 7, 2 PASS 4140 4652 146 94 1878 2110 553 356
FRAME 8, 1 AND 3 PASS 6222 364 2822 1376
FRAME 8, 2 PASS 4952 4559 161 94 2246 2068 609 355
125
Table 20 19XR,XRV Compressor Weights
*Transmission weight does not include rotor, shaft, and gear.
For two-stage compressors (Frame E) there are two impellers.
Weight listed is for each one.
NOTE: The weights indicated do not include motor, stator, rotor, low
speed shaft, motor case, motor end cover, or any other related com-
ponents. See Tables 21A-21E.
Table 21A 19XR,XRV Compressor and Motor Weights* Standard and High-Efficiency Motors
Compressor Frame Size 2
*Total compressor weight is the sum of the compressor aerody-
namic components (compressor weight column), stator, rotor, and
end bell cover weights.
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.
COMPONENT
FRAME 2
COMPRESSOR
WEIGHT
FRAME 3
COMPRESSOR
WEIGHT
FRAME 4
COMPRESSOR
WEIGHT
(Without Split
Ring Diffuser)
FRAME 4
COMPRESSOR
WEIGHT
(With Split
Ring Diffuser)
FRAME 5
COMPRESSOR
WEIGHT
FRAME E
COMPRESSOR
WEIGHT
lb kg lb kg lb kg lb kg lb kg lb kg
SUCTION ELBOW 116 53 185 84 239 108 239 108 407 185 645 293
DISCHARGE ELBOW 100 45 125 57 157 71 157 71 325 147 290 132
TRANSMISSION* 320 145 400 181 656 298 656 298 1000 454 961 436
SUCTION HOUSING 370 168 400 181 585 265 810 367 1200 544 531 241
IMPELLER SHROUD 35 16 79 36 126 57 200 91 500 227 N/A N/A
COMPRESSOR BASE 1260 572 1565 710 1589 721 2020 916 3700 1678 2491 1130
DIFFUSER 35 16 67 30 130 59 130 59 350 159 N/A N/A
OIL PUMP 125 57 150 68 150 68 150 68 185 84 125 57
HIGH SPEED SHAFT
ASSEMBLY
15 7 12 5 30 14 30 14 65 29 94 43
IMPELLER 5 2 8 4 15 7 15 7 50 23
10
(avg)
5
(avg)
INTAKE WALL 89 40
DISCHARGE WALL 85 39
DIAPHRAGM 87 39
MISCELLANEOUS
(Incl. Low Speed Gear)
135 61 135 61 144 65 200 91 235 107 390 177
TOTAL COMPRESSOR
WEIGHT
(Less Motor and Elbows)
2300 1043 2816 1277 3425 1553 4211 1910 7285 3304 4873 2212
MOTOR
CODE
ENGLISH SI
Compressor
Weight**
(lb)
60 Hz 50 Hz
End Bell
Cover
Weight
(lb)
Compressor
Weight**
(kg)
60 Hz 50 Hz
End Bell
Cover
Weight
(kg)
Stator
Weight
(lb)
Rotor
Weight
(lb)
Stator
Weight
(lb)
Rotor
Weight
(lb)
Stator
Weight
(kg)
Rotor
Weight
(kg)
Stator
Weight
(kg)
Rotor
Weight
(kg)
STANDARD-EFFICIENCY MOTORS / LOW VOLTAGE (200-575 v)
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 (200-575 v)
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
126
Table 21B 19XR,XRV Compressor and Motor Weights* Standard and High-Efficiency Motors
Compressor Frame Size 3
*Total compressor weight is the sum of the compressor aerody-
namic components (compressor weight column), stator, rotor, and
end bell cover weights.
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.
MOTOR
CODE
ENGLISH SI
Compressor
Weight**
(lb)
60 Hz 50 Hz
End Bell
Cover
Weight
(lb)
Compressor
Weight**
(kg)
60 Hz 50 Hz
End Bell
Cover
Weight
(kg)
Stator
Weight
(lb)
Rotor
Weight
(lb)
Stator
Weight
(lb)
Rotor
Weight
(lb)
Stator
Weight
(kg)
Rotor
Weight
(kg)
Stator
Weight
(kg)
Rotor
Weight
(kg)
STANDARD-EFFICIENCY MOTORS / LOW VOLTAGE (200-575 v)
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 1277 571 146 124
CRS
(380v)
2816 1328 346 274 1277 602 157 124
STANDARD-EFFICIENCY MOTORS / MEDIUM VOLTAGE (2400-4160 v)
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 (200-575 v)
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
127
Table 21B 19XR,XRV Compressor and Motor Weights* Standard and High-Efficiency Motors
Compressor Frame Size 3 (cont)
*Total compressor weight is the sum of the compressor aerody-
namic components (compressor weight column), stator, rotor, and
end bell cover weights.
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.
MOTOR
CODE
ENGLISH SI
Compressor
Weight**
(lb)
60 Hz 50 Hz
End Bell
Cover
Weight
(lb)
Compressor
Weight**
(kg)
60 Hz 50 Hz
End Bell
Cover
Weight
(kg)
Stator
Weight
(lb)
Rotor
Weight
(lb)
Stator
Weight
(lb)
Rotor
Weight
(lb)
Stator
Weight
(kg)
Rotor
Weight
(kg)
Stator
Weight
(kg)
Rotor
Weight
(kg)
HIGH-EFFICIENCY MOTORS / MEDIUM VOLTAGE (2400-4160 v)
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
128
Table 21C 19XR,XRV Compressor and Motor Weights* Standard and High-Efficiency Motors
Compressor Frame Size 4
*Total compressor weight is the sum of the compressor aerody-
namic components (compressor weight column), stator, rotor, and
end bell cover weights.
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.
MOTOR
CODE
ENGLISH SI
Compressor
Weight**
(lb)
Fixed Ring/
Split Ring
60 Hz 50 Hz
End Bell
Cover
Weight
(lb)
Compressor
Weight**
(kg)
60 Hz 50 Hz
End Bell
Cover
Weight
(kg)
Stator
Weight
(lb)
Rotor
Weight
(lb)
Stator
Weight
(lb)
Rotor
Weight
(lb)
Stator
Weight
(kg)
Rotor
Weight
(kg)
Stator
Weight
(kg)
Rotor
Weight
(kg)
STANDARD-EFFICIENCY MOTORS / LOW VOLTAGE (200-575 v)
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 (2400-4160 v)
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 381 236 1554 / 1910 760 157 821 173 107
DGS 3425 / 4211 1704 355 1998 422
236 (60 Hz)
318 (50 Hz)
1554 / 1910 773 161 906 191
107 (60 Hz)
142 (50 Hz)
DHS 3425 / 4211 1737 361 2056 443
236 (60 Hz)
318 (50 Hz)
1554 / 1910 788 164 933 201
107 (60 Hz)
142 (50 Hz)
DJS 3425 / 4211 1769 365 2101 464
236 (60 Hz)
318 (50 Hz)
1554 / 1910 802 166 953 210
107 (60 Hz)
142 (50 Hz)
STANDARD-EFFICIENCY MOTORS / MEDIUM VOLTAGE (6300-6900 v)
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 (200-575 v)
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
129
Table 21C 19XR,XRV Compressor and Motor Weights* Standard and High-Efficiency Motors
Compressor Frame Size 4 (cont)
*Total compressor weight is the sum of the compressor aerody-
namic 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.
MOTOR
CODE
ENGLISH SI
Compressor
Weight**
(lb)
60 Hz 50 Hz
End Bell
Cover
Weight
(lb)
Compressor
Weight**
(kg)
60 Hz 50 Hz
End Bell
Cover
Weight
(kg)
Stator
Weight
(lb)
Rotor
Weight
(lb)
Stator
Weight
(lb)
Rotor
Weight
(lb)
Stator
Weight
(kg)
Rotor
Weight
(kg)
Stator
Weight
(kg)
Rotor
Weight
(kg)
HIGH-EFFICIENCY MOTORS / LOW VOLTAGE (200-575v)
LBH 3425 / 4211 1873 364 1939 389 318 1554 / 1910 850 165 880 176 144
LCH 3425 / 4211 1939 389 2023 406 318 1554 / 1910 880 176 918 184 144
LDH 3425 / 4211 2023 406 2043 417 318 1554 / 1910 918 184 927 189 144
LEH 3425 / 4211 2043 417 2096 434 318 1554 / 1910 927 189 951 197 144
LFH 3425 / 4211 2096 434 2133 444 318 1554 / 1910 951 197 968 201 144
LGH 3425 / 4211 2133 444 2199 458 318 1554 / 1910 968 201 997 208 144
LHH 3425 / 4211 2199 458 2066 437 318 1554 / 1910 997 208 937 198 144
HIGH-EFFICIENCY MOTORS / MEDIUM VOLTAGE (2400-4160v)
DBH 3425 / 4211 1950 405 1950 405 318 1554 / 1910 885 184 885 184 144
DCH 3425 / 4211 1950 405 2025 429 318 1554 / 1910 885 184 919 195 144
DDH 3425 / 4211 1950 405 2025 429 318 1554 / 1910 885 184 919 195 144
DEH 3425 / 4211 2025 429 2100 452 318 1554 / 1910 919 195 953 205 144
DFH 3425 / 4211 2025 429 2100 452 318 1554 / 1910 919 195 953 205 144
DGH 3425 / 4211 2100 452 2200 480 318 1554 / 1910 953 205 998 218 144
DHH 3425 / 4211 2100 452 2320 575 318 1554 / 1910 953 205 1052 261 144
DJH 3425 / 4211 2100 452 2320 587 318 1554 / 1910 953 205 1052 266 144
DKH 3425 / 4211 2320 587 318 1554 / 1910 1052 266 144
HIGH-EFFICIENCY MOTORS / MEDIUM VOLTAGE (6300-6900v)
DDH 3425 / 4211 2150 536 2250 546 318 1554 / 1910 975 243 1021 248 144
DEH 3425 / 4211 2150 550 2250 550 318 1554 / 1910 975 249 1021 249 144
DFH 3425 / 4211 2250 575 2380 567 318 1554 / 1910 1021 261 1080 261 144
DGH 3425 / 4211 2250 599 2380 599 318 1554 / 1910 1021 272 1080 272 144
DHH 3425 / 4211 2380 604 2380 604 318 1554 / 1910 1080 274 1080 274 144
DJH 3425 / 4211 2380 614 2380 614 318 1554 / 1910 1080 279 1080 279 144
DKH 3425 / 4211 2380 614 318 1554 / 1910 1080 279 144
130
Table 21D 19XR,XRV Compressor and Motor Weights* Standard and High-Efficiency Motors
Compressor Frame Size 5
*Total compressor weight is the sum of the compressor aerody-
namic components (compressor weight column), stator, rotor, and
end bell cover weights.
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.
MOTOR
CODE
ENGLISH SI
Compressor
Weight**
(lb)
60 Hz 50 Hz
End Bell
Cover
Weight
(lb)
Compressor
Weight**
(kg)
60 Hz 50 Hz
End Bell
Cover
Weight
(kg)
Stator
Weight
(lb)
Rotor
Weight
(lb)
Stator
Weight
(lb)
Rotor
Weight
(lb)
Stator
Weight
(kg)
Rotor
Weight
(kg)
Stator
Weight
(kg)
Rotor
Weight
(kg)
STANDARD-EFFICIENCY MOTORS / LOW VOLTAGE (200-575 v)
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 (2400-4160 v)
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
EQS 7285 3081 872 414 3304 1398 396 188
STANDARD-EFFICIENCY MOTORS / MEDIUM VOLTAGE (6300-6900 v)
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 (200-575 v)
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
131
Table 21D 19XR,XRV Compressor and Motor Weights* Standard and High-Efficiency Motors
Compressor Frame Size 5 (cont)
*Total compressor weight is the sum of the compressor aerody-
namic components (compressor weight column), stator, rotor, and
end bell cover weights.
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.
MOTOR
CODE
ENGLISH SI
Compressor
Weight**
(lb)
60 Hz 50 Hz
End Bell
Cover
Weight
(lb)
Compressor
Weight**
(kg)
60 Hz 50 Hz
End Bell
Cover
Weight
(kg)
Stator
Weight
(lb)
Rotor
Weight
(lb)
Stator
Weight
(lb)
Rotor
Weight
(lb)
Stator
Weight
(kg)
Rotor
Weight
(kg)
Stator
Weight
(kg)
Rotor
Weight
(kg)
HIGH-EFFICIENCY MOTORS / LOW VOLTAGE (200-575 v)
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 (2400-4160 v)
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 (6300-6900 v)
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 (10000-11000 v)
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
HIGH-EFFICIENCY MOTORS / HIGH VOLTAGE (13800 v)
MHH 7285 3779 646 414 3304 1714 293 188
132
Table 21E 19XR,XRV Compressor and Motor Weights* Standard and High-Efficiency Motors
Compressor Frame Size E
*Total compressor weight is the sum of the compressor aerody-
namic components (compressor weight column), stator, rotor, and
end bell cover weights.
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.
MOTOR
CODE
ENGLISH SI
Compressor
Weight**
(lb)
60 Hz 50 Hz
End Bell
Cover
Weight
(lb)
Compressor
Weight**
(kg)
60 Hz 50 Hz
End Bell
Cover
Weight
(kg)
Stator
Weight
(lb)
Rotor
Weight
(lb)
Stator
Weight
(lb)
Rotor
Weight
(lb)
Stator
Weight
(kg)
Rotor
Weight
(kg)
Stator
Weight
(kg)
Rotor
Weight
(kg)
STANDARD-EFFICIENCY MOTORS / LOW VOLTAGE (380-575 v)
6H 4873 2843 741 2943 775 414 2212 1290 336 1335 352 188
6J 4873 2826 741 2943 775 414 2212 1281 336 1335 352 188
6K 4873 2943 775 2997 810 414 2212 1335 352 1359 367 188
6L 4873 2932 775 2997 810 414 2212 1330 352 1359 367 188
6M 4873 2986 810 3096 862 414 2212 1354 367 1404 391 188
6N 4873 2986 810 3203 914 414 2212 1354 367 1453 415 188
6P 4873 2986 810 3203 914 414 2212 1354 367 1453 415 188
STANDARD-EFFICIENCY MOTORS / MEDIUM VOLTAGE (2400-4160 v)
6H 4873 2744 706 2818 741 414 2212 1245 320 1278 336 188
6J 4873 2816 741 2892 775 414 2212 1277 336 1312 352 188
6K 4873 2816 741 2930 775 414 2212 1277 336 1329 352 188
6L 4873 2808 741 3005 810 414 2212 1274 336 1363 367 188
6M 4873 2892 775 3005 810 414 2212 1322 352 1363 367 188
6N 4873 2997 775 3143 879 414 2212 1359 352 1426 399 188
6P 4873 2967 810 3144 879 414 2212 1346 367 1426 399 188
6Q 4873 3081 872 414 2212 1398 396 188
HIGH-EFFICIENCY MOTORS / LOW VOLTAGE (380-460 v)
EH 4873 2939 776 2995 810 414 2212 1333 352 1359 367 188
EJ 4873 2944 776 3002 810 414 2212 1335 352 1362 367 188
EK 4873 2992 810 3110 862 414 2212 1357 367 1411 391 188
EL 4873 2299 810 3099 862 414 2212 1043 367 1406 391 188
EM 4873 2965 810 3210 914 414 2212 1345 367 1456 415 188
EN 4873 3015 855 3293 974 414 2212 1368 388 1494 442 188
EP 4873 3029 855 3289 974 414 2212 1374 388 1492 442 188
133
Table 21E 19XR,XRV Compressor and Motor Weights* Standard and High-Efficiency Motors
Compressor Frame Size E (cont)
*Total compressor weight is the sum of the compressor aerody-
namic components (compressor weight column), stator, rotor, and
end bell cover weights.
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.
MOTOR
CODE
ENGLISH SI
Compressor
Weight**
(lb)
60 Hz 50 Hz
End Bell
Cover
Weight
(lb)
Compressor
Weight**
(kg)
60 Hz 50 Hz
End Bell
Cover
Weight
(kg)
Stator
Weight
(lb)
Rotor
Weight
(lb)
Stator
Weight
(lb)
Rotor
Weight
(lb)
Stator
Weight
(kg)
Rotor
Weight
(kg)
Stator
Weight
(kg)
Rotor
Weight
(kg)
HIGH-EFFICIENCY MOTORS / LOW VOLTAGE (400-460 v)
MB 4873 2795 645 2856 665 414 2212 1268 293 1295 302 188
MC 4873 2873 672 2925 693 414 2212 1303 305 1327 314 188
MD 4873 2906 684 3013 724 414 2212 1318 310 1367 328 188
ME 4873 2956 704 3071 737 414 2212 1341 319 1392 334 188
MF 4873 3034 724 3153 791 414 2212 1376 328 1430 359 188
MG 4873 3071 737 414 2212 1393 334 188
HIGH-EFFICIENCY MOTORS / MEDIUM VOLTAGE (2400-4160 v)
EH 4873 2939 776 2997 810 414 2212 1333 352 1359 367 188
EJ 4873 2999 810 3108 862 414 2212 1360 367 1410 391 188
EK 4873 2988 810 3102 862 414 2212 1355 367 1407 391 188
EL 4873 2981 810 3065 872 414 2212 1352 367 1390 396 188
EM 4873 3031 855 3077 872 414 2212 1375 388 1396 396 188
EN 4873 3075 872 3260 974 414 2212 1395 396 1479 442 188
EP 4873 3081 872 3298 974 414 2212 1398 396 1496 442 188
HIGH-EFFICIENCY MOTORS / MEDIUM VOLTAGE (6300-6900 v)
EH 4873 2998 810 3097 862 414 2212 1360 367 1405 391 188
EJ 4873 3029 855 3100 862 414 2212 1374 388 1406 391 188
EK 4873 3049 855 3064 872 414 2212 1383 388 1390 396 188
EL 4873 3068 872 3060 872 414 2212 1390 396 1388 396 188
EM 4873 3072 872 414 2212 1393 396 188
EN 4873 3075 872 3260 974 414 2212 1395 396 1479 442 188
EP 4873 3081 872 3288 974 414 2212 1398 396 1491 442 188
HIGH-EFFICIENCY MOTORS / HIGH VOLTAGE (10000-11000 v)
MD 4873 3956 678 414 2212 1794 308 188
MF 4873 4062 719 414 2212 1842 326 188
MH 4873 3820 657 414 2212 1733 298 188
HIGH-EFFICIENCY MOTORS / HIGH VOLTAGE (13800 v)
MH 4873 3779 646 414 2212 1714 293 188
134
Table 22A 19XR,XRV Waterbox Cover Weights English (lb)

