EVERGREEN® 23XRV High-Efficiency Variable Speed Screw Chiller with Foxfire™ Compression Technology and PIC III Controls 50/60 Hz HFC-134a Start-Up, Operation and Maintenance Instructions SAFETY CONSIDERATIONS Screw 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 Vaporizer Temperature Control COMPRESSOR ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Oil Sump Temperature Control COMPRESSOR OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Oil Sump Temperature Control COMPRESSOR ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Remote Start/Stop Contacts . . . . . . . . . . . . . . . . . . . . . 38 Spare Safety and Spare Temperature Inputs. . . . . 38 Spare Alarm Contacts . . . . . . . . . . . . . . . . . . . . . . .
CONTENTS (cont) Page Operating the Optional Pumpout Unit . . . . . . . . . . . 69 Chillers with Storage Tanks . . . . . . . . . . . . . . . . . . . . . 70 • TRANSFER REFRIGERANT FROM PUMPOUT STORAGE TANK TO CHILLER • TRANSFER REFRIGERANT FROM CHILLER TO PUMPOUT STORAGE TANK • CHILLERS WITH ISOLATION VALVES • DISTILLING THE REFRIGERANT GENERAL MAINTENANCE . . . . . . . . . . . . . . . . . . . .72,73 Refrigerant Properties . . . . . . . . . . . . . . . . . . . . . . . . . . 72 Adding Refrigerant . . . . . . .
CONTENTS (cont) ABBREVIATIONS AND EXPLANATIONS Page Control Algorithms Checkout Procedure . . . . . . . . 80 Control Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 Control Modules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 • RED LED (Labeled as STAT) • GREEN LED (Labeled as COM) Notes on Module Operation . . . . . . . . . . . . . . . . . . . . . 98 Chiller Control Module (CCM) . . . . . . . . . . . . . . . . . . .
S – Special 23XRV – High Efficiency Variable Speed Screw Chiller Not Used Voltage Code 3 – 380-3-60 4 – 416-3-60 5 – 460-3-60 9 – 400-3-50 Cooler Size* 30-32 35-37 40-42 45-47 50-52 55-57 Drive Frame AA BA BB CC Condenser Size* 30-32 35-37 40-42 45-47 50-52 55-57 Motor Code P Q R S T U V Economizer Option E – With Economizer N – No Economizer R – Compressor Rectifier Max Input Amps† 440 520 520 608 Inverter Max Output Amps† 442 442 520 608 Max Motor Amps 265 283 306 334 368 421 440 a23-1533 *Firs
22 23 24 25 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 26 41 40 39 38 37 36 35 34 33 a23-1549 42 43 27 28 32 31 44 30 — — — — — — — — — — — — — — — — — — — — Discharge Pipe Assembly Compressor Discharge Check Valve Access Cover Condenser Relief Valves with Three-Way Valve Refrigerant Charging Valves Cooler Relief Valve Tubesheet Mounting Brackets Typical Waterbox Drain Coupling ASME Nameplate, Condenser Oil Pump Oil Pump Inlet Strainer Strainer Housing Sight Glass Discharge Iso
6 2 3 4 5 1 1 2 3 4 5 6 7 8 9 — — — — — — — — — Condenser Pressure Evaporator Pressure Compressor Discharge Temperature Compressor Discharge Pressure Compressor Discharge High Pressure Switch Compressor Motor Winding Temperature (Hidden) Evaporator Refrigerant Liquid Temperature (Hidden) Condenser Liquid Temperature Condenser Liquid Flow (Optional) 9 7 a23-1551 8 10 11 12 13 14 15 20 16 17 19 a23-1552 10 — Inductor Temperature Switch (Inside VFD Enclosure) 11 — VFD Rectifier Temperature (I
Cooler — The cooler (also known as the evaporator) is REFRIGERATION CYCLE maintained at low temperature/pressure so that evaporating refrigerant can remove heat from the liquid flowing through its internal tubes. The compressor continuously draws refrigerant vapor from the cooler. As the compressor suction reduces the pressure in the cooler, the remaining refrigerant boils at a fairly low temperature (typically 38 to 42 F [3 to 6 C]).
STANDARD 65 KAIC CIRCUIT BREAKER OPTIONAL 100 KAIC CIRCUIT BREAKER (SHIPPED LOOSE INSIDE OF CONTROL CENTER FOR FIELD INSTALLATION) a23-1620 Fig.
COOLER HGBP ISOLATION VALVE (OPTIONAL) HGBP SOLENOID VALVE VFD REFRIGERANT COOLING ISOLATION VALVE ECONOMIZER MUFFLER MOTOR VFD REFRIGERANT COOLING VFD SOLENOID COLD VALVE PLATE VFD REFRIGERANT COOLING ISOLATION VALVE FLASH ECONOMIZER STRAINER COMPRESSOR FILTER DRIER ORIFICE FILTER DRIER ISOLATION VALVES FLOAT VALVE CONDENSER FLOAT VALVE BUBBLER LINE a23-1622 Fig.
The oil sump contains temperature and pressure sensors and a 530 W oil heater. The oil sump is vented to the compressor suction to minimize the amount of refrigerant absorbed by the oil. The OIL SUMP TEMPERATURE is measured and displayed on the ICVC default screen and the COMPRESS screen. The oil sump pressure is used to calculate the OIL PRESSURE DELTA P. Operating OIL PRESSURE DELTA P must be at least 18 psid (124 kPa) after the OIL PRESS VERIFY TIME has elapsed.
The chiller capacity is controlled by varying the TARGET VFD SPEED from 0% to 100%. The PIC III controls monitor the compressor oil properties and set a COMPRESSOR MINIMUM SPEED to ensure sufficient compressor bearing lubrication under all operating conditions. If the oil pressure falls below the values specified in Table 1 during start-up, the PIC III control will shut down the chiller.
PIC III System Components (Fig. 11-14) — The Table 2 — Major PIC III Components and Panel Locations chiller control system is called PIC III (Product Integrated Control III). See Table 2. The PIC III controls the chiller by monitoring all operating conditions. The PIC III can diagnose a problem and let the operator know what the problem is and what to check. It promptly adjusts compressor speed to maintain leaving chilled liquid temperature.
10 21 11 20 1 2 8 9 13 5 8 22 FUSE REF FU1 FU2 FU3 FU4 FU5 FU6 FU7 FU8 FU9 FU10 FU11A&B A2–F1 19 18 17 a23-1626 1 2 3 4 5 6 7 8 9 10 11 — — — — — — — — — — — 16 16 8 14 12 15 3 Input Inductor Assembly Capacitor Bank Assembly Pre-Charge Resistor Assembly AC Contactor (3) Power Module Assembly Terminal Block, 10-Position (Extra low voltage) Power Module Assembly Fuse Block, 30A, 600V, Class CC Fuse, Class CC, 600V, 15A (2) Fuse, Class CC, 600V, 5A (1) Fuse, Class CC, 600V, 20A (3) 7 4
PRIMARY STATUS MESSAGE HAZARDOUS VOLTAGE FIELD WIRING TERMINAL BLOCK GROUND WIRE SECONDARY STATUS MESSAGE VAPORIZER HEATER CONTACTOR (6C) CONNECTOR CN1B CONTINUOUSLY • BLINKS ON FOR AN ALARM ONCE TO • BLINKS CONFIRM A STOP HOT GAS BYPASS CONTACTOR (3C) (OPTIONAL) OIL PUMP CONTACTOR (2C) 24V CONTROL TRANSFORMER (T1) OIL HEATER CONTACTOR (1C) CHL IN 58.4 CDL IN CDL OUT 76.1 85.2 OIL PRESS OILTEMP –0.5 130.6 STATUS 11-22-04 00:09 15.2 HOURS CHL OUT 59.
23XRPIC3 MAINSTAT Control Mode Run Status Start Inhibit Timer Occupied? System Alert/Alarm Chiller Start/Stop Remote Start Contact Temperature Reset Control Point Chilled Liquid Temp • Press ENTER to leave the selected decision or field and save changes. • Press NEXT to scroll the cursor bar down in order to highlight a point or to view more points below the current screen. • Press PREVIOUS to scroll the cursor bar up in order to highlight a point or to view points above the current screen.
