Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.Catalog No. 04-53190015-01 Printed in U.S.A. Form 19XRV-5SS Pg 1 312 12-11 Replaces: 19XRV-2SS

Start-Up, Operation, and Maintenance InstructionsSAFETY CONSIDERATIONS

Centrifugal liquid chillers are designed to provide safeand reliable service when operated within design speci-fications. When operating this equipment, use goodjudgment and safety precautions to avoid damage toequipment and property or injury to personnel.

Be sure you understand and follow the proceduresand safety precautions contained in the chiller instruc-tions as well as those listed in this guide.

DO NOT VENT refrigerant relief valves within a building. Outletfrom rupture disc or relief valve must be vented outdoors in accor-dance with the latest edition of ANSI/ASHRAE 15 (AmericanNational Standards Institute/American Society of Heating, Refrigerat-ing, and Air Conditioning Engineers). The accumulation of refrigerantin an enclosed space can displace oxygen and cause asphyxiation.PROVIDE adequate ventilation in accordance with ANSI/ASHRAE15, especially for enclosed and low overhead spaces. Inhalation ofhigh concentrations of vapor is harmful and may cause heart irregular-ities, unconsciousness, or death. Misuse can be fatal. Vapor is heavierthan air and reduces the amount of oxygen available for breathing.Product causes eye and skin irritation. Decomposition products arehazardous.DO NOT USE OXYGEN to purge lines or to pressurize a chiller forany purpose. Oxygen gas reacts violently with oil, grease, and othercommon substances.NEVER EXCEED specified test pressures, VERIFY the allowabletest pressure by checking the instruction literature and the design pres-sures on the equipment nameplate.DO NOT USE air for leak testing. Use only refrigerant or drynitrogen.DO NOT VALVE OFF any safety device.BE SURE that all pressure relief devices are properly installed andfunctioning before operating any chiller.THERE IS A RISK OF INJURY OR DEATH by electrocution. Highvoltage may be present on the motor leads even though the motor isnot running. Open the power supply disconnect before touchingmotor leads or terminals.

DO NOT WELD OR FLAMECUT any refrigerant line or vessel untilall refrigerant (liquid and vapor) has been removed from chiller.Traces of vapor should be displaced with dry air or nitrogen and thework area should be well ventilated. Refrigerant in contact with anopen flame produces toxic gases.DO NOT USE eyebolts or eyebolt holes to rig chiller sections or theentire assembly.DO NOT work on high-voltage equipment unless you are a qualifiedelectrician.DO NOT WORK ON electrical components, including controlpanels, switches, VFD, or oil heater until you are sure ALL POWERIS OFF and no residual voltage can leak from capacitors or solid-statecomponents.LOCK OPEN AND TAG electrical circuits during servicing. IFWORK IS INTERRUPTED, confirm that all circuits are deenergizedbefore resuming work.AVOID SPILLING liquid refrigerant on skin or getting it into theeyes. USE SAFETY GOGGLES. Wash any spills from the skin with

soap and water. If liquid refrigerant enters the eyes, IMMEDIATELYFLUSH EYES with water and consult a physician.NEVER APPLY an open flame or live steam to a refrigerant cylinder.Dangerous over pressure can result. When it is necessary to heatrefrigerant, use only warm (110 F [43 C]) water.DO NOT REUSE disposable (nonreturnable) cylinders or attempt torefill them. It is DANGEROUS AND ILLEGAL. When cylinder isemptied, evacuate remaining gas pressure, loosen the collar andunscrew and discard the valve stem. DO NOT INCINERATE.CHECK THE REFRIGERANT TYPE before adding refrigerant tothe chiller. The introduction of the wrong refrigerant can causedamage or malfunction to this chiller.

Operation of this equipment with refrigerants other than thosecited herein should comply with ANSI/ASHRAE 15 (latest edition).Contact Carrier for further information on use of this chiller with otherrefrigerants.DO NOT ATTEMPT TO REMOVE fittings, covers, etc., whilechiller is under pressure or while chiller is running. Be sure pressure isat 0 psig (0 kPa) before breaking any refrigerant connection.CAREFULLY INSPECT all relief devices, rupture discs, and otherrelief devices AT LEAST ONCE A YEAR. If chiller operates in acorrosive atmosphere, inspect the devices at more frequent intervals.DO NOT ATTEMPT TO REPAIR OR RECONDITION any reliefdevice when corrosion or build-up of foreign material (rust, dirt, scale,etc.) is found within the valve body or mechanism. Replace thedevice.DO NOT install relief devices in series or backwards.USE CARE when working near or in line with a compressed spring.Sudden release of the spring can cause it and objects in its path to actas projectiles.

DO NOT STEP on refrigerant lines. Broken lines can whip about andrelease 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 liftor move inspection covers or other heavy components. Even ifcomponents are light, use mechanical equipment when there is a riskof slipping or losing your balance.BE AWARE that certain automatic start arrangements CANENGAGE THE VFD, TOWER FAN, OR PUMPS. Open thedisconnect ahead of the VFD, tower fans, or pumps.USE only repair or replacement parts that meet the code requirementsof the original equipment.DO NOT VENT OR DRAIN waterboxes containing industrial brines,liquid, gases, or semisolids without the permission of your processcontrol group.DO NOT LOOSEN waterbox cover bolts until the waterbox has beencompletely drained.DO NOT LOOSEN a packing gland nut before checking that the nuthas a positive thread engagement.PERIODICALLY INSPECT all valves, fittings, and piping forcorrosion, rust, leaks, or damage.PROVIDE A DRAIN connection in the vent line near each pressurerelief device to prevent a build-up of condensate or rain water.

DANGER

WARNING

CAUTION

EVERGREEN19XRV

Hermetic Centrifugal Liquid Chillers with PIC III Controls and HFC-134a

50/60 Hz

2CONTENTSPage

SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . 1INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4ABBREVIATIONS AND EXPLANATIONS . . . . . . . . 4,5CHILLER FAMILIARIZATION . . . . . . . . . . . . . . . . . . . . 5-7Chiller Information Nameplate . . . . . . . . . . . . . . . . . . . . 5System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Motor-Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Control Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Variable Frequency Drive . . . . . . . . . . . . . . . . . . . . . . . . . 6Storage Vessel (Optional) . . . . . . . . . . . . . . . . . . . . . . . . 6REFRIGERATION CYCLE . . . . . . . . . . . . . . . . . . . . . . . . . 8MOTOR AND LUBRICATING OIL

COOLING CYCLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8VFD COOLING CYCLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . 9LUBRICATION CYCLE . . . . . . . . . . . . . . . . . . . . . . . . . 9,10Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Details. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Oil Reclaim System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 PRIMARY OIL RECOVERY MODE SECONDARY OIL RECOVERY METHODBearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9STARTING EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . 10-14Unit-Mounted VFD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10CONTROLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-57Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 ANALOG SIGNAL DISCRETE SIGNALGeneral. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15PIC III System Components . . . . . . . . . . . . . . . . . . . . . 15 INTERNATIONAL CHILLER VISUAL

CONTROLLER (ICVC) CHILLER CONTROL MODULE (CCM) OIL HEATER CONTACTOR (1C) OIL PUMP CONTACTOR (2C) HOT GAS BYPASS CONTACTOR RELAY (3C)

(Optional) CONTROL TRANSFORMERS (T1, T2) OPTIONAL TRANSFORMER (T3) SENSORS FLOW DETECTIONICVC Operation and Menus . . . . . . . . . . . . . . . . . . . . . . 19 GENERAL ALARMS AND ALERTS ICVC MENU ITEMS BASIC ICVC OPERATIONS (Using the Softkeys) TO VIEW STATUS FORCING OPERATIONS TIME SCHEDULE OPERATION TO VIEW AND CHANGE SET POINTS SERVICE OPERATIONPIC III System Functions . . . . . . . . . . . . . . . . . . . . . . . . 40 CAPACITY CONTROL ECW CONTROL OPTION CONTROL POINT DEADBAND PROPORTIONAL BANDS DIFFUSER CONTROL DEMAND LIMITING CHILLER TIMERS AND STARTS COUNTER OCCUPANCY SCHEDULESafety Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43Shunt Trip (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43Default Screen Freeze . . . . . . . . . . . . . . . . . . . . . . . . . . . 43Ramp Loading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46Rampdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46Capacity Override . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

PageHigh Discharge Temperature Control . . . . . . . . . . . . 46Compressor Bearing Temperature. . . . . . . . . . . . . . . 46Oil Sump Temperature and Pump Control . . . . . . . 46Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46Remote Start/Stop Controls . . . . . . . . . . . . . . . . . . . . . 47Spare Safety and Spare Temperature Inputs. . . . . 47Alarm (Trip) Output Contacts . . . . . . . . . . . . . . . . . . . . 47Kilowatt Output. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48Remote Reset of Alarms. . . . . . . . . . . . . . . . . . . . . . . . . 48Condenser Pump Control . . . . . . . . . . . . . . . . . . . . . . . 48Condenser Freeze Prevention . . . . . . . . . . . . . . . . . . . 48Evaporator Freeze Protection . . . . . . . . . . . . . . . . . . . 48Tower Fan Relay Low and High . . . . . . . . . . . . . . . . . . 48Auto. Restart After Power Failure. . . . . . . . . . . . . . . . 49Fast Power Source Transfers . . . . . . . . . . . . . . . . . . . . 49Water/Brine Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 RESET TYPE 1: 4 TO 20 mA TEMPERATURE RESET RESET TYPE 2: REMOTE TEMPERATURE RESET RESET TYPE 3Surge Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 HGBP OPTION =1 HGBP OPTION =2Surge Prevention Algorithm . . . . . . . . . . . . . . . . . . . . . 50Surge Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50Head Pressure Reference Output. . . . . . . . . . . . . . . . 51VFD Start-Up Speed Control. . . . . . . . . . . . . . . . . . . . . 51Lead/Lag Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 COMMON POINT SENSOR USAGE AND

INSTALLATION CHILLER COMMUNICATION WIRING LEAD/LAG OPERATION FAULTED CHILLER OPERATION LOAD BALANCING AUTO. RESTART AFTER POWER FAILUREIce Build Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 ICE BUILD INITIATION START-UP/RECYCLE OPERATION TEMPERATURE CONTROL DURING ICE BUILD TERMINATION OF ICE BUILD RETURN TO NON-ICE BUILD OPERATIONSAttach to Network Device Control . . . . . . . . . . . . . . . 55 ATTACHING TO OTHER CCN MODULESService Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 TO ACCESS THE SERVICE SCREENS TO LOG OUT OF NETWORK DEVICE TIME BROADCAST ENABLE HOLIDAY SCHEDULING DAYLIGHT SAVING TIME CONFIGURATIONSTART-UP/SHUTDOWN/RECYCLE

SEQUENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57-59Local Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57Shutdown Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58Automatic Soft Stop Amps Threshold . . . . . . . . . . . 58Chilled Water Recycle Mode . . . . . . . . . . . . . . . . . . . . . 59Safety Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59BEFORE INITIAL START-UP . . . . . . . . . . . . . . . . . . 59-77Job Data Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59Equipment Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59Using the Optional Storage Tank

and Pumpout System . . . . . . . . . . . . . . . . . . . . . . . . . 59Remove Shipping Packaging . . . . . . . . . . . . . . . . . . . . 59Open Oil Circuit Valves . . . . . . . . . . . . . . . . . . . . . . . . . . 59Oil Charge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60Tighten All Gasketed Joints and

Guide Vane Shaft Packing . . . . . . . . . . . . . . . . . . . . . 60Check Chiller Tightness . . . . . . . . . . . . . . . . . . . . . . . . . 60Refrigerant Tracer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62Leak Test Chiller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

3CONTENTS (cont)Page

Standing Vacuum Test . . . . . . . . . . . . . . . . . . . . . . . . . . 62Chiller Dehydration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65Inspect Water Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65Check Optional Pumpout Compressor

Water Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65Check Relief Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65Identify the VFD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 IDENTIFYING THE DRIVE BY PART NUMBERInput Power Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66Checking the Installation . . . . . . . . . . . . . . . . . . . . . . . . 66Inspect Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67Ground Fault Troubleshooting . . . . . . . . . . . . . . . . . . 67Carrier Comfort Network Interface . . . . . . . . . . . . . 67Power Up the Controls and

Check the Oil Heater . . . . . . . . . . . . . . . . . . . . . . . . . . 67 SOFTWARE VERSIONSoftware Configuration . . . . . . . . . . . . . . . . . . . . . . . . . 68Input the Design Set Points . . . . . . . . . . . . . . . . . . . . . 68Input the Local Occupied Schedule

(OCCPC01S) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68Input Service Configurations . . . . . . . . . . . . . . . . . . . . 68 PASSWORD INPUT TIME AND DATE CHANGE ICVC CONFIGURATION

IF NECESSARY TO CHANGE THE PASSWORD TO CHANGE THE ICVC DISPLAY FROM

ENGLISH TO METRIC UNITS CHANGE LANGUAGE MODIFY CONTROLLER IDENTIFICATION

IF NECESSARY INPUT EQUIPMENT SERVICE PARAMETERS

IF NECESSARY VERIFY VFD CONFIGURATION AND CHANGE

PARAMETERS IF NECESSARY VFD CHILLER FIELD SET UP AND VERIFICATION HAND CALCULATE VARIABLE PRIMARY FLOW

(VPF) SURGE PREVENTION CONFIGURATIONS CONFIGURE DIFFUSER CONTROL IF

NECESSARY MODIFY EQUIPMENT CONFIGURATION

IF NECESSARYPerform a Control Test . . . . . . . . . . . . . . . . . . . . . . . . . . 72 PRESSURE TRANSDUCER CALIBRATIONCheck Optional Pumpout System

Controls and Compressor. . . . . . . . . . . . . . . . . . . . . 74High Altitude Locations . . . . . . . . . . . . . . . . . . . . . . . . . 74Charge Refrigerant Into Chiller . . . . . . . . . . . . . . . . . . 74 CHILLER EQUALIZATION WITHOUT A

PUMPOUT UNIT CHILLER EQUALIZATION WITH

PUMPOUT UNIT TRIMMING REFRIGERANT CHARGEINITIAL START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77,78Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77Check Motor Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . 77Check Oil Pressure and Compressor Stop . . . . . . 78To Prevent Accidental Start-Up. . . . . . . . . . . . . . . . . . 78Check Chiller Operating Condition . . . . . . . . . . . . . . 78Instruct the Customer Operator . . . . . . . . . . . . . . . . . 78 COOLER-CONDENSER OPTIONAL PUMPOUT STORAGE TANK AND

PUMPOUT SYSTEM MOTOR COMPRESSOR ASSEMBLY MOTOR COMPRESSOR LUBRICATION SYSTEM CONTROL SYSTEM AUXILIARY EQUIPMENT DESCRIBE CHILLER CYCLES

Page REVIEW MAINTENANCE SAFETY DEVICES AND PROCEDURES CHECK OPERATOR KNOWLEDGE REVIEW THE START-UP, OPERATION, AND

MAINTENANCE MANUALOPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . 78-80Operator Duties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78Prepare the Chiller for Start-Up . . . . . . . . . . . . . . . . . 78To Start the Chiller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78Check the Running System . . . . . . . . . . . . . . . . . . . . . 78To Stop the Chiller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79After Limited Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . 79Preparation for Extended Shutdown . . . . . . . . . . . . 79After Extended Shutdown . . . . . . . . . . . . . . . . . . . . . . . 79Cold Weather Operation. . . . . . . . . . . . . . . . . . . . . . . . . 79Manual Guide Vane Operation. . . . . . . . . . . . . . . . . . . 79Refrigeration Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79PUMPOUT AND REFRIGERANT TRANSFER

PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81-84Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81Operating the Optional Pumpout Unit . . . . . . . . . . . 81 POSITIVE PRESSURE CHILLERS WITH

STORAGE TANKS CHILLERS WITH ISOLATION VALVES DISTILLING THE REFRIGERANTGENERAL MAINTENANCE . . . . . . . . . . . . . . . . . . . .84,85Refrigerant Properties . . . . . . . . . . . . . . . . . . . . . . . . . . 84Adding Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84Removing Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . 84Adjusting the Refrigerant Charge . . . . . . . . . . . . . . . 84Refrigerant Leak Testing . . . . . . . . . . . . . . . . . . . . . . . . 84Leak Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84Test After Service, Repair, or Major Leak . . . . . . . . 84 TESTING WITH REFRIGERANT TRACER TESTING WITHOUT REFRIGERANT TRACER TO PRESSURIZE WITH DRY NITROGENRepair the Leak, Retest, and Apply

Standing Vacuum Test . . . . . . . . . . . . . . . . . . . . . . . . 85Checking Guide Vane Linkage . . . . . . . . . . . . . . . . . . 85Trim Refrigerant Charge. . . . . . . . . . . . . . . . . . . . . . . . . 85WEEKLY MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . 85Check the Lubrication System . . . . . . . . . . . . . . . . . . 85SCHEDULED MAINTENANCE . . . . . . . . . . . . . . . . 86-88Service Ontime. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86Inspect the Control Panel . . . . . . . . . . . . . . . . . . . . . . . 86Check Safety and Operating Controls

Monthly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86Changing Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86Oil Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86Oil Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 TO CHANGE THE OILRefrigerant Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86Oil Reclaim Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86VFD Refrigerant Strainer . . . . . . . . . . . . . . . . . . . . . . . . 87Inspect Refrigerant Float System . . . . . . . . . . . . . . . 87Inspect Relief Valves and Piping . . . . . . . . . . . . . . . . 87Compressor Bearing and Gear

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87Inspect the Heat Exchanger Tubes

and Flow Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 COOLER AND OPTIONAL FLOW DEVICES CONDENSER AND OPTIONAL FLOW DEVICESWater Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87Water Treatment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88Inspect the VFD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88Recalibrate Pressure Transducers . . . . . . . . . . . . . . 88

4CONTENTS (cont)Page

Optional Pumpout System Maintenance . . . . . . . . . 88 OPTIONAL PUMPOUT COMPRESSOR OIL

CHARGE OPTIONAL PUMPOUT SAFETY CONTROL

SETTINGSOrdering Replacement Chiller Parts . . . . . . . . . . . . . 88TROUBLESHOOTING GUIDE . . . . . . . . . . . . . . . . 89-154Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89Checking Display Messages. . . . . . . . . . . . . . . . . . . . . 89Checking Temperature Sensors . . . . . . . . . . . . . . . . . 89 RESISTANCE CHECK VOLTAGE DROP CHECK SENSOR ACCURACY DUAL TEMPERATURE SENSORSChecking Pressure Transducers. . . . . . . . . . . . . . . . . 89 COOLER CONDENSER PRESSURE TRANSDUCER

AND OPTIONAL WATERSIDE FLOW DEVICECALIBRATION

TRANSDUCER REPLACEMENTControl Algorithms Checkout Procedure . . . . . . . . 90Control Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91Control Modules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 RED LED (Labeled as STAT) GREEN LED (Labeled as COM)Notes on Module Operation . . . . . . . . . . . . . . . . . . . . 107Chiller Control Module (CCM) . . . . . . . . . . . . . . . . . . 107 INPUTS OUTPUTSReplacing Defective Processor Modules . . . . . . . 108 INSTALLATIONGateway Status LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . 109 DRIVE STATUS INDICATOR MS STATUS INDICATOR NET A STATUS INDICATOR NET B STATUS INDICATORPhysical Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110APPENDIX A LIQUIFLO 2 ICVC

PARAMETER INDEX . . . . . . . . . . . . . . . . . . . . . . 155-164APPENDIX B LEAD/LAG WIRING . . . . . . . . 165,166APPENDIX C MAINTENANCE SUMMARY

AND LOG SHEETS . . . . . . . . . . . . . . . . . . . . . . . 167-170APPENDIX D OPTIONAL BACNET

COMMUNICATIONS WIRING. . . . . . . . . . . . . . 171-177INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178INITIAL START-UP CHECKLIST FOR

19XRV HERMETIC CENTRIFUGALLIQUID CHILLER . . . . . . . . . . . . . . . . . . . .CL-1 to CL-12

INTRODUCTIONPrior to initial start-up of the 19XRV unit, those involved in

the start-up, operation, and maintenance should be thoroughlyfamiliar with these instructions and other necessary job data.This book is outlined to familiarize those involved in thestart-up, operation, and maintenance of the unit with the con-trol system before performing start-up procedures. Proceduresin this manual are arranged in the sequence required for properchiller start-up and operation.

ABBREVIATIONS AND EXPLANATIONSFrequently used abbreviations in this manual include:

Words printed in all capital letters or in italics may beviewed on the International Chiller Visual Controller (ICVC)(e.g., LOCAL, CCN, ALARM, etc.).