LEGEND
NOTE: Weight for NIH 2-pass cover, 150 psig, is included in the heat
exchanger weights shown in Tables 18A and 18B.
WATERBOX DESCRIPTION
COOLER
Frame 1 Frame 2 Frame 3
Standard
Nozzles
Flanged
Standard
Nozzles
Flanged
Standard
Nozzles
Flanged
NIH, 1 Pass Cover, 150 psig 177 204 287 318 287 318
NIH, 2 Pass Cover, 150 psig 185 218 287 340 287 340
NIH, 3 Pass Cover, 150 psig 180 196 294 310 294 310
MWB End Cover, 150 psig 315 315 315 315
NIH/MWB Return Cover, 150 psig 136 136 243 243 243 243
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
WATERBOX DESCRIPTION
CONDENSER
Frame 1 Frame 2 Frame 3
Standard
Nozzles
Flanged
Standard
Nozzles
Flanged
Standard
Nozzles
Flanged
NIH, 1 Pass Cover, 150 psig 177 204 260 297 260 297
NIH, 2 Pass Cover, 150 psig 185 218 265 318 265 318
NIH, 3 Pass Cover, 150 psig 180 196 272 288 272 288
MWB End Cover, 150 psig 234 234 234 234
NIH/MWB Return Cover, 150 psig 136 136 225 225 225 225
NIH, 1 Pass Cover, 300 psig 248 301 379 454 379 454
NIH, 2 Pass Cover, 300 psig 255 324 379 486 379 486
NIH, 3 Pass Cover, 300 psig 253 288 401 436 401 436
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
NIH Nozzle-in-Head
MWB Marine Waterbox
135
Table 22A 19XR,XRV Waterbox Cover Weights English (lb) (cont)

LEGEND
NOTE: Weight for NIH 2-pass cover, 150 psig, is included in the heat
exchanger weights shown in Tables 18A and 18B.
WATERBOX DESCRIPTION
COOLER
Frame 4 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 202 256 224 276 257 330
NIH, 3 Pass Cover, 150 psig 473 489 617 634 765 791
MWB End Cover, 150 psig 317 317 393 393 487 487
NIH/MWB Return Cover, 150 psig 138 138 154 154 172 172
NIH, 1 Pass Cover, 300 psig 633 709 764 839 978 1053
NIH, 2 Pass Cover, 300 psig 626 689 761 867 927 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
WATERBOX DESCRIPTION
CONDENSER
Frame 4 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 191 245 224 298 245 330
NIH, 3 Pass Cover, 150 psig 503 519 629 655 772 843
MWB End Cover and Bolt-on End Cover,
150 psig
317 317 393 393 487 487
NIH/MWB Return Cover, 150 psig 138 138 154 154 172 172
NIH, 1 Pass Cover, 300 psig 633 709 764 839 978 1053
NIH, 2 Pass Cover, 300 psig 622 729 727 878 923 1074
NIH, 3 Pass Cover, 300 psig 655 689 785 838 995 1049
NIH/MWB End Cover, 300 psig 522 522 658 658 834 834
NIH Nozzle-in-Head
MWB Marine Waterbox
136
Table 22A 19XR,XRV Waterbox Cover Weights English (lb) (cont)

LEGEND
NOTE: Weight for NIH 2-pass cover, 150 psig, is included in the heat
exchanger weights shown in Tables 18A and 18B.
WATERBOX DESCRIPTION
COOLER
FRAME 7 FRAME 8
Standard Nozzles Flanged Standard Nozzles Flanged
NIH, 1 Pass Cover, 150 psig 329 441 417 494
NIH, 2 Pass Cover, 150 psig 426 541 540 693
NIH, 3 Pass Cover, 150 psig 1250 1291 1629 1687
MWB End Cover, 150 psig 844 844 1125 1125
NIH/MWB Return Cover, 150 psig 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
WATERBOX DESCRIPTION
CONDENSER
Frame 7 Frame 8
Standard
Nozzles
Flanged
Standard
Nozzles
Flanged
NIH, 1 Pass Cover, 150 psig 329 441 417 494
NIH, 2 Pass Cover, 150 psig 404 520 508 662
NIH, 3 Pass Cover, 150 psig 1222 1280 1469 1527
MWB End Cover, 150 psig 781 781 1007 1007
Bolt-on MWB End Cover, 150 psig 700 700 1307 1307
NIH/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
NIH Nozzle-in-Head
MWB Marine Waterbox
137
Table 22B 19XR,XRV Waterbox Cover Weights SI (kg)

LEGEND
NOTE: Weight for NIH 2-pass cover, 1034 kPa, is included in the
heat exchanger weights shown in Table 18A and 18B.
WATERBOX DESCRIPTION
COOLER
FRAME 1 FRAME 2 FRAME 3
Standard
Nozzles
Flanged
Standard
Nozzles
Flanged
Standard
Nozzles
Flanged
NIH, 1 Pass Cover, 1034 kPa 80 92 130 144 130 144
NIH, 2 Pass Cover, 1034 kPa 84 99 130 154 130 154
NIH, 3 Pass Cover, 1034 kPa 82 88 133 141 133 141
MWB End Cover, 1034 kPa 143 143 143 143
NIH/MWB Return Cover, 1034 kPa 62 62 110 110 110 110
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
WATERBOX
DESCRIPTION
CONDENSER
Frame 1 Frame 2 Frame 3
Standard
Nozzles
Flanged
Standard
Nozzles
Flanged
Standard
Nozzles
Flanged
NIH, 1 Pass Cover, 1034 kPa 80 92 118 135 118 135
NIH, 2 Pass Cover, 1034 kPa 84 99 120 144 120 144
NIH, 3 Pass Cover, 1034 kPa 82 88 123 131 123 131
MWB End Cover, 1034 kPa 106 106 106 106
NIH/MWB Return Cover, 1034 kPa 62 62 102 102 102 102
NIH, 1 Pass Cover, 2068 kPa 112 137 172 206 172 206
NIH, 2 Pass Cover, 2068 kPa 116 147 172 220 172 220
NIH, 3 Pass Cover, 2068 kPa 115 131 182 198 182 198
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
NIH Nozzle-in-Head
MWB Marine Waterbox
138
Table 22B 19XR,XRV Waterbox Cover Weights SI (kg) (cont)

LEGEND
NOTE: Weight for NIH 2-pass cover, 1034 kPa, is included in the
heat exchanger weights shown in Tables 18A and 18B.
WATERBOX
DESCRIPTION
COOLER
Frame 4 Frame 5 Frame 6
Standard
Nozzles
Flanged
Standard
Nozzles
Flanged
Standard
Nozzles
Flanged
NIH, 1 Pass Cover, 1034 kPa 67 84 76 104 85 101
NIH, 2 Pass Cover, 1034 kPa 92 116 102 125 117 150
NIH, 3 Pass Cover, 1034 kPa 215 222 280 288 347 359
MWB End Cover, 1034 kPa 144 144 178 178 221 221
NIH/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 284 313 345 394 420 489
NIH, 3 Pass Cover, 2068 kPa 299 315 361 376 452 476
NIH/MWB End Cover, 2068 kPa 237 237 298 298 378 378
WATERBOX DESCRIPTION
CONDENSER
Frame 4 Frame 5 Frame 6
Standard
Nozzles
Flanged
Standard
Nozzles
Flanged
Standard
Nozzles
Flanged
NIH, 1 Pass Cover, 1034 kPa 67 84 76 104 85 101
NIH, 2 Pass Cover, 1034 kPa 87 111 102 135 111 150
NIH, 3 Pass Cover, 1034 kPa 228 235 285 297 350 382
MWB End Cover and Bolt-on End Cover, 1034 kPa 144 144 178 178 221 221
NIH/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 282 331 330 393 419 487
NIH, 3 Pass Cover, 2068 kPa 297 313 356 376 451 476
NIH/MWB End Cover, 2068 kPa 237 237 298 298 378 378
NIH Nozzle-in-Head
MWB Marine Waterbox
139
Table 22B 19XR,XRV Waterbox Cover Weights SI (kg) (cont)