For Discrete Points — Press YES select the desired state. 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 SERVICE 1 1 1 1 (ENTER A 4-DIGIT PASSWORD) List the Status Tables List the Service Tables Display The Setpoint Table • MAINSTAT • STARTUP • COMPRESS • HEAT_EX • POWER • VFD_STAT • ICVC_PWD List the Schedules Select a Status Table PREVIOUS NEXT SELECT EXIT • Base Demand Limit • LCL Setpoint • ECL Setpoint • Ice Build Setpoint • Tow
SERVICE TABLE NEXT PREVIOUS SELECT EXIT ALARM HISTORY ALERT HISTORY ALERT HISTORY Display Alert History (The table holds up to 25 alerts with the most recent alert at the top of the screen.) Display Alarm History (The table holds up to 25 alarms and alerts with the most recent alarm at the top of the screen.
SERVICE MENU CONTINUED FROM PREVIOUS PAGE VFD CONFIG DATA EQUIPMENT SERVICE 4 4 4 4 (ENTER A 4-DIGIT PASSWORD) Service Tables: • OPTIONS • SETUP1 • SETUP2 • LEADLAG • RAMP_DEM • TEMP_CTL Select a Service Table PREVIOUS NEXT Service Tables: • VFD CONFIG P ASSWORD • VFD_CONF SELECT EXIT Select a Service Table Parameter SELECT PREVIOUS NEXT EXIT Modify a Service Table Parameter INCREASE DECREASE QUIT ENABLE DISABLE QUIT ENTER (ANALOG VALUES) ENTER (DISCRETE VALUES) TIME AND DATE Display Time a
TIME SCHEDULE OPERATION (Fig. 20) 1. On the Menu screen, press SCHEDULE . b. Press ENABLE to select days in the day-of-week fields. Press DISABLE to eliminate days from the period. 2. Press NEXT or PREVIOUS to highlight the desired schedule. 7. Press ENTER to register the values and to move horizontally (left to right) within a period. OCCPC01S — LOCAL Time Schedule OCCPC02S — ICE Build Schedule OCCPC03S — CCN Time Schedule 8. Press EXIT to leave the period or override. 3.
5. Press INCREASE or DECREASE to change the selected set point value. 2. There are 5 set points on this screen: BASE DEMAND LIMIT, LCL SETPOINT (leaving chilled liquid set point), ECL SETPOINT (entering chilled liquid set point), ICE BUILD SETPOINT and TOWER FAN HIGH SETPOINT. Only one of the CONTROL POINT SOURCES (LCL or ECL) can be active at one time. The control point source that is active is determined from the TEMP_CTL screen. See the Service Operation section, page 45. 3.
Table 3 — ICVC Display Data (cont) EXAMPLE 2 — MAINTSTAT DISPLAY SCREEN To access this display from the ICVC default screen: 1. Press MENU . 2. Press STATUS ( MAINSTAT will be highlighted). 3. Press SELECT .
Table 3 — ICVC Display Data (cont) EXAMPLE 4 — COMPRESS DISPLAY SCREEN To access this display from the ICVC default screen: 1. Press MENU . 2. Press STATUS . 3. Scroll down to highlight COMPRESS . 4. Press SELECT .
Table 3 — ICVC Display Data (cont) EXAMPLE 6 — POWER DISPLAY SCREEN To access this display from the ICVC default screen: 1. Press MENU . 2. Press STATUS . 3. Scroll down to highlight POWER . 4. Press SELECT .
Table 3 — ICVC Display Data (cont) EXAMPLE 7 — VFD VFD_STAT SCREEN To access this display from the ICVC default screen: 1. Press MENU . 2. Press STATUS . 3. Scroll down to highlight VFD_STAT . 4. Press SELECT .
Table 3 — ICVC Display Data (cont) EXAMPLE 9 — SETPOINT DISPLAY SCREEN To access this display from the ICVC default screen: 1. Press MENU . 2. Press SETPOINT (Base Demand Limit will be highlighted). 3. Press SELECT . DESCRIPTION Base Demand Limit Control Point Source LCL Setpoint ECL Setpoint Ice Build Setpoint Tower Fan High Setpoint STATUS 40-100 UNITS % POINT DLM DEFAULT 100 10-60 F (-12.2-15.6 C) 15-65 F (-9.4-18.3 C) 15-60 F (-9.4-15.
Table 3 — ICVC Display Data (cont) EXAMPLE 11 — OVERRIDE DISPLAY SCREEN To access this display from the ICVC default screen: 1. Press MENU . 2. Press SERVICE . 3. Scroll down to highlight CONTROL ALGORITHM STATUS . 4. Press SELECT . 5. Scroll down to highlight OVERRIDE .
Table 3 — ICVC Display Data (cont) EXAMPLE 13 — VFD_HIST DISPLAY SCREEN To access this display from the ICVC default screen: 1. Press MENU . 2. Press SERVICE . 3. Scroll down to highlight CONTROL ALGORITHM STATUS . 4. Press SELECT . 5. Scroll down to highlight VFD_HIST .
Table 3 — ICVC Display Data (cont) EXAMPLE 15 — WSMCHLRE DISPLAY SCREEN To access this display from the ICVC default screen: 1. Press MENU . 2. Press SERVICE . 3. Scroll down to highlight CONTROL ALGORITHM STATUS . 4. Press SELECT . 5. Scroll down to highlight WSMDEFME . DESCRIPTION WSM Active? Chilled Water Temp Equipment Status Commanded State CHW Setpoint Reset Value Current CHW Set Point STATUS 0/1 0.0-99.9 0/1 UNITS NO/YES ° F (°C) OFF/ON TEXT ^ F (^C) ° F (°C) 0.0-25.0 0.0-99.
Table 3 — ICVC Display Data (cont) EXAMPLE 17 — VFD_CONF DISPLAY SCREEN To access this display from the ICVC default screen: 1. Press MENU . 2. Press SERVICE . 3. Scroll down to highlight VFD CONFIG DATA . 4. Press SELECT . 5. Scroll down to highlight VFD_CONF .
Table 3 — ICVC Display Data (cont) EXAMPLE 19 — SETUP1 DISPLAY SCREEN To access this display from the ICVC default screen: 1. Press MENU . 2. Press SERVICE . 3. Scroll down to highlight EQUIPMENT SERVICE . 4. Press SELECT . 5. Scroll down to highlight SETUP1 .
Table 3 — ICVC Display Data (cont) EXAMPLE 21 — LEAD/LAG DISPLAY SCREEN To access this display from the ICVC default screen: 1. Press MENU . 2. Press SERVICE . 3. Scroll down to highlight EQUIPMENT SERVICE . 4. Press SELECT . 5. Scroll down to highlight LEADLAG .
PIC III System Functions Table 4 — Capacity Control Conditions NOTE: Words not part of paragraph headings and printed in all capital letters can be viewed on the ICVC (e.g., LOCAL, CCN, RUNNING, ALARM, etc.) Words printed in both all capital letters and italics can also be viewed on the ICVC and are parameters (CONTROL MODE ADDED EXAMPLES, etc.) with associated values (e.g., modes, temperatures, pressures, percentages, on, off, enable, disable, etc.).
to START. For more information on forced starts, see Local Start-Up, page 46. The schedules also can be overridden to keep the chiller in an occupied state for up to 4 hours, on a one time basis. See the Time Schedule Operation section, page 21. Figure 20 shows a schedule for a typical office building with a 3-hour, off-peak, cool-down period from midnight to 3 a.m., following a weekend shutdown. Holiday periods are in an unoccupied state 24 hours per day.
2. Motor load ramp loading (AMPS OR KW RAMP %/ MIN) limits the percent per minute rate at which the compressor motor current or compressor motor load increases. The AMPS OR KW RAMP %/MIN rate is configured by the operator on the RAMP_DEM screen in amps or kilowatts. If kilowatts is selected for the DEMAND LIMIT SOURCE, the MOTOR RATED LOAD KILOWATTS must be entered (information found on the machine Electrical Data Nameplate) in the VFD_CONF screen.