Words printed in both all capital letters and italics can alsobe viewed on the ICVC and are parameters (e.g., CONTROLMODE, COMPRESSOR START RELAY, ICE BUILDOPTION, etc.) with associated values (e.g., modes, tempera-tures, percentages, pressures, on, off, etc.).

Words printed in all capital letters and in a box representsoftkeys on the ICVC control panel (e.g., , ,

, , etc.).

CAUTIONThis unit uses a microprocessor control system. Do notshort or jumper between terminations on circuit boards ormodules; control or board failure may result.Be aware of electrostatic discharge (static electricity) whenhandling or making contact with circuit boards or moduleconnections. Always touch a chassis (grounded) part todissipate body electrostatic charge before working insidethe VFD enclosure.Use extreme care when handling tools near boards andwhen connecting or disconnecting terminal plugs. Circuitboards can easily be damaged. Always hold boards by theedges and avoid touching components and connections.This equipment uses, and can radiate, radio frequencyenergy. If not installed and used in accordance with theinstruction manual, it may cause interference to radiocommunications. It has been tested and found to complywith the limits for a Class A computing device pursuant toSubpart J of Part 15 of FCC Rules, which are designed toprovide reasonable protection against such interferencewhen operated in a commercial environment. Operation ofthis equipment in a residential area is likely to causeinterference, in which case the user, at his own expense,will be required to take whatever measures may berequired to correct the interference.Always store and transport replacement or defective boardsin anti-static shipping bag.

CCM Chiller Control ModuleCCN Carrier Comfort NetworkCCW CounterclockwiseCW ClockwiseECDW Entering Condenser WaterECW Entering Chilled WaterEMS Energy Management SystemHGBP Hot Gas BypassI/O Input/OutputICVC International Chiller Visual ControllerLCD Liquid Crystal DisplayLCDW Leaving Condenser WaterLCW Leaving Chilled WaterLED Light-Emitting DiodeOLTA Overload Trip AmpsPIC III Product Integrated Controls IIIRLA Rated Load AmpsSI International System of UnitsTXV Thermostatic Expansion ValveUPC Universal Protocol CardVFD Variable Frequency Drive

ENTER EXITINCREASE QUIT

5Factory-installed additional components are referred to asoptions in this manual; factory-supplied but field-installedadditional components are referred to as accessories.

The chiller software part number of the 19XRV unit islocated on the back of the ICVC.

CHILLER FAMILIARIZATION(Fig. 1 and 2)

Chiller Information Nameplate The informationnameplate is located on the right side of the chiller controlpanel.

27 10 Q 19843

Week of Year

Year of Manufacture

Unique Number

Place of Manufacture

MODEL NUMBER NOMENCLATURE

SERIAL NUMBER BREAKDOWN

Cooler Size20-22 (Frame 2 XRV)30-32 (Frame 3 XRV)35-37 (Frame 3 XRV)40-42 (Frame 4 XRV)45-47 (Frame 4 XRV)50-54 (Frame 5 XRV)5A-5C (Frame 5 XRV)*55-59 (Frame 5 XRV)5F-5H (Frame 5 XRV)*5K-5R (Frame 5 XRV)5T-5Z (Frame 5 XRV)60-64 (Frame 6 XRV)6K-6R (Frame 6 XRV)65-69 (Frame 6 XRV)6T-6Z (Frame 6 XRV) 70-74 (Frame 7 XRV)7K-7R (Frame 7 XRV)75-79 (Frame 7 XRV)7T-7Z (Frame 7 XRV)80-84 (Frame 8 XRV)8K-8R (Frame 8 XRV)85-89 (Frame 8 XRV)8T-8Z (Frame 8 XRV)

Condenser Size20-22 (Frame 2 XRV)30-32 (Frame 3 XRV)35-37 (Frame 3 XRV)40-42 (Frame 4 XRV)45-47 (Frame 4 XRV)50-54 (Frame 5 XRV)55-59 (Frame 5 XRV)60-64 (Frame 6 XRV)65-69 (Frame 6 XRV)70-74 (Frame 7 XRV)75-79 (Frame 7 XRV)80-84 (Frame 8 XRV)85-89 (Frame 8 XRV)

Compressor Code(First Digit Indicates Compressor Frame Size)**

Motor Code

Motor Efficiency CodeH High EfficiencyS Standard Efficiency

Motor Voltage CodeCode 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

10000-3-5011000-3-5011000-3-6010000-3-60

Special Order Indicator StandardS Special Order

Description19XRV Ultra High Efficiency Variable Speed

Hermetic Centrifugal Liquid Chiller

19XRV 52 51 473 DG H 64

Fig. 1 19XRV Identification

a19-1969

* Refer to 19XRV Computer Selection Program for details on these sizes. Frame sizes with K-R and T-Z are with 1 in. OD evaporator tubing.** For Frame 4 compressors, second digit will be a letter (example 4G3) on units equipped with

split ring diffuser.Refer to the 19XRV Computer Selection Program for motor code details.

a19-1937

6System Components The components include thecooler and condenser heat exchangers in separate vessels,compressor-motor, lubrication package, control panel, andVFD. All connections from pressure vessels have externalthreads to enable each component to be pressure tested with athreaded pipe cap during factory assembly.Cooler This vessel (also known as the evaporator) islocated underneath the compressor. The cooler is maintained atlower temperature/pressure so evaporating refrigerant canremove heat from water flowing through its internal tubes.Condenser The condenser operates at a highertemperature/pressure than the cooler and has water flowingthrough its internal tubes in order to remove heat from therefrigerant.

Motor-Compressor This component maintains sys-tem temperature and pressure differences and moves theheat-carrying refrigerant from the cooler to the condenser.

Control Panel The control panel is the user interfacefor controlling the chiller. It regulates the chillers capacity asrequired to maintain proper leaving chilled water temperature.The control panel: registers cooler, condenser, and lubricating system pressures

shows the chiller operating condition and the alarmshutdown conditions

records the total chiller operating hours sequences chiller start, stop, and recycle under microproces-

sor control displays the status of the VFD provides access to other CCN (Carrier Comfort Network)

devices and energy management systems languages pre-installed at factory include: English, Chinese,

Japanese, and Korean. International Language Translator (ILT) is available for

conversion of extended ASCII characters.

Variable Frequency Drive (VFD) The VFD al-lows for the proper start and disconnect of electrical energy forthe compressor-motor, oil pump, oil heater, and control panel.

Storage Vessel (Optional) There are 2 sizes ofstorage vessels available. The vessels have double relief valves,a magnetically-coupled dial-type refrigerant level gage, aone-inch FPT drain valve, and a 1/2-in. male flare vapor con-nection 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 isolatethe chiller charge in either the cooler or condenser. An optionalpumpout system is used to transfer refrigerant from vessel tovessel.

719

18

17

16

15

13

14

1

3

4 5 76

8

9

11 1012

2

2826 27

26

25

2930

3132

33

34

35

36

20

21 22 23 24

Fig. 2 Typical 19XRV Components

LEGEND1 Guide Vane Actuator2 Split Ring Diffuser Actuator (Optional)3 Suction Elbow4 International Chiller Visual Control (ICVC)5 Chiller Identification Nameplate6 Cooler, Auto Reset Relief Valves7 Cooler Pressure Transducer8 Condenser In/Out Temperature Thermistors9 Condenser Waterflow Device (Optional

ICVC Inputs available)10 Cooler Waterflow Device (Optional

ICVC Inputs available)11 Cooler In/Out Temperature Thermistors12 Evaporator Saturation Temperature

Sensor (Hidden)13 Liquid Line Service Valve14 Typical Flange Connection15 Oil Level Sight Glasses16 Refrigerant Oil Cooler (Hidden)17 Oil Drain/Charging Valve (Hidden)18 Power Panel19 Compressor Motor Housing

LEGEND20 Condenser Auto. Reset Relief Valves21 VFD Circuit Breaker22 VFD Meter Package (Optional)23 Unit-Mounted VFD24 Motor Sight Glass25 Cooler Waterbox Cover26 ASME Nameplate (One Hidden)27 Typical Waterbox Drain Port28 Condenser Waterbox Cover29 Refrigerant Moisture/Flow Indicator30 Refrigerant Filter/Drier31 Liquid Line Isolation Valve (Optional)32 Linear Float Valve Chamber33 Tubesheet Mounting Brackets34 Discharge Isolation Valve (Optional)35 Refrigerant Charging Valve36 Condenser Pressure Transducer (Hidden)

REAR VIEW

FRONT VIEW

a19-1685

a19-1686

8REFRIGERATION CYCLEThe compressor continuously draws refrigerant vapor from

the cooler at a rate set by the amount of guide vane opening orcompressor speed. As the compressor suction reduces thepressure in the cooler, the remaining refrigerant boils at a fairlylow temperature (typically 38 to 42 F [3 to 6 C]). The energyrequired for boiling is obtained from the water flowing throughthe cooler tubes. With heat energy removed, the water becomescold enough to use in an air conditioning circuit or for processliquid cooling.

After taking heat from the water, the refrigerant vapor iscompressed. Compression adds still more heat energy, and therefrigerant 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]) waterflowing into the condenser tubes removes heat from the refrig-erant and the vapor condenses to liquid.

The liquid refrigerant passes through orifices into theFLASC (Flash Subcooler) chamber (Fig. 3). Since the FLASCchamber is at a lower pressure, part of the liquid refrigerantflashes to vapor, thereby cooling the remaining liquid. TheFLASC vapor is recondensed on the tubes which are cooled byentering condenser water. The liquid drains into a float cham-ber between the FLASC chamber and cooler. Here, a floatvalve forms a liquid seal to keep FLASC chamber vapor fromentering the cooler. When liquid refrigerant passes through thevalve, some of it flashes to vapor in the reduced pressure on thecooler side. In flashing, it removes heat from the remainingliquid. The refrigerant is now at a temperature and pressure atwhich the cycle began.

MOTOR AND LUBRICATING OILCOOLING CYCLE

The motor and the lubricating oil are cooled by liquid re-frigerant taken from the bottom of the condenser vessel(Fig. 3). Refrigerant flow is maintained by the pressure differ-ential that exists due to compressor operation. After the refrig-erant flows past an isolation valve, an in-line filter, and a sightglass/moisture indicator, the flow is split between the motorcooling and oil cooling systems.

