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

Catalog No. 532-310 Printed in U.S.A. Form 23XRV-1SS Pg 1 9-06 Replaces: NewBook 2

Tab 5e

Start-Up, Operation and Maintenance

InstructionsSAFETY CONSIDERATIONSScrew liquid chillers are designed to provide safe and

reliable service when operated within design specifications.When operating this equipment, use good judgment andsafety precautions to avoid damage to equipment and prop-erty or injury to personnel.

Be sure you understand and follow the procedures andsafety precautions contained in the chiller instructions, aswell as those listed in this guide.

DO NOT VENT refrigerant relief valves within a building. Outlet fromrupture disc or relief valve must be vented outdoors in accordance withthe latest edition of ANSI/ASHRAE 15 (American National StandardsInstitute, American Society of Heating, Refrigeration, and Air Condi-tioning Engineers), latest edition. The accumulation of refrigerant in anenclosed space can displace oxygen and cause asphyxiation.

PROVIDE adequate ventilation in accordance with ANSI/ASHRAE 15,especially for enclosed and low overhead spaces. Inhalation of high con-centrations of vapor is harmful and may cause heart irregularities,unconsciousness, or death. Misuse can be fatal. Vapor is heavier than airand reduces the amount of oxygen available for breathing. Productcauses eye and skin irritation. Decomposition products are hazardous.

DO NOT USE OXYGEN to purge lines or to pressurize a chiller forany purpose. Oxygen gas reacts violently with oil, grease, and othercommon substances.

NEVER EXCEED specified test pressures. VERIFY the allowable testpressure by checking the instruction literature and the design pressureson the equipment nameplate.

DO NOT USE air for leak testing. Use only refrigerant or dry nitrogen.

DO NOT VALVE OFF any safety device.

BE SURE that all pressure relief devices are properly installed andfunctioning before operating any chiller.

RISK OF INJURY OR DEATH by electrocution. High voltage ispresent on motor leads even though the motor is not running. Open thepower supply disconnect before touching motor leads or terminals.

DO NOT WELD OR FLAMECUT any refrigerant line or vessel untilall refrigerant (liquid and vapor) has been removed from chiller. Tracesof vapor should be displaced with dry air or nitrogen and the work areashould be well ventilated. Refrigerant in contact with an open flameproduces toxic gases.

DO NOT USE eyebolts or eyebolt holes to rig chiller sections or theentire assembly.

DO NOT work on high-voltage equipment unless you are a qualified

electrician.DO NOT WORK ON electrical components, including control centers,switches, starters, or oil heater until you are sure ALL POWER ISOFF and no residual voltage can leak from capacitors or solid-statecomponents.

LOCK OPEN AND TAG electrical circuits during servicing. IFWORK IS INTERRUPTED, confirm that all circuits are deenergizedbefore resuming work.

DO NOT syphon refrigerant.

AVOID SPILLING liquid refrigerant on skin or getting it into the eyes.USE SAFETY GOGGLES. Wash any spills from the skin with soapand liquid. If liquid refrigerant enters the eyes, IMMEDIATELYFLUSH EYES with water and consult a physician.

NEVER APPLY an open flame or live steam to a refrigerant cylinderDangerous over pressure can result. When it is necessary to heat refrigerant, use only warm (110 F [43 C]) water.

DO NOT REUSE disposable (nonreturnable) cylinders or attempt torefill them. It is DANGEROUS AND ILLEGAL. When cylinder isemptied, evacuate remaining gas pressure, loosen the collar, andunscrew and discard the valve stem. DO NOT INCINERATE.

CHECK THE REFRIGERANT TYPE before adding refrigerant to thechiller. The introduction of the wrong refrigerant can cause damage ormalfunction to this chiller.

Operation of this equipment with refrigerants other than those citedherein should comply with ANSI/ASHRAE 15 (latest edition)Contact Carrier for further information on use of this chiller with other

refrigerants.DO NOT ATTEMPT TO REMOVE fittings, covers, etc., while chilleis under pressure or while chiller is running. Be sure pressure is at0 psig (0 kPa) before breaking any refrigerant connection.

CAREFULLY INSPECT all relief devices, rupture discs, and otherrelief devices AT LEAST ONCE A YEAR. If chiller operates in a cor-rosive atmosphere, inspect the devices at more frequent intervals.

DO NOT ATTEMPT TO REPAIR OR RECONDITION any reliedevice when corrosion or build-up of foreign material (rust, dirt, scaleetc.) is found within the valve body or mechanism. Replace the device.

DO NOT install relief devices in series or backwards.

USE CARE when working near or in line with a compressed springSudden release of the spring can cause it and objects in its path to act asprojectiles.

DO NOT STEP on refrigerant lines. Broken lines can whip about andrelease refrigerant, causing personal injury.

DO NOT climb over a chiller. Use platform, catwalk, or stagingFollow safe practices when using ladders.

USE MECHANICAL EQUIPMENT (crane, hoist, etc.) to lift or moveinspection covers or other heavy components. Even if components arelight, use mechanical equipment when there is a risk of slipping orlosing your balance.

BE AWARE that certain automatic start arrangements CAN ENGAGETHE COMPRESSOR, TOWER FAN, OR PUMPS. Open the disconnect aheadof the starter, tower fan, or pumps. Shut off the chiller orpump before servicing equipment.

USE only repair or replacement parts that meet the code requirementof the original equipment.

DO NOT VENT OR DRAIN waterboxes containing industrial brineswater, gases, or semisolids without the permission of your process con

trol group.DO NOT LOOSEN waterbox cover bolts until the waterbox has beencompletely drained.

DOUBLE-CHECK that coupling nut wrenches, dial indicators, or otheitems have been removed before rotating any shafts.

DO NOT LOOSEN a packing gland nut before checking that the nuhas a positive thread engagement.

