9XR,XRV Hermetic Centrifugal Liquid Chillers with PIC II Controls and HFC-134a 50/60 Hz Start-Up, Operation, and Maintenance Instructions SAFETY CONSIDERATIONS Centrifugal liquid chillers are designed to provide safe and reliable service when operated within design specifications. When operating this equipment, use good judgment and safety precautions to avoid damage to equipment and property or injury to personnel.
CONTENTS Page • DIFFUSER CONTROL • DEMAND LIMITING • CHILLER TIMERS AND STARTS COUNTER • OCCUPANCY SCHEDULE Safety Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Pump and Fan Control . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Shunt Trip (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Function Loss Trip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Default Screen Freeze . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONTENTS (cont) Page Perform a Control Test . . . . . . . . . . . . . . . . . . . . . . . . . . 82 • GUIDE VANE CALIBRATION • COOLER AND CONDENSER PRESSURE TRANSDUCER AND WATERSIDE FLOW DEVICE CALIBRATION Check Optional Pumpout System Controls and Compressor. . . . . . . . . . . . . . . . . . . . . 84 High Altitude Locations . . . . . . . . . . . . . . . . . . . . . . . . . 84 Charge Refrigerant Into Chiller . . . . . . . . . . . . . . . . . .
Page APPENDIX B — LEAD/LAG WIRING . . . . . . . . 177,178 APPENDIX C — MAINTENANCE SUMMARY AND LOG SHEETS . . . . . . . . . . . . . . . . . . . . . . . 179-181 APPENDIX D — OPTIONAL BACNET COMMUNICATIONS WIRING. . . . . . . . . . . . . . 182-188 INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189 INITIAL START-UP CHECKLIST FOR 19XR, XRV HERMETIC CENTRIFUGAL LIQUID CHILLER . . . . . . . . . . . . . . . . . . . .
Control Panel — The control panel is the user interface CAUTION for controlling the chiller. It regulates the chiller’s capacity as required to maintain proper leaving chilled water temperature.
Description 19XR — High Efficiency Hermetic Centrifugal Liquid Chiller 19XRV — Ultra High Efficiency Variable Speed Hermetic Centrifugal Liquid Chiller Special Order Indicator – — Standard S — Special Order Cooler Size 10-12 (Frame 1 XR) 15-17 (Frame 1 XR) 20-22 (Frame 2 XR) 30-32 (Frame 3 XR) 35-37 (Frame 3 XR) 40-42 (Frame 4 XR) 45-47 (Frame 4 XR) 50-54 (Frame 5 XR) 5A-5C (Frame 5 XR)* 55-59 (Frame 5 XR) 5F-5H (Frame 5 XR)* 5K-5R (Frame 5 XR) 5T-5Z (Frame 5 XR) 60-64 (Frame 6 XR) 6K-6R (Frame 6 XR) 65-6
FRONT VIEW 1 2 3 4 5 17 6 1 2 3 4 5 6 7 8 16 7 8 15 14 13 — — — — — — — — 9 — 10 — 11 12 13 14 15 16 17 — — — — — — — LEGEND Guide Vane Actuator Suction Elbow International Chiller Visual Control (ICVC) Chiller Identification Nameplate Cooler, Auto Reset Relief Valves Cooler Pressure Transducer Condenser In/Out Temperature Thermistors Optional Condenser Waterflow Device (ICVC Inputs available) Cooler In/Out Temperature Thermistors Optional Cooler Waterflow Device (ICVC Inputs available) Refrigerant
MOTOR AND OIL COOLING CYCLE VFD COOLING CYCLE The motor and the lubricating oil are cooled by liquid refrigerant taken from the bottom of the condenser vessel (Fig. 3). Refrigerant flow is maintained by the pressure differential that exists due to compressor operation. After the refrigerant flows past an isolation valve, an in-line filter, and a sight glass/moisture indicator, the flow is split between the motor cooling and oil cooling systems.
smaller babbitted thrust face, designed to handle counterthrust forces. For compressors equipped with hydrodynamic bearings, the high speed shaft assembly is supported by two journal bearings located at the transmission end and mid-span, behind the labyrinth seal. The transmission side of the midspan bearing also contains a tilting shoe type thrust bearing which opposes the main axial forces tending to pull the impeller towards the suction end.
REAR MOTOR BEARING FWD MOTOR BEARING OIL SUPPLY TO FORWARD HIGH SPEED BEARING LABYRINTH GAS LINE MOTOR COOLING LINE OIL FILTER FLOW SIGHT GLASS ISOLATION VALVE TXV BULB PRESSURE TRANSDUCER OIL PUMP ISOLATION VALVES OIL COOLER FILTER STRAINER OIL HEATER OIL PUMP MOTOR EDUCTOR FILTER ISOLATION VALVE SIGHT GLASS OIL SKIMMER LINE a19-1965 Fig. 4 — Lubrication System 1. 2. 3. 4. 5. 6. 7.
starter automatically connects the phase windings into a delta configuration. Starter control, monitoring, and motor protection is provided by Carrier’s Integrated Starter Module (ISM) except for Benshaw MX3™ wye-delta starters which do not use an ISM. WARNING The main circuit breaker on the front of the starter disconnects the main motor power only. Power is still energized for two other circuits.
mechanically linked actuator motor. The guide vane is a variable flow pre-whirl assembly that controls the refrigeration effect in the cooler by regulating the amount of refrigerant vapor flow into the compressor. An increase in guide vane opening increases capacity. A decrease in guide vane opening decreases capacity. The microprocessor-based control center protects the chiller by monitoring the digital and analog inputs and executing capacity overrides or safety shutdowns, if required.
SPEED VOLTS AMPS Hz RUNNING AUTO MAN Forward Reverse REMOTE JOG AUTO PROGRAM RUN JOB Kw TORQUE FORWARD REVERSE Password PROGRAM SPEED RUNNING VOLTS AMPS Hz REMOTE JOG AUTO Kw TORQUE FORWARD REVERSE Password PROGRAM AUTO MAN Forward Reverse PROGRAM RUN JOB ENTER ENTER OPTIONAL METER PACKAGE MANUAL RESET Fig.
• power panel — 115 v control voltage transformer primaries (may be rewired to accomodate 230 vac) — 115 vac power for oil heater and actuators (oil heaters may be rewired to accomodate 230 vac) — up to 575 v for oil pump power • starter cabinet — chiller power wiring (per job requirement) PIC II System Components — The chiller control system is called the PIC II (Product Integrated Control II). See Table 1. The PIC II controls the operation of the chiller by monitoring all operating conditions.
stopping the compressor, condenser, chilled water pumps, tower fan, spare alarm contacts, and the shunt trip. The ISM monitors starter inputs such as line voltage, motor current, ground fault, remote start contact, spare safety, condenser high pressure, oil pump interlock, starter 1M, and run contacts. It shuts down the chiller if communications with the ICVC are lost. The ISM can also act as the interface for PIC II to the VFD controller. The ISM module directly measures current and voltage for each phase.
greater than, or within 0.6° F (0.33° C) of the LEAVING CHILLED WATER temperature, its value is displayed as 0.6° F (0.33° C) below LEAVING CHILLED WATER temperature. When the chiller is running, if the computed value for CONDENSER REFRIG TEMP is less than, or within 1.2° F (0.67° C) of the LEAVING COND WATER temperature, its value is displayed as 1.2° F (0.67° C) above LEAVING COND WATER temperature.
Table 2 — Standard Instrumentation Sensors TYPE Temperature Pressure Angular Position Pressure Switch Temperature Switch LOCATION MONITORED REMARKS Entering Chilled Water Cooler Inlet Nozzle Leaving Chilled Water Cooler Outlet Nozzle Entering Condenser Water Condenser Inlet Nozzle Leaving Condenser Water Condenser Outlet Nozzle Evaporator Saturation Sensor Well on Bottom of Evaporator Compressor Discharge Compressor Volute Oil Sump Compressor Oil Sump Compressor Thrust Bearing Redundant Sensor Provided
19XR_II BASIC ICVC OPERATIONS (Using the Softkeys) — To perform any of the operations described below, the PIC II must be powered up and have successfully completed its self test. • Press QUIT to leave the selected decision or field without saving any changes.
2. Press NEXT or PREVIOUS to highlight the desired status table.
DEFAULT SCREEN LOCAL CCN RESET MENU (SOFTKEYS) Start Chiller In CCN Control Start Chiller in Local Control Clear Alarms Access Main Menu STATUS SCHEDULE SETPOINT List the Status Tables SERVICE 1 1 1 1 (ENTER A 4-DIGIT PASSWORD) (VALUES SHOWN AT FACTORY DEFAULT) List the Service Tables • MAINSTAT • VPF_STAT • VDO_STAT • STARTUP • COMPRESS • HEAT_EX • POWER • VFD_STAT • ICVC_PWD Select a Status Table PREVIOUS NEXT Select a Modification Point PREVIOUS NEXT Modify a Discrete Point START STOP ON OFF
SERVICE TABLE NEXT PREVIOUS SELECT EXIT ALERT HISTORY ALARM HISTORY Alert History (The table holds up to 25 alerts with the most recent alert at the top of the screen.) See Note. Display Alarm History (The table holds up to 25 alarms with the most recent alarm at the top of the screen.) See note.
SERVICE MENU CONTINUED FROM PREVIOUS PAGE ISM STARTER CONFIG DATA EQUIPMENT SERVICE 4 4 4 4 (ENTER A 4-DIGIT PASSWORD) (VALUES SHOWN AT FACTORY DEFAULT) Service Tables: • OPTIONS • VDO_SRD • SETUP1 • SETUP2 • LEADLAG • RAMP_DEM • TEMP_CTL Select a Service Table PREVIOUS NEXT Service Tables: • ISM (STARTER) CONFIG PASSWORD • ISM_CONF SELECT EXIT Select a Service Table Parameter SELECT PREVIOUS NEXT EXIT Modify a Service Table Parameter INCREASE DECREASE QUIT ENABLE DISABLE QUIT ENTER (ANALOG VA
TIME SCHEDULE OPERATION (Fig. 20) On the Menu screen, press SCHEDULE . 4. Press NEXT or PREVIOUS to highlight the desired schedule. OCCPC01S — LOCAL Time Schedule OCCPC02S — ICE BUILD Time Schedule OCCPC03S — CCN Time Schedule Fig. 20 — Example of Time Schedule Operation Screen 5. Press SELECT to view the desired time schedule. 10. Press EXIT to leave the period or override. 6. Press NEXT or PREVIOUS to highlight the desired period or override to change. 11.
5. Press INCREASE or DECREASE to change the selected set point value. 2. There are 5 set points on this screen: BASE DEMAND LIMIT, LCW SETPOINT (leaving chilled water set point), ECW SETPOINT (entering chilled water set point), ICE BUILD SETPOINT, and TOWER FAN HIGH SETPOINT. Only one of the chilled water set points can be active at one time. The set point that is active is determined from the SERVICE menu. The ECW option is activated on the TEMP_CTL screen and Ice Build is enabled on the OPTIONS screen.
Table 3 — ICVC Display Data (cont) EXAMPLE 1 — CHILLER DISPLAY DEFAULT SCREEN The following data is displayed in the Default screen. DESCRIPTION (PRIMARY MESSAGE) (SECONDARY MESSAGE) (DATE AND TIME) Compressor Ontime Entering Chilled Water Leaving Chilled Water Evaporator Refrigerant Temperature (See Note 1) Entering Condenser Water Leaving Condenser Water Condenser Refrigerant Temperature Oil Pressure Oil Sump Temp Average Line Current STATUS UNITS 0-500000.
Table 3 — ICVC Display Data (cont) EXAMPLE 3 — VPF STAT DISPLAY SCREEN To access this display from the ICVC default screen: 1. Press MENU . 2. Press STATUS . 3. Scroll down to highlight VPF_STAT . 4. Press SELECT .