Table 5 — Protective Safety Limits and Control Settings MONITORED PARAMETER Temperature Sensors Out of Range Pressure Transducers Out of Range High Compressor Discharge Temperature High Motor Temperature ALARM OR ALERT STATE 260-271, 140,141 262-272 231 162 103 233 102 Low Evaporator Temperature (Freeze Protection) 243 232 104 Transducer Voltage Fault High Condenser Pressure - Control - Switch - Prestart Low Condenser Pressure (Freeze Protection) 239 235 207 106 244 154 Oil - Low Pressure - Low Press
followed by the LOCAL or CCN softkey. This ensures that, if the automatic system is malfunctioning, the chiller will not repeatedly cycle on and off. If the AUTORESTART OPTION and the REMOTE CONTACT OPTION in the OPTIONS screen are enabled, the REMOTE CONTACTS must be closed in order for the chiller to restart following a power failure.
Spare Alarm Contacts — One normally open trip alarm contact is provided in the control center cabinet. The contact ratings are provided in the certified drawings. The contacts are located on terminals 9 and 10 of the hazardous voltage terminal strip in the control center cabinet. If the CONDENSER PRESSURE is greater than or equal to the COND PRESS OVERRIDE, the condenser pump will energize to try to decrease the pressure and Alert 151 will be generated.
2 permits ±30 F (±17 C) of automatic reset to the ECL SETPOINT or LCL SETPOINT based on a temperature sensor wired to the CCM module (see wiring diagrams or certified drawings). The temperature sensor must be wired to CCM terminal J4-13 and J4-14. To configure Reset Type 2, enter the temperature of the remote sensor at the point where no temperature reset will occur (REMOTE TEMP -> NO RESET). Next, enter the temperature at which the full amount of reset will occur (REMOTE TEMP -> FULL RESET).
ACTIVE DELTA T (actual temperature difference between the LEAVING CHILLED LIQUID and ENTERING CHILLED LIQUID) is on the left side of the line plotted in Fig. 22A and 22B, the algorithm will energize the hot gas bypass valve to falsely load the chiller. If the ACTIVE DELTA T falls to the right side of the line plotted in Fig 22A and 22B by more than the HGBP DEADBAND, the hot gas bypass valve is deenergized.
sensor option must not be used if liquid bypass around the operating chiller is occurring. CHILLER COMMUNICATION WIRING — Refer to the chiller’s Installation Instructions, Carrier Comfort Network® Interface section for information on chiller communication wiring. LEAD/LAG OPERATION — The PIC III not only has the ability to operate 2 chillers in lead/lag, but it can also start a designated standby chiller when either the lead or lag chiller is faulted and capacity requirements are not met.
are also stopped. If the configured lead chiller stops for an alarm condition, the configured lag chiller takes the lead chiller’s place as the lead chiller, and the standby chiller serves as the lag chiller. If the configured lead chiller does not complete the start-up before the PRESTART FAULT TIMER (configured in LEADLAG screen) elapses, then the lag chiller starts and the lead chiller shuts down. The lead chiller then monitors the start request from the acting lead chiller.
chiller has a 45-second delay. The standby chiller has a 90-second delay. The delay time is added after the chiller liquid flow is verified. The delay must elapse before the oil pump is turned on. The Auto restart 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.
See Fig. 19 for additional screens and tables available from the SERVICE screens listed above. Use the EXIT softkey to return to the main MENU screen. communicating properly, the “UPLOAD IN PROGRESS” message will flash and the new module can now be viewed. Whenever there is a question regarding which module on the ICVC is currently being shown, check the device name descriptor on the upper left hand corner of the ICVC screen. See Fig. 25.
SCHEDULE softkeys. Scroll down and select the current schedule. Scroll down and select OVERRIDE, and set the desired override time period. Another condition for start-up must be met for chillers that have the REMOTE CONTACTS OPTION on the EQUIPMENT SERVICE, OPTIONS screen set to ENABLE. For these chillers, the REMOTE START CONTACT parameter on the MAINSTAT screen must be CLOSED. From the ICVC default screen, press the MENU and STATUS softkeys. Scroll to high-light MAINSTAT and press the SELECT softkey.
When a stop signal occurs, the controls set TARGET VFD SPEED to 0. This will cause the compressor to reduce speed to the point where line amps equal the configured SOFT STOP AMPS THRESHOLD. (In a recycle shut down, the compressor will probably be at or below the soft stop threshold amps when the stop signal is received.) At that point, or one minute after the stop signal occurs (whichever is earlier), the VFD is set to STOP.
2. ECL CONTROL OPTION is ENABLED AND ice build is not active (ECL control): The CONTROL POINT has not been increased by at least 1° F in the last 5 min. AND ENTERING CHILLED LIQUID temperature is less than the CONTROL POINT minus 5° F OR ENTERING CHILLED LIQUID temperature is less than the CONTROL POINT AND the difference between ENTERING CHILLED LIQUID — LEAVING CHILLED LIQUID is less than RECYCLE SHUTDOWN DELTA T. 3. The LEAVING CHILLED LIQUID temperature is less than the EVAP REFRIG TRIPPOINT plus 3° F.
WARNING Never charge liquid refrigerant into the chiller if the pressure in the chiller is less than 35 psig (241 kPa). Charge as a gas only, with the cooler and condenser pumps running, until this pressure is reached, using PUMPDOWN and TERMINATE PUMPDOWN MODE on the ICVC. Flashing of liquid refrigerant at low pressures can cause tube freeze-up and considerable damage. c. Leak test chiller as outlined in Steps 3 - 7. 2. If the pressure readings are abnormal for chiller condition: a.
a23-1614 50 Fig.
3/8" MALE FLARE RELIEF VALVE CONN. W LEVEL GAGE 0' - 9 " [229mm] TYPICAL 1/2" DIA. K.O. ELECTRICAL CONN. (PUMPOUT POWER) 0' - 5 1/2" [140mm] D E (2) 1" NPT RELIEF VALVE OUTLET (SEE FIELD INSTALLATION NOTES) PRESSURE GAGE R 1' - 7 " [483mm] T 0' - 5 7/8 " [149mm] a23-1541 B TOP VIEW 1/2" MALE FLARE VAPOR CONN. NOTES: 1. 3/4" NPT PUMPOUT CONDENSER WATER OUTLET CONN. ELECTRICAL SERVICE ACCESS SPACE 20 3/4" X 8 3/4" X 4 1/2" (BOTH SIDES) 3/4" NPT PUMPOUT CONDENSER WATER INLET CONN.
RATED DRY WEIGHT AND REFRIGERANT CAPACITY ENGLISH (lb) TANK SIZE TANK OD (in.) 0428 0452 24.00 27.
COOLER INLET ISOLATION VALVE 11 COOLER REFRIGERANT PUMPOUT VALVE 7 COOLER CHARGING VALVE 1b COOLER USE CONDENSER CHARGING VALVE TO ADD CHARGE 1a CONTROL CENTER DISCHARGE ISOLATION VALVE (OPTIONAL) SHIPPING BRACE (REMOVE PRIOR TO START-UP) PRESSURE RELIEF SAFETY VALVE 10 PUMPOUT COMPRESSOR = SERVICE VALVE ON CHILLER (FIELD SUPPLIED) = MAINTAIN AT LEAST 2 FT (610mm) CLEARANCE AROUND STORAGE TANK FOR SERVICE AND OPERATION WORK.
Table 9A — 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 9B — HFC-134a Pressure — Temperature (C) PRESSURE (psig) 6.50 7.52 8.60 9.66 10.79 11.96 13.17 14.42 15.72 17.06 18.45 19.88 21.37 22.90 24.48 26.11 27.80 29.53 31.32 33.17 35.08 37.04 39.06 41.14 43.28 45.48 47.
8. If the reading continues to change after several attempts, perform a leak test up to the maximum 160 psig (1103 kPa) pressure. Locate and repair the leak, and repeat dehydration. Chiller Dehydration — Dehydration is recommended if the chiller has been open for a considerable period of time, if the chiller is known to contain moisture, or if there has been a complete loss of chiller holding charge or refrigerant pressure.