PERIODICALLY INSPECT all valves, fittings, and piping for corro-sion, rust, leaks, or damage.

PROVIDE A DRAIN connection in the vent line near each pressurerelief device to prevent a build-up of condensate or rain water.

23XRVHermetic Screw Liquid Chillers with

PIC III Controls50/60 Hz

HFC-134a

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CONTENTS

Page

SAFETY CONSIDERATIONS. . . . . . . . . . . . . . . . . . . . . . 1

INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

ABBREVIATIONS AND EXPLANATIONS . . . . . . . . . . 4

23XRV CHILLER FAMILIARIZATION. . . . . . . . . . . . . 4-8Chiller Identification Nameplate. . . . . . . . . . . . . . . . . . 4System Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Motor-Compressor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Control Center. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Storage Vessel (Optional) . . . . . . . . . . . . . . . . . . . . . . . . 8

REFRIGERATION CYCLE . . . . . . . . . . . . . . . . . . . . . . 8-10

MOTOR COOLING CYCLE. . . . . . . . . . . . . . . . . . . . . . . 10

LUBRICATION CYCLE . . . . . . . . . . . . . . . . . . . . . . . . 10-12Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Details. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Oil Reclaim System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Capacity Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

CONTROLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-46Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 ANALOG SIGNAL DIGITAL SIGNALGeneral Controls Overview . . . . . . . . . . . . . . . . . . . . . . 12PIC III System Components . . . . . . . . . . . . . . . . . . . . . 12 INTERNATIONAL CHILLER VISUAL

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

(Optional) VFD REFRIGERANT COOLING SOLENOID

VALVE (5C) VAPORIZER HEATER CONTACTOR (6C)

CONTROL TRANSFORMERS (T1, T2)ICVC Operation and Menus. . . . . . . . . . . . . . . . . . . . . . 15 GENERAL ALARMS AND ALERTS ICVC MENU ITEMS BASIC ICVC OPERATIONS (Using the Softkeys) TO VIEW STATUS OVERRIDE OPERATIONS TIME SCHEDULE OPERATION TO VIEW AND CHANGE SET POINTS SERVICE OPERATIONPIC III System Functions . . . . . . . . . . . . . . . . . . . . . . . . 34 CAPACITY CONTROL FORCED NORMAL CONDITIONS

CAPACITY INCREASE CAPACITY DECREASE ECL CONTROL OPTION CHILLED LIQUID DEADBAND PROPORTIONAL BANDS AND PROPORTIONAL

GAIN DEMAND LIMITING CHILLER TIMERS OCCUPANCY SCHEDULESafety Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35Shunt Trip. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36Default Screen Freeze . . . . . . . . . . . . . . . . . . . . . . . . . . . 36Ramp Loading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36Capacity Override. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36Compressor Minimum Speed Override. . . . . . . . . . 36

PageVaporizer Temperature Control

COMPRESSOR ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36Oil Sump Temperature Control

COMPRESSOR OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . 36Oil Sump Temperature Control

COMPRESSOR ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38Remote Start/Stop Contacts . . . . . . . . . . . . . . . . . . . . . 38Spare Safety and Spare Temperature Inputs. . . . . 38Spare Alarm Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Refrigerant Leak Detector. . . . . . . . . . . . . . . . . . . . . . . 394 to 20 mA Kilowatt Output . . . . . . . . . . . . . . . . . . . . . . 39Remote Reset of Alarms. . . . . . . . . . . . . . . . . . . . . . . . . 39Condenser Pump Control . . . . . . . . . . . . . . . . . . . . . . . 39Condenser Freeze Prevention. . . . . . . . . . . . . . . . . . . 39Tower Fan Relay Low and High . . . . . . . . . . . . . . . . . . 39Auto. Restart After Power Failure. . . . . . . . . . . . . . . . 40Liquid/Brine Temperature Reset . . . . . . . . . . . . . . . . . 40 RESET TYPE 1 RESET TYPE 2 RESET TYPE 3Demand Limit Control Option . . . . . . . . . . . . . . . . . . . 40Hot Gas Bypass (Optional) Algorithm . . . . . . . . . . . 40Head Pressure Output Reference. . . . . . . . . . . . . . . . 41Lead/Lag Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

COMMON POINT SENSOR INSTALLATION CHILLER COMMUNICATION WIRING LEAD/LAG OPERATION FAULTED CHILLER OPERATION LOAD BALANCING AUTO. RESTART AFTER POWER FAILUREAttach to Network Device Control . . . . . . . . . . . . . . . 44 ATTACHING TO OTHER CCN MODULESService Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 TO ACCESS THE SERVICE SCREENS TO LOG OUT OF DEVICE HOLIDAY SCHEDULING

START-UP/SHUTDOWN/RECYCLESEQUENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46-48

Local Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Shutdown Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47Automatic Soft Stop Amps Threshold. . . . . . . . . . . 47Chilled Liquid Recycle Mode . . . . . . . . . . . . . . . . . . . . 47Safety Shutdown. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

BEFORE INITIAL START-UP . . . . . . . . . . . . . . . . . . 48-64Job Data Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48Equipment Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48Using the Optional Storage Tank

and Pumpout System . . . . . . . . . . . . . . . . . . . . . . . . . 48Remove Shipping Packaging. . . . . . . . . . . . . . . . . . . . 48Open Oil Circuit Valves . . . . . . . . . . . . . . . . . . . . . . . . . . 48Oil Charge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48Tighten All Gasketed Joints. . . . . . . . . . . . . . . . . . . . . 48Check Chiller Tightness . . . . . . . . . . . . . . . . . . . . . . . . . 49Refrigerant Tracer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Leak Test Chiller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49Chiller Dehydration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55Inspect Liquid Piping. . . . . . . . . . . . . . . . . . . . . . . . . . . . 55Check Optional Pumpout Compressor