Table 3 — ICVC Display Data (cont) EXAMPLE 4 — STARTUP DISPLAY SCREEN To access this display from the ICVC default screen: 1. Press MENU . 2. Press STATUS . 3. Scroll down to highlight STARTUP . 4. Press SELECT .
Table 3 — ICVC Display Data (cont) EXAMPLE 6 — HEAT_EX DISPLAY SCREEN To access this display from the ICVC default screen: 1. Press MENU . 2. Press STATUS . 3. Scroll down to highlight HEAT_EX . 4. Press SELECT .
Table 3 — ICVC Display Data (cont) EXAMPLE 8 — ISM_STAT DISPLAY SCREEN To access this display from the ICVC default screen: 1. Press MENU . 2. Press STATUS . 3. Scroll down to highlight ISM_STAT . 4. Press SELECT .
Table 3 — ICVC Display Data (cont) EXAMPLE 10 — SETPOINT DISPLAY SCREEN To access this display from the ICVC default screen: 1. Press MENU . 2. Press SETPOINT . 3. Press SELECT . DESCRIPTION Base Demand Limit Control Point LCW Setpoint ECW Setpoint Ice Build Setpoint Tower Fan High Setpoint STATUS 40-100 UNITS % POINT DLM DEFAULT 100 10-120 15-120 15-60 55-105 DEG F DEG F DEG F DEG F lcw_sp ecw_sp ice_sp TFH_SP 50.0 60.0 40.
Table 3 — ICVC Display Data (cont) EXAMPLE 13 — LL_MAINT DISPLAY SCREEN To access this display from the ICVC default screen: 1. Press MENU . 2. 3. 4. 5. 6. Press SERVICE . Scroll down to highlight CONTROL ALGORITHM STATUS . Press SELECT . Scroll down to highlight LL_MAINT. Press SELECT .
Table 3 — ICVC Display Data (cont) EXAMPLE 14B — SURGPREV DISPLAY SCREEN (Machines with Serial Numbers 1410Qxxxxx and Later or Version 9 or Later Software) To access this display from the ICVC default screen: 1. Press MENU . 2. 3. 4. 5. 6. Press SERVICE . Scroll down to highlight CONTROL ALGORITHM STATUS . Press SELECT . Scroll down to highlight SURGPREV . Press SELECT .
Table 3 — ICVC Display Data (cont) EXAMPLE 16 — WSMCHRLE DISPLAY SCREEN To access this display from the ICVC default screen: 1. Press MENU . 2. 3. 4. 5. 6. Press SERVICE . Scroll down to highlight CONTROL ALGORITHM STATUS . Press SELECT . Scroll down to highlight WSMCHRLE . Press SELECT . DESCRIPTION WSM Active? Chilled Water Temp Equipment Status Commanded State CHW setpt Reset Value Current CHW Set Point STATUS 0/1 0.0-99.9 0/1 XXXXXXXX 0.0-25.0 0.0-99.
Table 3 — ICVC Display Data (cont) EXAMPLE 18 — ISM_CONF DISPLAY SCREEN To access this display from the ICVC default screen: 1. Press MENU . 2. 3. 4. 5. Press SERVICE . Scroll down to highlight ISM (STARTER) CONFIG DATA . Press SELECT . Enter password (4444 Factory Default). 6. Scroll down to highlight ISM_CONF . 7. Press SELECT .
Table 3 — ICVC Display Data (cont) EXAMPLE 19A — OPTIONS DISPLAY SCREEN (Machines with Serial Numbers Prior to 1410Qxxxxx) To access this display from the ICVC default screen: 1. Press MENU . 2. 3. 4. 5. 6. Press SERVICE . Scroll down to highlight EQUIPMENT SERVICE . Press SELECT . Scroll down to highlight OPTIONS . Press SELECT . DESCRIPTION Auto Restart Option Remote Contacts Option Soft Stop Amps Threshold Surge / Hot Gas Bypass Surge Limit/HGBP Option Select: Surge=0, HGBP=1 Min.
Table 3 — ICVC Display Data (cont) EXAMPLE 19B — OPTIONS DISPLAY SCREEN (Machines with Serial Numbers 1410Qxxxxx and Later or Version 9 or Later Software) To access this display from the ICVC default screen: 1. Press MENU . 2. 3. 4. 5. 6. Press SERVICE . Scroll down to highlight EQUIPMENT SERVICE . Press SELECT . Scroll down to highlight OPTIONS . Press SELECT .
Table 3 — ICVC Display Data (cont) EXAMPLE 21 — SETUP1 DISPLAY SCREEN To access this display from the ICVC default screen: 1. Press MENU . 2. 3. 4. 5. 6. Press SERVICE . Scroll down to highlight EQUIPMENT SERVICE . Press SELECT . Scroll down to highlight SETUP1 . Press SELECT DESCRIPTION Comp Motor Temp Override Cond Press Override Comp Discharge Alert Comp Thrust Brg Alert Comp Thrust Brg Trip Thrust Brg Reset Factor STATUS 150-200 90-165 125-200 10-20 160-185 1.0-3.
Table 3 — ICVC Display Data (cont) EXAMPLE 22 — SETUP2 DISPLAY SCREEN To access this display from the ICVC default screen: 1. Press MENU . 2. 3. 4. 5. 6. Press SERVICE . Scroll down to highlight EQUIPMENT SERVICE . Press SELECT . Scroll down to highlight SETUP2 . Press SELECT .
Table 3 — ICVC Display Data (cont) EXAMPLE 24 — RAMP_DEM DISPLAY SCREEN To access this display from the ICVC default screen: 1. Press MENU . 2. 3. 4. 5. 6. Press SERVICE . Scroll down to highlight EQUIPMENT SERVICE . Press SELECT . Scroll down to highlight RAMP_DEM . Press SELECT .
• The SETPOINT menu allows set point adjustments, such as the entering chilled water and leaving chilled water setpoints. • The SERVICE menu can be used to view or modify information on the Alarm History, Alert History, Control Test, Control Algorithm Status, Equipment Configuration, ISM Starter Configuration data, Equipment Service, Time and Date, Attach to Network Device, Log Out of Network Device, and ICVC Configuration screens. For more information on the menu structures, refer to Fig. 18 and 19.
PROPORTIONAL DEC (Decrease) BAND, and PROPORTIONAL ECW (Entering Chilled Water), GAIN in the SERVICE/EQUIPMENT SERVICE/SETUP2 screen. Increasing the PROPORTIONAL INC BAND or PROPORTIONAL DEC BAND, or decreasing PROPORTIONAL ECW GAIN will reduce the rate of the capacity control response (within limits). See also "PROPORTIONAL BANDS" on page 42. Parameters used in the capacity control determination are displayed in the SERVICE/CONTROL ALGORITHM STATUS/CAPACITY screen and in the STATUS /COMPR screen.
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.
GUIDE VANE POSITION. This is done in accordance with a compressor build-specific “schedule” entered in the SETUP2 screen. The schedule consists of guide vane and diffuser positions for three points (designated as the 25%, 50%, and 75% Load Points). In order for the schedule to be valid, the guide vane values must be ascending and the diffuser values must be descending for the three points. Diffuser actuator output is controlled by a 4 to 20 mA output from CCM terminals J8-3(+) and J8-4(–).
SOURCE is within the DEMAND LIMIT PROP BAND (configurable in the RAMP_DEM table). Demand Limit Control Option — The demand limit control option (20 mA DEMAND LIMIT OPT) is externally controlled by a 4 to 20 mA signal from an energy management system (EMS). The option is set up on the RAMP_DEM screen.
Faults or protective devices within the optional VFD can shut down the chiller. STAT display screen). It cannot be started or run during an unoccupied time period (when OCCUPIED? is set to NO on the MAINSTAT display screen). These time periods can be set for each day of the week and for holidays. The day begins with 0000 hours and ends with 2400 hours. The default setting for OCCUPIED? is YES, unless an unoccupied time period is in effect.
Table 6 — Protective Safety Limits and Control Settings MONITORED PARAMETER Temperature Sensors Out of Range Pressure Transducers Out of Range STATE 260-270, 272,140, 141 260-270 231 Compressor Discharge Temperature 149 103 Motor Winding Temperature 233 Motor Winding Temperature 102 Compressor Thrust Bearing Temperature 101 Compressor Thrust Bearing Temperature 150 Compressor Thrust Bearing Temperature 234 243 232 Low Refrigerant Temperature (Freeze Protection) 104 Transducer Voltage Faul
Table 6 — Protective Safety Limits and Control Settings (cont) MONITORED PARAMETER STATE Low Pressure 142 Oil - Pressure Sensor Fault 227 Oil - Low Temperature 105 211/145 211/145 Line Voltage - High 211/145 108 212/146 Line Voltage - Low 107 LIMIT OIL PRESSURE DELTA P < 18 PSID and startup complete OIL PRESSURE DELTA P > 4 PSI immediately before oil pump turned on OIL SUMP TEMP < 150 deg F and [OIL SUMP TEMP < CALC EVAP SAT TEMP + 50 deg F(27.
Table 6 — Protective Safety Limits and Control Settings (cont) MONITORED PARAMETER STATE Overload Trip 217 Locked Rotor Trip Excessive Amps 218 208 LIMIT Any LOAD CURRENT PHASE > 108% for Excessive Time Period Motor Locked Rotor Amps exceeded PERCENT LOAD CURRENT > 110% for 30 sec.
Ramp Loading — The ramp loading control slows down the rate at which the compressor loads up. This control can prevent the compressor from loading up during the short period of time when the chiller is started and the chilled water loop has to be brought down to CONTROL POINT. This helps reduce electrical demand charges by slowly bringing the chilled water to CONTROL POINT. The total power draw during this period remains almost unchanged. There are two methods of ramp loading with the PIC II.
Table 7 — Capacity Overrides OVERRIDE CONDITION (Configurable Override Paramter) High Condenser Pressure (COND PRESS OVERRIDE) High Motor Temperature (COMP MOTOR TEMP OVERRIDE) Low Evaporator Temperature (REFRIG OVERRIDE DELTA T) High Compressor Lift (Surge Prevention) (SURGE/HGBP DELTA T,P) High Compressor Lift (Surge Prevention) (Tsmin, IGVmin, Tsmax, IGVmax, Shapefac) Manual Guide Vane Target (TARGET GUIDE VANE POS) Manual Speed Control (TARGET VFD SPEED) FIRST STAGE SET POINT (Capacity Inhibit) SECOND
refrigerant leak detector. Enabling REFRIGERANT LEAK OPTION (OPTIONS screen) will allow the PIC II controls to go into an alarm state at a user configured level (REFRIGERANT LEAK ALARM mA). The input is configured for 4 to 20 mA by setting the DIP switch 1 on SW2 at the ON position, or configured for 1 to 5 vdc by setting switch 1 at the OFF position. The output of the refrigerant leak detector is displayed as REFRIGERANT LEAK SENSOR on the MAINSTAT screen.