LEGEND
NOTE: Weight for NIH 2-pass cover, 1034 kPa, is included in the
heat exchanger weights shown in Tables 18A and 18B.
WATERBOX
DESCRIPTION
COOLER
Frame 7 Frame 8
Standard
Nozzles
Flanged
Standard
Nozzles
Flanged
NIH, 1 Pass Cover, 1034 kPa 149 200 189 224
NIH, 2 Pass Cover, 1034 kPa 193 245 245 314
NIH, 3 Pass Cover, 1034 kPa 567 586 739 765
MWB End Cover, 1034 kPa 383 383 510 510
NIH/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
WATERBOX DESCRIPTION
CONDENSER
FRAME 7 FRAME 8
Standard
Nozzles
Flanged
Standard
Nozzles
Flanged
NIH, 1 Pass Cover, 1034 kPa 149 200 189 224
NIH, 2 Pass Cover, 1034 kPa 183 236 230 300
NIH, 3 Pass Cover, 1034 kPa 554 580 666 693
MWB End Cover, 1034 kPa 354 354 457 457
Bolt-on MWB End Cover, 1034 kPa 318 318 593 593
NIH/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
NIH Nozzle-in-Head
MWB Marine Waterbox
140
Table 23 Component Weights
*To determine compressor frame size, refer to 19XR,XRV Computer
Selection Program.
Included in total cooler weight.
NOTE: VFD sizes are available on select heat exchanger models;
consult the 19XR,XRV Computer Selection program.
Table 24 Optional Pumpout Electrical Data
LEGEND
Table 25 Motor Voltage Code
COMPONENT
FRAME 2
COMPRESSOR*
FRAME 3
COMPRESSOR*
FRAME 4
COMPRESSOR*
FRAME 5
COMPRESSOR*
FRAME E
COMPRESSOR*
lb kg lb kg lb kg lb kg lb kg
Suction Elbow 116 53 185 84 239 108 407 185 645 293
Discharge Elbow 100 45 125 57 157 71 325 147 290 132
Control Panel 34 15 34 15 34 15 34 15 34 15
Optional Cooler Inlet Isolation Valve 8 4 13 6 20 9 24 11 24 11
Optional Discharge Isolation Valve 26 12 46 21 74 34 108 49 93 42
Std Tier VFD 380, 400, and 460-v
(230, 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 A) 1600 726 1600 726
Std Tier VFD 380, 400, and 460-v (765 A) 1600 726
Std Tier VFD 380, 400, and 460-v
(855, 960, 1070 A)
1600 726 1600 726 1600 726
Std Tier VFD 380, 400, and 460-v (1275 A) 3000 1361 3000 1361 3000 1361
Std Tier VFD 380, 400, and 460-v (1530 A) 3000 1361 3000 1361
LiquiFlo 2 VFD 380, 400, and 460-v (442 A) 1600 726 1600 726
LiquiFlo 2 VFD 380, 400, and 460-v (608 A) 1600 726 1600 726
LiquiFlo 2 VFD 380, 400, and 460-v (900 A) 2800 1270 2800 1270 2800 1270
LiquiFlo 2 VFD 380, 400, and 460-v (1200 A) 2850 1293 2850 1293 2850 1293
LiquiFlo 2 VFD 575-v (390 A) 2200 998 2200 998
VFD Shelf 1049 476 1049 476 1049 476
PUMPOUT UNIT VOLTS-PH-Hz MAX RLA LRA
19XR04026501 208/230-3-60 15.8 105
19XR04026501 208/230-3-50 15.8 105
19XR04026502 460-3-60 7.8 52
19XR04026503 400-3-50 7.8 52
LRA Locked Rotor Amps
RLA Rated Load Amps
MOTOR VOLTAGE CODE
Code Volts Frequency
60 200 60
61 230 60
62 380 60
63 416 60
64 460 60
65 575 60
66 2400 60
67 3300 60
68 4160 60
69 6900 60
6A 11000 60
6B 10000 60
6C 13800 60
50 230 50
51 346 50
52 400 50
53 3000 50
54 3300 50
55 6300 50
5A 10000 50
5B 11000 50
141
19XR,XRV COMPRESSOR FRAME 2 THROUGH FRAME 5 FITS AND CLEARANCES (in.)
*Depends on impeller size, contact your Carrier Service Represen-
tative for more information.
NOTES:
1. All clearances for cylindrical surfaces are diametrical.
2. Dimensions shown are with rotors in the thrust position.
3. Frame 3 rolling element style high speed shaft and bearing
assembly cannot be pulled from impeller end. The transmission
assembly must be removed from the compressor casting (after
the impeller is removed) and the bearing temperature sensor
must be removed from the high speed shaft and bearing assem-
bly before the high speed shaft and bearing assembly can be
separated from the transmission.
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. 58 Compressor Fits and Clearances Single-Stage Compressors
ITEM
COMPRESSOR FRAME 2 FRAME 3 FRAME 4 FRAME 5
Code 201-299, 2ZZ 321-389, 3ZZ 421-487, 4B1-4W7 501-599
DESCRIPTION
Oil Film
Bearings
Rolling
Element
Bearings
Oil Film
Bearings
Rolling
Element
Bearings
Oil Film
Bearings
Rolling
Element
Bearings
A Low Speed Journal-Gear End .0050/.0040 .0050/.0040 .0055/.0043 .0055/.0043 .0069/.0059 .0069/.0059
B Low Speed Journal-Motor End .0050/.0040 .0050/.0040 .0053/.0043 .0053/.0043 .0065/.0055 .0065/.0055
C1 Low Speed Labyrinth to Thrust Disk .0115/.0055 N/A .010/.005 N/A N/A N/A
C2 Labyrinth to Low Speed Shaft N/A .010/.005 .0095/.0055 .0095/.0055 .013/.009 .013/.009
D Low Speed Shaft Thrust Float .020/.008 .020/.008 .023/.008 .023/.008 .020/.008 .020/.008
E Impeller Eye to Shroud * * * * * *
F1 Impeller Bore to Shaft-Rear .0020/.0005 .0025/.0010 .0014/.0029 .0014/.0029 .0019/.0005 .0019/.0005
F2 Impeller Bore to Shaft-Front N/A N/A .0005/.0025 .0005/.0025 .0014/.0000 N/A
G Impeller Discharge to Shroud * * * * * *
H Impeller Spacer to Shaft .0025/.0010 .0025/.0010 .0025/.0010 .0025/.0010 .0024/.0010 .0024/.0010
I Slinger to Shaft .0013/.0005 .0012/.0004 .0012/.0004 .0012/.0004 .0012/.0004 .0012/.0004
J Labyrinth to Slinger .013/.009 .010/.006 .010/.006 .010/.006 .010/.006 .010/.006
K Labyrinth to Impeller .012/.008 .012/.008 .012/.008 .012/.008 .012/.008 .012/.008
L High Speed Journal-Impeller End .0047/.0037 N/A .0040/.0028 N/A .0048/.0038 N/A
M
Thrust Assembly Seal Ring Axial
Clearance
.006/.002 N/A .006/.002 N/A .006/.002 N/A
N Thrust Assembly Seal Ring to Shaft .0045/.0015 N/A .0045/.0015 N/A .0045/.0015 N/A
O High Speed Shaft Thrust Float .014/.008 0 Float .014/.008 Float .014/.008 0 Float
P High Speed Journal-Gear End .0050/.0040 N/A .0048/.0038 N/A .0062/.0052 N/A
COMPRESSOR, TRANSMISSION AREA (FRAME 5 COMPRESSOR SHOWN)
a19-1635
SEE VIEW A1 OR A2 A 2
3
SEE VIEW B
4
1
D
LEGEND
1 Oil Heater Retaining Nut (Not Shown)
2 Bull Gear Retaining Bolt
3 Demister Bolts (Not Shown)
4 Impeller Bolt
142
C1
B
THRUST
THRUST
C1
C2
B
Fig. 58 Compressor Fits and Clearances Single-Stage Compressors (cont)
VIEW A1
LOW SPEED SHAFT THRUST DISK
FRAME 2 COMPRESSORS
VIEW A2
LOW SPEED SHAFT THRUST DISK
FRAME 3, 4, AND 5 COMPRESSORS
a19-1636 a19-1637
P
O
F1
H
E
F2
K
I
J
IMPELLER SHIMMING
TO BE DETERMINED
AT ASSEMBLY
SEE VIEW C
THRUST
SEE
NOTE 5
G
L
VIEW B HIGH SPEED SHAFT, ORIGINAL DESIGN (OIL FILM BEARINGS) AND IMPELLER SECTION
a19-1639
143
+0.0007
-0.0007
0.0011
0.0013
THRUST
0.025
0.005
INTERFERENCE
0.0011
0.0013
INTERFERENCE
+0.0007
-0.0007
0.0050
0.0020
0.0012
0.0004
VIEW B HIGH SPEED SHAFT WITH ROLLING ELEMENT BEARINGS
Fig. 58 Compressor Fits and Clearances Single-Stage Compressors (cont)
a19-1640
N
M
VIEW C HIGH SPEED SHAFT RING SEAL
a19-1641
144
Fig. 59 Compressor Fits and Clearances Two-Stage Compressors
19XR,XRV COMPRESSOR FRAME E FITS AND CLEARANCES
ITEM
COMPRESSOR FRAME E
Code E31-E69
DESCRIPTION
Rolliing Element
Bearings
A Low Speed Journal - Gear End .0069/.0059
B Low Speed Journal - Motor End .0065/.0059
C1 Low Speed labyrinth to thrust Disk N/A
C2 Labyrinth to Low Speed Shaft .013/.009
D Low Speed Shaft thrust Float .20/.008
LEGEND
1 Oil Heater Retaining Nut
2 Bull Gear Retaining Bolt
3 Demister Bolts
4 First Impeller Nut (Inner)
5 Second Impeller Nut (Outer)
6 Guide Vane Shaft Seal (Not Shown)
145
Fig. 59 Compressor Fits and Clearances Two-Stage Compressors (cont)
VIEW E
VIEW D
REAR, HIGH SPEED SHAFT BEARING
0.0007-0.0007
[0/017-0.017]
0.003-0.0011
[0.008-0.027]
Interference fit
THRUST
C1
C2
B
VIEW A2
LOW SPEED SHAFT THRUST DISK
a19-1637
146
CAUTION
USE COPPER CONDUCTORS ONLY
UTILISEZ DES CONDUCTEURS EN CUIVRE SEULMENT
ALWAYS USE 2 WRENCHES TO TIGHTEN
TERM INSULATOR TO MOTOR 15-35 ft. lb.
BRASS NUT TO TERM INSULATOR 3 ft. lb. max
ADAPTOR TO TERM STUD 20-35 ft. lb.
LUG BOLTS (1/2") 32-45 ft. lb.
Insulate entire connection with electrical insulation
including 1 inch of cable insulation and 1 inch of the
term insulator.
!
TERMINAL STUD INSULATION
ADAPTER
BRASS NUT
TERMINAL
INSULATOR
1
2
3
13
CAUTION
USE COPPER CONDUCTORS ONLY
UTILISEZ DES CONDUCTEURS EN CUIVRE SEULMENT
ALWAYS USE 2 WRENCHES TO TIGHTEN
TERM INSULATOR TO MOTOR 15-35 ft. lb.
CABLE LUG NUT 40-45 ft. lb.
Insulate entire connection with electrical insulation
including 1 inch of cable insulation and 1 inch of the
term insulator.
!
TAPE TO EXTEND TO AND OVER
LEAD WIRE INSULATION
AFTER ATTACHING LEAD, THIS AREA
TO BE WRAPPED WITH ONE LAYER OF
THERMAL INSULATION PUTTY AND AT
LEAST FOUR LAYERS OF APPROPRIATE
ELECTRICAL INSULATING TAPE.
1
2
3
12
6
4
5
MOTOR LEAD INSTALLATION LABELS
19XR,XRV COMPRESSOR ASSEMBLY TORQUES FRAME 2-5
* Not shown.
19XR,XRV COMPRESSOR ASSEMBLY TORQUES FRAME E
Fig. 60 Compressor Assembly Torques Single and Two-Stage Compressors
ITEM
COMPRESSOR FRAME 2 FRAME 3 FRAME 4 FRAME 5
Code 201-299, 2ZZ 321-389, 3ZZ 421-487, 4B1-4W7 501-599
1 Oil Heater Retaining Nut ft-lb (Nm) N/A 18-22 (25-30) 18-22 (25-30) 18-22 (25-30)
2 Bull Gear Retaining Bolt ft-lb (Nm) 80-90 (108-122) 80-90 (108-122) 80-90 (108-122) 80-90 (108-122)
3 Demister Bolts ft-lb (Nm) 15-19 (20-26) 15-19 (20-26) 15-19 (20-26) 15-19 (20-26)
4 Impeller bolt Torque ft-lb (Nm) 32-48 (43-65) 55-60 (75-81) 55-60 (75-81) 160-225 (217-305)
5* Guide Vane Shaft Seal Nut ft-lb (Nm) 25 (34) 25 (34) 25 (34) 25 (34)
ITEM
COMPRESSOR FRAME 2
Code E31-E69
1 Oil Heater Retaining Nut ft-lb (Nm) 18-22 (24-30)
2 Bull Gear Retaining Bolt ft-lb (Nm) 80-90 (108-122)
3 Demister Bolts ft-lb (Nm) 15-19 (20-26)
4 Impeller Nut (Inner) ft-lb (Nm) 250 (339)
5 Impeller Nut (Outer) ft-lb (Nm) 100 (136)
6* Guide Vane Shaft Seal Nut ft-lb (Nm) 25 (34)
a19-1642
a19-1643
147







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a19-1872
148
Fig. 62 PIC II Control Panel Wiring Schematic (Frame 2, 3, 4 and E Compressors without Split Ring
Diffuser)
a19-1870
149
Fig. 62 PIC II Control Panel Wiring Schematic (Frame 2, 3, 4 and E Compressors without Split Ring
Diffuser) (cont)
a19-1870
150
a19-1871
Fig. 63 PIC II Control Panel Wiring Schematic (Frame 4 and 5 Compressors with Split Ring Diffuser)
151
Fig. 63 PIC II Control Panel Wiring Schematic (Frame 4 and 5 Compressors with Split Ring Diffuser)
(cont)
LEGEND
AUX Auxiliary
BRG Bearing
C Contactor
CB Circuit Breaker
CCM Chiller Control Module
CCN Carrier Comfort Network
COMPR Compressor
COND Condenser
DISCH Discharge
DL/DP Datalink or Dataport
ENT Entering
EVAP Evaporator
EXT External
FR Frame
GND Ground
G.V. Guide Vane
HGBP Hot Gas Bypass
HT EXCH Heat Exchanger
ICVC International Chiller Visual Controller
ISM Integrated Starter Module
L Main Supply Power

LVG Leaving
N.O. Normally Open
PRESS Pressure
REQMT Requirement
TEMP Temperature
TB Terminal Board
UPC 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
152
Fig. 64 Benshaw, Inc. Wye-Delta Unit Mounted Starter Wiring Schematic (Low Voltage)
a19-1873
153
Fig. 64 Benshaw, Inc. Wye-Delta Unit Mounted Starter Wiring Schematic (Low Voltage) (cont)
AUX Auxiliary
BR Bridge Rectifier
CB Circuit Breaker
CR Control Relay
COND Condenser
CPU Central Processing Unit
CVC/
ICVC

Chiller Visual Controller

CT Current Transformer
EVAP Evaporator
FU Fuse
GND Ground
HPR High Pressure Relay
L Main Supply Power
LL Control Power Supply
M Contactor
O/L Overload Reset
PFCC Power Factor
Correction Capacitor
RLA Rated Load Amps
SCR Silicone Controller Rectifier
ST Shunt Trip
TB Terminal Block
Wire Node Symbol
may have terminal block
Benshaw supplied
terminal block
Terminal Strip
Power Connection
PC Board Terminals
Twisted Pair
Twisted Shielded Pair
Shield Wire
Field Wiring
LEGEND
NOTES:
LED status with power applied and prior to run command.
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.
Optional.
1
"ON"
"OFF"
2
3
4
5
6
a19-1874
154
Fig. 65 Benshaw, Inc. Solid-State Unit Mounted Starter Wiring Schematic
NOTES:
LED status with power applied and prior to RUN command.
Transformer T1 primary fuses FU1/FU2 value dependent on
system voltage and model, per Chart 1. Transformer connec-
tions per transformer nameplate connection diagram.
CT1-CT3 are sized per Chart 2.
Optional for all starters.
CT7-CTI2 are optional for all starters.
Circuit breaker CB2 rated at 30 amps for models 19XRA,
19XRC, 19XTR.
1
2
3
4
5
6
"ON"
"OFF "
7
8
9
155
Fig. 65 Benshaw, Inc. Solid-State Unit Mounted Starter Wiring Schematic (cont)
CHART 1
SYSTEM
VOLTAGE
3 KVA XFMR
FU1-2 AMPS
2 KVA XFMR
FU1-2 AMPS
1 KVA XFMR
FU1-2 AMPS
200 30 20 12
230 30 20 10
346 20 12 7
380 20 12 6
400 15 12 6
415 15 12 6
480 15 10 5
575 12 8 4

CHART 2
STARTER RLA
RANGE
MX3 CT RATIO
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
CHART 3
STARTER
RLA RANGE
L1, L2, L3 CONDUCTORS
PER PHASE (Load Side)
95-205
262 MCM DLO BLK
1 cond per phase
206-259
373 MCM DLO BLK
1 cond per phase
260-298
373 MCM DLO BLK
1 cond per phase
299-398
262 MCM DLO BLK
2 cond per phase
399-501
262 MCM DLO BLK
2 cond per phase
502-597
373 MCM DLO BLK
2 cond per phase
598-687
373 MCM DLO BLK
2 cond per phase
688-791
444 MCM DLO BLK
2 cond per phase
792-854
444 MCM DLO BLK
2 cond per phase
855-979
373 MCM DLO BLK
3 cond per phase
980-1194
444 MCM DLO BLK
3 cond per phase
1195-1390
444 MCM DLO BLK
3 cond per phase
156
F
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.

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a19-1875
157
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161
Fig. 69 Typical Low-Voltage Variable Frequency Drive (VFD) Wiring Schematic (575 v) (cont)
a19-1880
162
LEGEND FOR FIG. 69

AUX Auxiliary
CB Circuit Breaker
CCM Chiller Control Module
CCN Carrier Comfort Network
COMM Communications
CT Current Transformer
FU Fuse
G Chassis Ground
GV Guide Vane
HPR High Discharge Pressure Relay
HPS High Pressure Switch
ICVC International Chiller Visual Controller
IGBT Insulated Gate Bipolar Transistor
ISM Integrated Starter Module
J Junction
ST Shunt Trip
T Transformer
TB Terminal Block
VFD Variable Frequency Drive
1C Compressor Oil Heater Contactor
1M Start Contactor
2C Oil Pump Contactor
3C Hot Gas Bypass Relay
Field Control Wiring
Field Power Wiring
Factory Wiring
Shielded Cable
Twisted Pair Wiring
Male/Female Connector
Terminal Block Connection
Wire Splice or Junction
Cam Switch
Component Terminal
Thermistor
Transducer
Fusible Link
Potentiometer
Pressure Switch
-
+
Compr Oil Pump Terminal
Cartridge Fuse
Earth Ground
Resistor
Chassis Ground
Light
Temperature Switch
Common Potential
Dry Contact
VFD Terminal
Current Transformer, Polarized
(Direction Determined by )
Transformer
IGBT
Diode
Silicon Controlled Rectifier
163
LEGEND FOR FIG. 70
19XR with Unit-Mounted VFD with ISM
See Notes on page 166.
REFERENCE
NUMBER
EXPLANATION
1
3 Phase Under/Over Voltage (Line Side)
Phase Loss/Imbalance/Reversal (Line Side)
Frequency Shift (Line Side)
kW Transducer/kW Hours/Demand kW
Over Current
Control Power Transformer (3KVA)
Controls and Oil Heater Fused Disconnect (FU2)
Oil Pump Circuit Fused Disconnect (FU1)
Phase to Ground Fault Protection
3 Phase Analog Volts/Amps Meter Package
2 System Feeder (Short Circuit, Ground Fault and Protection)
A Evaporator Liquid Pump Starter Disconnect
B Evaporator Liquid Pump Motor Starter
C Condenser Liquid Pump Starter Disconnect
D Condenser Liquid Pump Motor Starter
E Cooling Tower Fan Motor Starter Disconnect (Low Fan/#1)
F Cooling Tower Fan Motor Starter (Low Fan/#1)
G Cooling Tower Fan Motor Starter Disconnect (High Fan/#2)
H Cooling Tower Fan Motor Starter (High Fan/#2)
J Spare Safety Devices [N.C.] See Note 3.1
K Remote Start/Stop Device [N.O] See Note 3.1
L Remote Alarm See Note 3.3
M Remote Annunciator See Note 3.3
N Lug Adapters See Note 2.3
P Ice Build Start/Terminate Device See Note 3.1
164
Fig. 70 19XR Typical Wiring with Unit-Mounted Variable Frequency Drive with ISM
(Integrated Starter Module)
a19-2078
NOTE: See Legend on page 163.
165
Fig. 70 19XR Typical Wiring with Unit-Mounted Variable Frequency Drive with ISM
(Integrated Start Module) (cont)
a19-1714
166
NOTES FOR FIG. 70
19XR with Unit-Mounted VFD with ISM
I. GENERAL
1.0 Variable Frequency Drive (VFD) Starters shall be designed
and manufactured in accordance with Carrier Engineering
Requirement Z-416.
1.1 All field-supplied conductors, devices, and the field
installation wiring, and termination of conductors and
devices, must be in compliance with all applicable codes
and job specifications.
1.2 The routing of field-installed conduit and conductors and
the location of field-installed devices must not interfere with
equipment access or the reading, adjusting, or servicing of
any component.
1.3 Equipment installation and all starting and control devices,
must comply with details in equipment submittal drawings
and literature.
1.4 Contacts and switches are shown in the position they would
assume with the circuit de-energized and the chiller shut
down.
1.5 WARNING Do not use aluminum conductors.
1.6 Installer is responsible for any damage caused by improper
wiring between VFD and machine.
1.7 All field-installed wiring is field-supplied.
II. POWER WIRING TO VFD
2.0 Provide a local means of disconnecting power to VFD.
Provide short circuit protection for the chiller and
interconnecting wire at the branch feeder. The short circuit
protection shall be fused type or equivalent circuit breaker.
2.1 Metal conduit must be used for the power wires from VFD to
branch feeder.
2.2 Line side power conductor rating must meet the VFD
nameplate voltage and chiller full load amps (minimum cir-
cuit ampacity).
2.3 Lug adapters may be required if installation conditions
dictate that conductors be sized beyond the minimum
ampacity required. Disconnect lugs will accommodate the
quantity (#) and size (MCM) cables (per phase) as indicated
in table below. If larger lugs are required, the lugs can be
purchased from Cutler-Hammer.
2.4 Compressor motor and controls must be grounded by using
equipment grounding lugs provided inside unit-mounted
VFD enclosure.
2.5 Metering current transformers (CTs), if present, have an
inner diameter of 2
3
/
4
in. Caution should be taken when
selecting power wiring so that all power cables can pass
through the CTs.
III. CONTROL WIRING
3.0 Field supplied control conductors to be at least 18 AWG or
larger.
3.1 Ice build start/terminate device contacts, remote start/stop
device contacts and spare safety device contacts (devices
not supplied by Carrier), must have 24 VAC rating. MAX
current is 60 mA, nominal current is 10 mA. Switches with
gold plated bifurcated contacts are recommended.
3.2 Each integrated contact output can control loads (VA) for
evaporator pump, condenser pump, tower fan low, tower fan
high, and alarm annunciator devices rated 5 amps at 115
VAC and up to 3 amps at 277 VAC.
Do not use control transformers in the control center as the
power source for external or field-supplied contactor coils,
actuator motors or any other loads.
3.4 Do not route control wiring carrying 30 v or less within a
conduit which has wires carrying 50 v or higher or along
side wires carrying 50 v or higher.
3.5 Spare 4-20 mA output signal is designed for controllers with a
non-grounded 4-20 mA input signal and a maximum input
impedance of 500 ohms.
3.8 Flow devices to confirm evaporator or condenser pump flow
are not required. However; if flow devices are used, wire as
shown in diagram below. Remove jumper installed at these
terminals and wire in a 4.3 K resistor in its place. The flow
device and resistor must be installed in parallel at these termi-
nals such that the resistor provides a signal when the flow
device is open.
CAUTION
To prevent damage to machine, do NOT punch holes or drill into
the top surface of the VFD enclosure for field wiring. Knockouts
are provided on the side of the VFD enclosure for field wiring
connections.
VFD
Max Input
Amps
Standard 65KAIC
Lug Capacity (Per Phase)
No. of Conductors Conductor Range
390 3 2/0-400 MCM
CAUTION
Control wiring for Carrier to start pumps and tower fan motors
and establish flows must be provided to assure machine protec-
tion. If primary pump, tower fan, and flow control is by other
means, also provide parallel means for control by Carrier. Fail-
ure to do so could result in machine freeze-up or overpressure.
CCM
J3 (LOWER)
167
LEGEND FOR FIG. 71