LF20 0608CC R LF20 = LiquiFlo 2.0 Continuous Ampere Rating and Frame Size Coolant Method R = Refrigerant R134a a23-1629 Fig. 36 — Identifying the Drive Model Number The control center is designed to operate in the following environmental conditions: WARNING DC bus capacitors retain hazardous voltage after input power has been disconnected.
9. Check that the incoming power is within ± 10% of chiller nameplate voltage. 10. All wiring should be installed in conformance with the applicable local, national, and international codes (for example, NEC/CEC). Verify that a properly sized ground wire is installed and a suitable earth ground is used. Check for and eliminate any grounds between the power leads. Verify that all ground leads are unbroken. Check Control Center CAUTION BE AWARE that certain automatic start arrangements can engage the VFD.
b. 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. c. If the readings are unsatisfactory, repeat the test with the motor leads disconnected from the motor. Satisfactory readings in this second test indicate the fault is in the power leads.
TO CHANGE THE PASSWORD — The password may be changed from the ICVC CONFIGURATION screen. 1. Press the MENU and SERVICE softkeys. Enter the current password and highlight ICVC CONFIGURATION. Press the SELECT softkey. Only the last 6 entries on the ICVC CONFIG screen can be changed: BUS #, ADDRESS #, BAUD RATE, US IMP/METRIC, PASSWORD, and LID LANGUAGE.
Confirm that the following parameters in the VFD_CONF screen match the values on the Machine Electrical Data Nameplate (see Fig. 37): • Motor Nameplate Voltage — Voltage required to run at motor rating. • Compressor 100% Speed — Compressor speed required to run at chiller design point. • Rated Line Voltage — Nominal line voltage selected for the job site. • Rated Line Amps — Line current required for the chiller to run at the design point.
OCCDEFCS — The OCCDEFCS screen contains the Local and CCN time schedules, which can be modified here or on the SCHEDULE screen as described previously. HOLIDAYS — From the HOLIDAYS screen, the days of the year that holidays are in effect can be configured. See the holiday paragraphs in the Controls section for more details. BRODEF — The BRODEF screen defines the start and end of daylight savings time. By default this feature is enabled.
0.25 amp fuses for the primary side of the transformer, the compressor overloads, an internal thermostat, a compressor contactor, refrigerant low pressure cut-out and a refrigerant high pressure cutout. The high pressure cutout is factory set to open at 185 psig (1276 kPa) and reset at 140 psig (965 kPa). The low pressure cutout is factory set to open at 7 psia (–15.7 in. HG) and close at 9 psia (–11.6 in. HG). Ensure the watercooled condenser has been connected.
Refer to Fig. 2 and 8 for isolation valve locations. Charge Refrigerant into Chiller CAUTION CAUTION Whenever turning the discharge isolation valve, be sure that the spring-loaded lever lock fully engages within one of the latch plate detents. This will prevent the valve from opening or closing during service work or during chiller operation.
Table 13 — Refrigerant Charges FRAME SIZE COOLER LENGTH ft (m) 12 (3.6) 3 14 (4.3) 12 (3.6) 4 14 (4.3) 12 (3.6) 5 14 (4.
or PREVIOUS softkeys highlight CHILLER START/STOP. The 3 softkeys that appear represent 3 choices: SHIPPING BRACKET • • • START — forces the chiller ON STOP — forces the chiller OFF RELEASE — puts the chiller under remote or schedule control. To return the chiller to normal control, press the RELEASE softkey followed by the ENTER softkey. For more information, see Local Start-Up, page 46. The default ICVC screen message line indicates which command is in effect.
5. The condenser pressure and temperature varies with the chiller design conditions. Typically the pressure will range between 60 to 135 psig (329 to 780 kPa) with a corresponding temperature range of 60 to 105 F (15 to 41 C). The condenser entering liquid temperature may be controlled below the specified design entering liquid temperature to save on compressor kilowatt requirements but, not be below 55 F (12.8 C). 6. Cooler pressure and temperature also will vary with the design conditions.
After Extended Shutdown — Ensure the liquid sys- Cold Weather Operation — When the entering con- tem drains are closed. It may be advisable to flush the liquid circuits to remove any soft rust which may have formed. This is a good time to brush the tubes and inspect the Schrader fittings on the optional liquid side flow devices for fouling, if necessary. Check the cooler pressure on the ICVC default screen and compare it to the original holding charge that was left in the chiller.
Press. Temp Refrigerant Liquid Pressure In Out GPM COOLER MODEL NO. Temp In Out Press. Temp Refrigerant Liquid Pressure In Out GPM CONDENSER SERIAL NO. COMPRESSOR Oil Oil Oil Comp. Avg. Avg. Reclaim Reclaim Oil Temp Press Sump Disch. Line Line Delta T Output Level Delta P Temp Temp Current Voltage In Out CONCENTRATOR REFRIGERANT TYPE Line kW OPERVFD ATOR Avg. Rectifier Coolant INITIALS Load Inverter Temp Temp Flow Current VFD Fig.
ed) during operation. Rotate the valve stem fully counterclockwise to open. Frontseating the valve closes the refrigerant line and opens the gage port to compressor pressure. 2. Ensure that the compressor holddown bolts have been loosened to allow free spring travel. 3. Open the refrigerant inlet valve on the pumpout compressor. 4. Oil should be visible in the pumpout unit compressor sight glass under all operating conditions and during shutdown.
charging valve 10 to let liquid refrigerant drain into the chiller. Chillers with Storage Tanks — In the Valve/Condi- tion tables that accompany these instructions, the letter “C” indicates a closed valve. Figures 31-33 and 42 show the locations of the valves. VALVE CONDITION CAUTION VALVE 2 VALVE CONDITION VALVE CONDITION VALVE 3 COMPRESSOR VALVE 5 a23-1546 LEAVING WATER CONDENSER OIL FILL FITTING OIL SEPARATOR VALVE CONDITION Fig.
This operation can be done in Automatic or On mode. In Automatic mode, the compressor will stop automatically at approximately 15 in. Hg vacuum (51 kPa absolute). c. Place valves in the following positions: VALVE CONDITION 1a 1b 2 C 3 4 5 C 6 7 C 10 C 11 d. Close valve 1a. e. Turn off pumpout compressor. f. Close valves 1b, 3, and 4. d. Run the pumpout compressor until the chiller pressure reaches 35 psig (241 kPa); then, shut off the pumpout compressor.
Safety Data Sheet and the latest ASHRAE Safety Guide for Mechanical Refrigeration to learn more about safe handling of this refrigerant. 4. Crack open valve 5, gradually increasing pressure in the evacuated chiller vessel to 35 psig (241 kPa). Feed refrigerant slowly to prevent tube freeze-up. 5. Leak test to ensure chiller vessel integrity. 6. Open valve 5 fully.
2. Open the charging valve fully. 3. Slowly open the cylinder regulating valve. 4. Observe the pressure gage on the chiller and close the regulating valve when the pressure reaches test level. Do not exceed 140 psig (965 kPa). 5. Close the charging valve on the chiller. Remove the copper tube if no longer required. SCHEDULED MAINTENANCE Establish a regular maintenance schedule based on the actual chiller requirements such as chiller load, run hours, and cooler and condenser liquid quality.
SSU at 210 F (99 C) . . . . . . . . . . . . . . . . . . . 91 ± 7 Pour Point (maximum) . . . . . . . . . . . . . . . . . . . –6 F (–21 C) Flash Point (minimum) . . . . . . . . . . . . . . . . . . 428 F (220 C) Moisture Content (maximum). . . . . . . . . . . . . . . . . . .50 ppm Acid Number (maximum) . . . . . . . . . . . 0.15 mg KOH/gram Critical Solution Temperature with HFC-134a (maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . –8 F(–22 C) 3.