TER temperature is greater than the TOWER FAN HIGH SETPOINT (SETPOINT menu, default 75 F [23.9 C]). The TOWER FAN RELAY HIGH is turned off when the CONDENSER WATER PUMP is off or the EVAPORATOR REFRIG TEMP is less than the EVAP REF OVERRIDE TEMP and ENTERING CONDENSER WATER is less than 70 F (21.1 C), or the difference between EVAPORATOR PRESSURE and CONDENSER PRESSURE is less than 28 Psid (193 kPa), and ENTERING CONDENSER WATER temperature is less than TOWER FAN HIGH SETPOINT minus 3 F (5.4 C).
use a 1 to 5 vdc input instead of 4 to 20 mA, install a 25-ohm resistor in series with the + lead at terminal J5-2. SETPOINT (from the SETPOINT screen) and a Water/Brine Reset value, if any. CONTROL POINT is limited to a minimum of 35 F (+1.7 C) for water, or 10 F (–12.2 C) for brine. Three types of chilled water or brine reset are available and can be viewed or modified on the TEMP_CTL screen, which is accessed from the EQUIPMENT SERVICE table.
and in Table 3. The Default settings use one set of values for the low, mid, and full load points. These surge characteristics are factory set based on the original selection, with the values printed on a label fixed to the bottom of interior face of the control panel. A line is drawn between these points as shown in Fig. 25. Sample points for a four point line are shown.
to the sum of HGBP ON DELTA T plus HGBP OFF DELTA T See Fig. 26. Surge Prevention Algorithm with VFD — This is an operator configurable feature that can determine if lift conditions are too high for the compressor and then take corrective action. Lift is defined as the difference between the saturated temperature at the impeller eye and at the impeller discharge. The maximum lift a particular impeller wheel can perform varies with the gas flow through the impeller and the diameter of the impeller.
the graph (default settings are shown) describe a line the algorithm uses to determine the maximum lift of the compressor for the particular maximum operating speed. When the actual differential pressure between the cooler and condenser (delta P) and the temperature difference between the entering and leaving chilled water (delta T) are above the line on the graph (as defined by the minimum and full load points), the algorithm operates in Surge Prevention mode.
water bypass around the operating chiller occurs. However, if water bypass around the operating chiller is unavoidable, a common point sensor in the mixed LEAVING CHILLED WATER piping should be provided and enabled for the Lead chiller. CHILLER COMMUNICATION WIRING — Refer to the chiller’s Installation Instructions, Carrier Comfort Network® Interface section for information on chiller communication wiring.
the chilled liquid system. A PULLDOWN TIMER can be configured to delay starting the lag chiller so it does not excessively cycle on and off for short time periods when intermittent slugs of warm ENTERING CHILLED WATER pass through the chillers. A larger PULLDOWN TIMER entry gives the warm slug of water more time to pass through the chillers before the lag chiller can start. The chiller CONTROL POINT can be configured to either LEAVING CHILLED WATER or ENTERING CHILLED WATER temperature.
delay sequence occurs whether the chiller is in CCN or LOCAL mode and is intended to stagger the compressor motor starts. Preventing the motors from starting simultaneously helps reduce the inrush demands on the building power system. CURRENT on the MAINSTAT screen) is less than the lead chiller percent capacity. NOTE: The use of AVERAGE LINE CURRENT or PERCENT MOTOR KILOWATTS in the Lag chiller shutdown decision is based on the DEMAND LIMIT SOURCE configuration in the RAMP_DEM screen.
3. Remote Contacts/Ice Level Input — Ice build operation terminates when the ICE BUILD TERMINATION parameter is set to 1 (CONTACTS) and the ice build contacts are open and the ICE BUILD RECYCLE is set to DSABLE (0). In this case, the contacts provide ice level termination control. The contacts are used to stop the ice build function when a time period on the ice build schedule (OCCPC02S) is set for ice build operation.
If this occurs, return to Step 1 and try to access the SERVICE screens again. If the password is correct, the softkey labels change to: information on another device. Therefore, a CCN module must be attached when this screen is entered. To attach any CCN device, highlight it using the SELECT softkey and press the ATTACH softkey. The message “UPLOADING TABLES, PLEASE WAIT” displays. The ICVC then uploads the highlighted device or module.
DAYLIGHT SAVING TIME CONFIGURATION — The BRODEF table also defines Daylight Saving Time changes. This feature is by default enabled, and the settings should be reviewed and adjusted if desired. The following line-item entries are configurable for both Daylight Savings Time “Start” and “Stop,” and they are defined in Table 8. To disable the Daylight Savings Time function simply enter 0 minutes for “Start Advance” and “Stop Back.
Failure to verify any of the requirements up to this point will result in the PIC II aborting the start and displaying the applicable pre-start alert mode of failure on the ICVC default screen. A pre-start failure does not advance the STARTS IN 12 HOURS counter. Any failure after the 1CR relay has energized results in a safety shutdown, advances the starts in 12 hours counter by one, and displays the applicable shutdown status on the ICVC display.
The soft stop amps threshold function can be terminated and the compressor motor deenergized immediately by depressing the STOP button twice.
• 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.
Table 10 — Bolt Torque Requirements, Foot Pounds BOLT SIZE (in.
Fig.
Table 11A — HFC-134a Pressure — Temperature (F) TEMPERATURE, F 0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 76 78 80 82 84 86 88 90 92 94 96 98 100 102 104 106 108 110 112 114 116 118 120 122 124 126 128 130 132 134 136 138 140 Table 11B — HFC-134a Pressure — Temperature (C) PRESSURE (psig) 6.50 7.52 8.60 9.66 10.79 11.96 13.17 14.42 15.72 17.06 18.45 19.88 21.37 22.90 24.48 26.11 27.80 29.53 31.32 33.17 35.08 37.04 39.06 41.14 43.28 45.
Do not apply a greater vacuum than 29.82 in. Hg vac (757.4 mm Hg) or go below 33 F (.56 C) on the wet bulb vacuum indicator. At this temperature and pressure, isolated pockets of moisture can turn into ice. The slow rate of evaporation (sublimation) of ice at these low temperatures and pressures greatly increases dehydration time. 5. Valve off the vacuum pump, stop the pump, and record the instrument reading. 6. After a 2-hour wait, take another instrument reading.
c. Divide the 60-second resistance reading by the 10-second reading. The ratio, or polarization index, must be one or higher. Both the 10 and 60-second readings must be at least 50 megohms. If the readings on a field-installed starter are unsatisfactory, repeat the test at the motor with the power leads disconnected. Satisfactory readings in this second test indicate the fault is in the power leads. NOTE: Unit-mounted starters do not have to be megohm tested. 10.
• Frame 4 compressor — 10 gal (37.8 L) • Frame 4 compressor with split ring diffuser option — 12 gal (45.0 L) • Frame 5 compressor — 18 gal (67.8 L) The chiller is shipped with oil in the compressor. When the sump is full, the oil level should be no higher than the middle of the upper sight glass, and minimum level is the bottom of the lower sight glass (Fig. 2). If oil is added, it must meet Carrier’s specification for centrifugal compressor use as described in the Oil Specification section.
NOTE: The default CCN Occupied Schedule OCCPC03S is configured to be occupied (software versions 4.0 and later). 1. Press the MENU and SERVICE softkeys. Enter the password and highlight ICVC CONFIGURATION. Press the SELECT softkey. 2. Use the ENTER softkey to scroll to US IMP/METRIC. 3. Press the softkey that corresponds to the units desired for display on the ICVC (e.g., US or METRIC). CHANGE LANGUAGE (ICVC Only) — By default, the ICVC displays information in English.
Table 12 — Job Site Parameters PARAMETER TABLE ISM_CONF — Select 0 for full voltage, 1 for Starter Type reduced voltage, or 2 for solid state or 3 for variable frequency drive. Motor Rated Line ISM_CONF — Motor rated voltage from chiller Voltage information nameplate. ISM_CONF — Enter ratio (reduced to a ratio to Volt Transformer 1) of power transformer wired to terminal J3 of Ratio ISM. If no transformer is used enter 1. Motor Rated ISM_CONF — Per chiller nameplate data.
• • • • Output Voltage Output Current Kilowatts Torque PROGRAM MODE — This mode displays and modifies the configuration parameters of the VFD microprocessor. Particular parameters, parameter numbers, and error log information can be displayed when in Program mode. Press the PROGRAM softkey until the PROGRAM LED is illuminated to enter the Program mode.
Press and keys to move through following parameters. P.nnn — General Parameters U.nnn — Vector Control Parameters* H.nnn — Volts/Hertz Control Parameters R.nnn — RMI Remote Monitor Interface Parameters E.nnn — Error Log (See fault codes) A United Technologies Company TM REFRIGERATION MACHINE MODEL NUMBER SERIAL NO. MACHINE COMP'R COOLER CONDENSER ECON STOR TANK *Vector control is not used in this configuration. Press ENTER softkey to select a parameter menu screen. RATED TONS RATED iKW LBS.
Press the PROGRAM softkey to access the parameter screen to modify or view the following job specific parameters: 6. Verify the conduit for the power wiring in securely connected to the VFD flanged cover and runs continuously to the branch protection. 7. Verify that the incoming and outgoing wires have been properly connected inside of the line reactor enclosure if a separate line reactor has been added to the chiller. 8.
2. Adjust VFD parameter P.009 (Input offset) if outside the tolerance. The VFD will declare an "Aln" Alarm if P.009 is too small. 3. Verify that the actual speed signal feedback to the chiller controller is 0% by accessing the ACTUAL VFD SPEED in the ICVC COMPRESS screen. 4. Verify ACTUAL VFD SPEED is 0% to 1% on the ICVC. 5. Adjust VFD parameter r.002 (Analog Output Offset) if outside the tolerance. A "C" will be displayed next to ACTUAL VFD SPEED if r.002 is too small.
3. Use the arrow key to increment the value to 26. This is the password number. 4. Press the ENTER softkey to save the value. P.051 will by displayed. NOTE: Parameter programming is disabled when the PASSWORD LED is on and enabled when the PASSWORD LED is off. 5. Select parameter P.006 from the VFD Keypad. 6. Press the ENTER softkey to access the parameter. 7. Use the arrow key to increment the value to 107.
If surge prevention occurs too soon or too late at a load that falls between two SURGE/HGBP DELTA T points it is acceptable to change the two adjacent SURGE/HGBP DELTA P points simultaneously to keep the slope of the modified surge prevention curve nearer to the original curve. This is illustrated in Fig. 36. If the adjustment is needed between (∆T1, ∆P1) and (∆T2, ∆P2) adjust both P1 and P2 by the same amount. Do the same between any two points.
If surge is encountered then the surge line is probably too optimistic or high. Note following parameters from ICVC at surge: • EVAPORATOR REFRIGERANT TEMP • EVAPORATOR PRESSURE • CONDENSER REFRIG TEMP • CONDENSER PRESSURE • ACTUAL GUIDE VANE POSITION • AVERAGE LINE CURRENT If ACTUAL GUIDE VANE POSITION is less than 30%, go to Step 1. If ACTUAL GUIDE VANE POSITION is greater than 60%, then go to Step 3. 1. Do not change SURGE LINE SHAPE FACTOR from the value selected by Chiller Builder (ECAT).
GUIDE VANE POSITION less than 30) or if Step 4 failed (with ACTUAL GUIDE VANE POSITION greater than 60), then perform this step. Do not change SURGE LINE SHAPE FACTOR from the value specified by Chiller Builder (ECAT). Reset SURGE/HGBP DELTA TSMIN and SURGE/HGBP DELTA TSMAX to the value specified by Chiller Builder (ECAT). Decrease SURGE/HGBP DELTA TSMIN and SURGE/HGBP DELTA TSMAX in steps of 1° F up to 5 times. Monitor chiller for surge.
should be only one device on a CCN network which is designated as the Time Broadcaster. ALARM ROUTING — This is in the table SERVICE–> EQUIPMENT CONFIGURATION–>NET_OPT under the heading Alarm Configuration. ALARM ROUTING consists of an 8-bit binary number. Only bits 1, 2, and 4 (counting from the left, first) are used. The others do not matter. The bits can be set by any device which can access and change configuration tables.
If 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.
3. Slowly open the refrigerant cooling isolation valve. The chiller cooler and condenser pressures will gradually equalize. This process takes approximately 15 minutes. 4. Once the pressures have equalized, the cooler isolation valve, the condenser isolation valve, and the hot gas isolation valve may now be opened. Refer to Fig. 43 and 44 for the location of the valves. Increase the sensitivity of the flow switch by turning the adjustment potentiometer clockwise until the yellow LED is lit.