AC Alternating Current
ACB Analog Control Board
AWG American Wire Gage
CBx Circuit Breaker
CPTx Control Power Transformer
CTx Current Transformer
DI Drive Input Contactor
DI-IV Drive Input Contactor Intellivac Module
DIC Drive Input Control Relay
DICR1 Drive Input Contactor Pilot Relay
DIIS Drive Input Isolating Switch
DILR Drive Input Line Reactor
DIOL Drive Input Overload
DIOLx Drive Input Overload Auxiliary Relay
DITB Drive Input Contactor Terminal Blocks
DSx Disconnect Switch
EMC Electro-Magnetic Choke
ES Ethernet Switch
FLT Fault Relay
Fx Fuse
GFCT Ground Fault Current Transformer
GND Ground
GRD Ground
HECSU Hall Effect Current Sensor (U Phase)
HECSW Hall Effect Current Sensor (W Phase)
HPR High Pressure Relay
IFM Interface Module
ISM Integrated Starter Module
LFC Line Filter Capacitors
LFRNx Line Reactor Fan x
LV Low Voltage
LVx External Low Voltage Supply
MFC Motor Filter Capacitors
MFN1C Main Fan Contactor
MFN1MP Main fan Motor Protector
MOV Metal Oxide Varistor
MSR Monitoring Safety Relay
MSRXx Monitoring Safety Relay Auxiliary Relay x
MV Medium Voltage
NR Neutral Resistor
PE Earth Ground
PFN1 Powerflex Interface Board
PP Carrier Power Panel
PS1A AC/DC Converter
PS2 DC/DC Converter
PS4 AC/DC Converter
RUN Run Relay
SS Surge Suppressor
ST Shunt Trip
VFD Variable Frequency Drive
VSBx Voltage Sensing Board
WRN Warning Relay
XIOx External Inputs/Outputs
1M Start Relay
66 Carrier ISM to be programmed by Carrier before
start-up. Relay contacts shown without signal
power applied.
71 Calibrate for 4-20 mA; 0-5 vdc (Default 0-10 vdc).
100 WARNING: Ground must be connected to prevent
high voltages from being applied to drive control
boards.
104 Located in drive low voltage control section.
105 Device is mounted on the low voltage door of the
drive.