Flow to the motor cooling system passes through an orificeand into the motor. Once past the orifice, the refrigerant isdirected over the motor by a spray nozzle. The refrigerantcollects in the bottom of the motor casing and is then drainedback into the cooler through the motor refrigerant drain line.An orifice (in the motor shell) maintains a higher pressure inthe motor shell than in the cooler. The motor is protected by atemperature sensor imbedded in the stator windings. Anincrease in motor winding temperature past the motor overrideset point overrides the temperature capacity control to hold,and if the motor temperature rises 10 F (5.5 C) above this setpoint, closes the inlet guide vanes. If the temperature risesabove the safety limit, the compressor shuts down.

Refrigerant that flows to the oil cooling system is regulatedby thermostatic expansion valves (TXVs). The TXVs regulateflow into the oil/refrigerant plate and frame-type heat exchang-er (the oil cooler in Fig. 3). The expansion valve bulbs controloil temperature to the bearings. The refrigerant leaving the oilcooler heat exchanger returns to the chiller cooler.

OPTIONALUNITMOUNTEDVFD(VARIABLEFREQUENCYDRIVE)HEATEXCHANGER

THERMOSTATICEXPANSIONVALVE(TXV)

ORIFICEFITTING

MOISTURE/FLOWINDICATOR

FILTERDRIER

FLOAT VALVECHAMBER

REFRIGERANTCOOLINGISOLATION VALVE

MOTOR

CONDENSER ISOLATION VALVE (OPTION)ORIFICE FITTINGTRANSMISSIONDIFFUSER

GUIDE VANEMOTOR

GUIDE VANES

IMPELLER

FLASC CHAMBER

CONDENSERCONDENSERWATER

STATOR

ROTOR

OILPUMP

COMPRESSOR

COOLER ISOLATIONVALVE (OPTION)

DISTRIBUTIONPIPE

REFRIGERANTLIQUID

REFRIGERANTVAPOR

REFRIGERANTLIQUID/VAPOR

OIL

CHILLEDWATER

OILCOOLER

OILFILTER

VFD COOLINGORIFICE

Fig. 3 Refrigerant Motor Cooling and Oil Cooling Cyclesa19-1851

9VFD COOLING CYCLEThe unit-mounted variable frequency drive (VFD) is cooled

in a manner similar to the motor and lubricating oil coolingcycle (Fig. 3).

If equipped with a unit-mounted VFD, the refrigerant linethat feeds the motor cooling and oil cooler also feeds the heatexchanger on the unit-mounted VFD. Refrigerant is meteredthrough an orifice. The refrigerant leaving the heat exchangerreturns to the cooler.

LUBRICATION CYCLESummary The oil pump, oil filter, and oil cooler makeup a package located partially in the transmission casing of thecompressor-motor assembly. The oil is pumped into a filterassembly to remove foreign particles and is then forced into anoil cooler heat exchanger where the oil is cooled to properoperational temperatures. After the oil cooler, part of the flowis directed to the gears and the high speed shaft bearings; theremaining flow is directed to the motor shaft bearings. Oildrains into the transmission oil sump to complete the cycle(Fig. 4).

Details Oil is charged into the lubrication system througha hand valve. Two sight glasses in the oil reservoir permit oillevel observation. Normal oil level is between the middle of theupper sight glass and the top of the lower sight glass when thecompressor is shut down. The oil level should be visible in atleast one of the 2 sight glasses during operation. Oil sumptemperature is displayed on the ICVC (International ChillerVisual Controller) default screen. During compressor opera-tion, 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 oilpressure relief valve maintains 18 to 30 psid (124 to 207 kPad)differential pressure in the system at the pump discharge. Thenormal oil pressure on compressors equipped with rollingelement bearings is between 18 and 40 psid (124 and276 kPad). This differential pressure can be read directly fromthe ICVC default screen. The oil pump discharges oil to the oilfilter assembly. This filter can be closed to permit removal ofthe filter without draining the entire oil system (see Mainte-nance sections, pages 84 to 88 for details). The oil is then pipedto the oil cooler heat exchanger. The oil cooler uses refrigerantfrom the condenser as the coolant. The refrigerant cools the oilto a temperature between 120 and 140 F (49 and 60 C).

As the oil leaves the oil cooler, it passes the oil pressuretransducer and the thermal bulb for the refrigerant expansionvalve on the oil cooler. The oil is then divided. Part of the oilflows to the thrust bearing, forward pinion bearing, and gearspray. The rest of the oil lubricates the motor shaft bearings andthe rear pinion bearing. The oil temperature is measured in thebearing housing as it leaves the thrust and forward journalbearings. The outer bearing race temperature is measured oncompressors with rolling element bearings. The oil then drainsinto the oil reservoir at the base of the compressor. The PIC III(Product Integrated Control III) measures the temperature ofthe oil in the sump and maintains the temperature during shut-down (see Oil Sump Temperature and Pump Control section,page 46). This temperature is read on the ICVC default screen.

During chiller start-up, the PIC III energizes the oil pumpand provides 45 seconds of pre-lubrication to the bearings afterpressure is verified before starting the compressor. Duringshutdown, the oil pump will run for 60 seconds topost-lubricate after the compressor shuts down. The oil pump

can also be energized for testing purposes during a ControlTest.

Ramp loading can slow the rate of guide vane opening tominimize oil foaming at start-up. If the guide vanes openquickly, the sudden drop in suction pressure can cause anyrefrigerant in the oil to flash. The resulting oil foam cannot bepumped efficiently; therefore, oil pressure falls off and lubrica-tion is poor. If oil pressure falls below 15 psid (103 kPad)differential, the PIC III will shut down the compressor.

If the controls are subject to a power failure that lasts morethan 3 hours, the oil pump will be energized periodically whenthe power is restored. This helps to eliminate refrigerant thathas migrated to the oil sump during the power failure. Thecontrols energize the pump for 30 seconds every 30 minutesuntil the chiller is started.

Oil Reclaim System The oil reclaim system returnsoil lost from the compressor housing back to the oil reservoirby recovering the oil from 2 areas on the chiller. The guidevane housing is the primary area of recovery. Oil is also recov-ered by skimming it from the operating refrigerant level in thecooler vessel.PRIMARY OIL RECOVERY MODE Oil is normally re-covered through the guide vane housing on the chiller. This ispossible because oil is normally entrained with refrigerant inthe chiller. As the compressor pulls the refrigerant up from thecooler into the guide vane housing to be compressed, the oilnormally drops out at this point and falls to the bottom of theguide vane housing where it accumulates. Using discharge gaspressure to power an eductor, the oil is drawn from the housingand is discharged into the oil reservoir.SECONDARY OIL RECOVERY METHOD The sec-ondary method of oil recovery is significant under light loadconditions, when the refrigerant going up to the compressorsuction does not have enough velocity to bring oil along. Underthese conditions, oil collects in a greater concentration at thetop level of the refrigerant in the cooler. This oil and refrigerantmixture is skimmed from the side of the cooler and is thendrawn up to the guide vane housing. There is a filter in this line.Because the guide vane housing pressure is much lower thanthe cooler pressure, the refrigerant boils off, leaving the oilbehind to be collected by the primary oil recovery method.

Bearings The 19XRV compressor assemblies includefour radial bearings and four thrust bearings. The low speedshaft assembly is supported by two journal bearings locatedbetween the motor rotor and the bull gear. The bearing closer tothe rotor includes a babbitted thrust face which opposes thenormal axial forces which tend to pull the assembly towardsthe transmission. The bearing closer to the bull gear includes asmaller babbitted thrust face, designed to handle counterthrustforces.

For most 19XRV compressors the high speed shaft assem-bly is supported by two journal bearings located at thetransmission end and mid-span, behind the labyrinth seal. Thetransmission side of the midspan bearing also contains a tiltingshoe type thrust bearing which opposes the main axial forcestending to pull the impeller towards the suction end. Theimpeller side face of the midspan bearing includes a babbittedthrust face, designed to handle counterthrust forces.

For 19XRV Frame 3 compressors built since mid-2001, thehigh speed shaft assembly has been redesigned to utilize rollingelement bearings (radial and thrust). Machines employing therolling element bearings can be expected to have higher oilpressure and thrust bearing temperatures than those compres-sors using the alternate bearing design.

10

STARTING EQUIPMENTAll 19XRV units are equipped with a VFD to operate the

centrifugal hermetic compressor motor. A power panel controlsthe oil pump, and various auxiliary equipment. The VFD andpower panel are the main field wiring interfaces for the install-ing contractor. The VFD is mounted directly on the chiller.NOTE: This publication provides start-up and service informa-tion for the LiquiFlo 2.0 (LF2) VFDs. For information onStd Tier VFDs, refer to associated Start-Up and ServiceInstructions for the Rockwell PowerFlex 755 VFD or theEaton LCX 9000 VFD.

Three separate circuit breakers are inside the VFD. Circuitbreaker CB1 is the VFD circuit breaker. The disconnect switchon the VFD front cover is connected to this breaker. Circuitbreaker CB1 supplies power to the VFD.

Circuit breaker CB2 supplies 115-v power to the oil pumpcontrol panel, oil heater, and portions of the VFD controls.

Unit-Mounted VFD The 19XRV chiller is equippedwith a variable frequency drive motor controller mounted onthe condenser. See Fig. 5-7. This VFD is used with low voltagemotors between 380 and 460 vac. It reduces the starting currentinrush by controlling the voltage and frequency to the compres-sor motor. Once the motor has accelerated to minimum speed,the PIC III modulates the compressor speed and guide vaneposition to control chilled water temperature. The VFD isfurther explained in the Controls section and TroubleshootingGuide section, pages 15 and 89.

Operational parameters and fault codes are displayed rela-tive to the drive. Refer to specific drive literature along withtroubleshooting sections. The display is also the interface forentering specific chiller operational parameters. These parame-ters have been preprogrammed at the factory. An adhesivebacked label on the inside of the drive has been provided forverification of the specific job parameters. See Initial Start-UpChecklist section for details.

ISOLATIONVALVE

SIGHTGLASS

FILTER

ISOLATIONVALVE

OIL SKIMMER LINE

FILTEREDUCTOR

OIL PUMPTXV BULB PRESSURE

TRANSDUCERISOLATIONVALVESOILCOOLER OIL PUMP MOTOR

OIL HEATER

MOTORCOOLING LINE

LABYRINTHGAS LINE

FWD MOTORBEARING

OIL SUPPLY TOFORWARD HIGH SPEED BEARING

SIGHT GLASS

FLOW

OILFILTER

REAR MOTORBEARING

STRAINER

Fig. 4 Lubrication Systema19-1965

WARNINGThe main circuit breaker (CB1) on the front of the VFDdisconnects the main VFD current only. Power is still ener-gized for the other circuits. Two more circuit breakersinside the VFD must be turned off to disconnect power tothe oil pump, PIC III controls, and oil heater.