4. Apply thread locking adhesive (P/N 24221 [10 ml] or 24231 [50 ml]) the 3/8-in. - 16 bolts that hold the float valve in place. See Fig. 47 for a view of the float valve design. Inspect the orientation of the float slide pin. It must be pointed toward the bubbler tube for proper operation. 5. Apply gasket sealant (P/N 19XL680-002) to both sides of new gasket when reinstalling cover. Inspect Condenser Refrigerant Float System — Perform this inspection when the condenser is opened for service. See Fig. 47.
FILTER DRIER ISOLATION VALVE MOISTURE INDICATOR VFD REFRIGERANT COOLING ISOLATION VALVES (2) VFD REFRIGERANT STRAINER REFRIGERANT FILTER/DRIER FILTER/DRIER ISOLATION VALVE a23-1616 Fig. 45 — Refrigerant Filter/Drier 1 ORIFICE SCREEN 2 3 4 a23-1631 5 Fig.
Higher than normal condenser pressures, together with the inability to reach full refrigeration load, usually indicate dirty tubes or air in the chiller. If the refrigeration log indicates a rise above normal condenser pressures, check the condenser refrigerant temperature against the leaving condenser liquid temperature. If this reading is more than what the design difference is supposed to be, then the condenser tubes may be dirty or liquid flow may be incorrect.
Relieve refrigerant pressure and add oil to the pumpout unit as follows: 1. Refer to Fig. 42. 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.
CHECK SENSOR ACCURACY — Place the sensor in a medium of known temperature and compare that temperature to the measured reading. The thermometer used to determine the temperature of the medium should be of laboratory quality with 0.5º F (.25º C) graduations. The sensor in question should be accurate to within 2º F (1.2º C). See Fig. 3 for sensor locations. Temperature sensors are inserted into a thermowell in the refrigerant or liquid circuits.
TRANSDUCER REPLACEMENT — Since the pressure transducers are mounted on Schrader-type fittings, there is no need to remove refrigerant from the vessel when replacing the transducers. Disconnect the transducer wiring by pulling up on the locking tab while pulling up on the weather-tight connecting plug from the end of the transducer. Do not pull on the transducer wires. Unscrew the transducer from the Schrader fitting. When installing a new transducer, do not use pipe sealer (which can plug the sensor).
vessels are isolated. The Terminate Lockout feature ends the Pumpdown/Lockout after the pumpdown procedure is reversed and refrigerant is added. Control Test — The Control Test feature can check all the thermistor temperature sensors, pressure transducers, pumps and their associated flow devices, the oil reclaim output, the head pressure output, and other control outputs such as tower fans, VFD cooling solenoid, shut trip relay, oil heaters, alarm relay, and hot gas bypass.
Table 15 — ICVC Primary and Secondary Messages and Custom Alarm/Alert Messages with Troubleshooting Guides (cont) D. PRE-START ALERTS: These alerts are only declared after a start command is issued and only delay start-up. When alert is corrected, the start-up will continue. No reset is necessary.
Table 15 — ICVC Primary and Secondary Messages and Custom Alarm/Alert Messages with Troubleshooting Guides (cont) E. START-UP IN PROGRESS PRIMARY MESSAGE STARTUP IN PROGRESS SECONDARY MESSAGE OCCUPIED MODE REMOTE CONTACT CLOSED START COMMAND IN EFFECT CAUSE/REMEDY Chiller is starting. Time schedule is occupied (OCCUPIED? = YES). Chiller is starting. REMOTE CONTACTS OPTION is set to ENABLE. Remote contacts input on terminal block TB1 terminals 23 and 24 are closed.
Table 15 — ICVC Primary and Secondary Messages and Custom Alarm/Alert Messages with Troubleshooting Guides (cont) G. NORMAL RUN WITH OVERRIDES STATE PRIMARY MESSAGE SECONDARY MESSAGE ALARM MESSAGE PRIMARY CAUSE 120 RUN CAPACITY LIMITED HIGH CONDENSER PRESSURE 120->Condenser Pressure [VALUE] exceeded limit of [LIMIT]*. 121 RUN CAPACITY LIMITED HIGH MOTOR TEMPERATURE 121->Comp Motor Winding Temp [VALUE] exceeded limit of [LIMIT]*.
Table 15 — ICVC Primary and Secondary Messages and Custom Alarm/Alert Messages with Troubleshooting Guides (cont) H.
Table 15 — ICVC Primary and Secondary Messages and Custom Alarm/Alert Messages with Troubleshooting Guides (cont) I.
Table 15 — ICVC Primary and Secondary Messages and Custom Alarm/Alert Messages with Troubleshooting Guides (cont) I. CHILLER PROTECTIVE LIMIT FAULTS (cont) STATE PRIMARY MESSAGE SECONDARY MESSAGE ALARM MESSAGE PRIMARY CAUSE 215 PROTECTIVE LIMIT LOW DC BUS VOLTAGE 215->Low DC Bus Voltage: [VALUE] exceeded limit of [LIMIT]* 216 PROTECTIVE LIMIT LINE VOLTAGE IMBALANCE 216->Line Voltage Imbalance; Check VFD Fault History for Values.
Table 15 — ICVC Primary and Secondary Messages and Custom Alarm/Alert Messages with Troubleshooting Guides (cont) I.
Table 15 — ICVC Primary and Secondary Messages and Custom Alarm/Alert Messages with Troubleshooting Guides (cont) I. CHILLER PROTECTIVE LIMIT FAULTS (cont) STATE 234 235 236 237 238 239 240 241 242 243 244 PRIMARY MESSAGE SECONDARY MESSAGE ALARM MESSAGE PRIMARY CAUSE ADDITIONAL CAUSE/REMEDY Check for low oil level in oil sump sight glass. See Table 5.
Table 15 — ICVC Primary and Secondary Messages and Custom Alarm/Alert Messages with Troubleshooting Guides (cont) I. CHILLER PROTECTIVE LIMIT FAULTS (cont) PRIMARY MESSAGE SECONDARY MESSAGE 245 PROTECTIVE LIMIT VFD SPEED OUT OF RANGE 245->Actual VFD Speed exceeded limit of Target VFD Speed ± 10%]*.
Table 15 — ICVC Primary and Secondary Messages and Custom Alarm/Alert Messages with Troubleshooting Guides (cont) J.
Table 15 — ICVC Primary and Secondary Messages and Custom Alarm/Alert Messages with Troubleshooting Guides (cont) J. CHILLER ALERTS (cont) STATE PRIMARY MESSAGE SECONDARY MESSAGE ALARM MESSAGE PRIMARY CAUSE 150 AUTORESTART PENDING HIGH DC BUS VOLTAGE 150->High DC Bus Voltage: [VALUE] Exceeded Limit of [LIMIT]* 151 CONDENSER PRESSURE ALERT PUMP RELAY ENERGIZED 151->High Condenser Pressure [VALUE]: Pump Energized to Reduce Pressure.
Table 15 — ICVC Primary and Secondary Messages and Custom Alarm/Alert Messages with Troubleshooting Guides (cont) J.
Table 16 — Fault Description and Corrective Actions FAULT FAULT CODE 2 Auxiliary Input 3 Power Loss TYPE* DESCRIPTION 1 1, 3 Input is open. DC bus voltage remained below 85% of nominal for longer than Power Loss Time (185). Enable/disable with Fault Config 1 (238). DC bus voltage fell below the minimum value of 407V DC at 400/480V input. DC bus voltage exceeded maximum value.
Table 16 — Fault Description and Corrective Actions (cont) FAULT CODE 48 FAULT TYPE* DESCRIPTION ACTION Params Defaulted 4 The drive was commanded to write default values to EEPROM.
Table 16 — Fault Description and Corrective Actions (cont) FAULT CODE 203 204 205 207 FAULT TYPE* DESCRIPTION ACTION FAULT STATE 246 Inverter OverCurrent U, V, W 4 High current was detected in an IGBT. Check parameters in VFD_CONF screen. Invtr Gate Kill 4 Inverter gate kill contact is open. 207 235 208 209 210 211 212 213 214 215 Rectifier Dsat R, S, T 4 High current was detected in an IGBT. 1. Check that condenser high pressure switch is wired to the VFD gate kill contact. 2.