Liquid Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55Check Relief Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55Identify the VFD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 IDENTIFYING THE DRIVE BY PART NUMBERCheck Starter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57Input Power Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57Checking the Installation . . . . . . . . . . . . . . . . . . . . . . . . 57Inspect Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57Ground Fault Troubleshooting. . . . . . . . . . . . . . . . . . . 58Carrier Comfort Network Interface. . . . . . . . . . . . . 58

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CONTENTS (cont)

PagePower Up the Controls and Check the

Oil Heater. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58Software Configuration . . . . . . . . . . . . . . . . . . . . . . . . . 59Input the Design Set Points . . . . . . . . . . . . . . . . . . . . . 59Input the Local Occupancy Schedule

(OCCPC01S) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59Input Service Configurations. . . . . . . . . . . . . . . . . . . . 59 PASSWORD INPUT TIME AND DATE

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

TO METRIC UNITS MODIFY CONTROLLER IDENTIFICATION

IF NECESSARY INPUT EQUIPMENT SERVICE PARAMETERS

IF NECESSARY MODIFY EQUIPMENT CONFIGURATION

IF NECESSARYPerform a Control Test. . . . . . . . . . . . . . . . . . . . . . . . . . 61Pressure Transducer and Optional Flow

Device Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 ZERO POINT CALIBRATION HIGH END CALIBRATION

Check Optional Pumpout SystemControls and Compressor. . . . . . . . . . . . . . . . . . . . . 62High Altitude Locations. . . . . . . . . . . . . . . . . . . . . . . . . 62Charge Refrigerant Into Chiller . . . . . . . . . . . . . . . . . . 63 CHILLER EQUALIZATION WITHOUT A

PUMPOUT UNIT CHILLER EQUALIZATION WITH PUMPOUT UNIT TRIMMING REFRIGERANT CHARGE

INITIAL START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64,65Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64Check Oil Pressure and Compressor Stop. . . . . . 65To Prevent Accidental Start-Up. . . . . . . . . . . . . . . . . . 65Check Chiller Operating Condition. . . . . . . . . . . . . . 65Instruct the Customer Operator. . . . . . . . . . . . . . . . . 65 COOLER-CONDENSER

OPTIONAL PUMPOUT STORAGE TANK ANDPUMPOUT SYSTEM

COMPRESSOR ASSEMBLY COMPRESSOR LUBRICATION SYSTEM CONTROL SYSTEM AUXILIARY EQUIPMENT DESCRIBE CHILLER CYCLES REVIEW MAINTENANCE SAFETY DEVICES AND PROCEDURES CHECK OPERATOR KNOWLEDGE REVIEW THE START-UP, OPERATION AND

MAINTENANCE MANUAL

OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . 66-68Operator Duties. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66Prepare the Chiller for Start-Up . . . . . . . . . . . . . . . . . 66

To Start The Chiller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66Check the Running System . . . . . . . . . . . . . . . . . . . . . 66To Stop the Chiller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 FAILURE TO STOPAfter Limited Shutdown. . . . . . . . . . . . . . . . . . . . . . . . . 66Preparation for Extended Shutdown . . . . . . . . . . . . 66After Extended Shutdown . . . . . . . . . . . . . . . . . . . . . . . 67Cold Weather Operation. . . . . . . . . . . . . . . . . . . . . . . . . 67Refrigeration Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

PUMPOUT AND REFRIGERANT TRANSFERPROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69-72

Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69Operating the Optional Pumpout Unit. . . . . . . . . . . 69

Page

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 . . . . . . . . . . . . . . . . . . . . . . . . . . 72Adding Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72Removing Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . 72Adjusting the Refrigerant Charge . . . . . . . . . . . . . . . 72Refrigerant Leak Testing. . . . . . . . . . . . . . . . . . . . . . . . 72Refrigerant Leak Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . 72Test After Service, Repair, or Major Leak. . . . . . . . 72 REFRIGERANT TRACER TO PRESSURIZE WITH DRY NITROGENRepair the Refrigerant Leak, Retest, and Apply

Standing Vacuum Test. . . . . . . . . . . . . . . . . . . . . . . . 73Trim Refrigerant Charge. . . . . . . . . . . . . . . . . . . . . . . . . 73

WEEKLY MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . 73

Check the Lubrication System . . . . . . . . . . . . . . . . . . 73

SCHEDULED MAINTENANCE . . . . . . . . . . . . . . . . 73-78Service Ontime. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73Inspect the Control Center. . . . . . . . . . . . . . . . . . . . . . 73Check Safety and Operating Controls

Monthly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73Changing Oil and Oil Filter. . . . . . . . . . . . . . . . . . . . . . 73Oil Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74Oil Heater. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74Refrigerant Filter/Drier. . . . . . . . . . . . . . . . . . . . . . . . . . 74Oil Strainers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74VFD Refrigerant Strainer. . . . . . . . . . . . . . . . . . . . . . . . 74Vaporizer Refrigerant Return Line Orifice. . . . . . . 74Compressor Inlet Bearing Oil Orifice . . . . . . . . . . . . 74Inspect Condenser Refrigerant Float System. . . . 75Inspect Relief Valves and Piping . . . . . . . . . . . . . . . . 77Compressor Bearing Maintenance. . . . . . . . . . . . . . 77

Compressor Rotor Check. . . . . . . . . . . . . . . . . . . . . . . 77Motor Insulation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77Inspect the Heat Exchanger Tubes. . . . . . . . . . . . . . 77 COOLER CONDENSERWater/Brine Leaks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77Water/Brine Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . 77Inspect the Control Center. . . . . . . . . . . . . . . . . . . . . . 77Recalibrate Pressure Transducers . . . . . . . . . . . . . . 78Optional Pumpout System Maintenance. . . . . . . . . 78 OPTIONAL PUMPOUT COMPRESSOR