WARNINGDo not touch the power wiring or motor terminals whilevoltage is present, or serious injury will result.

11

OPTIONAL METERPACKAGE

Fig. 5 LF2 Variable Frequency Drive (VFD) External

442A AND 608A VFDs

900A AND 1200A VFDs

a19-1718

a19-1725

12

4

12

53 6

8 711, 1

17

13

16

18

19

1, 2

14, 15, 1 9, 10

3 4 5 6 9

11 1012, 13, 715, 7

7, 8

141617

1 2

Fig. 6 LF2 Variable Frequency Drive (VFD) Internal

442A AND 608A VFDs

900A AND 1200A VFDs

a19-1726

a19-1727

1 Fuse Block, 30A, 600V, Class CC2 Fuse, Class CC, 600V, 20A (3)3 AC Contactor (3) Pre-Charge4 Input Conductor Assembly5 Pre-Charge Resistor Assembly6 Power Module Assembly7 Power Module Namplate8 Terminal Block, 10-Position (2)9 Line Sync Board Cover

10 Line Sync PC Board Assembly11 Fuse, Class CC, 600V, 1A (3)12 Capacitor Bank Assembly13 Fan, 115V (3)14 Fuse, Class CC, 600V, 5A (1)15 Fuse, Class CC, 600V, 20A (1)16 Circuit Breaker, Control Power,

600V, 15A17 Transformer, 3k VA18 Circuit Breaker, 600V19 Lug, Ground, 2-600 MCM

1 Circuit Breaker, 600V2 Lug, Ground, 2-600 MCM3 Input Conductor Assembly4 Capacitor Bank Assembly5 Pre-Charge Resistor

Assembly6 AC Contactor (3)

Pre-Charge7 Fuse Block, 30A, 600V,

Class CC8 Fuse, Class CC, 600V,

20A (3)9 Power Module Assembly

10 Power Module Namplate11 Terminal Block,

10-Position (2)12 Fuse, Class CC, 600V,

20A (1)13 Fuse, Class CC, 600V,

5A (1)14 Transformer, 3k VA15 Fuse, Class CC, 600V,

1A (3)16 Fan, 115V (3)17 Circuit Breaker, Control

Power, 600V, 15A

13

25

1

2

43

1514

13

11 8

1

4

12

10

837

116

10

9

5

6

7

8

22

20

19

21

18

16

17

23

24

20

2526

*The inverter control assembly (item 16) and rectifier control assembly (item 18) are physically similar but are loaded with different software. These boards are NOT interchangeable.442A AND 608A VFDs

Fig. 7 LF2 Power Module Components

1 Wire Harness Assembly, Gate Driver 10 Wire Harness Assembly, Power Supply, Lower Gate 19 AC Line I/O Assembly2 Current Feedback Device, 1000 A 11 Insulation Sheet 20 Connector, Terminal Block, 32-Pin3 Wire Harness Assembly, Power Supply, Logic 12 Rectifier Power Interface Assembly 21 NTC Assembly4 80 W Power Supply Assembly 13 Wire Harness Assembly, Current Feedback Device 22 Internal Fan5 Terminal Block, 2-Position 14 Wire Harness Assembly, DC Bus Bleeder Resistors 23 DPI Communications Interface Assembly6 Cable Assembly, 40-Pin 15 Wire Harness Assembly, Line Sync 24 VFD Gateway7 Cable Assembly, 30-Pin 16 Inverter Control Assembly* 25 Wire Harness Assembly, Control Sync8 Wire Harness Assembly, Power Supply, Upper Gate 17 Standard I/O Option, 24 V Assembly 26 Cable Assembly, 20-pin9 Inverter Power Interface Assembly 18 Rectifier Control Assembly*

a23-1627stacked

Door Open

Door Closed

14

1

18

17

16

3

15

14

13

6

4

6X

32

2X

5

UNDER TOP COVER

7

8

9

10

11

12

2X

Fig. 7 LF2 Power Module Components (cont)

Door Open

Door Closed

a19-1728

a19-1729

900A AND 1200A VFDs

1 Wire Harness Assembly, Internal Fan 6 Internal Fan, 24 VDC 12 Combined I/O PCB Assembly2 Wire Harness Assembly, DC Power 7 Cable, Mini DIN, 8 Pos., Male/Male, 13 Wire Harness Assembly, RTD, Inverter Side3 Wire Harness Assembly, Current Feedback 1 Meter Long 14 Current Feedback Device, 2000A

Device, Rectifier Side 8 Cable Assembly, 40-Pin 15 Wire Harness Assembly, RTD, Rectifier Side4 Wire Harness Assembly, Current Feedback 9 RS-485 Communications Assembly 16 Wire Harness Assembly, Gate Driver

Device, Inverter Side 10 Cable Assembly, 20-Pin 17 Combined Power PCB Assembly, 1215 Amps5 Wire Harness Assembly, DC Bus Resistors 11 Combined Control PCB Assembly 18 Internal Fan, 24 VDC

15

CONTROLSDefinitionsANALOG SIGNAL An analog signal varies in proportionto the monitored source. It quantifies values between operatinglimits. (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: Aswitch produces a discrete signal indicating whether a value isabove or below a set point or boundary by generating an on/off,high/low, or open/closed signal.)

General The 19XRV hermetic centrifugal liquid chillercontains a microprocessor-based control panel that monitorsand controls all operations of the chiller. See Fig. 8 and 9. Themicroprocessor control system matches the cooling capacity ofthe chiller to the cooling load while providing state-of-the-artchiller protection. The system controls the cooling load withinthe set point plus the deadband by sensing the leaving chilledwater or brine temperature and regulating the inlet guide vanevia a mechanically linked actuator motor. The guide vane is avariable flow pre-whirl assembly that controls the refrigerationeffect in the cooler by regulating the amount of refrigerantvapor flow into the compressor. An increase in guide vaneopening increases capacity. A decrease in guide vane openingdecreases capacity. The microprocessor-based controls protectthe chiller by monitoring the digital and analog inputs andexecuting capacity overrides or safety shutdowns, if required.

PIC III System Components The chiller controlsystem is called the PIC III (Product Integrated Control III).See Table 1. The PIC III controls the operation of the chiller bymonitoring all operating conditions. The PIC III can diagnose aproblem and let the operator know what the problem is andwhat to check. It promptly positions the guide vanes tomaintain leaving chilled water temperature. It can interfacewith auxiliary equipment such as pumps and cooling tower

fans to turn them on when required. It continually checks allsafeties to prevent any unsafe operating condition. It also regu-lates the oil heater while the compressor is off and regulates thehot gas bypass valve, if installed. The PIC III controls providecritical protection for the compressor motor and controls theVFD. The PIC III can interface with the Carrier ComfortNetwork (CCN) system if desired. It can communicate withother PIC I, PIC II, or PIC III equipped chillers and other CCNdevices.

The PIC III consists of 3 modules housed inside 3 majorcomponents. The component names and corresponding controlvoltages are listed below (also see Table 1): control panel

all extra low-voltage wiring (24 v or less) power panel

115 vac control voltage (per job requirement) 115 vac power for oil heater and actuators up to 460 vac for oil pump power

VFD cabinet chiller power wiring (per job requirement)

Table 1 Major PIC III Components andPanel Locations*

*See Fig. 5-11.

PIC III COMPONENT PANEL LOCATIONInternational Chiller Visual Controller (ICVC) and Display Control PanelChiller Control Module (CCM) Control PanelControl Transformer Circuit Breakers CB1, CB2 Control PanelOil Heater Contactor (1C) Power PanelOil Pump Contactor (2C) Power PanelHot Gas Bypass Relay (3C) (Optional) Power PanelControl Transformers (T1, T2, T3) Power PanelTemperature Sensors See Fig. 8.Pressure Transducers See Fig. 8.

COOLER CHARGINGVALVE (HIDDEN)

CONTROLPANEL

SPLIT RINGDIFFUSERACTUATOR(OPTIONAL)

GUIDE VANEACTUATOR OIL SUMPPRESSURE

TRANSDUCER POWERPANEL

OIL SUMPTEMPERATURESENSOR

OIL PUMPDISCHARGEPRESSURE

WATERSENSORCABLES

HGBPACTUATOR(OPTIONAL)

VFD COOLINGSOLENOID

VFD ENCLOSUREEVAPORATOR SATURATIONTEMPERATURE SENSOR(ON BOTTOM OF COOLER)

CONDENSER CHARGINGVALVE (HIDDEN)

CONDENSER3-WAY SHUTOFFVALVE

CONDENSERPRESSURETRANSDUCER

WATERSENSORCABLES

COOLERPRESSURETRANSDUCER

Fig. 8 Chiller Controls and Sensor Locationsa19-1730

16

INTERNATIONAL CHILLER VISUAL CONTROLLER(ICVC) The ICVC is the brain of the PIC III system. Thismodule contains all the operating software needed to controlthe chiller. The ICVC is mounted to the control panel (Fig. 10)and is the input center for all local chiller set points, schedules,configurable functions, and options. The ICVC has a stopbutton, an alarm light, four buttons for logic inputs, and abacklight display. The backlight will automatically turn offafter 15 minutes of non-use. The functions of the four buttonsor softkeys are menu driven and are shown on the displaydirectly above the softkeys.

The viewing angle of the ICVC can be adjusted for opti-mum viewing. Remove the 2 bolts connecting the control panelto the brackets attached to the cooler. Place them in one of theholes to pivot the control panel forward to backward to changethe viewing angle. To change the contrast of the display, accessthe adjustment on the back of the ICVC. See Fig. 10.

The ICVC features 4 factory programmed languages: English (default) Chinese Japanese KoreanNOTE: Pressing any one of the four softkey buttons will acti-vate the backlight display without implementing a softkeyfunction.

The ICVC may be identified by viewing the back of theplate on which the display is mounted. (Open the control paneldoor to view.) Note any of the following distinguishing featuresin Table 2.