Table 16 — Fault Description and Corrective Actions (cont) FAULT CODE 231 Rctfr HW Unk 4 232 Rctfr Not OK 4 233 Precharge closed 4 234 Precharge open 4 235 Rctfr Pwr Board 4 236 Rctfr I/O Board 4 237 Not at Voltage 4 238 Rectfr Not Logged In 4 239 Power Phased ACB 4 FAULT TYPE* DESCRIPTION ACTION Rectifier portion of power structure hard- 1. Verify connection between rectifier control ware reported unexpected fault. board and rectifier power board. 2.
2. If a green LED is on continuously, check the communication wiring. If a green LED is off, check the red LED operation. If the red LED is normal, check the SIO address switches (Fig. 49 and 50). Confirm all SW1 SIO address dip switches on the CCM are in the OFF position. All system operating intelligence resides in the ICVC. Some safety shutdown logic resides in the VFD Gateway in case communications are lost between the VFD and ICVC. Outputs are controlled by the CCM and VFD Gateway as well. 3.
Table 17A — Thermistor Temperature (F) vs Resistance/Voltage Drop TEMPERATURE (F) –25 –24 –23 –22 –21 –20 –19 –18 –17 –16 –15 –14 –13 –12 –11 –10 –9 –8 –7 –6 –5 –4 –3 –2 –1 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 PIC III VOLTAGE DROP (V) 4.700 4.690 4.680 4.670 4.659 4.648 4.637 4.625 4.613 4.601 4.588 4.576 4.562 4.549 4.535 4.521 4.507 4.492 4.477 4.461 4.
Table 17B — Thermistor Temperature (C) vs Resistance/Voltage Drop TEMPERATURE (C) –33 –32 –31 –30 –29 –28 –27 –26 –25 –24 –23 –22 –21 –20 –19 –18 –17 –16 –15 –14 –13 –12 –11 –10 –9 –8 –7 –6 –5 –4 –3 –2 –1 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 PIC III VOLTAGE DROP (V) 4.722 4.706 4.688 4.670 4.650 4.630 4.608 4.586 4.562 4.538 4.512 4.486 4.458 4.429 4.399 4.368 4.336 4.303 4.269 4.233 4.196 4.158 4.119 4.079 4.037 3.994 3.
J11 DISCRETE OUTPUTS SW1 SIO ADDRESS DIPSWITCH SET ALL TO “OFF” J12 DISCRETE OUTPUTS J1 24 VAC ANALOG OUT J8 SIO J7 SIO J6 SW2 V/I INPUT CONFIGURATION V/I INPUTS J5 a23-1617 STAT COMM THERMISTORS J4 DIFF PRESSURE J3 PRESSURE J2 Fig. 50 — Chiller Control Module (CCM) Replacing Defective ICVC Modules — The module replacement part number is printed on a small label on the rear of the ICVC module.
Service Tool, release the force on SERVICE ONTIME after the desired value has been set. TOTAL COMPRESSOR STARTS and TOTAL COMPRESSOR ONTIME can only be changed prior to the first completed start. If a start is completed and the COMPRESSOR STARTS or COMPRESSOR ON TIME are both incorrect, the ICVC software must be downloaded again before these settings can be changed. 9. Check and recalibrate pressure transducer readings (refer to page 79).
DPI COMMUNICATIONS INTERFACE BOARD INVERTER LED RECTIFIER LED a19-1634 INVERTER STATUS LIGHT COLOR Green Yellow Red Red Inverter Green Rectifier STATE Flashing Steady Flashing Steady Flashing Steady DESCRIPTION Drive ready, but not running and no faults are present. Drive running, no faults are present. The drive is not ready. A VFD start inhibit is in effect. Normal condition when chiller not running because the ICVC has issued a stop command. An alarm condition exits.
Table 22 — 23XRV Heat Exchanger Weights English Dry Rigging Weight (lb)* CODE 30 31 32 35 36 37 40 41 42 45 46 47 50 51 52 55 56 57 Cooler Only Condenser Only 4148 4330 4522 4419 4627 4845 5008 5178 5326 5463 5659 5830 5827 6053 6196 6370 6631 6795 3617 3818 4023 4529 4758 4992 4962 5155 5347 5525 5747 5967 6013 6206 6387 6708 6930 7138 Metric (SI) Dry Rigging Weight (kg)* Machine Charge Refrigerant Weight (lb) With Without Economizer Economizer 800 650 800 650 800 650 910 760 910 760 910 760 900 750
Table 25A — 23XRV Waterbox Cover Weights — English (lb)* FRAMES 3, 4, AND 5 WATERBOX DESCRIPTION NIH,1 pass Cover 150 PSIG NIH,2 pass Cover 150 PSIG NIH,3 pass Cover 150 PSIG NIH Plain End, 150 PSIG MWB End Cover, 150 PSIG* NIH,1 pass Cover 300 PSIG NIH,2 pass Cover 300 PSIG NIH,3 pass Cover 300 PSIG NIH Plain End, 300 PSIG MWB End Cover, 300 PSIG* COOLER CONDENSER Frame 3 Frame 4 Frame 5 Frame 3 Frame 4 Frame 5 Victaulic Victaulic Victaulic Victaulic Victaulic Victaulic Flanged Flanged Flanged Flanged Fla
Table 28 — 23XRV Compressor Torque Specification Chart LOCATION/USAGE Hermetic Term, Outlet Casing Sub-Assembly Motor Side Seal Installation Inlet Seal Installation Inlet Seal Installation Bearing Cover Installation Outlet Casing Process Bolts Motor Terminal Cover Install and Lube Block Motor Housing and Bearing Cover Installation Discharge Flange Motor Stator Sub-Assembly Bearing Cover Lube Plug Rotor Caps & Male Axial Seal Plug Installation Plug Installation Rotor Housing Motor Housing Air Gap Check Motor
a23-1641 107 Fig. 53 — 23XRV Controls Schematic NOTES: 1. This feature is standard in the 23XRV controls, but requires a controller with a non-grounded 4-20mA or 1-5Vdc output signal, not by Carrier. 2. This feature is standard in the 23XRV controls, but requires an external controller with a non-grounded 4-20mA output signal, not by Carrier. 3. This feature is standard in the 23XRV controls, but requires a sensor package option, by Carrier. (Item #3 see option listing.) 4. Pins shown for reference only.
a23-1588 Fig.
a23-1589 Fig.
120A 118 116 114 110 K1A TS1 20A 600V 2 T1 T2 T3 A2 L1 L2 L3 A1 15 3 14 13 154 PRECHARGE CONTACTORS 132 PRECHARGE RESISTORS 10 , 600W 137A,B FU4 139 R4 128 FU7 127 136 4x 140J 2V FU5 FU6 150A 600V 129 119A 117 115 IND1 INPUT INDUCTOR MAIN CIRCUIT BREAKER CB1 GND 138 20A 600V 1uF 113 46uF ea 100k , 50W FILTER CAP ASSY a23-1633 1 4 R R5 131 FU8 130A 7 1 L1 155 A1 L3 L2 L1 13 5 L2 T1 14 A2 T3 T2 8 2 S 9 3 T K1B 156 6 L3 140
fig55-notes-chart Fig.
a23-1585 Fig.
a23-1586 Fig.
NOTES FOR FIG. 55 3.1 GENERAL 1.0 Variable frequency drive (VFD) shall be designed and manufactured in accordance with Carrier engineering requirements. 1.1 All field-supplied conductors, devices and the fieldinstallation wiring, termination of conductors and devices, must be in compliance with all applicable codes and job specifications. 1.
1 2 3 1 — — — BLACK WHITE RED DRAIN WIRE 115 Field Wiring DRAIN WIRE BLACK WHITE RED DRAIN WIRE NOTE: Field-supplied terminal strip must be located in control panel. 3 BLACK WHITE RED 2 Fig.
A19-1717 116 Fig.
a23-1598 117 Fig.