1b REFRIGERANT CHARGING VALVE CHILLER CONDENSER VESSEL 1a REFRIGERANT CHARGING VALVE CHILLER COOLER VESSEL COOLER 11 REFRIGERANT ISOLATION VALVE TEE FOR CHARGING PRESSURE RELIEF SAFETY VALVE 10 STORAGE TANK LIQUID VALVE 7 OIL SEPARATOR LIQUID LINE SERVICE VALVE PUMPOUT COMPRESSOR = SERVICE VALVE ON CHILLER (FIELD SUPPLIED) = SERVICE VALVE ON PUMPOUT UNIT PUMPOUT CONDENSER 2 3 4 5 = MAINTAIN AT LEAST 2 FT (610mm) CLEARANCE AROUND STORAGE TANK FOR SERVICE AND OPERATION WORK.
Table 16A — Refrigerant (HFC-134a) Charge with Compressor End Cooler Nozzles Code 10* 11* 12* 15* 16* 17* 20 21 22 30 31 32 35 36 37 40 41 42 45 46 47 50 51 52 53 54 55 56 57 58 59 5A 5B 5C 5F 5G 5H 5K 5L 5M 5P 5Q 5R 5T 5U 5V 5X 5Y 5Z 60 61 62 63 64 65 66 67 68 69 English Machine Charge Refrigerant Weight (lb) Cooler Condenser 290 200 310 200 330 200 320 250 340 250 370 250 345 225 385 225 435 225 350 260 420 260 490 260 400 310 480 310 550 310 560 280 630 280 690 280 640 330 720 330 790 330 750 400 840
Table 16B — 19XR Heat Exchanger Data — Drive End Entering Cooler Water Code 10* 11* 12* 15* 16* 17* 20 21 22 30 31 32 35 36 37 40 41 42 45 46 47 50 51 52 53 54 55 56 57 58 59 5A 5B 5C 5F 5G 5H 5K 5L 5M 5P 5Q 5R 5T 5U 5V 5X 5Y 5Z 60 61 62 63 64 65 66 67 68 69 English Machine Charge Refrigerant Weight (lb) Cooler Condenser 328 226 357 226 387 226 405 275 441 275 477 275 416 252 459 252 505 252 510 308 565 308 626 308 577 349 639 349 709 349 726 338 783 338 840 338 821 383 874 383 949 383 897 446 974 446 10
5. The PIC II eventually shows an alarm for motors amps not sensed. Reset this alarm and continue with the initial start-up. 6. Disengage the main VFD disconnect. Open the VFD enclosure, move the VFD Test/Run switch into the “RUN” position. Close the VFD enclosure and engage the main VFD disconnect. TRIMMING REFRIGERANT CHARGE — The 19XR chiller is shipped with the correct charge for the design duty of the chiller. Trimming the charge can best be accomplished when the design load is available.
REVIEW THE START-UP OPERATION, AND MAINTENANCE MANUAL. To Prevent Accidental Start-Up — A chiller STOP override setting may be entered to prevent accidental start-up during service or whenever necessary. Access the MAINSTAT screen and using the NEXT or PREVIOUS softkeys, highlight the CHILLER START/STOP parameter. Override the current START value by pressing the SELECT softkey. Press the STOP softkey followed by the ENTER softkey. The word SUPVSR! displays on the ICVC indicating the override is in place.
demand charge for the short period of high demand operation. Pulldown rate can be based on load rate or temperature rate and is accessed on the EQUIPMENT SERVICE screen, RAMP_DEM table (Table 3, Example 24). operation or to control the guide vanes in an emergency. Manual operation is possible by overriding the target guide vane position. Access the COMPRESS screen on the ICVC and scroll down to highlight TARGET GUIDE VANE POS.
Press. Temp Refrigerant In Water Out GPM Pressure COOLER In Out Temp MACHINE MODEL NO. Press. Temp Refrigerant In Out GPM Pressure Water CONDENSER In Out Temp MACHINE SERIAL NO. BEARING TEMP Fig. 46 — Refrigeration Log REMARKS: Indicate shutdowns on safety controls, repairs made and oil or refrigerant added or removed. Include amounts. TIME DATE Plant Press. Diff.
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.
b. Slowly open valve 5 and refrigerant charging valves 7 and 10 to allow liquid refrigerant to drain by gravity into the storage tank. Transfer Refrigerant from Pumpout Storage Tank to Chiller WARNING VALVE CONDITION During transfer of refrigerant into and out of the 19XRV storage tank, carefully monitor the storage tank level gage. Do not fill the tank more than 90% of capacity to allow for refrigerant expansion. Overfilling may result in damage to the tank and personal injury.
d. Run the pumpout compressor until the chiller condenser reaches 18 in. Hg vacuum (41 kPa absolute) in Manual or Automatic mode. Monitor pressure at the chiller control panel and refrigerant gages. e. Close valve 1b. f. Turn off pumpout compressor. g. Close valves 1a, 2, and 5. c. Equalize the refrigerant in the chiller cooler and condenser. d. Turn off chiller water pumps and pumpout condenser water supply. e. Turn on pumpout compressor to push liquid out of the chiller cooler vessel. f.
leak rate for the entire chiller is more than 10% of the operating refrigerant charge per year. In addition, Carrier recommends that leaks totalling less than the above rate but more than a rate of 0.1% of the total charge per year should be repaired during annual maintenance or whenever the refrigerant is transferred for other service work. 3. Transfer remaining refrigerant. a. Close valve 3. b. Open valve 2. VALVE CONDITION 1a 1b 2 3 C 4 C 5 6 7 C 10 C 11 c. Turn on pumpout condenser water. d.
GUIDE VANE ACTUATOR SHAFT SUCTION HOUSING GUIDE VANE ACTUATOR SET SCREWS GUIDE VANE ACTUATOR SPROCKET DRIVE CHAIN ACTUATOR BRACKET CL OS E CHAIN GUARD O P HOLDDOWN BOLTS (3) EN GUIDE VANE SHAFT GUIDE VANE SPROCKET a19-1731 Fig. 49 — Guide Vane Actuator Linkage loss that is not related to service will eventually return to the sump. It must be removed when the level is high. An oil heater is controlled by the PIC II to maintain oil temperature (see the Controls section) when the compressor is off.
TO CHANGE THE OIL 1. Transfer the refrigerant into the chiller condenser vessel (for isolatable vessels) or to a pumpout storage tank. 2. Mark the existing oil level. 3. Open the control and oil heater circuit breaker. 4. When the chiller pressure is 5 psig (34 kPa) or less, drain the oil reservoir by opening the oil charging valve (Fig. 2). Slowly open the valve against refrigerant pressure. 5. Change the oil filter at this time. See Changing Oil Filter section. 6.
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.
Relieve refrigerant pressure and add oil to the pumpout unit as follows: 1. Close service valves 2 and 4. 2. Run the pumpout compressor in Automatic mode for one minute or until the vacuum switch is satisfied and compressor shuts off. 3. Move the pumpout selector switch to OFF. Pumpout compressor shell should now be under vacuum. 4. Oil can be added to the shell with a hand oil pump through the access valve in the compressor base.
See Fig. 2 for sensor locations. The sensors are immersed directly in the refrigerant or water circuits. When installing a new sensor, apply a pipe sealant or thread sealant to the sensor threads. An additional thermistor, factory installed in the bottom of the cooler barrel, will read as EVAPORATOR REFRIGERANT TEMP on the HEAT_EX display screen. This thermistor provides additional protection against a loss of water flow.
Table 17 — ICVC Primary and Secondary Messages and Custom Alarm/Alert Messages with Troubleshooting Guides A. MANUAL STOP PRIMARY MESSAGE MANUALLY STOPPED — PRESS TERMINATE PUMPDOWN MODE SHUTDOWN IN PROGRESS SECONDARY MESSAGE CCN OR LOCAL TO START TO SELECT CCN OR LOCAL SHUTDOWN IN PROGRESS COMPRESSOR UNLOADING COMPRESSOR DEENERGIZED ICE BUILD SHUTDOWN IN PROGRESS OPERATION COMPLETE RECYCLE RESTART PENDING PROBABLE CAUSE/REMEDY PIC II in OFF mode, press CCN or LOCAL softkey to start unit.
Table 17 — ICVC Primary and Secondary Messages and Custom Alarm/Alert Messages with Troubleshooting Guides (cont) D. PRE-START ALERTS: These alerts only delay start-up. When alert is corrected, the start-up will continue. No reset is necessary.
Table 17 — ICVC Primary and Secondary Messages and Custom Alarm/Alert Messages with Troubleshooting Guides (cont) E. START-UP IN PROGRESS PRIMARY MESSAGE STARTUP IN PROGRESS STARTUP IN PROGRESS STARTUP IN PROGRESS AUTORESTART IN PROGRESS AUTORESTART IN PROGRESS AUTORESTART IN PROGRESS SECONDARY MESSAGE OCCUPIED MODE REMOTE CONTACT CLOSED CAUSE/REMEDY Chiller is starting. Time schedule is Occupied (OCCUPIED? = YES) Chiller is starting. REMOTE CONTACTS OPTION is set to ENABLE.
Table 17 — ICVC Primary and Secondary Messages and Custom Alarm/Alert Messages with Troubleshooting Guides (cont) G. NORMAL RUN WITH OVERRIDES ICVC FAULT STATE 120 121 PRIMARY MESSAGE SECONDARY MESSAGE PRIMARY CAUSE HIGH CONDENSER PRESSURE 120->Condenser Pressure [VALUE] exceeded limit of [LIMIT]*. HIGH MOTOR TEMPERATURE 121->Comp Motor Winding Temp [VALUE] exceeded limit of [LIMIT]*.
Table 17 — ICVC Primary and Secondary Messages and Custom Alarm/Alert Messages with Troubleshooting Guides (cont) H.
Table 17 — ICVC Primary and Secondary Messages and Custom Alarm/Alert Messages with Troubleshooting Guides (cont) I.
Table 17 — ICVC Primary and Secondary Messages and Custom Alarm/Alert Messages with Troubleshooting Guides (cont) I. CHILLER PROTECTIVE LIMIT FAULTS (cont) ICVC FAULT STATE PRIMARY MESSAGE SECONDARY MESSAGE HIGH MOTOR TEMPERATURE 233 PRIMARY CAUSE 233->Comp Motor Winding Temp [VALUE] exceeded limit of [LIMIT]*. PROTECTIVE LIMIT HIGH BEARING TEMPERATURE 234->Comp Thrust Brg Temp [VALUE] exceeded limit of [LIMIT]*.
Table 17 — ICVC Primary and Secondary Messages and Custom Alarm/Alert Messages with Troubleshooting Guides (cont) I. CHILLER PROTECTIVE LIMIT FAULTS (cont) ICVC FAULT STATE PRIMARY MESSAGE 240 PROTECTIVE LIMIT 241 LOSS OF COMMUNICATION 242 LOSS OF COMMUNICATION 243 PRIMARY CAUSE LOW DISCHARGE SUPERHEAT 240->Check for Oil in Refrigerant or Overcharge of Refrigerant. WITH STARTER MODULE 241->Loss of Communication With Starter. WITH CCM MODULE 242->Loss of Communication With CCM.
Table 17 — ICVC Primary and Secondary Messages and Custom Alarm/Alert Messages with Troubleshooting Guides (cont) I. CHILLER PROTECTIVE LIMIT FAULTS (cont) ICVC FAULT STATE 248 249 250 PRIMARY MESSAGE SPARE TEMPERATURE #1 248->Spare Temperature #1 [VALUE] exceeded limit of [LIMIT]*. SPARE TEMPERATURE #2 249->Spare Temperature #2 [VALUE] exceeded limit of [LIMIT]*.
Table 17 — ICVC Primary and Secondary Messages and Custom Alarm/Alert Messages with Troubleshooting Guides (cont) J.
Table 17 — ICVC Primary and Secondary Messages and Custom Alarm/Alert Messages with Troubleshooting Guides (cont) J.
Table 17 — ICVC Primary and Secondary Messages and Custom Alarm/Alert Messages with Troubleshooting Guides (cont) K.