Table 2 Identification Features of the ICVC

CHILLER CONTROL MODULE (CCM) This module islocated in the control panel. The CCM provides the input andoutputs necessary to control the chiller. This module monitorsrefrigerant pressure, entering and leaving water temperatures,and outputs control for the guide vane actuator, oil heaters, andoil pump. The CCM is the connection point for optionaldemand limit, chilled water reset, remote temperature reset,and motor kilowatt output.OIL HEATER CONTACTOR (1C) This contactor is lo-cated in the power panel (Fig. 11) and operates the heater at115 v. It is controlled by the PIC III to maintain oil temperatureduring chiller shutdown. Refer to the control panel wiringschematic.OIL PUMP CONTACTOR (2C) This contactor is locatedin the power panel. It operates all 380 to 480-v oil pumps.The PIC III energizes the contactor to turn on the oil pump asnecessary.HOT GAS BYPASS CONTACTOR RELAY (3C)(Optional) This relay, located in the power panel, controlsthe opening of the hot gas bypass valve. The PIC III energizesthe relay during low load, high lift conditions.

OIL COOLER THERMOSTATICEXPANSION VALVE (TXV)

OIL COOLER THERMOSTATICEXPANSION VALVE (TXV) BULB

OIL HEATER TERMINALBOX

HIGH PRESSURESWITCH LOCATION

COMPRESSOR DISCHARGETEMPERATURE SENSOR

CABLE

GUIDE VALVEACTUATOR CABLE

DIFFUSER PRESSUREAND DIFFUSER ACTUATOR

CABLE (FRAME 4 & 5COMPRESSOR ONLY)

OIL RECLAIMSIGHT GLASS

CABLE FROMCONTROL PANEL

COMPRESSOR OIL SUMPTEMPERATURE CABLE

COMPRESSOR OIL SUMPPRESSURE CABLE

BEARING TEMPERATURESENSOR CABLE

COMPRESSOR OIL DISCHARGEPRESSURE CABLE

MOTOR TEMPERATURESENSOR CABLE

Fig. 9 19XRV Compressor Controls and Sensor Locations

a19-1606

CONTROLLERCOLOR

OF PLATE

CEPL No. (hardware) SOFTWARE

OTHER MARKINGS

ICVC Metallic CEPL 130445-02CESR

131350-0X

PIC III Marking on back of green circuit board

17

CONTROLPANELSIDE VIEW

REMOVABLEBOLT

HINGE

CHILLER IDENTIFICATION NAMEPLATE

OIL HEATER CONDUIT CONTROL PANELPOWER CONDUIT

OPTIONAL HOT GASBYPASS CONDUIT

3C HOT GAS BYPASSRELAY (OPTIONAL)

T3-20 VAC POWER TRANSFORMERFOR DATAPORT/DATALINK (OPTIONAL)

T2-24 VAC POWER TRANSFORMERFOR ICVC AND CCM

T1-24 VAC POWER TRANSFORMERFOR HOT GAS BYPASS RELAY,OIL PUMP CONTACTOR, ANDOIL HEATER CONTACTOR

T1 T2 T3

OIL HEATERCONTACTOR

11 12 13

21 22 23

11 12 13

21 22 23

3

1

6 5

4 2

51

50

43

17

C

B

A

OIL PUMPCONTACTOR

CARRIER COMFORT NETWORK (CCN)

INTERFACECONTROL POWER

CIRCUIT BREAKERS

OPTIONALDATAPORT/DATALINKCIRCUIT BREAKERS

SURGE/HGBP PARAMETER

LABELCHILLER CONTROL MODULE (CCM)

HUMIDITY SENSOR

CONTROL PANEL INTERNAL VIEW

Fig. 10 Control Panel

Fig. 11 Power Panel

a19-1607

a19-1742

a19-1609

a19-1610

a19-1611

18

CONTROL TRANSFORMERS (T1, T2) These transform-ers convert incoming control voltage to 24 vac power for the3 power panel contactor relays, CCM, and ICVC.OPTIONAL TRANSFORMER (T3) This transformer pro-vides 20 vac control power to DataPort/DataLINKmodules.SENSORS Two types of temperature sensors are used:

Figure 12 shows a typical temperature sensor for whichsensor wells are used, in systems having an ICVC controller.For this type, the sensor cable cannot be separated from thesensor itself, but the sensor can be readily removed from thewell without breaking into the fluid boundary.

The second type of temperature sensor is a thermistor,which is installed either in the motor windings or at the thrustbearing within the compressor. Both of these have redundantsensors such that if one fails, the other can be connected exter-nal to the machine. See Table 3 for a list of standard instrumen-tation sensors.

The PIC III control determines refrigerant temperature inthe condenser and evaporator from pressure in those vessels,read from the corresponding pressure transducers. See Fig. 13.The pressure values are converted to the equivalent saturationtemperatures for R-134a refrigerant. When the chiller is run-ning, if the computed value for EVAPORATOR REFRIGTEMP is greater than, or within 0.6 F (0.33 C) of the LEAV-ING CHILLED WATER temperature, its value is displayed as0.6 F (0.33 C) below LEAVING CHILLED WATER tempera-ture. When the chiller is running, if the computed value forCONDENSER REFRIG TEMP is less than, or within 1.2 F(0.67 C) of the LEAVING COND WATER temperature, itsvalue is displayed as 1.2 F (0.67 C) above LEAVING CONDWATER temperature.

Table 3 Standard Instrumentation Sensors

SHRINK WRAPSTRAIN RELIEF

1/8 NPTTHERMOWELL

REMOVABLETEMPERATURESENSOR

Fig. 12 Temperature Sensor Used with Thermal Well

a23-1624Fig. 13 Control Sensors

(Pressure Transducers, Typical)

a19-957

TYPE LOCATION MONITORED REMARKS

Temperature

Entering chilled water Cooler inlet nozzleLeaving chilled water Cooler outlet nozzleEntering condenser water Condenser inlet nozzleLeaving condenser water Condenser outlet nozzleEvaporator saturation Sensor well on bottom of evaporatorCompressor discharge Compressor voluteOil sump Compressor oil sumpCompressor thrust bearing Redundant sensor providedMotor winding Redundant sensor provided

Pressure

Evaporator Relief valve teeCondenser Relief valve teeOil sump Compressor oil sumpOil sump discharge Oil pump discharge lineDiffuser (Compressor internal) Only in machines equipped with split ring diffusersEntering chilled water (Optional) Cooler inlet nozzleLeaving chilled water (Optional) Cooler outlet nozzleEntering condenser water (Optional) Condenser inlet nozzleLeaving condenser water (Optional) Condenser outlet nozzle

Angular PositionGuide vane actuator Potentiometer inside of actuator

Split ring diffuser actuator (Optional)Potentiometer inside of actuator only on machines equipped with split ring diffusers (split ring diffuser position not dis-played on ICVC)

Pressure Switch High condenser (discharge) pressure Compressor volute, wired into the VFD control circuitTemperature Switch Oil pump motor winding temperature Wired into the oil pump control circuit

19

A Refrigerant Saturation Temperature sensor (thermistor) islocated in the base of the evaporator, sensing refrigeranttemperature directly. Evaporator and condenser water sidedifferential pressure transducers are not standard and are notrequired. The ICVC software uses the evaporator saturationrefrigerant temperature in place of differential pressure flowdetection to provide evaporator freeze protection.

Approach temperatures are shown in the HEAT_EX screen.EVAPORATOR APPROACH is defined as LEAVINGCHILLED WATER temperature minus EVAP SATURATIONTEMP (from the temperature sensor). CONDENSER AP-PROACH is defined as CONDENSER REFRIG TEMP(derived from condenser pressure) minus LEAVING CON-DENSER WATER temperature. When chiller is running, thedisplayed value for either approach will not be less than 0.2 F(0.1 C). If either approach value exceeds the value configuredin the SETUP1 screen, the corresponding Approach Alert mes-sage will be entered into the Alert History table.FLOW DETECTION Flow detection for the evaporatorand condenser is a required condition for start-up and used inthe freeze protection safety. Flow and no flow conditions aredetected from a combination of several measurements. Theusage of waterside differential pressure measurements is notstandard or required.

Positive determination of flow on the evaporator side ismade if the following conditions are true: (1) the EVAP SATU-RATION TEMP reads higher than 1 F (0.6 C) above theEVAP REFRIG TRIPPOINT, and (2) EVAP REFRIG TEMP(determined from the Evaporator Pressure sensor) is greaterthan the EVAP REFRIG TRIPPOINT. (If the unit is in Pump-down or Lockout mode, conditions (1) and (2) are not requiredto establish flow.) On the condenser side, positive determina-tion of flow is made if the following conditions are true: (1) theCONDENSER PRESSURE is less than 165 psig (1139 kPa),and (2) CONDENSER PRESSURE is less than the configuredCOND PRESS OVERRIDE threshold by more than 5 psi(34.5 kPa). In addition, if the waterside differential pressuremeasurement option is enabled, the waterside pressure differ-entials (cooler and condenser) must exceed their respectiveconfigured cutout thresholds.

A No Flow determination is made on the evaporator side if(1) the EVAP SATURATION TEMP reads lower than 1 F(0.6 C) below the EVAP REFRIG TRIPPOINT, or (2) EVAPREFRIG TEMP (determined from the Evaporator Pressuresensor) is less than the EVAP REFRIG TRIPPOINT and theEVAPORATOR APPROACH exceeds the configured EVAPAPPROACH ALERT threshold. On the condenser side, aNo Flow determination is also made if the CONDENSERAPPROACH exceeds the configured COND APPROACHALERT threshold and either (1) CONDENSER PRESSUREexceeds 165 psig (1139 kPa) or (2) CONDENSER PRES-SURE exceeds the configured COND PRESS OVERRIDEthreshold by more than 5 psi (34.5 kPa). In addition, if thewater side differential pressure measurement option is enabled,a differential below the configured EVAP or COND FLOWDELTA P CUTOUT value is sufficient to establish No Flow ineither heat exchanger.

If No Flow (for either cooler or condenser) has been deter-mined, and subsequently conditions change such that neitherconditions for Flow nor No Flow are all satisfied, the determi-nation will remain No Flow.

In the standard ICVC setup, waterside differential pressureindication is disabled by default. The displays for CHILLEDWATER DELTA P and CONDENSER WATER DELTA P inthe HEAT_EX screen will show *****. In order to enablethe option and display a value, change FLOW DELTA PDISPLAY to ENABLE in the SETUP1 screen. Pairs of pres-sure transducers may be connected to the CCM at terminalsJ3 13-24 in place of the standard resistors and jumpers to deter-mine water-side pressure differentials as in the standard ICVC

configuration. (NOTE: If the FLOW DELTA P DISPLAY isenabled, but the standard CCM connection is retained, a differ-ential value of approximately 28.5 psi (197 kPa) will always bedisplayed.)