APPENDIX A — ICVC PARAMETER INDEX PARAMETER 1st Current Alarm State 20mA Demand Limit Opt (Demand Limit & KW Ramp) 2nd Current Alarm State 3rd Current Alarm State 4th Current Alarm State 5th Current Alarm State Active Delta P Active Delta T Active Demand Limit Actual VFD Speed Actual VFD Speed Actual VFD Speed Actual VFD Speed (At Last Fault) Address # Alarm Configuration ALARM HISTORY Alarm Relay Test Alarm Routing (Alarm Configuration) ALERT HISTORY Amps or KW Load Ramp %/Min (Demand Limit and KW Ramp) Am
APPENDIX A — ICVC PARAMETER INDEX (cont) PARAMETER Comp Discharge Alert Comp Discharge Alert Comp Discharge Temp Comp Discharge Temp Comp Discharge Temp Comp Maximum Speed Comp Maximum Speed Comp Maximum Speed Comp Maximum Speed Comp Minimum Speed Comp Minimum Speed Comp Minimum Speed Comp Minimum Speed Comp Motor Frequency Comp Motor Frequency Comp Motor Frequency Comp Motor Frequency Comp Motor Frequency (At Last Fault) Comp Motor RPM Comp Motor RPM Comp Motor RPM Comp Motor RPM Comp Motor RPM (At Last Fa
APPENDIX A — ICVC PARAMETER INDEX (cont) PARAMETER MENU SOFTKEY Date SERVICE Day of Week SERVICE Daylight Savings SERVICE DC Bus Voltage STATUS DC Bus Voltage Reference STATUS DC Bus Voltage Reference (At Last Fault) SERVICE DC Bus Voltage (At Last Fault) SERVICE Decrease Ramp Time SERVICE Degrees Reset at 20 mA SERVICE (Temperature Reset Type 1) Degrees Reset (Temperature Reset Type 2) SERVICE Degrees Reset (Temperature Reset Type 3) SERVICE Delta P at 0% (4 mA) (Head Pressure Reference) SERVICE Delta P at
APPENDIX A — ICVC PARAMETER INDEX (cont) PARAMETER Head Pressure Output Control Test Head Pressure Reference Head Pressure Reference Head Pressure Reference HGBP Deadband HGBP Delta P1(Min Load Point) HGBP Delta P2(Full Load Point) HGBP Delta T HGBP Delta T1(Min Load Point) HGBP Delta T2(Full Load Point) HGBP On Delta T HGBP Off Delta T High DC Bus Voltage High Line Voltage Holiday HOLIDAYS Hot Gas Bypass HGBP Option Hot Gas Bypass Relay Hot Gas Bypass Relay Test Humidity Sensor Input Humidity Sensor Input
APPENDIX A — ICVC PARAMETER INDEX (cont) PARAMETER Leaving Chilled Liquid Leaving Chilled Liquid Leaving Chilled Liquid Leaving Chilled Liquid Leaving Cond Liquid Leaving Cond Liquid Leaving Cond Liquid LID Language Line Active Current Line Active Current (At Last Fault) Line Active Voltage Line Active Voltage (At Last Fault) Line Current % Imbalance Line Current Imbal Time Line Current Imbalance Line Current Imbalance Line Current Imbalance (At Last Fault) Line Current Ph 1(R) Line Current Ph 1(R)(At Last
APPENDIX A — ICVC PARAMETER INDEX (cont) PARAMETER Maximum Loadshed Time Min.
APPENDIX A — ICVC PARAMETER INDEX (cont) PARAMETER Proportional Dec Band (Capacity Control) Proportional ECL Gain (Capacity Control) Proportional Inc Band (Capacity Control) Pulldown Ramp Type: PULLDOWN Time PULLDOWN Timer Pulldown: Delta T / Min Pumpdown/Lockout Control Test Pumpdown/Lockout Control Test Pumps Control Test Rated Line Amps Rated Line Kilowatts Rated Line Voltage Re-alarm Time (Alarm Configuration) Reclaim Delta T Recovery Start Request (Lag Chiller) Recovery Start Request (Standby Chiller)
APPENDIX A — ICVC PARAMETER INDEX (cont) PARAMETER Single Cycle Dropout Single Cycle Dropout Skip Frequency 1 Skip Frequency 2 Skip Frequency 3 Skip Frequency Band Soft Stop Amps Threshold Software Part # Spare Alert/Alarm Enable Spare Safety Input Spare Temp #1 Enable (Spare Alert/Alarm Enable) Spare Temp #1 Limit (Spare Alert/Alarm Enable) Spare Temp #2 Enable (Spare Alert/Alarm Enable) Spare Temp #2 Limit (Spare Alert/Alarm Enable) Spare Temperature 1 Spare Temperature 1 Spare Temperature 1 Spare Tempera
APPENDIX A — ICVC PARAMETER INDEX (cont) PARAMETER Tower Fan High Setpoint Tower Fan Relay High Tower Fan Relay High Test Tower Fan Relay Low Tower Fan Relay Low Test Transducer Voltage Ref US IMP/Metric Values At Last Fault: Vaporizer Heater Vaporizer Heater Vaporizer Heater Mode Vaporizer Heater Test Vaporizer Temp Vaporizer Temp Vaporizer Temp VFD Checksum Error VFD Cold Plate Temp VFD Cold Plate Temp (At Last Fault) VFD Comm Fault VFD CONFIG DATA Password VFD Coolant Flow VFD Coolant Flow VFD Coolant So
APPENDIX B — MAINTENANCE SUMMARY AND LOG SHEETS 23XRV 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 charge. Change oil filter. Send oil sample out for analysis. Leak test.
APPENDIX B — MAINTENANCE SUMMARY AND LOG SHEETS 23XRV Weekly Maintenance Log Plant ___________________________ Machine Serial No. ________________________________ Machine Model No. ________________ Refrigerant Type __________________________________ DATE OIL LEVEL CHECK ALARMS / FAULTS OPERATOR INITIALS REMARKS NOTE: Equipment failures caused by lack of adherence to the Maintenance Interval Requirements are not covered under warranty.
APPENDIX B — MAINTENANCE SUMMARY AND LOG SHEETS 23XRV Maintenance Log for Monthly, Quarterly, and Annual Checks Month Date Operator UNIT SECTION Compressor Cooler 129 Condenser Controls Starter 1 / ACTION Change Oil Charge Record Oil Temperature Change Oil Filter Send Oil Sample Out for Analysis Leak Test Inspect and Clean Cooler Tubes Inspect Relief Valves Leak Test Record Water Pressure Differential Record Cooler Pressure Record Entering and Leaving Water Temperature Inspect Water Pumps Leak Test I
APPENDIX B — MAINTENANCE SUMMARY AND LOG SHEETS (cont) 23XRV Seasonal Shutdown Log Month Date Operator UNIT SECTION Cooler Condenser Controls 1 / 2 / / 3 / ACTION Isolate and Drain Waterbox Remove Waterbox Cover from One End Use Compressed Air to Clean Tubes Isolate and Drain Waterbox Remove Waterbox Cover from One End Use Compressed Air to Clean Tubes Do Not Disconnect Control Power NOTE: Equipment failures caused by lack of adherence to the Maintenance Interval Requirements are not covered under wa
APPENDIX C — OPTIONAL BACNET COMMUNICATIONS WIRING Optional BACnet* Communications Wiring — 6 5 7 8 2 34 5 6 10's 1 9 0 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 C — 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 C — OPTIONAL BACNET COMMUNICATIONS WIRING (cont) Fig. E — BT485 Terminator Installation temperature rating specifications list two acceptable alternatives. The Halar specification has a higher temperature rating and a tougher outer jacket than the SmokeGard specification, and it is appropriate for use in applications where the user is concerned about abrasion. The Halar jacket is also less likely to crack in extremely low temperatures.
APPENDIX C — OPTIONAL BACNET COMMUNICATIONS WIRING (cont) Table D — Open System Wiring Specifications and Recommended Vendors WIRING SPECIFICATIONS Wire Type RECOMMENDED VENDORS AND PART NUMBERS Connect Air Contractors Belden RMCORP 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 C — OPTIONAL BACNET COMMUNICATIONS WIRING (cont) COMMUNICATION LEDS — The LEDs indicate if the controller is communicating with the devices on the network. See Tables E and F. The LEDs should reflect communication traffic based on the baud rate set. The higher the baud rate the more solid the LEDs become. See Fig. B for location of LEDs on UPC Open module.