Table 17 — ICVC Primary and Secondary Messages and Custom Alarm/Alert Messages with Troubleshooting Guides (cont) K.
Table 17 — ICVC Primary and Secondary Messages and Custom Alarm/Alert Messages with Troubleshooting Guides (cont) K.
Table 18A — Thermistor Temperature (F) vs. Resistance/Voltage Drop TEMPERATURE (F) –25 –24 –23 –22 –21 –20 –19 –18 –17 –16 –15 –14 –13 –12 –11 –10 –9 –8 –7 –6 –5 –4 –3 –2 –1 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 PIC II VOLTAGE DROP (V) 4.700 4.690 4.680 4.670 4.659 4.648 4.637 4.625 4.613 4.601 4.588 4.576 4.562 4.549 4.535 4.521 4.507 4.492 4.477 4.461 4.
Table 18B — Thermistor Temperature (C) vs. Resistance/Voltage Drop TEMPERATURE (C) –33 –32 –31 –30 –29 –28 –27 –26 –25 –24 –23 –22 –21 –20 –19 –18 –17 –16 –15 –14 –13 –12 –11 –10 –9 –8 –7 –6 –5 –4 –3 –2 –1 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 PIC II VOLTAGE DROP (V) 4.722 4.706 4.688 4.670 4.650 4.630 4.608 4.586 4.562 4.538 4.512 4.486 4.458 4.429 4.399 4.368 4.336 4.303 4.269 4.233 4.196 4.158 4.119 4.079 4.037 3.994 3.
changes, control point overrides, hot gas bypass, surge prevention, etc. The tables are: NOTE: If the cooler or condenser vessels are at 0 psig (0 kPa) or are open to atmospheric pressure, the transducers can be calibrated for zero without removing the transducer from the vessel. 3. Access the HEAT_EX screen and view the particular transducer reading (the EVAPORATOR PRESSURE or CONDENSER PRESSURE parameter on the HEAT_EX screen).
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.
J11 DISCRETE OUTPUTS J12 DISCRETE OUTPUTS SW1 (S10 ADDRESS DIP SWITCH) SET ALL TO OFF J1 24 VAC ANALOG OUT J8 SIO J7 SIO J6 SW2 (V/I CONFIGURATION DIP SWITCH) V/I INPUTS J5 COMM STAT a19-1869 THERMISTORS J4 PRESSURE J2 DIFF PRESSURE J3 Fig.
8. Set the current time and date in the SERVICE/TIME AND DATE screen. Set the CCN Bus and Address in the SERVICE / ICVC CONFIGURATION screen. Press the alarm RESET softkey (from the default screen). Upload via Service Tool or manually reenter all non-default configuration values. (Refer to pages CL-3 through CL-13.) If the correct VFD Configuration values are displayed in the ISM_CONF table when that table is viewed, simply press EXIT then SAVE to reload all of them.
3. Place the SCR between the roll pins on the heat sink assemblies so the roll pins fit into the small holes in each side of the SCR. NOTE: Ensure the SCR is installed so the cathode side is the side from which the red wire extends. The heatsink is labeled to show the correct orientation. 4. Finger tighten the clamp. Ensure both bolts are tightened an equal amount so that the loader bar is square in the heatsink. See Fig. 55. 5.
Table 20A — 19XR Heat Exchanger Data — Drive End Entering Cooler Water English Code 10† 11† 12† 15† 16† 17† 20 21 22 30 31 32 35 36 37 40 41 42 45 46 47 50 51 52 53 54 55 56 57 58 59 5A 5B 5C 5F 5G 5H 5K 5L 5M 5P 5Q 5R 5T 5U 5V 5X 5Y 5Z 60 61 62 63 64 65 66 67 68 69 Dry Rigging Weight (lb)* Cooler Only Condenser Only 2707 2777 2848 2969 3054 3141 3407 3555 3711 4071 4253 4445 4343 4551 4769 4908 5078 5226 5363 5559 5730 5713 5940 6083 6141 6192 6257 6517 6682 6751 6811 5124 5177 5243 5577 5640 5716 4993
Table 20A — 19XR Heat Exchanger Data — Drive End Entering Cooler Water (cont) English Code 6K 6L 6M 6P 6Q 6R 6T 6U 6V 6X 6Y 6Z 70 71 72 73 74 75 76 77 78 79 7K 7L 7M 7P 7Q 7R 7T 7U 7V 7X 7Y 7Z 80 81 82 83 84 85 86 87 88 89 8K 8L 8M 8P 8Q 8R 8T 8U 8V 8X 8Y 8Z Dry Rigging Weight (lb)* Cooler Only Condenser Only 5716 5804 5894 5768 5852 5938 6230 6330 6433 6293 6388 6487 9942 10330 10632 10715 10790 10840 11289 11638 11738 11828 8728 8959 9161 8792 9023 9229 9431 9698 9932 9510 9777 10016 12664 12998 13347
Table 20B — 19XR Heat Exchanger Data — Compressor End Entering Cooler Water English Code 10† 11† 12† 15† 16† 17† 20 21 22 30 31 32 35 36 37 40 41 42 45 46 47 50 51 52 53 54 55 56 57 58 59 5A 5B 5C 5F 5G 5H 5K 5L 5M 5P 5Q 5R 5T 5U 5V 5X 5Y 5Z 60 61 62 63 64 65 66 67 68 69 Dry Rigging Weight (lb)* Cooler Only Condenser Only 2707 2777 2848 2968 3054 3141 3407 3555 3711 4071 4253 4445 4343 4551 4769 4908 5078 5226 5363 5559 5730 5713 5940 6083 6141 6192 6257 6517 6682 6751 6811 5124 5177 5243 5577 5640 5716
Table 20B — 19XR Heat Exchanger Data — Compressor End Entering Cooler Water (cont) English Code 6K 6L 6M 6P 6Q 6R 6T 6U 6V 6X 6Y 6Z 70 71 72 73 74 75 76 77 78 79 7K 7L 7M 7P 7Q 7R 7T 7U 7V 7X 7Y 7Z 80 81 82 83 84 85 86 87 88 89 8K 8L 8M 8P 8Q 8R 8T 8U 8V 8X 8Y 8Z Dry Rigging Weight (lb)* Cooler Only Condenser Only 5716 5804 5894 5768 5852 5938 6230 6330 6433 6293 6388 6487 9942 10330 10632 10715 10790 10840 11289 11638 11738 11828 8728 8959 9161 8792 9023 9229 9431 9698 9932 9510 9777 10016 12664 12998
Table 21 — 19XR Additional Data for Marine Waterboxes* HEAT EXCHANGER FRAME, PASS FRAME 2, 1 AND 3 PASS FRAME 2, 2 PASS FRAME 3, 1 AND 3 PASS FRAME 3, 2 PASS FRAME 4, 1 AND 3 PASS FRAME 4, 2 PASS FRAME 5, 1 AND 3 PASS FRAME 5, 2 PASS FRAME 6, 1 AND 3 PASS FRAME 6, 2 PASS FRAME 7, 1 AND 3 PASS FRAME 7, 2 PASS FRAME 8, 1 AND 3 PASS FRAME 8, 2 PASS FRAME 2, 1 AND 3 PASS FRAME 2, 2 PASS FRAME 3, 1 AND 3 PASS FRAME 3, 2 PASS FRAME 4, 1 AND 3 PASS FRAME 4, 2 PASS FRAME 5, 1 AND 3 PASS FRAME 5, 2 PASS FRAME 6, 1 A
Table 22 — 19XR Compressor Weights COMPONENT SUCTION ELBOW DISCHARGE ELBOW TRANSMISSION* SUCTION HOUSING IMPELLER SHROUD COMPRESSOR BASE DIFFUSER OIL PUMP HIGH SPEED SHAFT ASSEMBLY IMPELLER MISCELLANEOUS (Incl.
Table 23B — 19XR Compressor and Motor Weights — Compressor Frame Size 3 ENGLISH SI 50 Hz End Bell End Bell MOTOR Compressor Compressor Cover Cover CODE Rotor Stator Rotor Stator Rotor Stator Rotor Stator Weight** Weight** Weight†† Weight Weight†† Weight Weight Weight†† Weight Weight†† Weight Weight (kg) (lb) (kg) (lb) (lb) (lb) (lb) (kg) (kg) (kg) (kg) (lb) 60 Hz 60 Hz 50 Hz STANDARD-EFFICIENCY MOTORS / LOW VOLTAGE (200-575v) CBS 2816 1146 219 1188 236 274 1277 520 99 539 107 124 CCS 2816
Table 23B — 19XR Compressor and Motor Weights — Compressor Frame Size 3 (cont) ENGLISH SI 50 Hz End Bell End Bell MOTOR Compressor Compressor Cover Cover CODE Stator Rotor Stator Rotor Stator Rotor Stator Rotor Weight** Weight** Weight†† Weight Weight†† Weight Weight Weight†† Weight Weight†† Weight Weight (kg) (lb) (kg) (lb) (lb) (lb) (lb) (lb) (kg) (kg) (kg) (kg) 60 Hz 60 Hz 50 Hz HIGH-EFFICIENCY MOTORS / MEDIUM VOLTAGE (2400-4160v) CBH 2816 1114 242 1156 255 274 1277 505 110 524 116 124
Table 23C — 19XR Compressor and Motor Weights — Compressor Frame Size 4 ENGLISH SI 60 Hz 60 Hz 50 Hz MOTOR Compressor CODE Stator Rotor Stator Rotor Weight** Weight†† Weight Weight†† Weight (lb) (lb) (lb) (lb) (lb) 50 Hz End Bell Compressor Cover Stator Rotor Stator Rotor Weight** Weight Weight†† Weight Weight†† Weight (kg) (lb) (kg) (kg) (kg) (kg) End Bell Cover Weight (kg) STANDARD-EFFICIENCY MOTORS / LOW VOLTAGE (200-575v) DBS 3425 / 4211 1570 324 1725 347 236 1554 / 1910 712 147 782 1
Table 23D — 19XR Compressor and Motor Weights — Compressor Frame Size 4 (cont) ENGLISH SI 50 Hz End Bell End Bell MOTOR Compressor Compressor Cover Cover CODE Stator Rotor Stator Rotor Stator Rotor Stator Rotor Weight** Weight** Weight†† Weight Weight†† Weight Weight Weight†† Weight Weight†† Weight Weight (kg) (lb) (kg) (lb) (lb) (lb) (lb) (lb) (kg) (kg) (kg) (kg) 60 Hz 60 Hz 50 Hz HIGH-EFFICIENCY MOTORS / LOW VOLTAGE (200-575v) LBH 3425 / 4211 1873 364 1939 389 318 1554 / 1910 850 165 880 1
Table 23E — 19XR Compressor and Motor Weights — Compressor Frame Size 5 ENGLISH SI 50 Hz End Bell End Bell MOTOR Compressor Compressor Cover Cover CODE Stator Rotor Stator Rotor Stator Rotor Stator Rotor Weight** Weight** Weight†† Weight Weight†† Weight Weight Weight†† Weight Weight†† Weight Weight (kg) (lb) (kg) (lb) (lb) (lb) (lb) (lb) (kg) (kg) (kg) (kg) 60 Hz 60 Hz 50 Hz STANDARD-EFFICIENCY MOTORS / LOW VOLTAGE (200-575v) EHS 7285 2843 741 2943 775 414 3304 1290 336 1335 352 188 EJS 7
Table 23E — 19XR Compressor and Motor Weights — Compressor Frame Size 5 (cont) ENGLISH SI 50 Hz End Bell End Bell MOTOR Compressor Compressor Cover Cover CODE Stator Rotor Stator Rotor Stator Rotor Stator Rotor Weight** Weight** Weight†† Weight Weight†† Weight Weight Weight†† Weight Weight†† Weight Weight (kg) (lb) (kg) (lb) (lb) (lb) (lb) (lb) (kg) (kg) (kg) (kg) 60 Hz 60 Hz 50 Hz HIGH-EFFICIENCY MOTORS / LOW VOLTAGE (200-575v) MBH 7285 2795 645 2856 665 414 3304 1268 293 1295 302 188 MCH