OIL CHARGE OPTIONAL PUMPOUT SAFETY

CONTROL SETTINGSOrdering Replacement Chiller Parts. . . . . . . . . . . . . 78

TROUBLESHOOTING GUIDE . . . . . . . . . . . . . . . . 78-117Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78Checking the Display Messages. . . . . . . . . . . . . . . . . 79Checking Temperature Sensors . . . . . . . . . . . . . . . . . 79 RESISTANCE CHECK VOLTAGE DROP CHECK SENSOR ACCURACY DUAL TEMPERATURE SENSORSChecking Pressure Transducers . . . . . . . . . . . . . . . . 79 COOLER CONDENSER PRESSURE TRANSDUCER

AND LIQUIDSIDE FLOW DEVICE CALIBRATION TRANSDUCER REPLACEMENT

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CONTENTS (cont)

Page

Control Algorithms Checkout Procedure. . . . . . . . 80Control Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81Control Modules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 RED LED (Labeled as STAT) GREEN LED (Labeled as COM)Notes on Module Operation . . . . . . . . . . . . . . . . . . . . . 98Chiller Control Module (CCM) . . . . . . . . . . . . . . . . . . . 98 INPUTS

OUTPUTSReplacing Defective Processor Modules . . . . . . . 101 INSTALLATIONGateway Status LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . 102 DRIVE STATUS INDICATOR MS STATUS INDICATOR NET A STATUS INDICATOR NET B STATUS INDICATORPhysical Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

APPENDIX A ICVC PARAMETER INDEX . . 118-126

INDEX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .127INITIAL START-UP CHECKLIST FOR

23XRV HERMETIC SCREWLIQUID CHILLER. . . . . . . . . . . . . . . . . . . .CL-1 to CL-12

INTRODUCTION

Prior to initial start-up of the 23XRV chiller, those involvedin the start-up, operation, and maintenance should be thoroughlyfamiliar with these instructions and other necessary job data.This book is outlined to familiarize those involved in the start-up, operation and maintenance of the unit with the control sys-tem before performing start-up procedures. Procedures in thismanual are arranged in the sequence required for proper chillerstart-up and operation.

ABBREVIATIONS AND EXPLANATIONS

Frequently used abbreviations in this manual include:

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

Words printed in both all capital letters and italics can alsobe viewed on the ICVC and are parameters (e.g., CONTROLMODE, COMPRESSOR START RELAY,etc.) with associated

values (e.g., modes, temperatures, percentages, pressures, on,off, etc.).

Words printed in all capital letters and in a box represent

softkeys on the ICVC control center (e.g., , ,

, , etc.).

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

The chiller software part number of the 23XRV unit is lo-cated on the back of the ICVC.

23XRV CHILLER FAMILIARIZATION(Fig. 1, 2, and 3)

Chiller Identification Nameplate The chilleridentification nameplate is located on the right side of thechiller control center.

System Components The components includecooler and condenser, heat exchangers in separate vessels,motor-compressor, lubrication system, control center, andoptional economizer. All connections from pressure vesselshave threads, flanges, or victaulic grooves to enable each com-ponent to be pressure tested during factory assembly.

This unit uses a microprocessor control system. Do notshort or jumper between terminations on circuit boards or

modules. Control or board failure may result.Be aware of electrostatic discharge (static electricity) whenhandling or making contact with circuit boards or moduleconnections. Always touch a chassis (grounded) part to dis-sipate body electrostatic charge before working inside con-trol center.

Use extreme care when handling tools near circuit boardsand when connecting or disconnecting terminal plugs. Cir-cuit boards can be damaged easily. Always hold boards bythe edges, and avoid touching components and connections.

This equipment uses, and can radiate, radio frequencyenergy. If not installed and used in accordance with theinstruction manual, it may interfere with radio communica-tions. This equipment has been tested and found to comply

with the limits for a Class A computing device pursuant toSubpart J of Part 15 of FCC Rules, which are designed toprovide reasonable protection against such interferencewhen operated in a commercial environment. Operation ofthis equipment in a residential area is likely to cause inter-ference, in which case the user, at his own expense, will berequired to take whatever measures may be required to cor-rect the interference.

Always store and transport replacement or defective boardsin an anti-static shipping bag.

CCM Chiller Control ModuleCCN Carrier Comfort NetworkCCW CounterclockwiseCSM Chillervisor System ManagerCW ClockwiseDPI LF2 VFD Drive Peripheral Interface BoardECDL Entering Condenser LiquidECL Entering Chilled Liquid

EMS Energy Management SystemHGBP Hot Gas BypassICVC International Chiller Visual ControllerIGBT Insulated Gate Bipolar TransistorI/O Input/OutputKAIC Kiloamps Interrupt CapacityLCD Liquid Crystal DisplayLCDL Leaving Condenser LiquidLCL Leaving Chilled LiquidLED Light-Emitting DiodeLEI Local Equipment Interface TranslatorLF2 Reliance LiquiFlo 2 VFD with Active

RectifierOIM Reliance Operator Interface ModuleOLTA Overload Trip AmpsPIC III Product Integrated Control IIIRLA Rated Load AmpsRS485 Communications Type used by ICVC and CCMSCR Silicon Controlled RectifierSI International System of UnitsSIO Sensor Input/OutputTB1 Control Center Terminal Block 1TB2 Control Center Terminal Block 2VFD Variable Frequency Drive

ENTER EXIT

INCREASE QUIT

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20

19

18 17

1615

1413

1211

109

8

7

6

5

4321

21

*First number denotes frame size.Maximum limits only. Additional application limits apply that may reduce these ampacities.