If waterside differential pressure transducers are used, flowis detected from differential pressure between sensors (pressuretransducers) located in water inlet and outlet nozzles, for eachheat exchanger. The thresholds for flow determination (EVAPFLOW DELTA P CUTOUT, COND FLOW DELTA P CUT-OUT) are configured in the SETUP1 screen. If the measureddifferential is less than the corresponding cutout value for5 seconds, the determination is that flow is absent. If no flow isdetected after WATER FLOW VERIFY TIME (configured inthe SETUP1 screen) after the pump is commanded to start bythe PIC, a shutdown will result, and the corresponding loss-of-flow alarm (alarm state 229 or 230) will be declared. If themeasured differential exceeds the Flow Delta P cutout value,flow is considered to be present.

Alternatively, normally open flow switches may be used forflow indication. In this case, install an evaporator side flowswitch in parallel with a 4.3k ohm resistor between CCMterminals J3 17-18, replacing the jumper. See page 136. For acondenser side flow switch do the same between CCM termi-nals J3 23-24. If this type of flow switch circuit is used, it isimportant to perform a zero point calibration (with the flowswitch open).

ICVC Operation and Menus (Fig. 14-20)GENERAL The ICVC display automatically reverts to the default

screen after 15 minutes if no softkey activity takes place andif the chiller is not in the pump down mode (Fig. 14).

If a screen other than the default screen is displayed on theICVC, the name of that screen is in the top line. See Fig. 15.

The ICVC may be set to display either English or SI units.Use the ICVC configuration screen (accessed from the Ser-vice menu) to change the units. See the Service Operationsection, page 56.

NOTE: The date format on the default screen is MM-DD-YYfor English units and DD-MM-YY for SI metric units. Local Operation In LOCAL mode, the PIC III accepts

commands from the ICVC only and uses the local timeoccupancy schedule to determine chiller start and stoptimes. The PIC III can be placed in the local operating modeby pressing the LOCAL softkey. When RUN STATUS isREADY, the chiller will attempt to start up.

CCN Operation In CCN mode, the PIC III accepts inputfrom any CCN interface or module (with the proper author-ity) as well as from the local ICVC. The PIC III uses theCCN time occupancy schedule to determine start and stoptimes. The PIC III can be placed in the local operating modeby pressing the CCN softkey. When RUN STATUS isREADY, the chiller will attempt to start up.

OFF The control is in OFF mode when neither theLOCAL nor CCN softkey cue is highlighted. Pressing theSTOP key or an alarm will place the control in this mode.The PIC III control must be in this mode for certain opera-tions, such as performing a Control Test or accessing VFDConfiguration parameters.

ALARMS AND ALERTS An alarm shuts down the com-pressor. An alert does not shut down the compressor, but itnotifies the operator that an unusual condition has occurred. Analarm (*) or alert (!) is indicated on the STATUS screens on thefar right field of the ICVC display screen.

Alarms are indicated when the ICVC alarm light (!) flashes.The primary alarm message is displayed on the default screen.An additional, secondary message and troubleshooting infor-mation are sent to the ALARM HISTORY table.

20

When an alarm is detected, the ICVC default screen willfreeze (stop updating) at the time of alarm. The freeze enablesthe operator to view the chiller conditions at the time of alarm.The STATUS tables will show the updated information. Onceall alarms have been cleared (by pressing the soft-key), the default ICVC screen will return to normal operation.

An alarm condition must be rectified before a RESET willbe processed. However, an alert will clear automatically assoon as the associated condition is rectified.ICVC MENU ITEMS To perform any of the operationsdescribed below, the PIC III must be powered up and havesuccessfully completed its self test. The self test takes placeautomatically, after power-up.

Press the softkey to view the list of menu struc-tures: , , , and

. See Fig. 16. The STATUS menu allows viewing and limited calibration

or modification of control points and sensors, relays andcontacts, and the options board.

The SCHEDULE menu allows viewing and modification ofthe local and CCN time schedules and Ice Build time sched-ules.

The SETPOINT menu allows set point adjustments, such asthe entering chilled water and leaving chilled water setpoints.

The SERVICE menu can be used to view or modify infor-mation on the Alarm History, Control Test, Control Algo-rithm Status, Equipment Configuration, VFD Configurationdata, Equipment Service, Time and Date, Attach to Net-work Device, Log Out of Network Device, and ICVC Con-figuration screens. See Fig. 17.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 softkeysto scroll down to the desired item or table. Use the softkey to select that item. The softkey choices that appear nextdepend on the selected table or menu. The softkey choices andtheir functions are described below.BASIC ICVC OPERATIONS (Using the Softkeys) Toperform any of the operations described below, the PIC IIImust be powered up and have successfully completed its selftest. Press to leave the selected decision or field without

saving any changes.

Press to leave the selected decision or field andsave changes.

Press to scroll the cursor bar down in order tohighlight a point or to view more points below the currentscreen.

Press to scroll the cursor bar up in order tohighlight a point or to view points above the current screen.

Press to view the next screen level (high-lightedwith the cursor bar), or to override (if allowable) the high-lighted point value.

Press to return to the previous screen level.

Press or to change the high-lighted point value.

RESET

MENUSTATUS SCHEDULE SETPOINT

SERVICE

STATUS SCHEDULE SETPOINTSERVICE

NEXT PREVIOUSSELECT

QUIT

ENTER

NEXT

PREVIOUS

SELECT

EXIT

INCREASE DECREASE

RUNNING TEMP CONTROLLEAVING CHILLED WATER

01-01-95 11:4828.8 HOURS

CHW IN CHW OUT EVAP REF

CDW IN CDW OUT COND REF

OIL PRESS OIL TEMP % AMPS IN

CCN LOCAL RESET MENU

55.1 44.1 40.785.0 95.0 98.1

21.8 132.9 93

PRIMARY STATUSMESSAGE

COMPRESSORON TIME

DATE TIME

SOFT KEYS MENULINEEACH KEY'S FUNCTION ISDEFINED BY THE MENU DESCRIPTION

ON MENU LINE ABOVE

ALARM LIGHT(ILLUMINATEDWHEN POWER ON)

STOP BUTTON HOLD FOR ONESECOND TO STOP

BLINKS CONTINUOUSLYON FOR AN ALARMBLINKS ONCE TOCONFIRM A STOP

SECONDARYSTATUSMESSAGE

Fig. 14 ICVC Default Screen

a19-1613

CONTROL TESTCONTROL ALGORITHM STATUSEQUIPMENT CONFIGURATIONVFD CONFIGURATION DATAEQUIPMENT SERVICETIME AND DATEATTACH TO NETWORK DEVICELOG OUT OF DEVICEICVC CONFIGURATION

ALARM HISTORY19XRV_II SERVICE

Fig. 15 ICVC Service Screen

a19-1614

21

CCN LOCAL RESET MENU DEF AUL T SCREEN

Start Chiller In CCN Control

Start Chiller in Local Control

Clear Alarm s

ST AT US SCHEDULE SETPOINT SER VICE

(SOFTKEYS)

Access Main Menu

List theStatus Tables

Display The Setpoint T able

(ENTER A 4-DIGIT P ASSWORD) (V ALUES SHOWN AT F ACT O RY DEF AUL T) List the Service Ta bles

OCCPC01S LOCAL TIME SCHEDUL E OCCPC02S ICE BUILD TIME SCHEDULE OCCPC03S CCN TIME SCHEDULE

List the Schedules

1

ALARM HIST OR Y ALER T HIST OR Y CONTROL T EST CONTROL ALGORITHM ST AT US EQUIPMENT CONFIGURA TION VFD CONFIG DA TA EQUIPMENT SER VICE TIME AND DA TE AT T ACH TO NETWORK DEVICE LOG OUT OF DEVICE ICVC CONFIGURA TIO N

Base Demand Limit LCW Setpoint ECW Setpoint Ice Build Setpoint To wer Fan High Setpoint

EXI T SELECT PREVIOUS NEXT Select a Schedule

1 2 3 4 5 6 7 8

Overrid e

ENABL E D ISABL E

EXI T SELECT PREVIOUS NEXT Select a Ti me Period/Override

Modify a Schedule Ti me

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 EXI T

ST AR T ON

ST OP OF F

RELEASE ENTER

EXI T NEXT PREVIOUS SELECT

ENTER ENABL E DISABL E QUI T

DECREASE INCREASE ENTER RELEASE

Select a Modification Point

Modify a Discrete Point

Modify an Analog Point

Modify Control Options

MAINSTAT

ST AR TU P COMPRESS HEA T_E X POWER VFD_S TAT ICVC_PWD

Modify the Setpoint DECREASE INCREASE QUI T ENTER

NEXT PREVIOUS SELECT EXI T Select the Setpoint

NEXT PREVIOUS SELECT EXI T

SEE FIGURE 17

VPF_STAT

Fig. 16 19XRV Chiller Display Menu Structure (ICVC)

a19-1988

22

NEXT PREVIOUS SELECT EXI T SER VICE T ABLE

Display Alarm History (The table holds up to 25 alarms with the most recent alarm at the top of the screen.)

CCM Thermistors CCM Pressure T ransducers Pump s Discrete Outputs IGV and SRD Actuator Head Pressure Output Dif fuser Actuator Pumpdown/Lockout T erminate Lockout Guide V ane Calibration

CONTINUED ON NEXT P AGE

CONTROL ALGORITHM STATUS

CONTROL TEST

ALARM HIST OR Y

List the Control T ests

NEXT PREVIOUS SELECT EXI T Select a T est

List the Control Algorithm Status Tables CAPACITY (Capacity Control) OVERRIDE (Override Status) LL_MAINT (Lead Lag Status) VFD_HIST (VFD Alarm History) LOADSHED CUR_ALARM (Current A larm S ta te) WSMDEFME (W ater System Manager Control Status) OCCDEFCM (T ime Schedule Status)

NEXT PREVIOUS SELECT EXI T Select a T able

NET_OPT BRODEF OCCDEFCS HOLID AY S CONSUME RUNTIME

(ANALOG VALUES) (DISCRETE VALUES)

Select a Parameter NEXT PREVIOUS SELECT EXI T

Modify a Parameter

ENTER ENABL E DISABL E QUI T

DECREASE INCREASE ENTER QUI T

NEXT PREVIOUS SELECT EXI T Select a Ta bl e

EQUIPMENT CONFIGURA TION List the Equipment Configuration T ables

CAP ACITY (Capacity Control Algorithm ) OVERRIDE (Override Status) LL_MAINT (LEADLAG Status) WSMDEFM2 (W ater System Manager Control Status)

Maintenance T able Data

NEXT PREVIOUS SELECT EXI T Data Select Ta bl e

OCCPC01S (Local Status) OCCPC02S (CCN, ICE BUILD Status) OCCPC03S (CCN Status)

OCCDEFM (T ime Schedule Status)

SELECT (USE ENTER) TO SCROL L DOWN

(The table holds up to 25 alerts with the most recent alert at the top of the screen.)