Table 24A — 19XR Waterbox Cover Weights — English (lb) FRAMES 1, 2, and 3 — COOLER Frame 1 WATERBOX DESCRIPTION Frame 2 Flanged Flanged 282 318 282 318 287 340 287 340 196 294 310 294 310 136 136 243 243 243 243 — — 315 315 315 315 Flanged 177 204 185 218 NIH, 3 Pass Cover, 150 psig 180 NIH Plain End Cover, 150 psig NIH, 1 Pass Cover, 150 psig NIH, 2 Pass Cover, 150 psig MWB End Cover, 150 psig Frame 3 Standard Nozzles Standard Nozzles Standard Nozzles MWB Return Cov
Table 24A — 19XR Waterbox Cover Weights — English (lb) (cont) FRAMES 4, 5, and 6 — COOLER Frame 4 WATERBOX DESCRIPTION Frame 5 Frame 6 Standard Nozzles Flanged Standard Nozzles Flanged Standard Nozzles Flanged NIH, 1 Pass Cover, 150 psig 148 185 168 229 187 223 NIH, 2 Pass Cover, 150 psig 202 256 222 276 258 331 NIH, 3 Pass Cover, 150 psig 472 488 617 634 765 791 NIH Plain End Cover, 150 psig 138 138 154 154 172 172 MWB End Cover, 150 psig 314 314 390 390 487 487
Table 24A — 19XR Waterbox Cover Weights — English (lb) (cont) FRAMES 7 and 8 — COOLER FRAME 7 WATERBOX DESCRIPTION Standard Nozzles FRAME 8 Flanged Standard Nozzles Flanged NIH, 1 Pass Cover, 150 psig 329 441 417 NIH, 2 Pass Cover, 150 psig 426 541 531 685 NIH, 3 Pass Cover, 150 psig 1250 1291 1629 1687 NIH Plain End Cover, 150 psig 315 315 404 404 MWB End Cover, 150 psig 844 844 1339 1339 MWB Return Cover, 150 psig 494 315 315 404 404 NIH, 1 Pass Cover, 300 psig 1712 18
Table 24B — 19XR Waterbox Cover Weights — SI (kg) FRAMES 1, 2, and 3 — COOLER FRAME 1 WATERBOX DESCRIPTION FRAME 2 FRAME 3 Flanged Standard Nozzles Flanged 128 144 128 144 130 154 130 154 89 133 141 133 141 62 62 110 110 110 110 — — 143 143 143 143 Flanged Standard Nozzles 80 93 84 99 NIH, 3 Pass Cover, 1034 kPa 82 NIH Plain End Cover, 1034 kPa MWB End Cover, 1034 kPa Standard Nozzles NIH, 1 Pass Cover, 1034 kPa NIH, 2 Pass Cover, 1034 kPa MWB Return Cover, 1034 kPa
Table 24B — 19XR Waterbox Cover Weights — SI (kg) (cont) FRAMES 4, 5, and 6 — COOLER Frame 4 WATERBOX DESCRIPTION Standard Nozzles Frame 5 Flanged Standard Nozzles Frame 6 Flanged Standard Nozzles Flanged NIH, 1 Pass Cover, 1034 kPa 67 84 76 104 85 101 NIH, 2 Pass Cover, 1034 kPa 92 116 101 125 117 150 NIH, 3 Pass Cover, 1034 kPa 214 221 280 288 347 359 63 63 70 70 78 78 142 142 177 177 221 221 NIH Plain End Cover, 1034 kPa MWB End Cover, 1034 kPa MWB Return Cover, 10
Table 24B — 19XR Waterbox Cover Weights — SI (kg) (cont) FRAMES 7 and 8 — COOLER Frame 7 WATERBOX DESCRIPTION Frame 8 Standard Nozzles Flanged Standard Nozzles Flanged NIH, 1 Pass Cover, 1034 kPa 149 200 189 224 NIH, 2 Pass Cover, 1034 kPa 193 245 241 311 NIH, 3 Pass Cover, 1034 kPa 567 586 739 765 NIH Plain End Cover, 1034 kPa 143 143 183 183 MWB End Cover, 1034 kPa 383 383 607 607 MWB Return Cover, 1034 kPa 143 143 183 183 NIH, 1 Pass Cover, 2068 kPa 777 854 1070 11
Table 25 — 19XR Component Weights FRAME 2 FRAME 3 FRAME 4 FRAME 5 COMPRESSOR* COMPRESSOR* COMPRESSOR* COMPRESSOR* COMPONENT lb kg lb kg Suction Elbow 116 lb 53 185 84 239 108 407 185 Discharge Elbow 100 45 125 57 157 71 325 147 34 15 34 15 34 15 34 15 11 Control Panel† Optional Cooler Inlet Isolation Valve kg lb kg 8 4 13 6 20 9 24 26 12 46 21 74 34 108 Std Tier VFD — 380, 400, and 460-v (335, 445 A) 650 295 650 295 — — — — Std Tier VFD — 380, 400,
19XRV COMPRESSOR FITS AND CLEARANCES (in.) COMPRESSOR Code ITEM A B C1 C2 D E F1 F2 G H I J K L M N O P FRAME 2 201-299, 2ZZ FRAME 3 FRAME 4 FRAME 5 321-389, 3ZZ 421-487, 4B1-4W7 501-599 Rolling Rolling Rolling Oil Film Oil Film Oil Film Element Element Element DESCRIPTION Bearings Bearings Bearings Bearings Bearings Bearings Low Speed Journal-Gear End .0050/.0040 .0050/.0040 .0055/.0043 .0055/.0043 .0069/.0059 .0069/.0059 Low Speed Journal-Motor End .0050/.0040 .0050/.0040 .0053/.0043 .0053/.0043 .
SEE VIEW A1 OR A2 A 3 2 SEE VIEW B D 4 1 COMPRESSOR, TRANSMISSION AREA (FRAME 5 COMPRESSOR SHOWN) 1) OIL HEATER RETAINING NUT (NOT SHOWN) 2) BULL GEAR RETAINING BOLT 3) DEMISTER BOLTS (NOT SHOWN) 4) IMPELLER BOLT a19-1635 COMPRESSOR, TRANSMISSION AREA C1 C2 THRUST THRUST B C1 B a19-1637 a19-1636 VIEW A2 LOW SPEED SHAFT THRUST DISK VIEW A1 LOW SPEED SHAFT THRUST DISK Fig.
G SEE NOTE 5 E H O F1 F2 THRUST P I J IMPELLER SHIMMING TO BE DETERMINED AT ASSEMBLY L K SEE VIEW C a19-1639 VIEW B — HIGH SPEED SHAFT, ORIGINAL DESIGN (OIL FILM BEARINGS) AND IMPELLER SECTION 0.025 0.005 +0.0007 -0.0007 0.0050 0.0020 +0.0007 -0.0007 THRUST 0.0011 0.0013 INTERFERENCE 0.0011 0.0013 INTERFERENCE 0.0012 0.0004 a19-1640 VIEW B — HIGH SPEED SHAFT WITH ROLLING ELEMENT BEARINGS Fig.
N M a19-1641 VIEW C — HIGH SPEED SHAFT RING SEAL a19-1642 a19-1643 MOTOR LEAD INSTALLATION LABELS 19XR COMPRESSOR ASSEMBLY TORQUES COMPRESSOR Code 1 Oil Heater Retaining Nut — ft-lb (N·m) 2 Bull Gear Retaining Bolt — ft-lb (N·m) 3 Demister Bolts — ft-lb (N·m) 4 Impeller bolt Torque — ft-lb (N·m) 5* Guide Vane Shaft Seal Nut — ft-lb (N·m) * Not shown.
a19-1870 Fig.
a19-1870 Fig.
a19-1871 Fig.
AUX BRG C CB CCM CCN COMP’R COND DISCH DL/DP ENT EVAP EXT FR GND G.V. HGBP HT EXCH ICVC ISM L — — — — — — — — — — — — — — — — — — — — — LEGEND Auxiliary Bearing Contactor Circuit Breaker Chiller Control Module Carrier Comfort Network Compressor Condenser Discharge Datalink or Dataport Entering Evaporator External Frame Ground Guide Vane Hot Gas Bypass Heat Exchanger International Chiller Visual Controller Integrated Starter Module Main Supply Power LVG N.O.
AUX C CB CCM COMM COMPR DISCH — — — — — — — Auxiliary Contactor Circuit Breaker Chiller Control Module Communication Compressor Discharge FR G GRD GVA HGBP HT EXCH ISM — — — — — — — Frame Ground Ground Guide Vane Actuator Hot Gas Bypass Heat Exchanger Integrated Starter Module — — — — — — Main Supply Power Normally Open Pressure Requirement Transformer Terminal Board LEGEND * ** Option Wiring Denotes Conductor Male/Female Conne Wire Splice Denotes Power Panel Terminal Denotes Mach.
LEGEND AUX C CB CT DS FU G HPR — — — — — — — — Auxiliary Contactor Circuit Breaker Current Transformer Disconnect Switch Fuse Ground High Pressure Relay ISM L LL M RES S TB UPC — — — — — — — — Integrated Starter Module Main Supply Power Control Power Supply Contactor Resistor Contactor Terminal Block UPC Open Controller NOTES: 1. Power factor correction capacitors (when required) are connected ahead of all current transformers for proper calibration and sensing by the ISM and IQDP4130. 2.
LEGEND AUX C CB CT DS FU G — — — — — — — Auxiliary Contactor Circuit Breaker Current Transformer Disconnect Switch Fuse Ground HPR ISM L LL M RES S TB — — — — — — — — High Pressure Relay Integrated Starter Module Main Supply Power Control Power Supply Contactor Resistor Contactor Terminal Block NOTES: 1. Power factor correction capacitors (when required) are connected ahead of all current transformers for proper calibration and sensing by the ISM and IQDP4130. 2. For metering option see Fig. 63. Fig.
CT ISM VFD LEGEND — Current Transformer — Integrated Starter Module — Variable Frequency Drive Represents Twisted Wire To Door Fig. 62 — Ground Fault Phase Current Option AM CT L VM — — — — LEGEND Ammeter Current Transformer Main Power Supply Voltmeter Represents Twisted Wire To Door Fig.
Fig. 64 — Benshaw, Inc.
LEGEND AUX BR CB CR COND CPU CVC/ ICVC CT EVAP FU GND — — — — — — — — — — — Auxiliary Bridge Rectifier Circuit Breaker Control Relay Condenser Central Processing Unit Chiller Visual Controller Current Transformer Evaporator Fuse Ground HPR L LL M O/L PFCC — — — — — — RLA SCR ST TB — — — — High Pressure Relay Main Supply Power Control Power Supply Contactor Overload Reset Power Factor Correction Capacitor Rated Load Amps Silicone Controller Rectifier Shunt Trip Terminal Block NOTES: 1 LED status with
NOTES: 1 LED status with power applied and prior to RUN command. "ON" "OFF " 2 Transformer T1 primary fuses FU1/FU2 value dependent on system voltage and model, per Chart 1. Transformer connections per transformer nameplate connection diagram. 3 4 5 CT1-CT3 are sized per Chart 2. Optional for all starters. 6 7 8 CT7-CTI2 are optional for all starters. 9 Circuit breaker CB2 rated at 30 amps for models 19XRA, 19XRC, 19XTR. Fig. 65 — Benshaw, Inc.