Fig. 1 Model Number Identification

1 Motor Terminal Cover Plate2 Variable Frequency Drive3 International Chiller Visual Controller (ICVC)4 Discharge Pipe/Relief Valve5 Condenser6 Oil Reclaim Actuator7 Vaporizer Sight Glass8 Oil Filter Assembly (Hidden)9 Vaporizer

10 Oil Sump Charging/Drain Valve11 Oil Sump12 Condenser Refrigerant Pumpout Valve13 Condenser Float Chamber14 Cooler Inlet Isolation Valve15 ASME Nameplate, Economizer (Hidden)16 Filter Drier17 Oil Sump Heater18 Condenser Supply/Return End Waterbox19 Cooler Supply/Return End Waterbox20 Motor Cooling Supply Line21 VFD Circuit Breaker/Disconnect

Fig. 2 Typical 23XRV Component Locations

23XRV High EfficiencyVariable Speed Screw Chiller

Cooler Size*30-3235-3740-4245-4750-5255-57

Condenser Size*30-3235-3740-4245-4750-5255-57

Economizer OptionE With EconomizerN No Economizer

SSpecial

R Compressor

Not Used

Voltage Code3 380-3-604 416-3-605 460-3-609 400-3-50

DriveFrame

AABABBCC

Rectifier MaxInput Amps

440520520608

Inverter MaxOutput Amps

442442520608

Motor CodePQRSTUV

Max Motor Amps265283306334368421440

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222324

25

26

27

28

293032 31

33

35 343637

38394041

50

49

48

47

46

45

51

444342

22 Discharge Pipe Assembly23 Compressor Discharge Check Valve Access Cover24 Condenser Relief Valves with Three-Way Valve25 Refrigerant Charging Valves26 Cooler Relief Valve27 Tubesheet Mounting Brackets28 Typical Waterbox Drain Coupling29 ASME Nameplate, Condenser30 Oil Pump31 Oil Pump Inlet Strainer32 Strainer Housing Sight Glass33 Discharge Isolation Valve (Option or Accessory)

34 Machine Electrical Data Nameplate35 Refrigeration Machine Nameplate36 Oil Sump Sight Glass37 Filter Drier Isolation Valve with Schrader38 Economizer39 Motor Cooling Sight Glass40 Filter/Drier Isolation Valve41 Vaporizer Drain Sight Glass

42 VFD Cold Plate Refrigeration Inlet Connection(Outlet Hidden)

43 VFD Refrigerant Cooling Solenoid Valve44 Compressor Nameplate45 Compressor Lubrication Block46 Economizer Muffler47 Vaporizer Condenser Gas Isolation Valve48 Hot Gas Bypass Isolation and Trim Valve49 VFD Cooling Refrigerant Strainer50 Cooler Refrigerant Pumpout Valve51 ASME Nameplate, Cooler

Fig. 2 Typical 23XRV Component Locations (cont)

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7

64

2

1

35

8

9

19

18

18

17

16

15

14

111012 13

20

Fig. 3 Typical 23XRV Sensor Locations

1 Condenser Pressure2 Evaporator Pressure3 Compressor Discharge Temperature4 Compressor Discharge Pressure5 Compressor Discharge High Pressure Switch6 Compressor Motor Winding Temperature (Hidden)7 Evaporator Refrigerant Liquid Temperature (Hidden)8 Condenser Liquid Temperature

9 Condenser Liquid Flow (Optional)

10 Inductor Temperature Switch(Inside VFD Enclosure)

11 VFD Rectifier Temperature(Inside Power Module)

12 VFD Cold Plate Temperature(Inside VFD Enclosure)

13 VFD Inverter Temperature(Inside Power Module)

14 Humidity Sensor (Inside VFD Enclosure)15 Oil Pressure Leaving Filter (Hidden)16 Oil Sump Pressure (Hidden)17 Oil Sump Temperature (Hidden)18 Vaporizer Temperature

19 Evaporator Liquid Temperature20 Evaporator Liquid Flow (Optional)

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Cooler The cooler (also known as the evaporator) ismaintained at low temperature/pressure so that evaporatingrefrigerant can remove heat from the liquid flowing through itsinternal tubes.

Condenser This vessel is located underneath thecompressor. The condenser operates at a higher temperature/pressure than the cooler and has liquid flowing through itsinternal tubes to remove heat from the refrigerant.

Motor-Compressor The motor-compressor main-tains system temperature/pressure differences and moves the

heat carrying refrigerant from the cooler to the condenser. SeeFig. 4.

Muffler The muffler provides acoustical attenuation. Acheck valve just downstream of the muffler prevents reversecompressor rotation during shutdown.

Control Center The control center is the user inter-face for controlling the chiller and regulating the chillerscapacity to maintain the proper chilled liquid temperature. SeeFig. 5. The control center: registers cooler, condenser, and lubricating system pressures shows chiller operating condition and alarm shutdown

conditions records the total chiller operating hours, starts, and the

number of hours the chiller has been currently running

sequences chiller start, stop, and recycle under microproces-sor control

provides access to other Carrier Comfort Network devices provides machine protection

Storage Vessel (Optional) Two sizes of storagevessels are available. The vessels have double relief valves,a magnetically coupled dial-type refrigerant level gage, a1-in. FPT drain valve, and a 1/2-in. male flare vapor connectionfor the pumpout unit. A 30-in.-0-400 psi (101-0-2750 kPa)gage is also supplied with each unit.

NOTE: If a storage vessel is not used at the jobsite, factory-installed optional isolation valves may be used to isolate thechiller charge in either the cooler or condenser. An optionalpumpout compressor system is used to transfer refrigerant

from vessel to vessel.

REFRIGERATION CYCLE

The compressor continuously draws refrigerant vapor fromthe cooler. As the compressor suction reduces the pressure inthe cooler, the remaining refrigerant boils at a fairly low tem-perature (typically 38 to 42 F [3 to 6 C]). The energy requiredfor boiling is obtained from the liquid flowing through thecooler tubes. With heat energy removed, the liquid becomescold enough for use in an air-conditioning circuit or processliquid cooling.