WIRING
Factory Wiring
Field Wiring
Mechanically Connected
Conductor, Crossing of Paths or Conductors Not
Connected
Conductor, Junction of Connected Paths, Con-
ductors or Wires
Conductor, Separable or Jacks Engaged
Terminal
Terminal (Rockwell Automation use only)
Terminal Blocks
Barrier
Wired To/From Destination
SWITCHES AND INPUT DEVICES
Contact Normally Open (Make)
Contact Normally Closed (Break)
OUTPUT DEVICES
Fan (3 Phase Induction Motor)
Induction Machine
RESISTORS, CAPS, WINDINGS AND
GROUND
Capacitor
Winding
Transformer, Current
PROTECTION
Circuit Breaker, Control/Power
Fuse, Control/Power
Surge Suppressor
POWER ELECTRONIC DEVICES
Symmetrical Gate-Commutated Thyristor and
Gate Driver Board
MISCELLANEOUS
Note Number Indicator
Contact Location Description
Relay Location Description
Key Interlock on Isolation Switch
Key Interlock on MV Door
Multiple Barrel Key Interlock on Isolation Switch
Multiple Barrel Key Interlock on MV Door
Transfer Block
168
DRIVE INPUT
ISOLATING SWITCH
POTENTIAL
TRANSFORMER
CONTROL POWER
TRANSFORMER
DRIVE INPUT CONTACTOR
DRIVE INPUT
OVERLOAD
CARRIER
ISM MODULE
DRIVE INPUT
LINE REACTOR
LINE FILTER
CAPACITORS
COMMON
MODE CHOKE
MOTOR FILTER
CAPACITORS
CHILLER
MOTOR
MAIN COOLING
FAN
MAIN FAN
CONTACTOR
MAIN FAN MOTOR
PROTECTOR
DISCONNECT
SWITCH 1
CONTROL POWER
TRANSFORMER ISOLATED GATE
DRIVE
POWER
SUPPLY
LINE VOLTAGE (SEE JOBSHEET)
FIELD SUPPLIED
FOR VFD USE ONLY, CHILLER
CONTROL POWER MUST BE
FIELD SUPPLIED SEPARATELY
3 LV AND 1 115 V POWER SUPPLY IS REQUIRED AND MUST BE
FIELD SUPPLIED WITH BRANCH CIRCUIT PROTECTION
(8 kVA MINIMUM REQUIRED)
Fig. 71 Typical Medium-Voltage Variable Frequency Drive (VFD) Wiring Schematic
a19-2060
169
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170
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a19-2062
172
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a19-2063
173
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a19-2061
174
CONTINUED
ON NEXT PAGE
Fig. 71 Typical Medium-Voltage Variable Frequency Drive (VFD) Wiring Schematic (cont)
a19-2064
175
CONTINUED
FROM PREVIOUS
PAGE
Fig. 71 Typical Medium-Voltage Variable Frequency Drive (VFD) Wiring Schematic (cont)
a19-2066
176
NOTES FOR FIG. 71
19XR with Free-Standing Medium Voltage VFD
I. GENERAL
1.0 Variable Frequency Drive (VFD) shall be designed and
manufactured in accordance with Carrier Engineering
Requirement Z-416.
1.1 All field-supplied conductors, devices, and the field installa-
tion wiring, termination of conductors and devices, must be
in compliance with all applicable codes and job specifica-
tions.
1.2 The routing of field-installed conduit and conductors and
the location of field-installed devices must not interfere with
equipment access or the reading, adjusting, or servicing of
any component.
1.3 Equipment installation and all starting and control devices,
must comply with details in equipment submittal drawings
and literature.
1.4 Contacts and switches are shown in the position they would
assume with the circuit de-energized and chiller shutdown.
1.5 WARNING - Do not use aluminum conductors.
1.6 Installer is responsible for any damage caused by improper
wiring between VFD and machine.
1.7 All field-installed wiring is field-supplied.
II. POWER WIRING TO VFD
2.0 Provide a means of disconnecting power to VFD.
2.1 Lug adapters may be required if installation conditions dic-
tate that conductors be sized beyond the minimum ampac-
ity required. Contact VFD supplier for lug information.
2.2 Compressor motor and controls must be grounded by using
equipment grounding lug provided inside VFD enclosure.
III. CONTROL WIRING
3.0 Field supplied control conductors to be at least 18 AWG or
larger.
3.1 Optional Ice build start/terminate device contacts, optional
remote start/stop device contacts and optional spare safety
device contacts (devices not supplied by Carrier), must
have 24 VAC rating. MAX current is 60 mA, nominal current
is 10 mA. Switches with gold plated bifurcated contacts are
recommended.
3.2 Remove jumper wire between ISM J2-1 and ISM J2-2
before connecting auxiliary safeties between these
terminals.
3.3 Each integrated contact output can control loads (VA) for
evaporator pump, condenser pump, tower fan low, tower fan
high, and alarm annunciator devices rated 5 amps at 115
VAC and up to 3 amps at 277 VAC.
Do not use control transformers in the control center as the
power source for external or field-supplied contactor coils,
actuator motors or any other loads.
3.4 Do not route control wiring carrying 30 v or less within a
conduit which has wires carrying 50 v or higher or along
side wires carrying 50 v or higher.
3.5 Control wiring between VFD and power panel must be sep-
arate shielded cables with minimum rating 600 v, 80 C.
Ground shield at VFD
3.6 If optional pumpout/oil pump circuit breaker is not supplied
within the starter enclosure, it must be located within sight
of machine with wiring routed to suit.
3.7 When providing conductors for oil pump motor and oil
heater power, refer to sizing data on label located on the
chiller power panel, equipment submittal documentation or
equipment product data catalog.
3.8 Spare 4-20 mA output signal is designed for controllers with
a non-grounded 4-20 mA input signal and a maximum input
impedance of 500 ohms.
IV. POWER WIRING BETWEEN FREE-STANDING VFD AND
COMPRESSOR MOTOR
4.0 Medium voltage (over 600 volts) compressor motors have
(3) terminals. Connections are
9
/
16
-in. threaded stud. A
compression lug with a single
9
/
16
-in. diameter hole can be
connected directly to the stud or 3 adapters are supplied for
connecting a NEMA lug. Use suitable connectors and insu-
lation for high voltage alternating current cable terminations
(these items are not supplied by Carrier). Compressor
motor starter must have nameplate stamped as to conform-
ing with Carrier Engineering requirement "Z-416."
4.1 Power conductor rating must meet minimum unit nameplate
voltage and compressor motor RLA. Refer to the label
located on the side of the chiller control panel, equipment
submittal documentation or equipment product data catalog
for conductor sizing data. (Conductor as defined below may
be a single lead or multiple smaller ampacity leads in paral-
lel for the purpose of carrying the equivalent or higher cur-
rent of a single larger lead.)
When (3) conductors are used:
Minimum ampacity per conductor = 1.25 x compressor RLA
When 96) conductors are used:
Minimum ampacity per conductor = 1.25 x compressor
RLA/2
4.2 When more than one conduit is used to run conductors
from VFD to compressor motor terminal box, an equal num-
ber of leads from each phase (conductor) must be in each
conduit to prevent excessive heating. (For example, con-
ductors to motor terminals 1, 2, and 3 in one conduit, and to
1, 2, and 3 in another conduit).
4.4 Compressor motor power conductors may enter terminal
box through top, left side or bottom left using holes cut by
contractor to suit conduit. Flexible conduit should be used
for the last few feet to the terminal box for unit vibration iso-
lation. Use of stress cones may require an oversize (spe-
cial) motor terminal box (not supplied by Carrier).
4.3 Compressor motor frame to be grounded in accordance
with the National Electrical Code (NFPA-70) and applicable
codes. Means for grounding compressor motor is a #4
AWG to 500 MCM pressure connector, supplied and
located in the lower left side corner of the compressor
motor terminal box.
4.5 Do not allow motor terminals to support weight of wire
cables. Use cable supports and strain reliefs as required.
4.6 Use backup wrench when tightening lead connectors to
motor terminal studs. Torque to 30-35 ft-lb max.
4.7 Do not exceed 100 ft. maximum power cable length
between the VFD and motor terminals without consulting
Carrier for special requirements.
CAUTION
To prevent damage to machine, do NOT punch holes or drill into
the top surface of the VFD enclosure for field wiring. Field wiring
knockouts are provided on the top and side of the VFD enclo-
sure for field wiring connections.
CAUTION
Control wiring for Carrier to start pumps and tower fan motors
and establish flows must be provided to assure machine protec-
tion. If primary pump, tower fan, and flow control is by other
means, also provide parallel means for control by Carrier. Fail-
ure to do so could result in machine freeze-up or overpressure.
177
APPENDIX A ICVC PARAMETER INDEX
PARAMETER
MENU
SOFTKEY
TABLE SCREEN NAME CONFIGURABLE
1CR Start Complete STATUS ISM_STAT
1CR Stop Complete STATUS ISM_STAT
1M Start/Run Fault STATUS ISM_STAT
1M/2M Stop Fault STATUS ISM_STAT
1st Current Alarm State SERVICE CONTROL ALGORITHM STATUS CUR_ALM
20mA Demand Limit Opt SERVICE EQUIPMENT SERVICE RAMP_DEM X
2M Start/Run Fault STATUS ISM_STAT
2nd Current Alarm State SERVICE CONTROL ALGORITHM STATUS CUR_ALM
3rd Current Alarm State SERVICE CONTROL ALGORITHM STATUS CUR_ALM
4th Current Alarm State SERVICE CONTROL ALGORITHM STATUS CUR_ALM
5th Current Alarm State SERVICE CONTROL ALGORITHM STATUS CUR_ALM
Active Delta Tsat STATUS COMPRESS
Active Delta Tsat STATUS HEAT_EX
Active Delta Tsat SERVICE CONTROL ALGORITHM STATUS SURGEPREV
Active Demand Limit STATUS MAINSTAT
Active Region SERVICE CONTROL ALGORITHM STATUS SURGEPREV
Actual Guide Vane Pos STATUS STARTUP
Actual Guide Vane Pos STATUS COMPRESS
Actual Guide Vane Pos STATUS HEAT_EX
Actual Guide Vane Pos SERVICE CONTROL ALGORITHM STATUS CAPACITY
Actual Guide Vane Pos SERVICE CONTROL ALGORITHM STATUS SURGEPREV
Actual Line Current STATUS POWER
Actual Line Voltage STATUS POWER
Actual Superheat SERVICE CONTROL ALGORITHM STATUS OVERRIDE
Actual VFD Speed STATUS COMPRESS
Actual VFD Speed SERVICE CONTROL ALGORITHM STATUS CAPACITY
Address SERVICE ICVC CONFIGURATION
Alarm Relay STATUS MAINSTAT
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
Auto Chilled Water Reset STATUS MAINSTAT
Auto Demand Limit Input STATUS MAINSTAT
Auto Restart Option SERVICE EQUIPMENT SERVICE OPTIONS X
Average Line Current STATUS MAINSTAT
Average Line Current STATUS POWER
Average Line Voltage STATUS POWER
Base Demand Limit SETPOINT SETPOINT X
Baud Rate SERVICE ICVC CONFIGURATION
Broadcast Option SERVICE EQUIPMENT CONFIGURATION NET_OPT x
Bus Number SERVICE ICVC CONFIGURATION
Calc Evap Sat Temp STATUS HEAT_EX
Calc Evap Sat Temp SERVICE CONTROL ALGORITHM STATUS OVERRIDE
CCN Mode ? STATUS ICVCPSWD
Chill Water Pulldown/Min STATUS HEAT_EX
Chilled Medium SERVICE EQUIPMENT SERVICE SETUP1 X
Chilled Water Deadband SERVICE EQUIPMENT SERVICE SETUP1 X
Chilled Water Delta P STATUS HEAT_EX
Chilled Water Delta T STATUS HEAT_EX
Chilled Water Delta T SERVICE CONTROL ALGORITHM STATUS SURGEPREV
Chilled Water Flow STATUS STARTUP
Chilled Water Pump STATUS STARTUP
Chilled Water Temp STATUS MAINSTAT
Chilled Water Temp SERVICE CONTROL ALGORITHM STATUS WSMCHLRE
Chiller Start/Stop STATUS MAINSTAT
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 WSMCHLRE
Commanded State SERVICE CONTROL ALGORITHM STATUS WSMCHLRE
Common Sensor Option SERVICE EQUIPMENT SERVICE LEADLAG X
Comp Discharge Alert SERVICE CONTROL ALGORITHM STATUS OVERRIDE
Comp Discharge Alert SERVICE EQUIPMENT SERVICE SETUP1 X
178
APPENDIX A ICVC PARAMETER INDEX (cont)
PARAMETER
MENU
SOFTKEY
TABLE SCREEN NAME CONFIGURABLE
Comp Discharge Temp STATUS COMPRESS
Comp Discharge Temp SERVICE CONTROL ALGORITHM STATUS OVERRIDE
Comp Motor Temp Override SERVICE CONTROL ALGORITHM STATUS OVERRIDE
Comp Motor Temp Override SERVICE EQUIPMENT SERVICE SETUP1 X
Comp Motor Winding Temp STATUS COMPRESS
Comp Motor Winding Temp SERVICE CONTROL ALGORITHM STATUS OVERRIDE
Comp Thrust Brg Alert SERVICE CONTROL ALGORITHM STATUS OVERRIDE
Comp Thrust Brg Alert SERVICE EQUIPMENT SERVICE SETUP1 X
Comp Thrust Brg Factor SERVICE EQUIPMENT SERVICE SETUP1 X
Comp Thrust Brg Reset STATUS COMPRESS
Comp Thrust Brg Reset SERVICE CONTROL ALGORITHM STATUS OVERRIDE
Comp Thrust Brg Temp STATUS COMPRESS
Comp Thrust Brg Temp SERVICE CONTROL ALGORITHM STATUS OVERRIDE
Comp Thrust Brg Trip SERVICE CONTROL ALGORITHM STATUS OVERRIDE
Comp Thrust Brg Trip SERVICE EQUIPMENT SERVICE SETUP1 X
Comp Thrust Lvg OilTemp STATUS COMPRESS
Comp Thrust Lvg OilTemp SERVICE CONTROL ALGORITHM STATUS OVERRIDE
Compressor Ontime STATUS MAINSTAT
Compressor Run Contact STATUS STARTUP
Compressor Start Contact STATUS STARTUP
Compressor Start Relay STATUS STARTUP
Cond Approach Alert SERVICE EQUIPMENT SERVICE SETUP1 X
Cond Flow Delta P Cutout SERVICE EQUIPMENT SERVICE SETUP1 X
Cond Hi Flow Alarm Opt SERVICE EQUIPMENT SERVICE SETUP1 X
Cond Hi Flow Del P Limit SERVICE EQUIPMENT SERVICE SETUP1 X
Cond Press Override SERVICE CONTROL ALGORITHM STATUS OVERRIDE
Cond Press Override SERVICE EQUIPMENT SERVICE SETUP1 X
Condenser Approach STATUS HEAT_EX
Condenser Freeze Point SERVICE EQUIPMENT SERVICE SETUP1 X
Condenser Pressure STATUS HEAT_EX
Condenser Pressure SERVICE CONTROL ALGORITHM STATUS OVERRIDE
Condenser Refrig Temp STATUS HEAT_EX
Condenser Refrig Temp SERVICE CONTROL ALGORITHM STATUS OVERRIDE
Condenser Water Delta P STATUS HEAT_EX
Condenser Water Flow STATUS STARTUP
Control Mode STATUS MAINSTAT
Control Point STATUS MAINSTAT
Control Point SERVICE CONTROL ALGORITHM STATUS CAPACITY
Control Point Error SERVICE CONTROL ALGORITHM STATUS CAPACITY
Current % Imbalance SERVICE ISM (STARTER) CONFIG DATA ISM_CONF X
Current CHW Setpoint SERVICE CONTROL ALGORITHM STATUS WSMCHLRE
Current Imbalance STATUS ISM_STAT
Current Imbalance Time SERVICE ISM (STARTER) CONFIG DATA ISM_CONF X
Degrees Reset SERVICE EQUIPMENT SERVICE TEMP_CTL X
Degrees Reset SERVICE EQUIPMENT SERVICE TEMP_CTL X
Degrees Reset At 20 Ma SERVICE EQUIPMENT SERVICE TEMP_CTL X
Delta P at 0% (4 Ma) SERVICE EQUIPMENT SERVICE OPTIONS X
Delta P at 100% (20 mA) SERVICE EQUIPMENT SERVICE OPTIONS X
Demand Kilowatt STATUS POWER
Demand Limit and KW Ramp SERVICE EQUIPMENT SERVICE RAMP_DEM 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 SERVICE ICVC CONFIGURATION
Device Name SERVICE ICVC CONFIGURATION
Diffuser Actuator STATUS COMPRESS
Diffuser Full Span mA SERVICE EQUIPMENT SERVICE VDO_SRD X
Diffuser Option SERVICE EQUIPMENT SERVICE VDO_SRD X
Disable Service Password STATUS ICVCPSWD
179
APPENDIX A ICVC PARAMETER INDEX (cont)
PARAMETER
MENU
SOFTKEY
TABLE SCREEN NAME CONFIGURABLE
ECW Control Option SERVICE EQUIPMENT SERVICE TEMP_CTL X
ECW Delta T SERVICE CONTROL ALGORITHM STATUS CAPACITY
ECW Reset SERVICE CONTROL ALGORITHM STATUS CAPACITY
ECW Setpoint SETPOINT SETPOINT X
Emergency Stop STATUS MAINSTAT
Enable Reset Type SERVICE EQUIPMENT SERVICE TEMP_CTL X
Entering Chilled Water STATUS HEAT_EX
Entering Chilled Water SERVICE CONTROL ALGORITHM STATUS CAPACITY
Entering Condenser Water STATUS HEAT_EX
Equipment Status SERVICE CONTROL ALGORITHM STATUS WSMCHLRE
Evap Approach Alert SERVICE EQUIPMENT SERVICE SETUP1 X
Evap Flow Delta P Cutout SERVICE EQUIPMENT SERVICE SETUP1 X
Evap Refrig Liquid Temp STATUS HEAT_EX
Evap Refrig Trippoint SERVICE EQUIPMENT SERVICE SETUP1 X
Evap Sat Override Temp SERVICE CONTROL ALGORITHM STATUS OVERRIDE
Evaporator Approach STATUS HEAT_EX
Evaporator Pressure STATUS HEAT_EX
Flow Delta P Display SERVICE EQUIPMENT SERVICE SETUP1 X
Frequency STATUS POWER
Frequency Out of Range STATUS ISM_STAT
Frequency=60 Hz? (No=50) SERVICE ISM (STARTER) CONFIG DATA ISM_CONF X
Ground Fault STATUS ISM_STAT
Ground Fault CT Ratio: 1 SERVICE ISM (STARTER) CONFIG DATA ISM_CONF X
Ground Fault Current SERVICE ISM (STARTER) CONFIG DATA ISM_CONF X
Ground Fault Persistence SERVICE ISM (STARTER) CONFIG DATA ISM_CONF X
Ground Fault Phase 1 STATUS POWER
Ground Fault Phase 1 SERVICE CONTROL ALGORITHM STATUS ISM_HIST
Ground Fault Phase 2 STATUS POWER
Ground Fault Phase 2 SERVICE CONTROL ALGORITHM STATUS ISM_HIST
Ground Fault Phase 3 STATUS POWER
Ground Fault Phase 3 SERVICE CONTROL ALGORITHM STATUS ISM_HIST
Ground Fault Protection? SERVICE ISM (STARTER) CONFIG DATA ISM_CONF X
Ground Fault Start Delay SERVICE ISM (STARTER) CONFIG DATA ISM_CONF X
Group Number SERVICE EQUIPMENT CONFIGURATION NET_OPT x
Guide Vane 25% Load (2) SERVICE EQUIPMENT SERVICE VDO_SRD X
Guide Vane 50% Load (2) SERVICE EQUIPMENT SERVICE VDO_SRD X
Guide Vane 75% Load (2) SERVICE EQUIPMENT SERVICE VDO_SRD X
Guide Vane Closure SERVICE EQUIPMENT SERVICE OPTIONS X
Guide Vane Delta STATUS COMPRESS
Guide Vane Delta SERVICE CONTROL ALGORITHM STATUS CAPACITY
Guide Vane Delta SERVICE CONTROL ALGORITHM STATUS SURGEPREV
Guide Vane Travel Limit SERVICE EQUIPMENT SERVICE SETUP2 X
Hardware Failure STATUS ISM_STAT
Head Pressure Reference STATUS HEAT_EX
HGBP Off Delta T SERVICE CONTROL ALGORITHM STATUS SURGEPREV