APPENDIX C — OPTIONAL BACNET COMMUNICATIONS WIRING (cont) Table G — Network Points List POINT DESCRIPTION 1st Current Alarm State Active Delta T Active Demand Limit Actual VFD Speed Auto Chilled Liq Reset Auto Demand Limit Input Base Demand Limit Calc Evap Sat Temp Chill Liq Pulldown/Min Chilled Liquid Temp Chilled Water Temp Chiller Start/Stop Comp Discharge Alert Comp Discharge Temp Comp Motor Frequency Comp Motor RPM Condenser Liquid Pump Condenser Pressure Condenser Refrig Temp CCN POINT NAME ALARM_01
APPENDIX C — OPTIONAL BACNET COMMUNICATIONS WIRING (cont) Table G — Network Points List (cont) POINT DESCRIPTION CCN POINT NAME Run Status READ/ WRITE UNITS DEFAULT VALUE STATUS R Service Ontime Shunt Trip Relay Stall Protection Counts Start Complete Stop Fault S_HRS TRIPR SPC START_OK AMPSTOP R/W R N/A System Alert/Alarm SYS_ALM R N/A R N/A System Cooling Demand Level System Demand Limiting Target VFD Speed Torque Current Tower Fan Relay High Tower Fan Relay Low User Defined Analog 1 User
INDEX Abbreviations and explanations 4 After limited shutdown 66 Attach to network device control 44 Automatic soft stop amps threshold 47 Auto.
INITIAL START-UP CHECKLIST FOR 23XRV HERMETIC SCREW LIQUID CHILLER (Remove and use for job file.) MACHINE INFORMATION: NAME ADDRESS CITY JOB NO. MODEL ZIP STATE S/N DESIGN CONDITIONS TONS (kW) BRINE FLOW RATE TEMPERATURE IN TEMPERATURE PRESSURE OUT DROP PASS SUCTION TEMPERATURE COOLER CONDENSER ****** From Chiller Nameplate: Line Voltage Rated Line Amps From VFD Nameplate: I.D. No.
Yes Yes No No Line Voltage: FIELD-DISASSEMBLED CHILLERS ONLY: Megger Test Motor if the VFD is removed from the chiller. Check continuity T1 to T1, etc. (Motor to starter, disconnect motor leads T1, T2, T3.) Do not megger VFD; disconnect leads to motor and megger the leads. MEGGER MOTOR “PHASE TO PHASE” T1-T2 T1-T3 T2-T3 “PHASE TO GROUND” T1-G T2-G T3-G 10-Second Readings: 60-Second Readings: Polarization Ratio: CONTROLS: SAFETY, OPERATING, ETC. Verify parameters in VFD_conf screen.
Start Liquid Pumps and Establish Liquid Flow Oil Level OK and Oil Temperature OK Oil Pressure Restart Compressor, Bring Up To Speed. Shut Down. Any Abnormal Coastdown Noise? Yes* *If yes, determine cause. START MACHINE AND OPERATE. COMPLETE THE FOLLOWING: A: Trim charge and record under Charge Refrigerant Into Chiller section on page 63. B: Complete any remaining control calibration and record under Controls section (pages 12-46). C: Take at least two sets of operational log readings and record.
DESCRIPTION Base Demand Limit LCL Setpoint ECL Setpoint Ice Build Setpoint Tower Fan High Setpoint RANGE 40 to 100 10 to 60 (-12.2 to 15.6) 15 to 65 (-9.4 to 18.3) 15-60 (-9.4 to 15.6) 55 to 105 (13 to 41) Upload all Control Configuration tables via Service Tool Yes UNITS % ° F (° C) ° F (° C) ° F (° C) ° F (° C) DEFAULT 100 50.0 (10.0) 60.0 (15.6) 40 (4.4) 75 (23.
23XRV PIC III LOCAL TIME SCHEDULE CONFIGURATION SHEET OCCPC01S 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 23XRV PIC III TIME SCHEDULE CONFIGURATION SHEET OCCPC02S Day Flag M T W T F S S H Occupied Time Unoccupied Time Period 1: Period 2: Period 3: Period 4: Period 5: Period 6: Period 7: Period 8: NOTE: Default setting is UNOCCUPIED 24 hours/day.
DESCRIPTION Motor Nameplate Voltage RANGE 480-480 UNITS VOLTS DEFAULT 480 Compressor 100% Speed 54-101 Hz 70 Rated Line Voltage 346-480 VOLTS 460 Rated Line Amps 10-5000 AMPS 200 Rated Line Kilowatts 0-999999 KW 100 Motor Rated Load KW 0-999999 KW 100 Motor Rated Load Amps 10-5000 AMPS 200 Motor Nameplate Amps 10-5000 AMPS 100 Motor Nameplate RPM 1500-3030 Motor Nameplate KW Inverter PWM Frequency (0=4 k Hz, 1=2 k Hz) Skip Frequency 1 0-999999 0.
23XRV PIC III OPTIONS TABLE CONFIGURATION SHEET DESCRIPTION Auto Restart Option Remote Contacts Option Soft Stop Amps Threshold RANGE 0/1 0/1 40 to 100 UNITS DSABLE/ENABLE DSABLE/ENABLE % DEFAULT DSABLE DSABLE 100 Hot Gas Bypass HGBP Option 0,1,2 0=DSABLE 1=HGBP 2=LOW LOAD HGBP 0=DSABLE 0.5 to 20 (.3 to 11.1) 10 to 170 (68.9 to 1172.2) ˆF (ˆC) PSI (kPa) 1.5 (.8) 150 (1034.2) 0.5 to 20 (.3 to 11.1) 30 to 250 (206.9 to 1724) 0.5 to 3 (.3 to 1.7) 0.5-10 (0.3-5.6) 1.0-10 (0.6-5.
DESCRIPTION Comp Motor Temp Override Cond Press Override Comp Discharge Alert Rectifier Temp Override Inverter Temp Override Chilled Medium Chilled Liquid 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 Oil Press Verify Time Liquid Flow Verify Time RANGE 150 - 200 (66 - 93) 145 - 166 (1000 - 1145) 125 to 160 (52 to 71) 155 to 170 (68 to 77) 155 to 170 (68 to 77) UNIT
23XRV PIC III SETUP2 TABLE CONFIGURATION SHEET DESCRIPTION Capacity Control Proportional Inc Band Proportional Dec Band Proportional ECL Gain VFD Control VFD Gain VFD Minimum Speed VFD Maximum Speed Vaporizer Heater Mode 0 = Normal, 1 = Service STATUS UNITS 2 to 10 2 to 10 1 to 3 0.1 to 1.5 15 to 50 15 to 100 0 to 1 DEFAULT 6.5 6.0 2.0 % % CL-9 0.
DESDRIPTION 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-10 DSABLE DSABLE 50 92 10 10 5 2 DSABLE 50 93 VALU
23XRV PIC III RAMP_DEM TABLE CONFIGURATION SHEET DESCRIPTION Pulldown Ramp Type: Select: Temp=0, kW=1 Demand Limit and kW Ramp Demand Limit Source Select: Amps=0, kW=1 Amps or kW Ramp % Min Demand Limit Prop Band Demand Limit At 20 mA 20 mA Demand Limit Opt Demand Watts Interval RANGE UNITS DEFAULT 0/1 1 0/1 0 5 to 20 3 to 15 40 to 100 0/1 5 to 60 % % DSABLE/ENABLE MIN VALUE 10 10 40 DSABLE 15 23XRV PIC III TEMP_CTL TABLE CONFIGURATION SHEET DESCRIPTION Control Point Source ECL Control Option Te
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 0/1 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 DSABLE/ENABLE HH:MM MIN MIN DEFAULT DSABLE VALUE 4 7 1 02:00 0 10 7 5 02:00 0 Copyright 2011 Carrier Corporation Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without not