After absorbing heat from the chilled liquid, the refrigerant

vapor is compressed. Compression adds still more energy, andthe refrigerant is quite warm (typically 90 to 130 F [32 to54 C]) when it is discharged from compressor into condenser.

Relatively cool (typically 65 to 85 F [18 to 29 C]) liquidflowing into the condenser tubes removes heat from the refrig-erant and the vapor condenses to liquid, refrigerant.

The liquid refrigerant in the condenser passes throughorifices into the FLASC (Flash Subcooler) chamber (Fig. 6).Since the FLASC chamber is at a lower pressure, part of theliquid refrigerant flashes to vapor, thereby cooling the remain-ing liquid. The FLASC vapor is recondensed on the tubeswhich are cooled by entering condenser liquid. The liquid thenpasses through a float valve assembly which forms a liquid sealto keep FLASC chamber vapor from entering the cooler.

An optional economizer can be installed between thecondenser and cooler. In this case, an in-line orifice on theeconomizer drain flange meters the refrigerant liquid into thecooler. Pressure in this chamber is intermediate betweencondenser and cooler pressures. At this lower pressure, some ofthe liquid refrigerant flashes to gas, cooling the remainingliquid. The flash gas, having absorbed heat, is returned directlyto the compressor at a point after suction cutoff (Fig. 7). Here itis mixed with gas from the suction cut-off point to produce anincrease in the mass flow of refrigerant transported andcompressed without either an increase in suction volume or achange in suction temperature.

The cooled liquid refrigerant in the economizer is meteredthrough an orifice into the cooler. Because pressure in the cool-er is lower than economizer pressure, some of the liquid flashesand cools the remainder to evaporator (cooler) temperature.The cycle is now complete.

DISCHARGE

COMPRESSOR LUBRICATION BLOCK MOTOR TERMINALACCESSCOVER

MOTOR COOLINGDRAIN

MOTOR TERMINALS ECONOMIZERPORT

MOTOR

COOLING

INLET

FLANGE

Fig. 4 Compressor

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VFDREFRIGERANTCOOLINGSOLENOIDVALVE

VFDREFRIGERANTCOOLINGISOLATIONVALVE

FILTER DRIERISOLATIONVALVES

VFDREFRIGERANTCOOLINGISOLATIONVALVE HGBP

SOLENOIDVALVE

HGBP ISOLATION VALVE (OPTIONAL)

REFRIGERANTISOLATIONVALVE (OPTIONAL)

CONDENSERISOLATIONVALVE (OPTIONAL)

COMPRESSOR

CONDENSER

FLOAT VALVE BUBBLER LINE

STRAINER FILTER DRIER

MOTORVFDCOLDPLATE

COOLER

STANDARD65 KAICCIRCUIT

BREAKER

OPTIONAL100 KAICCIRCUIT BREAKER(SHIPPED LOOSEINSIDE OF CONTROLCENTER FOR FIELDINSTALLATION)

Fig. 5 Standard and 100-KAIC Circuit Breaker Control Center

Fig. 6 Refrigerant Flow Schematic (Without Optional Flash Economizer)

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MOTOR COOLING CYCLE

One half of the motor is cooled by suction gas while theother half is cooled by liquid refrigerant taken from the bottomof the condenser vessel. The flow of liquid refrigerant is main-tained by the pressure differential that exists due to compressor

operation. The refrigerant flows through an isolation valve,in-line filter/drier, and a sight glass/moisture indicator(dry-eye), into the motor through the motor spray nozzle. SeeFig. 6 or 7.

The motor spray nozzle is orificed to control refrigerantflow through the gaps between the rotor and stator. The refrig-erant collects in the bottom of the motor casing and then drainsinto the cooler through the motor cooling drain line.

The motor is protected by a temperature sensor and atemperature switch imbedded in the stator windings. COMPMOTOR WINDING TEMP temperatures above the COMPMOTOR TEMP OVERRIDE threshold (see Capacity Over-ride section, page 36) will override the chilled liquid tempera-ture capacity control to hold. If the motor temperature rises10 F (5.5 C) above this threshold, the compressor will unload.If the COMP MOTOR WINDING TEMP rises above the220 F (104.4 C) safety limit, the compressor will shut down.

LUBRICATION CYCLE

Summary The 23XRV requires an oil pump. Oil flow isprovided by a magnetically coupled, motor-driven oil pump.Oil flows through the oil filter into the compressor rotors andbearings. The cycle is referred to as a high side oil system.

See Fig. 8.

Details The oil system: lubricates the roller bearings which support the male

and female rotors, and the ball bearings of the 23XRVcompressor.

lubricates the male and female rotors

Oil is charged into the system through a hand valve locatedon the bottom of the oil sump. Sight glasses on the oil sumppermit oil level observation. When the compressor is shutdown, an oil level should be visible in the oil sump sight glass.During operation, the oil level should always be visible in thestrainer housing sight glass. Approximately 7.5 gal. (28.4 L) ofoil is charged into the sump.

Oil from the compressor bearing drain is drained directlyinto the oil sump. Refrigerant is driven from the oil as it flowsaround the oil sump heater and into the strainer housing. Theoil pump draws the oil through a strainer and forces it throughan oil filter.