HGBP Off Delta T SERVICE EQUIPMENT SERVICE OPTIONS X
HGBP On Delta T SERVICE CONTROL ALGORITHM STATUS SURGEPREV
HGBP On Delta T SERVICE EQUIPMENT SERVICE OPTIONS X
HGBP/VFD Active SERVICE CONTROL ALGORITHM STATUS SURGEPREV
High Motor Amps STATUS ISM_STAT
Hot Gas Bypass Relay STATUS HEAT_EX
Hot Gas Bypass Relay SERVICE CONTROL ALGORITHM STATUS SURGEPREV
I2T Sum Heat-Phase 1 STATUS POWER
I2T Sum Heat-Phase 1 SERVICE CONTROL ALGORITHM STATUS ISM_HIST
I2T Sum Heat-Phase 2 STATUS POWER
I2T Sum Heat-Phase 2 SERVICE CONTROL ALGORITHM STATUS ISM_HIST
I2T Sum Heat-Phase 3 STATUS POWER
I2T Sum Heat-Phase 3 SERVICE CONTROL ALGORITHM STATUS ISM_HIST
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 SETPOINT X
180
APPENDIX A ICVC PARAMETER INDEX (cont)
PARAMETER
MENU
SOFTKEY
TABLE SCREEN NAME CONFIGURABLE
Ice Build Termination SERVICE EQUIPMENT SERVICE OPTIONS X
ISM Fault Status STATUS STARTUP
ISM Fault Status STATUS ISM_STAT
ISM Fault Status SERVICE CONTROL ALGORITHM STATUS ISM_HIST
ISM Power on Reset STATUS ISM_STAT
LAG % Capacity SERVICE EQUIPMENT SERVICE LEADLAG X
LAG Address SERVICE EQUIPMENT SERVICE LEADLAG X
LAG CHILLER: Mode SERVICE CONTROL ALGORITHM STATUS LL_MAINT
LAG CHILLER: Recovery Start Request SERVICE CONTROL ALGORITHM STATUS LL_MAINT
LAG CHILLER: Run Status SERVICE CONTROL ALGORITHM STATUS LL_MAINT
LAG CHILLER: Start/Stop SERVICE CONTROL ALGORITHM STATUS LL_MAINT
LAG Start Time SERVICE CONTROL ALGORITHM STATUS LL_MAINT
LAG START Timer SERVICE EQUIPMENT SERVICE LEADLAG X
LAG Stop Time SERVICE CONTROL ALGORITHM STATUS LL_MAINT
LAG STOP Timer SERVICE EQUIPMENT SERVICE LEADLAG X
LCW Reset SERVICE CONTROL ALGORITHM STATUS CAPACITY
LCW Setpoint SETPOINT SETPOINT X
LEAD CHILLER in Control SERVICE CONTROL ALGORITHM STATUS LL_MAINT
LEAD/LAG Configuration SERVICE EQUIPMENT SERVICE LEADLAG X
LEAD/LAG: Configuration SERVICE CONTROL ALGORITHM STATUS LL_MAINT
LEAD/LAG: Current Mode SERVICE CONTROL ALGORITHM STATUS LL_MAINT
Leaving Chilled Water STATUS HEAT_EX
Leaving Chilled Water SERVICE CONTROL ALGORITHM STATUS CAPACITY
Leaving Condenser Water STATUS HEAT_EX
LID Language SERVICE ICVC CONFIGURATION
Lift @ 100% Load (1) SERVICE EQUIPMENT SERVICE VDO_SRD X
Lift @ 25% Load (1) SERVICE EQUIPMENT SERVICE VDO_SRD X
Lift @ 25% Load (2) SERVICE EQUIPMENT SERVICE VDO_SRD X
Line Current Phase 1 STATUS POWER
Line Current Phase 1 SERVICE CONTROL ALGORITHM STATUS ISM_HIST
Line Current Phase 2 STATUS POWER
Line Current Phase 2 SERVICE CONTROL ALGORITHM STATUS ISM_HIST
Line Current Phase 3 STATUS POWER
Line Current Phase 3 SERVICE CONTROL ALGORITHM STATUS ISM_HIST
Line Frequency SERVICE CONTROL ALGORITHM STATUS ISM_HIST
Line Frequency Faulting SERVICE ISM (STARTER) CONFIG DATA ISM_CONF X
Line Voltage Phase 1 STATUS POWER
Line Voltage Phase 1 SERVICE CONTROL ALGORITHM STATUS ISM_HIST
Line Voltage Phase 2 STATUS POWER
Line Voltage Phase 2 SERVICE CONTROL ALGORITHM STATUS ISM_HIST
Line Voltage Phase 3 STATUS POWER
Line Voltage Phase 3 SERVICE CONTROL ALGORITHM STATUS ISM_HIST
Load Balance Option SERVICE CONTROL ALGORITHM STATUS LL_MAINT
Load Balance Option SERVICE EQUIPMENT SERVICE LEADLAG X
Loadshed SERVICE CONTROL ALGORITHM STATUS LOADSHED
Loadshed Function SERVICE CONTROL ALGORITHM STATUS LOADSHED
Loadshed Timer SERVICE CONTROL ALGORITHM STATUS LOADSHED
Locked Rotor Start Delay SERVICE ISM (STARTER) CONFIG DATA ISM_CONF X
Locked Rotor Trip STATUS ISM_STAT
Low Lift Profile Select SERVICE EQUIPMENT SERVICE VDO_SRD X
Maximum Loadshed Time SERVICE EQUIPMENT CONFIGURATION NET_OPT x
Minimum Load Point SERVICE EQUIPMENT SERVICE OPTIONS X
Minimum Output SERVICE EQUIPMENT SERVICE OPTIONS X
Model Number SERVICE ICVC CONFIGURATION
Motor Amps Not Sensed STATUS ISM_STAT
Motor Amps When Stopped STATUS ISM_STAT
Motor Current CT Ratio: 1 SERVICE ISM (STARTER) CONFIG DATA ISM_CONF X
Motor Kilowatt-Hours STATUS POWER
Motor Kilowatts STATUS POWER
Motor Locked Rotor Trip SERVICE ISM (STARTER) CONFIG DATA ISM_CONF X
Motor Percent Kilowatts STATUS MAINSTAT
Motor Rated Kilowatts SERVICE EQUIPMENT SERVICE RAMP_DEM X
181
APPENDIX A ICVC PARAMETER INDEX (cont)
PARAMETER
MENU
SOFTKEY
TABLE SCREEN NAME CONFIGURABLE
Motor Rated Line Voltage SERVICE ISM (STARTER) CONFIG DATA ISM_CONF X
Motor Rated Load Amps SERVICE ISM (STARTER) CONFIG DATA ISM_CONF X
Occupied? STATUS MAINSTAT
Oil Heater Relay STATUS COMPRESS
Oil Press Verify Time SERVICE EQUIPMENT SERVICE SETUP1 X
Oil Pump Delta P STATUS STARTUP
Oil Pump Delta P STATUS COMPRESS
Oil Pump Relay STATUS STARTUP
Oil Sump Temp STATUS COMPRESS
Over/Under Volt Time SERVICE ISM (STARTER) CONFIG DATA ISM_CONF X
Overload Trip STATUS ISM_STAT
Override Decrease Active SERVICE CONTROL ALGORITHM STATUS SURGEPREV
Override Inhibit Active SERVICE CONTROL ALGORITHM STATUS SURGEPREV
OverVoltage STATUS ISM_STAT
Overvoltage Threshold SERVICE ISM (STARTER) CONFIG DATA ISM_CONF X
Password SERVICE ICVC CONFIGURATION
Phase 1 Fault STATUS ISM_STAT
Phase 1 Faulted? SERVICE CONTROL ALGORITHM STATUS ISM_HIST
Phase 2 Fault STATUS ISM_STAT
Phase 2 Faulted? SERVICE CONTROL ALGORITHM STATUS ISM_HIST
Phase 3 Fault STATUS ISM_STAT
Phase 3 Faulted? SERVICE 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 X
Proportional Dec Band SERVICE EQUIPMENT SERVICE SETUP2 X
Proportional ECW Gain SERVICE EQUIPMENT SERVICE SETUP2 X
Proportional Inc Band SERVICE EQUIPMENT SERVICE SETUP2 X
Pulldown Ramp Type: SERVICE EQUIPMENT SERVICE RAMP_DEM X
PULLDOWN Time SERVICE CONTROL ALGORITHM STATUS LL_MAINT
PULLDOWN Timer SERVICE EQUIPMENT SERVICE LEADLAG X
Pulldown: Delta T / Min SERVICE CONTROL ALGORITHM STATUS LL_MAINT
Pulldown: Satisfied? SERVICE CONTROL ALGORITHM STATUS LL_MAINT
Ramp Loading Active SERVICE CONTROL ALGORITHM STATUS SURGEPREV
Re-alarm Time SERVICE EQUIPMENT CONFIGURATION NET_OPT x
Redline SERVICE CONTROL ALGORITHM STATUS LOADSHED
Reference Number SERVICE ICVC CONFIGURATION
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 MAINSTAT
Remote Contacts Option SERVICE EQUIPMENT SERVICE OPTIONS X
Remote Reset Option STATUS ICVCPSWD
Remote Reset Sensor STATUS MAINSTAT
Remote Start Contact STATUS MAINSTAT
Remote Temp->Full Reset SERVICE EQUIPMENT SERVICE TEMP_CTL X
Remote Temp->No Reset SERVICE EQUIPMENT SERVICE TEMP_CTL X
Reset Alarm ? STATUS ICVCPSWD
Restart Delta T SERVICE EQUIPMENT SERVICE SETUP1 X
Run Status STATUS MAINSTAT
Schedule Number SERVICE EQUIPMENT CONFIGURATION NET_OPT x
Serial Number SERVICE ICVC CONFIGURATION
Service Ontime STATUS MAINSTAT
Shunt Trip Relay STATUS STARTUP
Shutdown Delta T SERVICE EQUIPMENT SERVICE SETUP1 X
Single Cycle Dropout STATUS ISM_STAT
Single Cycle Dropout SERVICE ISM (STARTER) CONFIG DATA ISM_CONF X
Soft Stop Amps Threshold SERVICE EQUIPMENT SERVICE OPTIONS X
Software Part Number SERVICE ICVC CONFIGURATION
182
APPENDIX A ICVC PARAMETER INDEX (cont)
PARAMETER
MENU
SOFTKEY
TABLE SCREEN NAME CONFIGURABLE
Spare Safety Input STATUS STARTUP
Spare Temp #1 Enable SERVICE EQUIPMENT SERVICE SETUP1 X
Spare Temp #1 Limit SERVICE EQUIPMENT SERVICE SETUP1 X
Spare Temp #2 Enable SERVICE EQUIPMENT SERVICE SETUP1 X
Spare Temp #2 Limit SERVICE EQUIPMENT SERVICE SETUP1 X
Spare Temperature 1 STATUS COMPRESS
Spare Temperature 1 SERVICE CONTROL ALGORITHM STATUS LL_MAINT
Spare Temperature 2 STATUS COMPRESS
Spare Temperature 2 SERVICE CONTROL ALGORITHM STATUS LL_MAINT
Speed Change in Effect SERVICE CONTROL ALGORITHM STATUS SURGEPREV
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 COMPRESS
STANDBY % Capacity SERVICE EQUIPMENT SERVICE LEADLAG X
STANDBY Address SERVICE EQUIPMENT SERVICE LEADLAG X
STANDBY Chiller Option SERVICE EQUIPMENT SERVICE LEADLAG X
STANDBY CHILLER Recovery Start
Request
SERVICE CONTROL ALGORITHM STATUS LL_MAINT
STANDBY CHILLER Run Status SERVICE CONTROL ALGORITHM STATUS LL_MAINT
STANDBY CHILLER Start/Stop SERVICE CONTROL ALGORITHM STATUS LL_MAINT
STANDBY CHILLER: Mode SERVICE CONTROL ALGORITHM STATUS LL_MAINT
Start Inhibit Timer STATUS MAINSTAT
Starter Acceleration Fault STATUS ISM_STAT
Starter Fault STATUS STARTUP
Starter Fault STATUS ISM_STAT
Starter LRA Rating SERVICE ISM (STARTER) CONFIG DATA ISM_CONF X
Starter LRA Trip STATUS ISM_STAT
Starter Trans Relay STATUS STARTUP
Starter Type SERVICE ISM (STARTER) CONFIG DATA ISM_CONF X
Starts In 12 Hours STATUS MAINSTAT
Superheat Required SERVICE CONTROL ALGORITHM STATUS OVERRIDE
Surge Counts SERVICE CONTROL ALGORITHM STATUS SURGEPREV
Surge Delay Time SERVICE EQUIPMENT SERVICE OPTIONS X
Surge Delta % Amps SERVICE EQUIPMENT SERVICE OPTIONS X
Surge Limit/HGBP Option SERVICE CONTROL ALGORITHM STATUS SURGEPREV
Surge Limit/HGBP Option SERVICE EQUIPMENT SERVICE OPTIONS X
Surge Line Delta Tsat STATUS COMPRESS
Surge Line Delta Tsat STATUS HEAT_EX
Surge Line Delta Tsat SERVICE CONTROL ALGORITHM STATUS SURGEPREV
Surge Line High Offset SERVICE EQUIPMENT SERVICE OPTIONS X
Surge Line Shape Factor SERVICE EQUIPMENT SERVICE OPTIONS X
Surge Line Speed Factor SERVICE EQUIPMENT SERVICE OPTIONS X
Surge Prevention Active? STATUS COMPRESS
Surge Prevention Active? STATUS HEAT_EX
Surge Prevention Active? SERVICE CONTROL ALGORITHM STATUS SURGEPREV
Surge Protection Counts STATUS COMPRESS
Surge Protection Counts SERVICE CONTROL ALGORITHM STATUS SURGEPREV
Surge Time Period SERVICE EQUIPMENT SERVICE OPTIONS X
Surge/HGBP Deadband SERVICE EQUIPMENT SERVICE OPTIONS X
Surge/HGBP Delta Tsmax SERVICE EQUIPMENT SERVICE OPTIONS X
Surge/HGBP Delta Tsmin SERVICE EQUIPMENT SERVICE OPTIONS X
Surge/HGBP IGVmax SERVICE EQUIPMENT SERVICE OPTIONS X
Surge/HGBP IGVmin SERVICE EQUIPMENT SERVICE OPTIONS X
System Alert/Alarm STATUS MAINSTAT
Target Guide Vane Pos STATUS COMPRESS
Target Guide Vane Pos SERVICE CONTROL ALGORITHM STATUS CAPACITY
Target Guide Vane Pos SERVICE CONTROL ALGORITHM STATUS SURGEPREV
Target VFD Speed STATUS COMPRESS
Target VFD Speed SERVICE CONTROL ALGORITHM STATUS CAPACITY
Target VFD Speed SERVICE CONTROL ALGORITHM STATUS SURGEPREV
183
APPENDIX A ICVC PARAMETER INDEX (cont)
LEGEND
PARAMETER
MENU
SOFTKEY
TABLE SCREEN NAME CONFIGURABLE
Temp Pulldown Ramp SERVICE EQUIPMENT SERVICE TEMP_CTL X
Temperature Reset STATUS MAINSTAT
Temperature Reset SERVICE EQUIPMENT SERVICE TEMP_CTL X
Total Compressor Starts STATUS MAINSTAT
Total Error + Resets SERVICE CONTROL ALGORITHM STATUS CAPACITY
Tower Fan High Setpoint SETPOINT SETPOINT X
Tower Fan Relay High STATUS STARTUP
Tower Fan Relay Low STATUS STARTUP
UnderVoltage STATUS ISM_STAT
Undervoltage Threshold SERVICE ISM (STARTER) CONFIG DATA ISM_CONF X
US Imp / Metric SERVICE ICVC CONFIGURATION
VFD Current Limit SERVICE EQUIPMENT SERVICE SETUP2 X
VFD Gain 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 SURGEPREV
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 SURGEPREV
VFD Speed Factor SERVICE CONTROL ALGORITHM STATUS SURGEPREV
VFD Start Speed SERVICE EQUIPMENT SERVICE SETUP2 X
VFD Surge Line Gain SERVICE EQUIPMENT SERVICE SETUP2 X
Volt Transformer Ratio:1 SERVICE ISM (STARTER) CONFIG DATA ISM_CONF X
Voltage % Imbalance SERVICE ISM (STARTER) CONFIG DATA ISM_CONF X
Voltage Imbalance STATUS ISM_STAT
Voltage Imbalance Time SERVICE ISM (STARTER) CONFIG DATA ISM_CONF X
Water Flow Verify Time SERVICE EQUIPMENT SERVICE SETUP1 X
Water Pump STATUS STARTUP
WSM Active? SERVICE CONTROL ALGORITHM STATUS WSMCHLRE
CCN Carrier Comfort Network
CHW Chilled Water
ECW Entering Chilled Water
HGBP Hot Gas Bypass
ISM Integrated Starter Module
LCW Leaving Chilled Water
LID Local Interface Device
LRA Locked Rotor Amps
SRD Split Ring Diffuser
VFD Variable Frequency Drive
WSM Water System Manager
184
APPENDIX B LEAD/LAG WIRING
1
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185
APPENDIX B LEAD/LAG WIRING (cont)
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186
APPENDIX C MAINTENANCE SUMMARY AND LOG SHEETS
19XR,XRV Maintenance Interval Requirements
NOTE: Equipment failures caused by lack of adherence to the Main-
tenance Interval Requirements are not covered under warranty.
WEEKLY
Compressor Check Oil Level. Controls Review ICVC Alarm/Alert History.
Cooler None. Starter None.
Condenser None. Oil Reclaim None.
MONTHLY
Compressor None. Controls Perform an Automated Controls test.
Cooler None. Starter None.
Condenser None. Oil Reclaim None.
FIRST YEAR
Compressor
Change oil filter. Send oil sample out for anal-
ysis. Change oil if required by analysis. Leak
test.
Controls
Perform general cleaning. Tighten connections. Check
pressure transducers. Confirm accuracy of thermistors.
Cooler
Inspect and clean cooler tubes. Inspect relief
valves. Leak test. Verify water pressure differ-
ential. Inspect water pumps and cooling
tower.
Starter
Perform general cleaning. Tighten connections. Change
VFD refrigerant strainer.
Condenser
Replace refrigerant filter/drier. Inspect and
clean condenser tubes. Inspect relief valves.
Leak test. Verify water pressure differential.
Inspect water pumps and cooling tower.
Oil Reclaim Inspect oil sump strainer.
ANNUALLY
Compressor
Change oil filter. Send oil sample out for anal-
ysis. Change oil if required by analysis. Leak
test.
Controls
Perform general cleaning. Tighten connections. Check
pressure transducers. Confirm accuracy of thermistors.
Cooler
Inspect and clean cooler tubes. Inspect relief
valves. Leak test. Verify water pressure differ-
ential. Inspect water pumps and cooling
tower.
Starter
Perform general cleaning. Tighten connections. Change
VFD refrigerant strainer.
Condenser
Replace refrigerant filter/drier. Inspect and
clean condenser tubes. Inspect relief valves.
Leak test. Verify water pressure differential.
Inspect water pumps and cooling tower.
Oil Reclaim None.
EVERY 3-5 YEARS
Compressor None. Controls None.
Cooler Perform eddy current test. Starter None.
Condenser
Inspect float valve and strainer. Perform eddy
current test.
Oil Reclaim None.
EVERY 5 YEARS
Compressor
Change oil charge (if required based on oil
analysis or if oil analysis has not been per-
formed). Inspect compressor shafts and
bearings (every 5-10 years).
Controls None.
Cooler None. Starter None.
Condenser None. Oil Reclaim
Inspect oil sump strainer. Inspect oil sump heater. Replace
the oil reclaim filter.
SEASONAL SHUTDOWN
Compressor None. Controls Do not disconnect control power.
Cooler
Isolate and drain waterbox. Remove water-
box cover from one end. Use compressed air
to clear tubes.
Starter None.
Condenser
Isolate and drain waterbox. Remove water-
box cover from one end. Use compressed air
to clear tubes.
Oil Reclaim None.
187
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189
APPENDIX D BACNET COMMUNICATION OPTION
The following section is used to configure the UPC Open con-
troller which is used when the BACnet* communication 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 proce-
dure to assign an address:
1. If the UPC Open controller is powered, pull the screw ter-
minal connector from the controller's power terminals la-
beled 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 con-
troller's address. Set the Tens (10's) switch to the tens dig-
it of the address, and set the Ones (1's) switch to the ones
digit.
As an example in Fig. B, if the controllers 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.
BACNET DEVICE INSTANCE ADDRESS The UPC
Open controller also has a BACnet Device Instance address.
This Device Instance MUST be unique for the complete BAC-
net 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 In-
stance of 16101 + 20 which would be a Device Instance of
1610120.
10's
1's
1
3
4
5
2
7
8
9
6
0
1
3
4
5
2
7
8
9
6
0
Fig. B Address Rotary Switches
A48-8579
Fig. A UPC Open Controller
8
7
6
5
4
3
2
1
0
9
8
7
6
5
4
3
2
1
0
9
BACNET
BAUD RATE
DIP SWITCHES
ADDRESS
ROTARY
SWITCHES
POWER LED
RUN LED
ERROR LED
BACNET
CONNECTION
(BAS PORT)
BT485
TERMINATOR
Tx2 LED
Rx2 LED
Tx1 LED
Rx1 LED
EIA-485
JUMPERS
* Sponsored by ASHRAE (American Society of Heating, Refrigerat-
ing and Air-Conditioning Engineers).
A48-8578
190
APPENDIX D BACNET COMMUNICATION OPTION (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 con-
troller 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 termi-
nals 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.
Table A SW3 Protocol Switch Settings
for MS/TP
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 appro-
priate 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
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.
Wire the controllers on an MS/TP network segment in a dai-
sy-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 ports
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 current-
ly 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.