Alert History

ALERT HIST OR Y

SURGPREV (Surge Prevention)

Fig. 17 19XRV Service Menu Structure

a19-1989

23

NEXT PREVIOUS SELECT EXIT

SERVICE MENU CONTINUEDFROM PREVIOUS PAGE

Select a Service Table

Select a Service Table ParameterNEXT 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 TodayATTACH TO NETWORK DEVICEENTERDECREASEINCREASE EXIT

ENTERENABLE DISABLE QUIT

DECREASEINCREASE ENTERQUIT

Select a DeviceATTACHNEXT PREVIOUS SELECT

Modify Device AddressEXITINCREASE DECREASE ENTER

Use to attach ICVC to another CCN network or device Attach to "LOCAL" to enter this machine To upload new tables

Default ScreenMENURESETCCN 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

VFD CONFIG DATA

Service Tables: VFD (STARTER) CONFIG PASSWORD VFD_CONF

(ENTER A 4-DIGIT PASSWORD)(VALUES SHOWN AT FACTORY DEFAULT)4 4 4 4

ICVC CONFIGURATION

EXITINCREASE DECREASE ENTERICVC Configuration Table

To Modify ICVC CCN 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)

ENTERNOYES EXIT

(ANALOG VALUE)

(DISCRETE VALUE)

LEGENDCCN Carrier Comfort NetworkICVC International Chiller Visual ControllerPIC III Product Integrated Control IIIVFD Variable Frequency Drive

Fig. 17 19XRV Service Menu Structure (cont)

a19-1618

24

TO VIEW STATUS (Fig. 18) The status table shows theactual value of overall chiller status such as CONTROLMODE, RUN STATUS, AUTO CHILLED WATER RESET,and REMOTE RESET SENSOR.

1. On the menu screen, press to view the list ofpoint status tables.

2. Press or to highlight the desiredstatus table. The list of tables is:MAINSTAT Overall chiller statusVPF_STAT Variable primary flow surge preventionalgorithm statusSTARTUP Status required to perform start-up ofchillerCOMPRESS Status of sensors related to thecompressorHEAT_EX Status of sensors related to the heatexchangersPOWER Status of motor input powerVFD_STAT Status of VFDICVC_PWD Service menu password forcing accessscreen

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.

FORCING OPERATIONSTo 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.

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 seea value change, especially on kilopascal values.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 force and return thepoint to the PIC IIIs automatic control.

STATUS

NEXT PREVIOUS

SELECT

NEXT PREVIOUS

19XRV_II MAINSTAT POINT STATUSControl ModeRun StatusStart Inhibit TimerOccupied?System Alert/AlarmChiller Start/StopRemote Start ContactTemperature ResetControl PointChilled Water TempActive Demand LimitPercent Line Current

OFFReady

0.0 MinNO

NORMALSTOPOpen0.0 F

44.0 F44.6 F100%0.0%

Fig. 18 Example of Status Screen

a19-1615

NEXTPREVIOUS

SELECT

START STOP

INCREASEDECREASE

ENTER

NEXT PREVIOUS

SELECT

RELEASE

25

Force Indication A forced value is indicated bySUPVSR, SERVC, or BEST flashing next to the pointvalue on the STATUS table.TIME SCHEDULE OPERATION (Fig. 19)

1. On the Menu screen, press .

2. Press or to highlight the desiredschedule.OCCPC01S LOCAL Time ScheduleOCCPC02S ICE BUILD Time ScheduleOCCPC03S CCN Time Schedule

3. Press to view the desired time schedule.

4. Press or to highlight the desiredperiod or override to change.

5. Press to access the highlighted PERIOD orOVERRIDE.

6. a. Press or to change thetime values. OVERRIDE values are in one-hourincrements, up to 4 hours.

b. Press to select days in the day-of-weekfields. Press to eliminate days from theperiod.

7. Press to register the values and to move hori-zontally (left to right) within a period.

8. Press to leave the PERIOD or OVERRIDE.

9. Either return to Step 4 to select another PERIOD orOVERRIDE, or press again to leave the currenttime schedule screen and save the changes.

10. The Holiday Designation (HOLIDEF table) may befound in the Service Operation section, page 56. Themonth, day, and duration for the holiday must beassigned. The Broadcast function in the BRODEFtable also must be enabled for holiday periods tofunction.

TO VIEW AND CHANGE SET POINTS (Fig. 20)1. To view the SETPOINT table, from the MENU screen

press .

SCHEDULE

NEXT PREVIOUS

SELECT

NEXT PREVIOUS

SELECT

INCREASE DECREASE

ENABLEDISABLE

Fig. 19 Example of Time ScheduleOperation Screen

a19-1638

ENTER

EXIT

EXIT

SETPOINT

26

2. There are 5 set points on this screen: BASE DEMANDLIMIT, LCW SETPOINT (leaving chilled water setpoint), ECW SETPOINT (entering chilled water setpoint), ICE BUILD SETPOINT, and TOWER FANHIGH SETPOINT. Only one of the chilled water setpoints can be active at one time. The set point that isactive is determined from the SERVICE menu. See theService Operation section, page 56. The ice build (ICEBUILD) function is also activated and configured fromthe SERVICE menu.

3. Press or to highlight the desiredset 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 pre-vious screen.

SERVICE OPERATION To view the menu-driven pro-grams available for Service Operation, see Service Operationsection, page 56. For examples of ICVC display screens, seeTable 4.

NEXT PREVIOUS

SELECT

INCREASE DECREASE

ENTER

19XRV_II SETPOINT SELECTSETPOINTBase Demand LimitControl PointLCW SetpointECW SetpointICE BUILD SetpointTower Fan High Setpoint

100%

50.0 F60.0 F40.0 F85.0 F

Fig. 20 Example of Set Point Screena19-1619

27

Table 4 ICVC Display Data

1. Only 12 lines of information appear on the chiller display screenat any one time. Press the or softkey tohighlight a point or to view items below or above the currentscreen. Double click the softkey to page forward; pressthe softkey twice to page back.

2. To access the information shown in Examples 10 through 24,enter a 4-digit password after pressing the softkey. Ifno softkeys are pressed for 15 minutes, the ICVC automaticallylogs off (to prevent unrestricted access to PIC III controls) andreverts to the default screen. If this happens, re-enter the pass-word to access the tables shown in Examples 10 through 24.

3. Terms in the Description column of these tables are listed asthey appear on the chiller display screen.

4. The ICVC may be configured in English or Metric (SI) units usingthe ICVC CONFIGURATION screen. See the Service Operationsection, page 56, for instructions on making this change.

5. The items in the Reference Point Name column do not appear onthe chiller display screen. They are data or variable names usedin CCN or Building Supervisor (BS) software. They are listed inthese tables as a convenience to the operator if it is necessary tocross reference CCN/BS documentation or use CCN/BS pro-grams. For more information, see the 19XRV CCN literature.

6. Reference Point Names shown in these tables in all capital let-ters can be read by CCN and BS software. Of these capitalizednames, those preceded by a dagger () can also be changed(that is, written to) by the CCN, BS, and the ICVC. CapitalizedReference Point Names preceded by two asterisks (**) can bechanged only from the ICVC. Reference Point Names in lowercase type can be viewed by CCN or BS only by viewing thewhole table.

7. Alarms and Alerts: An asterisk (*) in the far right field of a ICVCstatus screen indicates that the chiller is in an alarm state; anexclamation point (!) in the far right field of the ICVC screen indi-cates an alert state. The * (or !) indicates that the value on thatline has exceeded (or is approaching) a limit. For more informa-tion on alarms and alerts, see the Alarms and Alerts section,page 19.

LEGEND

EXAMPLE 1 CHILLER DISPLAY DEFAULT SCREENThe following data is displayed in the Default screen.

NOTE: The last three entries are used to indicate operating mode to the PIC III. These values may be forced by the ICVC only.

IMPORTANT: The following notes apply to all Table 4examples.

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SERVICE

CCN Carrier Comfort NetworkCHW Chilled WaterECW Entering Chilled WaterHGBP Hot Gas BypassICVC International Chiller Visual ControllerLCW Leaving Chilled WatermA MilliampsP PressurePIC III Product Integrated Controls IIIPWM Pulse Width ModulatedSRD Split Ring DiffuserT TemperatureVFD Variable Frequency DriveWSM Water System Manager

DESCRIPTION STATUS UNITS REFERENCE POINT NAME(ALARM HISTORY) DISPLAY(PRIMARY MESSAGE)(SECONDARY MESSAGE)(DATE AND TIME)Compressor Ontime 0-500000.0 HOURS C_HRSEntering Chilled Water 40-245 DEG F ECW CHW INLeaving Chilled Water 40-245 DEG F LCW CHW OUTEvaporator Temperature 40-245 DEG F ERT EVAP REFEntering Condenser Water 40-245 DEG F ECDW CDW INLeaving Condenser Water 40-245 DEG F LCDW CDW OUTCondenser Temperature 40-245 DEG F CRT COND REFOil Pressure 0-420 PSI OILPD OILPRESSOil Sump Temp 40-245 DEG F OILT OIL TEMPAverage Line Current 0-999 % AMPS_% AMPS%

0-1 CCN0-1 LOCAL0-1 RESET

28

Table 4 ICVC Display Data (cont)EXAMPLE 2 MAINTSTAT 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), Tripout (7), Override (8), Tripout (9), Ctl Test (10),

Lockout (11), Pumpdown (12), Prestart (13)4. Normal (1), Alert (2), Alarm (3).5. All variables with capital letter point names are available for CCN read operation. Those shown with (*) support write operations for all CCN

devices.

EXAMPLE 3 VPF STAT DISPLAY SCREENTo 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 available for CCN read operation. Those shown with (**) shall support write operationsfor the ICVC only.

DESCRIPTION STATUS UNITS POINTControl Mode NOTE 2 NOTE 2 MODERun Status NOTE 3 NOTE 3 STATUSStart Inhibit Timer 0-15 min T_START