VFDREFRIGERANTCOOLINGSOLENOIDVALVE



HGBPSOLENOIDVALVE

HGBP ISOLATIONVALVE (OPTIONAL)

COMPRESSOR

CONDENSER

FLOAT VALVE BUBBLER LINE

STRAINER FILTER DRIER

FILTERDRIER ISOLATIONVALVES

MOTOR

VFDCOLDPLATE

COOLER

FLOAT VALVE

ECONOMIZER MUFFLER

FLASHECONOMIZER

ORIFICE

Fig. 7 Refrigerant Flow Schematic (With Optional Flash Economizer)

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The filter housing is capable of being isolated by upstreamand downstream valves to permit filter replacement. An oilpressure regulator valve directs excessive oil back into the oilsump. Oil supplied to the compressor is monitored by an oilpressure sensor. The OIL PRESSURE DELTA P is equal to thedifference between the oil pressure leaving the filter and the oilsump pressure. It is read directly from the ICVC (InternationalChiller Visual Controller) default screen.

Oil is supplied to the compressor through two separateinlets. One inlet leads to the suction bearings, the other leads tothe discharge bearings. Most of the oil drains back into the

sump while a small amount is used to lubricate the rotors.Rotor lubrication oil leaves the compressor mixed with thecompressed discharge refrigerant vapor.

The oil sump contains temperature and pressure sensors anda 530 W oil heater. The oil sump is vented to the compressorsuction to minimize the amount of refrigerant absorbed by theoil. The OIL SUMP TEMPERATURE is measured and dis-played on the ICVC default screen and the COMPRESSscreen. The oil sump pressure is used to calculate the OILPRESSURE DELTA P.

Operating OIL PRESSURE DELTA P must be at least18 psid (124 kPa) after the OIL PRESS VERIFY TIME haselapsed. Under normal full load conditions, oil pressure istypically 20 to 28 psid (138 to 193 kPa). If sufficient oil pres-

sure is not established or maintained the chiller will shut downAn oil pressure delta P sensor fault will be declared if the OILPRESSURE DELTA P is not less than 4 psid (27.6 kPa) prioto start-up.

ISOLATIONVALVE

CONDENSER

STRAINER

MISTELIMINATOR

COOLER

SIGHT GLASS

OILHEATER

MIST ELIMINATOR

SERVICEVALVE

OIL PUMPISOLATIONVALVE

PUMP

FILTER

OIL FILTERISOLATIONVALVE

ORIFICE

ACTUATED BALLVALVE

SIGHT GLASS

SIGHT GLASS

VAPORIZER

EXTERNAL OIL HEATER

ISOLATIONVALVE

COMPRESSOR OILDRAIN

TO COMPRESSOR

SUCTION

COMPRESSOROIL SUPPLY

PRESSUREREGULATORVALVE

OILSUMP

Fig. 8 Oil Flow Schematic

OIL REFRIGERANT OIL/REFRIGERANT MIXTURE

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If the oil pressure falls below the values specified in Table 1during start-up, the PIC III control will shut down the chiller.

Table 1 Oil Pressure Requirements

Oil Reclaim System The oil reclaim system recoversoil from the cooler, removes the refrigerant, filters and returnsthe oil back to the compressor. One or more oil reclaim nozzlesare positioned along the length of the cooler to draw the oil andrefrigerant mixture from the surface of the refrigerant level.The mixture passes through an oil reclaim modulating valveand into the vaporizer. The flow of refrigerant and oil is regu-lated to prevent the vaporizer from becoming overloaded withliquid refrigerant. The modulating valve position is adjusted inaccordance with the difference between the VAPORIZERTEMP and the EVAP REFRIG LIQUID TEMP. The 4 to 20mA signal from CCM terminals J8-3 and J8-4 is converted intoa 0 to 10V DC input to the oil reclaim modulating valve by a500 ohm resistor connected between CCM terminals J8-3 andJ8-4. The oil reclaim modulating valve closes when the chilleris shut down to prevent the vaporizer and oil sump from beingflooded with refrigerant. Do not manually open the oil reclaimmodulating valve when the chiller is shut down. Doing so willseverely degrade the viscosity of the oil in the sump. Flow ofrefrigerant and oil from the cooler can be observed through asight glass on top of the vaporizer.

The viscosity of the compressor oil is significantly reducedwhen it absorbs refrigerant. A combination of heat and lowpressure is used to vaporize the refrigerant that has beenabsorbed by the oil mixture reclaimed from the cooler.Condenser gas is used to warm the refrigerant and oil mixturein the vaporizer. Warm refrigerant is bled from the top of thecondenser, directed through a row of tubes that line the bottomof the vaporizer, and discharged into the cooler. A 1500 Wsurface mounted electric heater provides supplemental heat tothe vaporizer when the compressor is operating at lower loads.Refrigerant boiled out of the reclaimed mixture is vented to thecompressor suction. The concentrated oil mixture drains out ofthe vaporizer, through a sightglass, past the vaporizer tempera-ture sensor, and into the oil sump. A 530 W oil sump heatermaintains the temperature of the reclaimed oil and the oilreturned from the compressor at approximately 90 F (32.2 C)when the chiller is running and 140 F (60 C) when the chiller isoff. The oil sump is also vented to compressor suction toincrease oil viscosity by boiling off additional refrigerant.

Capacity Control The PIC III controls provide chilledliquid temperature control by modulating the frequency of thepower delivered by the VFD to the compressor motor. The

compressor speed is adjusted in response to the difference be-tween the CONTROL POINT and the LEAVING CHILLEDLIQUID or ENTERING CHILLED LIQUID temperatures.

The PIC III controls respond to the difference between theCONTROL POINT and LEAVING CHILLED LIQUIDtemperatures when the ECL CONTROL OPTION isDISABLED.

The PIC III controls respond to the difference between theCONTROL POINT and ENTERING CHILLED LIQUIDtemperatures when the ECL CONTROL OPTION isENABLED.

The chiller capacity is controlled by varying the TARGETVFD SPEED from 0% to 100%. The PIC III controls monitorthe compressor oil properties and set a COMPRESSOR MINI-MUM SPEED to ensure sufficient compressor bearing lubrica-tion under all operating conditions.