SYSTEM VOLTAGE 200 230 346 380 400 415 480 575 CHART 1 3 KVA XFMR 2 KVA XFMR FU1-2 AMPS FU1-2 AMPS 30 20 30 20 20 12 20 12 15 12 15 12 15 10 12 8 1 KVA XFMR FU1-2 AMPS 12 10 7 6 6 6 5 4 CHART 2 STARTER RLA MX3 CT RATIO RANGE 95-135 864:1 136-200 2640:1 201-231 2640:1 232-300 2640:1 301-340 2640:1 341-480 3900:1 481-580 3900:1 581-600 3900:1 601-740 3900:1 741-855 5760:1 856-1250 5760:1 STARTER RLA RANGE 95-205 206-259 260-298 299-398 399-501 502-597 598-687 688-791 792-854 855-979 980-1194 1195-1390 CH
a19-1875 157 Fig.
a19-1876 158 Fig.
Fig.
a19-1878 160 Fig.
Fig.
Fig.
a19-1879 163 Fig.
Fig.
LEGEND FOR FIG.
APPENDIX A — ICVC PARAMETER INDEX 1CR Start Complete MENU SOFTKEY STATUS 1CR Stop Complete STATUS ISM_STAT 1M Start/Run Fault STATUS ISM_STAT 1M/2M Stop Fault STATUS ISM_STAT PARAMETER 20 mA Demand Limit Opt 2M Start/Run Fault SERVICE TABLE SCREEN NAME ISM_STAT EQUIPMENT SERVICE STATUS RAMP_DEM X ISM_STAT Active Delta P SERVICE CONTROL ALGORITHM STATUS SURGPREV Active Delta T SERVICE CONTROL ALGORITHM STATUS SURGPREV Active Delta Tsat SERVICE CONTROL ALGORITHM STATUS SURGPRE
APPENDIX A — ICVC PARAMETER INDEX (cont) MENU SOFTKEY TABLE SCREEN NAME CCM Pressure Transducers Test SERVICE CONTROL TEST CCM Thermistors Test SERVICE CONTROL TEST CCM PRESS TRANSDUCERS CCM THERMISTORS PARAMETER CCN Mode STATUS CCN Time Schedule SCHEDULE CCN Time Schedule SERVICE Chill Water Pulldown/Min CONFIGURABLE ICVC_PSWD EQUIPMENT CONFIGURATION STATUS OCCPC03S X OCCDEFCS X HEAT_EX Chilled Medium SERVICE EQUIPMENT SERVICE SETUP1 X Chilled Water Deadband SERVICE Chilled
APPENDIX A — ICVC PARAMETER INDEX (cont) Condenser Freeze Point MENU SOFTKEY SERVICE Condenser Pressure SERVICE Condenser Pressure STATUS HEAT_EX Condenser Refrig Temp STATUS HEAT_EX PARAMETER Condenser Refrig. Temp. STATUS Condenser Refrig. Temp.
APPENDIX A — ICVC PARAMETER INDEX (cont) Discharge Alert MENU SOFTKEY SERVICE Discharge Temperature SERVICE CONTROL TEST DISCRETE OUTPUTS PARAMETER Discharge Temperature TABLE SCREEN NAME CONFIGURABLE EQUIPMENT SERVICE SETUP1 X CONTROL ALGORITHM STATUS OVERRIDE STATUS COMPRESS Discrete Outputs Test SERVICE ECW Control Option SERVICE EQUIPMENT SERVICE TEMP_CTL ECW Delta T SERVICE CONTROL ALGORITHM STATUS CAPACITY SERVICE CONTROL ALGORITHM STATUS CAPACITY ECW Reset ECW Setpoint
APPENDIX A — ICVC PARAMETER INDEX (cont) Guide Vane Position, Actual MENU SOFTKEY SERVICE Guide Vane Position, Actual STATUS PARAMETER Guide Vane Position, Actual Guide Vane Travel Limit Hardware Failure TABLE CONTROL ALGORITHM STATUS CONFIGURABLE CAPACITY COMPRESS STATUS SERVICE SCREEN NAME STARTUP EQUIPMENT SERVICE STATUS SETUP2 X ISM_STAT Head Press Ref. Delta P at 0% (4 mA) Head Press Ref. Delta P at 100% (20 mA) Head Press Ref.
APPENDIX A — ICVC PARAMETER INDEX (cont) TABLE SCREEN NAME CONFIGURABLE LAG STOP Timer MENU SOFTKEY SERVICE EQUIPMENT SERVICE LEADLAG X LAG STOP Timer SERVICE EQUIPMENT SERVICE LEADLAG X LCW Reset SERVICE CONTROL ALGORITHM STATUS CAPACITY PARAMETER LCW Setpoint SETPOINT LCW Setpoint SETPOINT X X LEAD CHILLER in Control SERVICE CONTROL ALGORITHM STATUS LL_MAINT LEAD/LAG Configuration SERVICE CONTROL ALGORITHM STATUS LL_MAINT LEAD/LAG Configuration SERVICE EQUIPMENT SERVICE L
APPENDIX A — ICVC PARAMETER INDEX (cont) Model Number MENU SOFTKEY SERVICE Model Number SERVICE ICVC CONFIGURATION Motor Amps Not Sensed STATUS ISM_STAT Motor Amps When Stopped STATUS ISM_STAT PARAMETER Motor Current CT Ratio:1 Motor Kilowatt-Hours Motor Kilowatts SERVICE TABLE ISM CONFIGURATION DATA Motor Percent Kilowatts STATUS pswd —> ISM_CONF X X POWER STATUS SERVICE CONFIGURABLE ICVC CONFIGURATION STATUS Motor Locked Rotor Trip SCREEN NAME POWER ISM CONFIGURATION DATA psw
APPENDIX A — ICVC PARAMETER INDEX (cont) Pumps Test MENU SOFTKEY SERVICE CONTROL TEST PUMPS Ramp Loading Active SERVICE CONTROL ALGORITHM STATUS SURGPREV Re-Alarm Time SERVICE EQUIPMENT CONFIGURATION NET_OPT X Recycle Restart Delta T SERVICE EQUIPMENT SERVICE SETUP1 X Recycle Shutdown Delta T SERVICE EQUIPMENT SERVICE SETUP1 X Reference Number SERVICE Refrig Override Delta T SERVICE EQUIPMENT SERVICE SETUP1 X Refrigerant Leak Alarm mA SERVICE EQUIPMENT SERVICE OPTIONS X R
APPENDIX A — ICVC PARAMETER INDEX (cont) Spare Temperature 2 MENU SOFTKEY SERVICE Spare Temperature 2 STATUS PARAMETER TABLE CONTROL ALGORITHM STATUS SCREEN NAME CONFIGURABLE LL_MAINT COMPRESS Speed Change in Effect SERVICE CONTROL ALGORITHM STATUS SURGPREV SRD 25% Load (1) SERVICE EQUIPMENT SERVICE VDO_SRD X SRD 50% Load (1) SERVICE EQUIPMENT SERVICE VDO_SRD X SRD 75% Load (1) SERVICE EQUIPMENT SERVICE VDO_SRD X SRD IGV Offset Select SERVICE EQUIPMENT SERVICE VDO_SRD X SRD
APPENDIX A — ICVC PARAMETER INDEX (cont) Surge Prevention Active? MENU SOFTKEY STATUS Surge Protection Counts SERVICE PARAMETER Surge Protection Counts TABLE SCREEN NAME CONTROL ALGORITHM STATUS SURGPREV CONFIGURABLE VPFSTAT STATUS COMPRESS Surge Time Period SERVICE EQUIPMENT SERVICE OPTIONS X Surge Time Period SERVICE EQUIPMENT SERVICE OPTIONS X Surge Time Period STATUS VPFSTAT Surge/HGBP Delta P1 SERVICE EQUIPMENT SERVICE OPTIONS X Surge/HGBP Deadband SERVICE EQUIPMEN
APPENDIX A — ICVC PARAMETER INDEX (cont) PARAMETER Tower Fan High Setpoint Tower Fan Relay High Tower Fan Relay Low Tower High Fan Setpoint Undervoltage MENU SOFTKEY SETPOINT TABLE SCREEN NAME X STATUS STARTUP STATUS STARTUP SETPOINT X STATUS Undervoltage Threshold SERVICE US Imp / Metric SERVICE VFD Current Limit SERVICE VFD Gain CONFIGURABLE ISM_STAT ISM CONFIGURATION DATA pswd —> ISM_CONF X ICVC CONFIGURATION X EQUIPMENT SERVICE SETUP2 X SERVICE CONTROL ALGORITHM STATUS CAPA
19XR Lead Lag Schematic Series Cooler Flow APPENDIX B — LEAD/LAG WIRING a19-1655 177
19XR Lead Lag Schematic Parallel Cooler Flow APPENDIX B — LEAD/LAG WIRING (cont) a19-1717 178
APPENDIX C — MAINTENANCE SUMMARY AND LOG SHEETS 19XR,XRV Maintenance Interval Requirements WEEKLY Compressor Check Oil Level. Controls Review ICVC Alarm/Alert History. Cooler None. Starter None. Condenser None. Oil Reclaim None. MONTHLY Compressor None. Controls Cooler None. Starter None. Perform an Automated Controls test. Condenser None. Oil Reclaim None. FIRST YEAR Compressor Cooler Condenser Change oil filter. Send oil sample out for analysis.
APPENDIX C — MAINTENANCE SUMMARY AND LOG SHEETS 19XR,XRV Monthly Maintenance Log Month Date Operator UNIT SECTION Compressor Cooler 180 Condenser Controls Starter Oil Reclaim 1 / / ACTION Change Oil Charge Change Oil Filter Send Oil Sample Out for Analysis Leak Test Inspect Compressor Rotors Bearing Inspection Inspect and Clean Cooler Tubes Inspect Relief Valves Leak Test Record Water Pressure Differential (PSI) Inspect Water Pumps Eddy Current Test Leak Test Inspect and Clean Condenser Tubes Record
APPENDIX C — MAINTENANCE SUMMARY AND LOG SHEETS 19XR,XRV Seasonal Shutdown Log Month Date Operator UNIT SECTION Cooler Condenser Controls 1 / / 2 / / ACTION Isolate and Drain Waterbox Remove Waterbox Cover from One End Use Compressed Air to Clean Tubes Isolate and Drain Waterbox Remove Waterbox Cover from One End Use Compressed Air to Clean Tubes Do Not Disconnect Control Power NOTE: Equipment failures caused by lack of adherence to the Maintenance Interval Requirements are not covered under warranty.
APPENDIX D — OPTIONAL BACNET COMMUNICATIONS WIRING Optional BACnet* Communications Wiring — 6 5 7 8 2 34 5 6 10's 1 9 0 A48-8579 2 34 7 8 9 0 1 The following section is used to configure the UPC Open controller which is used when the BACnet communications option is selected. The UPC Open controller is mounted in a separate enclosure below the main control box. TO ADDRESS THE UPC OPEN CONTROLLER — The user must give the UPC Open controller an address that is unique on the BACnet network.
APPENDIX D — OPTIONAL BACNET COMMUNICATIONS WIRING (cont) CONFIGURING THE BAS PORT FOR BACNET MS/ TP — Use the same baud rate and communication settings for all controllers on the network segment. The UPC Open controller is fixed at 8 data bits, No Parity, and 1 Stop bit for this protocol's communications. If the UPC Open controller has been wired for power, pull the screw terminal connector from the controller's power terminals labeled Gnd and HOT.
APPENDIX D — OPTIONAL BACNET COMMUNICATIONS WIRING (cont) A48-8582 Fig. E — BT485 Terminator Installation To install a BT485 terminator, push the BT485 terminator on to the BT485 connector located near the BACnet connector. NOTE: The BT485 terminator has no polarity associated with it. To order a BT485 terminator, consult Commercial Products i-Vu® Open Control System Master Prices. MS/TP WIRING RECOMMENDATIONS — Recommendations are shown in Tables C and D.
APPENDIX D — OPTIONAL BACNET COMMUNICATIONS WIRING (cont) Table D — Open System Wiring Specifications and Recommended Vendors WIRING SPECIFICATIONS Wire Type RECOMMENDED VENDORS AND PART NUMBERS Contractors Connect Air Belden RMCORP Wire and Cable International Description 22 AWG, single twisted shielded pair, low capacitance, CL2P, TC foam FEP, plenum rated. See MS/TP Installation Guide for specifications.