DS8 DS7 DS6 DS5 DS4 DS3
Off Off Off Off On Off
BAUD RATE DS2 DS1
9,600 Off Off
19,200 On Off
38,400 Off On
76,800 On On
Fig. C DIP Switches
A48-
8580
Fig. D Network Wiring
A48-8581
191
APPENDIX D BACNET COMMUNICATION OPTION (cont)
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 Recommen-
dations are shown in Tables C and D. The wire jacket and UL
temperature rating specifications list two acceptable alterna-
tives. 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
LEGEND
Fig. E BT485 Terminator Installation
A48-8582
SPECIFICATION RECOMMMENDATION
Cable Single twisted pair, low capacitance, CL2P, 22 AWG (7x30), TC foam FEP, plenum rated cable
Conductor 22 or 24 AWG stranded copper (tin plated)
Insulation Foamed FEP 0.015 in. (0.381 mm) wall 0.060 in. (1.524 mm) O.D.
Color Code Black/White
Twist Lay 2 in. (50.8 mm) lay on pair 6 twists/foot (20 twists/meter) nominal
Shielding Aluminum/Mylar shield with 24 AWG TC drain wire
Jacket
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.
DC Resistance 15.2 Ohms/1000 feet (50 Ohms/km) nominal
Capacitance 12.5 pF/ft (41 pF/meter) nominal conductor to conductor
Characteristic Impedance 100 Ohms nominal
Weight 12 lb/1000 feet (17.9 kg/km)
UL Temperature Rating
SmokeGard 167F (75C)
Halar -40 to 302F (-40 to 150C)
Voltage 300 Vac, power limited
Listing UL: NEC CL2P, or better
AWG American Wire Gage
CL2P Class 2 Plenum Cable
DC Direct Current
FEP Fluorinated Ethylene Polymer
NEC National Electrical Code
O.D. Outside Diameter
TC Tinned Copper
UL Underwriters Laboratories
192
APPENDIX D BACNET COMMUNICATION OPTION (cont)
Table D Open System Wiring Specifications and Recommended Vendors
LEGEND
LOCAL ACCESS TO THE UPC OPEN CONTROL-
LER The user can use a BACview
6
handheld keypad dis-
play unit or the Virtual BACview software as a local user inter-
face 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 BACview
6
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 re-
quire an additional USB link cable for connection.
See the BACview Installation and User Guide for instruc-
tions on connecting and using the BACview
6
device.
To order a BACview
6
Handheld (BV6H), consult Commer-
cial 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) num-
ber and CCN Bus number. The factory default settings for
CCN Element and CCN Bus number are 1 and 0 respectively.
If modifications to the default Element and Bus number are
required, both the ComfortLink and UPC Open configurations
must be changed.
The following configurations are used to set the CCN Ad-
dress and Bus number in the ComfortLink control. These con-
figurations can be changed using the scrolling marquee display
or accessory Navigator handheld device.
ConfigurationCCNCCN.A (CCN Address)
ConfigurationCCNCCN.B (CCN Bus Number)
The following configurations are used to set the CCN Ad-
dress and Bus Number in the UPC Open controller. These con-
figurations can be changed using the accessory BACview
6
display.
Navigation: BACviewCCN
Home: Element Comm Stat
Element: 1
Bus: 0
TROUBLESHOOTING If there are problems wiring or
addressing the UPC Open controller, contact Carrier Technical
Support.
WIRING SPECIFICATIONS RECOMMENDED VENDORS AND PART NUMBERS
Wire Type Description
Connect Air
International
Belden RMCORP
Contractors
Wire and Cable
MS/TP
Network (RS-485)
22 AWG, single twisted shielded pair, low capacitance, CL2P,
TC foam FEP, plenum rated. See MS/TP Installation Guide for
specifications.
W221P-22227 25160PV CLP0520LC
24 AWG, single twisted shielded pair, low capacitance, CL2P,
TC foam FEP, plenum rated. See MS/TP Installation Guide
for specifications.
W241P-2000F 82841 25120-OR
Rnet 4 conductor, unshielded, CMP, 18 AWG, plenum rated. W184C-2099BLB 6302UE 21450 CLP0442
AWG American Wire Gage
CL2P Class 2 Plenum Cable
CMP Communications Plenum Rated
FEP Fluorinated Ethylene Polymer
TC Tinned Copper
Fig. F BACview
6
Device Connection
A48-8583
193
APPENDIX D BACNET COMMUNICATION OPTION (cont)
COMMUNICATION LEDS The LEDs indicate if the
controller is communicating with the devices on the network.
See Tables E and F. The LEDs should reflect communication
traffic based on the baud rate set. The higher the baud rate the
more solid the LEDs become. See Fig. A for location of LEDs
on UPC Open module.
REPLACING THE UPC OPEN BATTERY The UPC
Open controller's 10-year lithium CR2032 battery provides a
minimum of 10,000 hours of data retention during power
outages.
Remove the battery from the controller, making note of the
battery's polarity. Insert the new battery, matching the battery's
polarity with the polarity indicated on the UPC Open
controller.
NETWORK POINTS LIST The points list for the control-
ler is shown in Table G.
Table E LED Status Indicators
Table F Run and Error LEDs Controller and Network Status Indication
IMPORTANT: Power must be ON to the UPC Open when
replacing the battery, or the date, time, and trend data will
be lost.
LED STATUS
Power
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.
Rx Lights when the controller receives data from the network segment; there is an Rx LED for Ports 1 and 2.
Tx Lights when the controller transmits data to the network segment; there is an Tx LED for Ports 1 and 2.
Run Lights based on controller status. See Table F.
Error Lights based on controller status. See Table F.
RUN LED ERROR LED STATUS
2 flashes per second Off Normal
2 flashes per second 2 flashes, alternating with Run LED Five minute auto-restart delay after system error
2 flashes per second 3 flashes, then off Controller has just been formatted
2 flashes per second 1 flash per second Controller is alone on the network
2 flashes per second On Exec halted after frequent system errors or control programs halted
5 flashes per second On Exec start-up aborted, Boot is running
5 flashes per second Off Firmware transfer in progress, Boot is running
7 flashes per second 7 flashes per second, alternating with Run LED Ten second recovery period after brownout
14 flashes per second 14 flashes per second, alternating with Run LED Brownout
194
APPENDIX D BACNET COMMUNICATION OPTION (cont)
Table G UPC Open Points List for Version 11 19XR Software
LEGEND
POINT DESCRIPTION
CCN
POINT NAME
READ/
WRITE
UNITS RANGE
BACNET
OBJECT ID
BACNET
OBJECT NAME
Active Demand Limit DEM_LIM R/W % 40 to 100 AV:6 dem_lim_1
Actual Guide Vane Position GV_POS R % AV:7 gv_pos_1
Actual Line Current AMP_A R A AV:8 amps_a_1
Actual Line Voltage VOLT_A R V AV:9 volt_a_1
Actual VFD Speed VFD_ACT R % AV:11 vfd_act_1
Calc Evap Sat Temp ERT R F AV:13 ert_1
Chilled Water Deadband CWDB R ^F AV:14 cwdb_1
Chilled Water Delta P CHWPD R ^F AV:15 chwpd_1
Chilled Water Delta T CHW_DT R ^F AV:16 chw_dt_1
Chilled Water Pump CHWP R BV:4 chwp_1
Chilled Water Temp CHW_TMP R F AV:17 chw_tmp_1
Chiller S/S CHIL_S_S R/W STOP/START BV:5 chil_s_s_1
Comp Discharge Temp CMPD R F AV:18 cmpd_1
Comp Motor Winding Temp MTRW R F AV:19 mtrw_1
Comp Thrust Brg Temp MTRB R F AV:20 mtrb_1
Condenser Pressure CRP R PSI AV:21 crp_1
Condenser Refrig Temp CRT R F AV:22 crt_1
Condenser Water Delta P CDWPD R PSI AV:23 cdwpd_1
Control Point LCW_STPT R/W F -10 to 120 AV:24 lcw_stpt_1
Cond Water Flow CDW_FLOW R BV:6 cdw_flow_1
Cond Water Pump CDP R BV:7 cdp_1
Current CHW Setpoint CHWSTPT R F AV:25 chwstpt_1
Demand Level 1 N/A R % AV:1
dmv_lvl_1_perct_
1
Demand Level 2 N/A R % AV:2
dmv_lvl_2_perct_
1
Demand Level 3 N/A R % AV:3
dmv_lvl_3_perct_
1
Element Communications Alarm N/A R BV:20
comm_lost_alm_
1
Element Comm Status N/A R BV:2999 element_stat_1
Emergency Stop EMSTOP R BV:8 emstop_1
Entering Chilled Water ECW R F AV:26 ecw_1
Entering Condenser Water ECDW R F AV:27 ecdw_1
Equipment Alarm N/A R BV:21 element_alarm_1
Evaporator Pressure ERP R PSI AV:28 erp_1
Frequency FREQ R Hz AV:30 freq_1
Hardware Failure HARDWARE R BV:9 hardware_1
Leaving Chilled Water - Prime
Variable
LCW R F AV:31 lcw_1
Leaving Condenser Water LCDW R F AV:32 lcdw_1
Local Schedule N/A R BV:2 schedule_1
Occupied? OCC R BV:10 occ_1
Oil Sump Temperature OILT R F AV:33 oilt_1
Overload Trip OVERLOAD R BV:12 overload_1
Power Factor POW_FACT R AV:34 pow_fact_1
Remote Start Contact REMCON R/W OPEN/CLOSE BV:11 remcon_1
Run Status STATUS R
0=Timeout
1=Ready
2=Recyle
3=Startup
4=Running
5=Demand
6=Ramping
7=not used
8=Override
9=Tripout
10=Control
AV:35 status_1
Service Ontime S_HRS R/W hr 0 to 32767 AV:36 s_hrs_1
CHW Chilled Water
R Read
VFD Variable Frequency Drive
W Write
195
APPENDIX D BACNET COMMUNICATION OPTION (cont)
Table G UPC Open Points List for Version 11 19XR Software (cont)
LEGEND
POINT DESCRIPTION
CCN
POINT NAME
READ/
WRITE
UNITS RANGE
BACNET
OBJECT ID
BACNET
OBJECT NAME
System Alert/Alarm SYS_ALM R
1=Normal
2=Alert
3=Alarm
AV:40 sys_alm_1
System Cooling Demand Level N/A R AV:9006
cool_demand_lev
el_1
System Demand Limiting N/A R BV:3 dem_lmt_act_1
Target Guide Vane Position GV_TRG R % AV:41 gv_trg_1
Target VFD Speed VFD_OUT R % AV:42 vfd_out_1
Twr Fan Relay High TFR_LOW R BV:13 tfr_high_1
Twr Fan Relay Low TFR_HIGH R BV:14 tfr_low_1
User Defined Analog 1 N/A R AV:2901 user_analog_1_1
User Defined Analog 2 N/A R AV:2902 user_analog_2_1
User Defined Analog 3 N/A R AV:2903 user_analog_3_1
User Defined Analog 4 N/A R AV:2904 user_analog_4_1
User Defined Analog 5 N/A R AV:2905 user_analog_5_1
User Defined Binary 1 N/A R BV:2911 user_binary_1_1
User Defined Binary 2 N/A R BV:2912 user_binary_2_1
User Defined Binary 3 N/A R BV:2913 user_binary_3_1
User Defined Binary 4 N/A R BV:2914 user_binary_4_1
User Defined Binary 5 N/A R BV:2915 user_binary_5_1
CHW Chilled Water
R Read
VFD Variable Frequency Drive
W Write
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Catalog No. 04-53190022-01 Printed in U.S.A. Form 19XR,XRV-CLT-9SS Pg 196 10-13 Replaces: 19XR-6SS
Carrier Corporation 2013
INDEX
Abbreviations and Explanations, 5
Accidental Start-Up (Prevent), 85
Adding Refrigerant, 92
Adjusting the Refrigerant Charge, 92
After Extended Shutdown, 86
After Limited Shutdown, 86
Alarm (Trip) Output Contacts, 53
Attach to Network Device Control, 61
Automatic Soft Stop Amps Threshold, 65
Auto. Restart After Power Failure, 54
BACnet Communication Option, 189-195
Bearings, 13
Before Initial Start-Up, 66-84
Capacity Override, 51
Carrier Comfort Network Interface, 71
Changing Oil Filter, 94
Charge Refrigerant Into Chiller, 82
Chilled Water Recycle Mode, 65
Chiller Control Module (CCM), 115
Chiller Dehydration, 70
Chiller Familiarization, 5-9
Chiller Information Nameplate, 5
Chiller Operating Condition (Check), 85
Chiller Tightness (Check), 66
Cold Weather Operation, 86
Compressor Bearing and Gear
Maintenance, 95
Compressor Bearing Temperature, 51
Condenser, 7
Condenser Freeze Prevention, 54
Condenser Pump Control, 53
Control Algorithms Checkout Procedure, 115
Control Panel, 7
Control Modules, 115
Control Test, 80, 115
Controls, 17-63
Cooler, 7
Default Screen Freeze, 50
Definitions (Controls), 17
Demand Limit Control Option, 55
Design Set Points, (Input), 73
Display Messages (Check), 97
Dry Run to Test Start-Up Sequence, 84
Economizer (option), 7
Equipment Required, 66
Evaporator Freeze Protection, 54
Extended Shutdown (Preparation for), 86
Factory-Mounted Starter or Variable
Frequency Drive, 7
Fast Power Source Transfer, 55
Function Loss Trip, 47
Guide Vane Linkage (Check), 92
Head Pressure Reference Output, 57
Heat Exchanger Tubes and Flow Devices
(Inspect), 96
High Altitude Locations, 82
High Discharge Temperature Control, 51
Hot Gas bypass Algorithm, 55
Ice Build Control, 60
ICVC Operation and Menus, 20
ICVC Parameter Index, 117-183
Initial Start-Up, 84-86
Initial Start-Up Checklist for 19XR,XRV
Hermetic Centrifugal Liquid Chiller, CL-1
to CL-14
Inspect the Control Panel, 93
Instruct the Customer Operator, 85
Integrated Starter Module (ISM), 115
Introduction, 5
Job Data Required, 66
Kilowatt Output, 53
Lead/Lag Control, 58
Lead/Lag Wiring, 184, 185
Leak Rate, 92
Leak Test Chiller, 67
Local Occupied Schedule (Input), 73
Local Start-Up, 63
Lubrication Cycle, 12-14
Lubrication System (Check), 93
Maintenance, 92-97
Maintenance Summary and Log Sheets,
186-188
Manual Guide Vane Operation, 87
Motor and Oil Cooling Cycle, 11
Motor-Compressor, 7
Motor Rotation (Check), 85
Notes on Module Operation, 115
Oil Changes, 94
Oil Charge, 72
Oil Cooler, 53
Oil Pressure and Compressor Stop
(Check), 85
Oil Reclaim Filter, 94
Oil Reclaim System, 13
Oil Specification, 94
Oil Sump Temperature and Pump Control, 51
Open Oil Circuit Valves, 66
Operating Instructions, 86, 87
Operating the Optional Pumpout Unit, 89
Operator Duties, 86
Optional Pumpout Compressor Water
Piping (Check), 71
Optional Pumpout System Controls and
Compressor (Check), 82
Optional Pumpout System Maintenance, 96
Optional Storage Tank and Pumpout
System, 66
Ordering Replacement Chiller Parts, 97
Overview (Troubleshooting Guide), 97
Physical Data, 119
PIC II System Components, 17
PIC II System Functions, 42
Power Up the Controls and Check the Oil
Heater, 72
Prepare the Chiller for Start-Up, 86
Pressure Transducers (Check), 114
Pressure Transducers (Recalibrate), 96
Prevent Accidental Start-Up, 85
Pump and Fan Control, 47
Pumpout and Refrigerant Transfer
Procedures, 87-92
Rampdown, 51
Ramp Loading, 51
Refrigerant Filter, 94
Refrigerant Float System (Inspect), 94
Refrigerant Leak Detector, 53
Refrigerant Leak Testing, 92
Refrigerant Properties, 92
Refrigerant Tracer, 66
Refrigeration Cycle, 10, 11
Refrigeration Log, 87
Relief Valves (Check), 71
Relief Valves and Piping (Inspect), 95
Remote Reset of Alarms, 53
Remote Start/Stop Controls, 53
Repair the Leak, Retest, and
Apply Standing Vacuum Test, 92
Replacing Defective Processor Modules, 118