APPENDIX D — OPTIONAL BACNET COMMUNICATIONS WIRING (cont) COMMUNICATION LEDS — The LEDs indicate if the controller is communicating with the devices on the network. IMPORTANT: Power must be ON to the UPC Open when See Tables E and F. The LEDs should reflect communication replacing the battery, or the date, time, and trend data will traffic based on the baud rate set. The higher the baud rate the be lost. more solid the LEDs become. See Fig.
APPENDIX D — OPTIONAL BACNET COMMUNICATIONS WIRING (cont) Table G — Network Points List % % % °F ^F ^F ^F N/A °F N/A °F °F °F N/A N/A PSI °F PSI °F °F % % % N/A DEFAULT VALUE N/A N/A N/A N/A N/A 1.
APPENDIX D — OPTIONAL BACNET COMMUNICATIONS WIRING (cont) Table G — Network Points List (cont) Service Ontime Surge Line Delta T CCN POINT NAME S_HRS DELTA_TX READ/ WRITE R/W R System Alert/Alarm SYS_ALM POINT DESCRIPTION System Cooling Demand Level System Demand Limiting Target Guide Vane Position Target VFD Speed Tower Fan Relay High Tower Fan Relay Low User Defined Analog 1 User Defined Analog 2 User Defined Analog 3 User Defined Analog 4 User Defined Analog 5 User Defined Binary 1 User Defined Bi
INDEX Abbreviations and Explanations, 5 Accidental Start-Up (Prevent), 89 Adding Refrigerant, 95 Adjusting the Refrigerant Charge, 95 After Extended Shutdown, 90 After Limited Shutdown, 90 Alarm (Trip) Output Contacts, 51 Attach to Network Device Control, 60 Automatic Soft Stop Amps Threshold, 64 Auto.
Copyright 2011 Carrier Corporation Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. Catalog No. 04-53190010-01 Printed in U.S.A.
INITIAL START-UP CHECKLIST FOR 19XR, XRV HERMETIC CENTRIFUGAL LIQUID CHILLER (Remove and use for job file.) MACHINE INFORMATION: NAME JOB NO.
Motor Voltage Line Voltages: Motor(s) Amps Motor Oil Pump Voltage Oil Pump Starter LRA Rating Controls/Oil Heater CONTROLS: SAFETY, OPERATING, ETC. Perform Controls Test (Yes/No) PIC II CAUTION COMPRESSOR MOTOR AND CONTROL PANEL MUST BE PROPERLY AND INDIVIDUALLY Yes CONNECTED BACK TO THE EARTH GROUND IN THE STARTER (IN ACCORDANCE WITH CERTIFIED DRAWINGS).
19XR, XRV PIC II SETPOINT TABLE CONFIGURATION SHEET DESCRIPTION Base Demand Limit LCW Setpoint ECW Setpoint Ice Build Setpoint Tower Fan High Setpoint RANGE 40 to 100 10 to 120 -9.4 to 48.9 15 to 120 -12.2 to 48.9 15 to 60 -9.4 to 15.6 55 to 105 13 to 41 UNITS % DEG F DEG C DEG F DEG C DEG F DEG C DEG F DEG C ICVC Software Version Number: ICVC Controller Identification: BUS: ADDRESS: CL-3 DEFAULT 100 50.0 10.0 60.0 15.6 40.0 4.
Day Flag M T W T F S S H Occupied Time Unoccupied Time Period 1: Period 2: Period 3: Period 4: Period 5: Period 6: Period 7: Period 8: NOTE: Default setting is OCCUPIED 24 hours/day. ICE BUILD 19XR, XRV PIC II TIME SCHEDULE CONFIGURATION SHEET OCCPC02S Day Flag M T W T F S S H Occupied Time Unoccupied Time Period 1: Period 2: Period 3: Period 4: Period 5: Period 6: Period 7: Period 8: NOTE: Default setting is UNOCCUPIED 24 hours/day.
19XR, XRV PIC II ISM_CONF TABLE CONFIGURATION SHEET DESCRIPTION Starter Type* (0=Full, 1=Red, 2=SS/VFD, 3=VFD) Motor Rated Line Voltage Volt Transformer Ratio: 1 Overvoltage Threshold Undervoltage Threshold Over/Under Volt Time Voltage% Imbalance Voltage Imbalance Time Motor Rated Load Amps Motor Locked Rotor Trip Locked Rotor Start Delay Starter LRA Rating Motor Current CT Ratio: 1 Current% Imbalance Current Imbalance Time Grnd Fault CT’s? Ground Fault CT Ratio: 1 Ground Fault Current Ground Fault Start De
DESCRIPTION Mid Load Point (T3, P3) Surge/HGBP Delta T3 Surge/HGBP Delta P3 RANGE UNITS DEFAULT 0.5 to 20 0.3 to 11.1 50 to 170 207 to 1172 ˆF ˆC PSI kPa 10 5.5 85 586 0.5 to 20 0.3 to 11.1 50 to 170 207 to 1172 0.5 to 3 0.3 to 1.7 ˆF ˆC PSI kPa ˆF ˆC 10 5.5 85 586 1.0 0.6 0.5 to 10.0 0.3 to 5.6 1.0 to 10.0 0.6 to 5.6 ˆF ˆC ˆF ˆC 2 1.1 4 2.
19XR, XRV PIC II OPTIONS TABLE CONFIGURATION SHEET — MACHINES WITH SERIAL NUMBERS 1410QXXXXX AND LATER OR VERSION 9 OR LATER SOFTWARE DESCRIPTION Auto Restart Option Remote Contacts Option Soft Stop Amps Threshold Surge / Hot Gas Bypass Surge Limit/HGBP Option Select: Surge=0, HGBP=1 Minimum Load Point Surge/HGBP Delta Tsmin Surge/HGBP IGVmin Full Load Point Surge/HGBP Delta Tsmax Surge/HGBP IGVmax Surge Line Shape Factor Surge Line Speed Factor Surge Line High Offset Surge/HGBP Deadband RANGE 0/1 0/1 40 t
DESCRIPTION Diffuser Control Diffuser Option Diffuser Full Span mA Guide Vane 25% Load (2) Guide Vane 50% Load (2) Guide Vane 75% Load (2) SRD 25% Load (1) SRD 50% Load (1) SRD 75% Load (1) Lift @ 25% Load (1) Lift @ 100% Load (1) Lift @ 25% Load (2) SRD IGV Offset Select Low Lift Profile Select RANGE 0/1 15 to 22 0 to 83 0 to 83 0 to 83 0 to 100 0 to 100 0 to 100 0 to 100 0 to 55.6 0 to 100 0 to 55.6 0 to 100 0 to 55.6 1 to 5 1 to 5 UNITS DEFAULT 0 18.0 6.4 22.9 41.3 73.5 35.1 19.5 52.4 29.1 67.5 37.
19XR, XRV PIC II SETUP1 TABLE CONFIGURATION SHEET DESCRIPTION Comp Motor Temp Override Cond Press Override Comp Discharge Alert Comp Thrust Brg Alert Comp Thrust Brg Trip Thrust Brg Reset Factor Chilled Medium Chilled Water Deadband Evap Refrig Trippoint Refrig Override Delta T Evap Approach Alert Cond Approach Alert Condenser Freeze Point Flow Delta P Display Evap Flow Delta P Cutout Cond Flow Delta P Cutout Cond Hi Flow Alarm Option Cond Hi Flow Del P Limit Water Flow Verify Time Oil Press Verify Time R
DESCRIPTION Capacity Control Proportional Inc Band Proportional DEC Band Proportional ECW Gain STATUS UNITS DEFAULT 2 to 10 2 to 10 1 to 3 Guide Vane Travel Limit 30 to 100 % 80 Diffuser Control* Diffuser Option Guide Vane 25% Load Pt Diffuser 25% Load Point Guide Vane 50% Load Pt Diffuser 50% Load Point Guide Vane 75% Load Pt Diffuser 75% Load Point Diffuser Full Span mA 0/1 0 to 78 0 to 100 0 to 78 0 to 100 0 to 78 0 to 100 15 to 22 DSABLE/ENABLE % % % % % % mA DSABLE 25 0 50 0 50 0 18 VFD Sp
19XR, XRV PIC II LEADLAG TABLE CONFIGURATION SHEET DESCRIPTION Lead Lag Control LEAD/LAG: Configuration DSABLE=0, LEAD=1, LAG=2, STANDBY=3 Load Balance Option Common Sensor Option LAG% Capacity LAG Address LAG START Timer LAG STOP Timer PRESTART FAULT Timer PULLDOWN Timer STANDBY Chiller Option STANDBY% Capacity STANDBY Address RANGE UNITS 0 to 3 0/1 0/1 25 to 75 1 to 236 2 to 60 2 to 60 2 to 30 1 to 30 0/1 25 to 75 1 to 236 DEFAULT 0 DSABLE/ENABLE DSABLE/ENABLE % MIN MIN MIN MIN DSABLE/ENABLE % CL-11
DESCRIPTION Pulldown Ramp Type: Select: Temp=0, Load=1 Demand Limit + kW Ramp Demand Limit Source Select: Amps=0, kW=1 Motor Load Ramp% Min Demand Limit Prop Band Demand Limit At 20 mA 20 mA Demand Limit Opt Motor Rated Kilowatts Demand Watts Interval RANGE UNITS DEFAULT 0/1 1 0/1 0 5 to 20 3 to 15 40 to 100 0/1 50 to 9999 5 to 60 % % DSABLE/ENABLE kW MIN VALUE 10 10 40 DSABLE 145 15 19XR, XRV PIC II TEMP_CTL TABLE CONFIGURATION SHEET DESCRIPTION Control Point ECW Control Option Temp Pulldown De
BROADCAST (BRODEF) CONFIGURATION SHEET DESCRIPTION Time Broadcast Enable Daylight Savings Start Month Start Day of Week Start Week Start Time Start Advance Stop Month Stop Day of Week Stop Week Stop Time Stop Back RANGE DSABLE/ENABLE 1 to 12 1 to 7 1 to 5 00:00 to 24:00 0 to 360 1 to 12 1 to 7 1 to 5 00:00 to 24:00 0 to 360 UNITS HH:MM MIN MIN CL-13 DEFAULT DSABLE 4 7 3 02:00 60 10 7 3 02:00 60 VALUE
DESCRIPTION Maximum Speed Speed Display Scaling Motor Voltage Frequency Motor Amps Line Voltage Over Frequency Limit PARAMETER P.004 P.028 H.000 H.001 H.002 H.021 H.022 RANGE DEFAULT COMMENTS 15 to H.022 * Job Sheet; 60 for 60 Hz 10 to 999 * Job Sheet; 60 for 60 Hz 100 to 690 * Selected line voltage 30 to 200 * 60 for 60 Hz Power Module Dependent * Selected motor 100% amps 300 to 565 * Selected line voltage 30 to 210 * 60 for 60 Hz *Variable by job — refer to component nameplates and labels.
ICVC DISPLAY AND ALARM SHUTDOWN STATE RECORD SHEET PRIMARY MESSAGE: DATE: SECONDARY MESSAGE: COMPRESSOR ONTIME: TIME: CHW IN CHW OUT EVAP REF CDW IN CDW OUT COND REF OILPRESS OIL TEMP AMPS % COMMUNICATION MESSAGE CCN LOCAL RESET CL-15 MENU
PRIMARY MESSAGE: DATE: SECONDARY MESSAGE: COMPRESSOR ONTIME: TIME: CHW IN CHW OUT EVAP REF CDW IN CDW OUT COND REF OILPRESS OIL TEMP AMPS % COMMUNICATION MESSAGE CCN LOCAL RESET MENU Copyright 2011 Carrier Corporation Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. Catalog No. 04-53190010-01 Printed in U.S.A.