Running System (Check), 86
Safety and Operating Controls (Check
Monthly), 94
Safety Considerations, 1, 2
Safety Controls, 47
Safety Shutdown, 66
Scheduled Maintenance, 93-97
Service Configurations (Input), 73
Service Ontime, 93
Service Operation, 62
Shipping Packaging (Remove), 66
Shunt Trip (Option), 47
Shutdown Sequence, 65
Software Configuration, 73
Solid-State Starters, 118
Spare Safety Inputs and Spare Temperature
Inputs, 53
Standing Vacuum Test, 70
Starter (Check), 72
Starting Equipment, 14-17
Starting Equipment (Inspect), 96
Start-Up (Initial), 84-86
Start-Up/Shutdown/Recycle Sequence, 63-66
Start the Chiller, 86
Stop the Chiller, 86
Storage Vessel, 7
Surge Prevention Algorithm with VFD, 56
Surge Prevention - Constant Flow and
Variable Primary Flow (VPF), 55
Surge Protection (Fixed Speed Chillers), 56
Surge Protection (VFD Chiller), 57
System Components, 5
Temperature Sensors (Check), 97
Test After Service, Repair, or Major Leak, 92
Tighten All Gasketed Joints and Guide Vane
Shaft Packing, 66
Tower Fan Relay Low and High, 54
Trim Refrigerant Charge, 93
Troubleshooting Guide, 97-176
Unit-Mounted Solid-State Starter, 14
Unit-Mounted VFD, 16
Unit-Mounted Wye-Delta Starter, 16
VFD Cooling Cycle, 12
VFD Field Set Up and Verification, 74
VFD Start-Up Speed Control, 57
Water/Brine Reset, 55
Water Leaks, 96
Water Piping (Inspect), 70
Water Treatment, 96
Weekly Maintenance, 93
Wiring (Inspect), 71
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Catalog No. 04-53190022-01 Printed in U.S.A. Form 19XR,XRV-CLT-9SS Pg CL-1 10-13 Replaces: 19XR-6SS
INITIAL START-UP CHECKLIST
FOR 19XR, XRV HERMETIC CENTRIFUGAL LIQUID CHILLER
(Remove and use for job file.)
MACHINE INFORMATION:
DESIGN CONDITIONS:
CONTROL/OIL HEATER: Volts 115 230
REFRIGERANT: Type: Charge
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:
RECORD PRESSURE DROPS: Cooler Condenser
CHARGE REFRIGERANT: Initial Charge Final Charge After Trim
NAME JOB NO.
ADDRESS MODEL
CITY STATE ZIP S/N
TONS BRINE
FLOW
RATE
TEMPERATURE
IN
TEMPERATURE
OUT
PRESSURE
DROP
PASS
SUCTION
TEMPERATURE
CONDENSER
TEMPERATURE
COOLER ******
CONDENSER ******
COMPRESSOR: Volts RLA OLTA
STARTER: Mfg Type S/N
OIL PUMP: Volts RLA OLTA
CARRIER OBLIGATIONS: Assemble... . . . . . . . . . . . . . . . . Yes No
Leak Test . . . . . . . . . . . . . . . . . . . Yes No
Dehydrate . . . . . . . . . . . . . . . . . . Yes No
Charging . . . . . . . . . . . . . . . . . . . Yes No
Operating Instructions Hrs.
YES NO
Was Machine Tight?
If Not, Were Leaks Corrected?
Was Machine Dehydrated After Repairs?
CHECK OIL LEVEL AND RECORD: ADD OIL: Yes No
Amount:
1/2 Top sight glass
1/2 Bottom sight glass
3/4
1/4
3/4
1/4
CL-2
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INSPECT WIRING AND RECORD ELECTRICAL DATA:
RATINGS:
Motor Voltage Motor(s) Amps Oil Pump Voltage Starter LRA Rating
Line Voltages: Motor Oil Pump Controls/Oil Heater
CONTROLS: SAFETY, OPERATING, ETC.
Perform Controls Test (Yes/No)
INITIAL START:
Line Up All Valves in Accordance With Instruction Manual:
Start Water Pumps and Establish Water Flow
Oil Level OK and Oil Temperature OK Check Oil Pump Rotation-Pressure
Check Compressor Motor Rotation (Motor End Sight Glass) and Record: Clockwise
Restart Compressor, Bring Up To Speed. Shut Down. Any Abnormal Coastdown Noise? Yes* No
*If yes, determine cause.
START MACHINE AND OPERATE. COMPLETE THE FOLLOWING:
A: Trim charge and record under Charge Refrigerant section.
B: Complete any remaining control calibration and record under Controls section.
C: Take at least two sets of operational log readings and record.
D: After machine has been successfully run and set up, shut down and mark shutdown oil and refrigerant levels.
E: Give operating instructions to owners operating personnel. Hours Given: Hours
F: Call your Carrier factory representative to report chiller start-up.
SIGNATURES:
CARRIER
TECHNICIAN
DATE
CUSTOMER
REPRESENTATIVE
DATE
CAUTION
COMPRESSOR MOTOR AND CONTROL PANEL MUST BE PROPERLY AND INDIVIDUALLY
CONNECTED BACK TO THE EARTH GROUND IN THE STARTER (IN ACCORDANCE WITH
CERTIFIED DRAWINGS).
Yes
WATER/BRINE PUMP CONTROL: Can the Carrier controls independently start the
pumps?
Condenser Water Pump Yes No
Chilled Water Pump Yes No
RUN MACHINE: Do these safeties shut down machine?
Condenser Water Flow Yes No
Chilled Water Flow Yes No
Pump Interlocks Yes No
CL-3
19XR, XRV PIC II SETPOINT TABLE CONFIGURATION SHEET
ICVC Software Version Number:
ICVC Controller Identification: BUS: ADDRESS:
DESCRIPTION RANGE UNITS DEFAULT VALUE
Base Demand Limit 40 to 100 % 100
LCW Setpoint
10 to 120
-9.4 to 48.9
DEG F
DEG C
50.0
10.0
ECW Setpoint
15 to 120
-12.2 to 48.9
DEG F
DEG C
60.0
15.6
Ice Build Setpoint
15 to 60
-9.4 to 15.6
DEG F
DEG C
40.0
4.4
Tower Fan High Setpoint
55 to 105
13 to 41
DEG F
DEG C
75
24
CL-4
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NOTE: Default setting is OCCUPIED 24 hours/day.
NOTE: Default setting is UNOCCUPIED 24 hours/day.
NOTE: Default setting is OCCUPIED 24 hours/day.
19XR, XRV PIC II TIME SCHEDULE CONFIGURATION SHEET OCCPC01S
Day Flag
Occupied
Time
Unoccupied
Time
M T W T F S S H
Period 1:
Period 2:
Period 3:
Period 4:
Period 5:
Period 6:
Period 7:
Period 8:
ICE BUILD 19XR, XRV PIC II TIME SCHEDULE CONFIGURATION SHEET OCCPC02S
Day Flag
Occupied
Time
Unoccupied
Time
M T W T F S S H
Period 1:
Period 2:
Period 3:
Period 4:
Period 5:
Period 6:
Period 7:
Period 8:
19XR, XRV PIC II TIME SCHEDULE CONFIGURATION SHEET OCCPC03S
Day Flag
Occupied
Time
Unoccupied
Time
M T W T F S S H
Period 1:
Period 2:
Period 3:
Period 4:
Period 5:
Period 6:
Period 7:
Period 8:
CL-5
19XR, XRV PIC II ISM_CONF TABLE CONFIGURATION SHEET
DESCRIPTION RANGE UNITS DEFAULT VALUE
Starter Type
(0=Full, 1=Red, 2=SS/VFD, 3=VFD)
0 to 3 1
Motor Rated Line Voltage 200 to 13200 VOLTS 460
Volt Transformer Ratio: 1 1 to 115 1
Overvoltage Threshold 105 to 115 % 115
Undervoltage Threshold 85 to 95 % 85
Over/Under Volt Time 1 to 10 SEC 5
Voltage% Imbalance 1 to 10 % 10
Voltage Imbalance Time 1 to 10 SEC 5
Motor Rated Load Amps 10 to 5000 AMPS 200
Motor Locked Rotor Trip 100 to 60000 AMPS 1000
Locked Rotor Start Delay 1 to 10 cycles 5
Starter LRA Rating 100 to 60000 AMPS 2000
Motor Current CT Ratio: 1 10 to 1000 100
Current% Imbalance 5 to 40 % 15
Current Imbalance Time 1 to 10 SEC 5
Grnd Fault CTs? 0/1 NO/YES YES
Ground Fault CT Ratio: 1 150 150
Ground Fault Current 1 to 25 AMPS 15
Ground Fault Start Delay 1 to 20 cycles 10
Ground Fault Persistence 1 to 10 cycles 5
Single Cycle Dropout 0/1 DSABLE/ENABLE DSABLE
Frequency-60 Hz? (No=50) 0/1 NO/YES YES
Line Frequency Faulting 0/1 DSABLE/ENABLE DSABLE
CL-6
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19XR, XRV PIC II OPTIONS TABLE CONFIGURATION SHEET
NOTE: No variables are available for CCN read or write operation.
DESCRIPTION RANGE UNITS DEFAULT VALUE
Auto Restart Option 0/1 DSABLE/ENABLE DSABLE
Guide Vane Closure 4 to 25 % 4
Remote Contacts Option 0/1 DSABLE/ENABLE DSABLE
Soft Stop Amps Threshold 40 to 100 % 100
Surge / Hot Gas Bypass
Surge Limit/HGBP Option 0, 1, 2 0
Select: Surge=0, HGBP=1
Low Load HGBP=2
Minimum Load Point
Surge/HGBP Delta Tsmin 0.0 to 150.0 F 45
Surge/HGBP IGVmin 0.0 to 110.0 % 5.0
Full Load Point
Surge/HGBP Delta Tsmax 0.0 to 150.0 F 70
Surge/HGBP IGVmax 0.0 to 110.0 % 5.0
Surge Line Shape Factor 1.000 to 0.000 0.040
Surge Line Speed Factor 0.00 to 3.00 1.85
Surge Line High Offset 0.1 to 3.0 1.0
Surge/HGBP Deadband 0.5 to 3 F 1
HGBP On Delta T 0.5 to 10.0 F 2.0
HGBP Off Delta T 0.5 to 10.0 F 4.0
Surge Protection
Surge Delta% Amps 5 to 40 % 20
Surge Time Period 7 to 10 MIN 8
Surge Delay Time 0 to 120 SEC 0
Ice Build Control
Ice Build Option 0/1 DSABLE/ENABLE DSABLE
Ice Build Termination 0 to 2 0
0=Temp, 1=Contact, 2=Both
Ice Build Recycle 0/1 DSABLE/ENABLE DSABLE
Refrigerant Leak Option 0/1 DSABLE/ENABLE DSABLE
Refrigerant Leak Alarm mA 4 to 20 mA 20
Head Pressure Reference
Delta P at 0% (4mA) 20 to 85 PSI 25
Delta P at 100% (20mA) 20 to 85 PSI 50
Minimum Output 0 to 100 % 0
CL-7
19XR, XRV PIC II VDO SRD TABLE CONFIGURATION SHEET .
NOTE: No variables are available for CCN read or write operation.
DESCRIPTION RANGE UNITS DEFAULT VALUE
Diffuser Control
Diffuser Option 0/1 0
Diffuser Full Span mA 15 to 22 mA 18.0
Guide Vane 25% Load (2) 0 to 83 % 6.4
Guide Vane 50% Load (2) 0 to 83 % 22.9
Guide Vane 75% Load (2) 0 to 83 % 41.3
SRD 25% Load (1) 0 to 100 % 73.5
SRD 50% Load (1) 0 to 100 % 35.1
SRD 75% Load (1) 0 to 100 % 19.5
Lift @ 25% Load (1)
0 to 100
0 to 55.6
^F
^C
52.4
29.1
Lift @ 100% Load (1)
0 to 100
0 to 55.6
^F
^C
67.5
37.5
Lift @ 25% Load (2)
0 to 100
0 to 55.6
^F
^C
27.2
15.1
SRD IGV Offset Select 1 to 5 3
Low Lift Profile Select 1 to 5 3
CL-8
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19XR, XRV PIC II SETUP1 TABLE CONFIGURATION SHEET
DESCRIPTION RANGE UNITS DEFAULT VALUE
Comp Motor Temp Override
150 to 200
66 to 93
DEG F
DEG C
200
93
Cond Press Override
90 to 165
621 to 1138
PSI
kPa
125
862
Comp Discharge Alert
125 to 200
52 to 93
DEG F
DEG C
200
93
Comp Thrust Brg Alert
10 to 20
6 to 11
F
C
10
6
Comp Thrust Brg Trip
160 to 185
71 to 85
DEG F
DEG C
185
85
Thrust Brg Reset Factor 1.0 to 3.0 1.4
Chilled Medium 0/1 WATER/BRINE WATER
Chilled Water Deadband
0.5 to 2.0
0.3 to 1.1
F
C
1.0
0.6
Evap Refrig Trippoint
0.0 to 40.0
-17.8 to 4.4
DEG F
DEG C
33
0.6
Refrig Override Delta T
2.0 to 5.0
1.1 to 2.8
F
C
3
1.7
Evap Approach Alert
0.5 to 15
1.1 to 2.8
F
C
5
2.8
Cond Approach Alert
0.5 to 15
0.3 to 8.3
F
C
6
3.3
Condenser Freeze Point
20 to 35
-28.9 to 1.7
DEG F
DEG C
34
1.1
Flow Delta P Display 0/1 DSABLE/ENABLE DSABLE
Evap Flow Delta P Cutout
0.5 to 50.0
3.4 to 344.8
PSI
kPa
5.0
34.5
Cond Flow Delta P Cutout
0.5 to 50.0
3.4 to 344.8
PSI
kPa
5.0
34.5
Cond Hi Flow Alarm Option 0/1 DSABLE/ENABLE DSABLE
Cond Hi Flow Del P Limit
0.5 to 50.0
3.4 to 344.8
PSI
kPa
50.0
344.8
Water Flow Verify Time 0.5 to 5 MIN 5
Oil Press Verify Time 15 to 300 SEC 40
Recycle Control
Restart Delta T
2.0 to 10.0
1.1 to 5.6
F
C
5
2.8
Shutdown Delta T
0.5 to 4.0
0.3 to 2.2
F
C
1
0.6
SPARE ALERT/ALARM ENABLE
Disable=0, Lo=1/3, Hi=2/4
Spare Temp #1 Enable 0 to 4 0
Spare Temp #1 Limit
40 to 245
40 to 118
DEG F
DEG C
245
118
Spare Temp #2 Enable 0 to 4 0
Spare Temp #2 Limit
40 to 245
40 to 118
DEG F
DEG C
245
118
CL-9
19XR, XRV PIC II SETUP2 TABLE CONFIGURATION SHEET
DESCRIPTION STATUS UNITS DEFAULT VALUE
Capacity Control
Proportional Inc Band 2 to 10 6.5
Proportional DEC Band 2 to 10 6.0
Proportional ECW Gain 1 to 3 2.0
Guide Vane Travel Limit 30 to 100 % 80
VFD Speed Control
VFD Option 0/1 DSABLE/ENABLE DSABLE
VFD Gain 0.1 to 1.5 0.75
VFD Increase Step 1 to 5 % 2
VFD Minimum Speed 65 to 100 % 70
VFD Maximum Speed 90 to 100 % 100
VFD Start Speed 65 to 100 % 100
VFD Surge Line Gain 2.0 to 3.5 2.0
VFD Current Limit 0 to 99999 amps 250
CL-10
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19XR, XRV PIC II LEADLAG TABLE CONFIGURATION SHEET
DESCRIPTION RANGE UNITS DEFAULT VALUE
Lead Lag Control
LEAD/LAG: Configuration
DSABLE=0, LEAD=1,
LAG=2, STANDBY=3
0 to 3 0
Load Balance Option 0/1 DSABLE/ENABLE DSABLE
Common Sensor Option 0/1 DSABLE/ENABLE DSABLE
LAG% Capacity 25 to 75 % 50
LAG Address 1 to 236 92
LAG START Timer 2 to 60 MIN 10
LAG STOP Timer 2 to 60 MIN 10
PRESTART FAULT Timer 2 to 30 MIN 5
PULLDOWN Timer 1 to 30 MIN 2
STANDBY Chiller Option 0/1 DSABLE/ENABLE DSABLE
STANDBY% Capacity 25 to 75 % 50
STANDBY Address 1 to 236 93
CL-11
19XR, XRV PIC II RAMP_DEM TABLE CONFIGURATION SHEET
19XR, XRV PIC II TEMP_CTL TABLE CONFIGURATION SHEET
DESCRIPTION RANGE UNITS DEFAULT VALUE
Pulldown Ramp Type:
Select: Temp=0, Load=1
0/1 1
Demand Limit + kW Ramp
Demand Limit Source
Select: Amps=0, kW=1
0/1 0
Motor Load Ramp% Min 5 to 20 10
Demand Limit Prop Band 3 to 15 % 10
Demand Limit At 20 mA 40 to 100 % 40
20 mA Demand Limit Opt 0/1 DSABLE/ENABLE DSABLE
Motor Rated Kilowatts 50 to 9999 kW 145
Demand Watts Interval 5 to 60 MIN 15
DESCRIPTION RANGE UNITS DEFAULT VALUE
Control Point
ECW Control Option 0/1 DSABLE/ENABLE DSABLE
Temp Pulldown Deg/Min
2 to 10
0.6 to 5.6
F
C
3
1.7
Temperature Reset
RESET TYPE 1
Degrees Reset At 20 mA
30 to 30
17 to 17
F
C
10
6
RESET TYPE 2
Remote Temp -> No Reset
40 to 245
40 to 118
DEG F
DEG C
85
29
Remote Temp -> Full Reset
40 to 245
40 to 118
DEG F
DEG C
65
18
Degrees Reset
30 to 30
17 to 17
F
C
10
6
RESET TYPE 3
CHW Delta T -> No Reset
0 to 15
0 to 8
F
C
10
6
CHW Delta T -> Full Reset
0 to 15
0 to 8
F
C
0
0
Degrees Reset
30 to 30
17 to 17
F
C
5
3
Select/Enable Reset Type 0 to 3 0
CL-12
BROADCAST (BRODEF) CONFIGURATION SHEET
DESCRIPTION RANGE UNITS DEFAULT VALUE
Time Broadcast Enable DSABLE/ENABLE DSABLE
Daylight Savings
Start Month 1 to 12 4
Start Day of Week 1 to 7 7
Start Week 1 to 5 3
Start Time 00:00 to 24:00 HH:MM 02:00
Start Advance 0 to 360 MIN 60
Stop Month 1 to 12 10
Stop Day of Week 1 to 7 7
Stop Week 1 to 5 3
Stop Time 00:00 to 24:00 02:00
Stop Back 0 to 360 MIN 60
CL-13
DISPLAY AND ALARM SHUTDOWN STATE RECORD SHEET
PRIMARY MESSAGE:
SECONDARY MESSAGE:
DATE: TIME:
COMPRESSOR ONTIME:
CHW IN
OILPRESS
CHW OUT
OIL TEMP
CDW IN CDW OUT
EVAP REF
COND REF
AMPS %
COMMUNICATION MESSAGE
CCN LOCAL RESET MENU
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Catalog No. 04-53190022 Printed in U.S.A. Form 19XR,XRV-CLT-9SS Pg CL-14 10-13 Replaces: 19XR-6SS
Carrier Corporation 2013
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DISPLAY AND ALARM SHUTDOWN STATE RECORD SHEET
PRIMARY MESSAGE:
SECONDARY MESSAGE:
DATE: TIME:
COMPRESSOR ONTIME:
CHW IN
OILPRESS
CHW OUT
OIL TEMP
CDW IN CDW OUT
EVAP REF
COND REF
AMPS %
COMMUNICATION MESSAGE
CCN LOCAL RESET MENU