CONTROLS

DefinitionsANALOG SIGNAL An analog signalvaries in proportionto the monitored source. It quantifies values between operatinglimits. (Example: A temperature sensor is an analog device be-cause its resistance changes in proportion to the temperature,generating many values.)

DISCRETE SIGNAL A discrete signal is a two-positionrepresentation of the value of a monitored source. (Example: Aswitch produces a discrete signal indicating whether a value is

above or below a set point or boundary by generating an on/off,high/low, or open/closed signal.)

General Controls Overview The 23XRV hermeticscrew liquid chiller contains a microprocessor-based controlcenter that monitors and controls all operations of the chiller.The microprocessor control system matches the coolingcapacity of the chiller to the cooling load while providingstate-of-the-art chiller protection. The system controls coolingcapacity within the set point plus the deadband by sensing theleaving chilled liquid or brine temperature (see Fig. 9 and 10)and regulating the compressor speed. Reducing the compressorspeed decreases the volume flow rate of refrigerant through thecompressor. Chiller protection is provided by the PIC IIIprocessor, which monitors the digital and analog inputs andexecutes capacity overrides or safety shutdowns, if required.

PIC III System Components (Fig. 11-14) Thechiller control system is called PIC III (Product IntegratedControl III). See Table 2. The PIC III controls the chiller bymonitoring all operating conditions. The PIC III can diagnose aproblem and let the operator know what the problem is andwhat to check. It promptly adjusts compressor speed to main-tain leaving chilled liquid temperature. It can interface withauxiliary equipment such as pumps and cooling tower fans toturn them on when required. It continually checks all safeties toprevent any unsafe operating condition. It also regulates the oilheater and regulates the hot gas bypass valve, if installed. ThePIC III controls provide critical protection for the compressormotor and control of the variable frequency drive.

The PIC III can interface with the Carrier Comfort

Network (CCN) system if desired. It can communicate withother PIC I, PIC II or PIC III equipped chillers and other CCNdevices, such as LEI (Local Equipment Interface).

TIME(SEC)

MINIMUM START-UP OILPRESSURE REQUIREMENT

HFC-134a

PSID kPaD

Before Oil Pump On < 4 27.6

After Oil Press Verify Time 18 124

During Start/Run 15 103

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The PIC III controls are housed inside the control centerenclosure. See Fig. 14. The component names are listedbelow (also see Table 2):

Table 2 Major PIC III Components andPanel Locations

INTERNATIONAL CHILLER VISUAL CONTROLLER(ICVC) The ICVC is the brain of the PIC III. Thismodule contains all the primary software needed to control thechiller. The ICVC is the input center for all local chiller setpoints, schedules, configurable functions, and optionsThe ICVC has a stop button, an alarm light, four buttons fologic inputs, and a backlight display. The backlight wilautomatically turn off after 15 minutes of non-use. The func-tions of the four buttons or softkeys are menu driven and areshown on the display directly above the softkeys. The ICVC ismounted on the Control Center door. See Fig. 2.

To change the contrast of the display, access the adjustmenon the back of the ICVC. See Fig. 11.

CHILLER CONTROL MODULE (CCM) This module islocated on the control panel in the control center. The CCMprovides the input and outputs necessary to control the chillerThis module monitors refrigerant pressure, entering andleaving liquid temperatures and pressures, and outputs controfor the oil reclaim valve, oil heaters, and oil pump. The CCM isthe connection point for optional demand limit, automaticchilled liquid reset, 4 to 20 mA kW output, remote temperaturereset, and refrigerant leak sensor.

VFD POWER MODULE This module is located in thecontrol center (see Fig. 12). The A/C line I/O assembly exe-cutes commands from the ICVC for functions such as startingand stopping the condenser and evaporator liquid pumps, towerfan and alarm contacts. The Standard I/O Option Assemblymonitors inputs such as remote start contact, spare safety, andhigh condenser pressure switch and provides the 4-20 mAHead Pressure Reference Output.

VFD GATEWAY MODULE The VFD Gateway Moduletranslates the protocols between the ICVC, CCM and VFDThis module also contains logic capable of an independensafety shutdown. It shuts down the chiller if communicationswith the ICVC are lost. See Fig. 13 for power module compo-nent locations.

OIL HEATER CONTACTOR (1C) This contactor is located on the control panel (Fig. 14) and operates the heater at115 V. It is controlled by the PIC III to maintain oil temperatureduring chiller shutdown.

OIL PUMP CONTACTOR (2C) This contactor is locatedin the control panel (Fig. 14) and operates the oil pump. The oipump is controlled by the PIC III to provide oil pressure duringpre-lube when the chiller is starting or running.

HOT GAS BYPASS CONTACTOR RELAY (3C)(Optional) This relay, located in the power panel, controlsthe opening of the hot gas bypass valve. The PIC III energizesthe relay based on hot gas bypass algorithm settings.

VFD REFRIGERANT COOLING SOLENOID VALVE(5C) This solenoid is located on the VFD cooling line. TheVFD cooling solenoid regulates the amount of time refrigeranis allowed to flow through the VFD cold plate to keep itstemperature within operating limits.

VAPORIZER HEATER CONTACTOR (6C) This contac

tor is located in the control panel (Fig. 14) and energizes thesurface mounted heater on the bottom of the vaporizer.

CONTROL TRANSFORMERS (T1, T2) These transformers convert incoming control voltage to 24 vac power for thepower panel contactor relays, CCM, ICVC, and 21 vac powefor the optional DataLINK or DataPort modules. Circuibreakers CB-1A, CB-1B, CB-2A and CB-2B for the controtransformers are located above the CCM.

PIC III COMPONENT PANEL LOCATIONInternational Chiller Visual Controller(ICVC) and Display

Control CenterPanel Door

VFD Power Module Inside Control Center

Chiller Control Module (CCM) Control Panel

Oil Heater Contactor (1C) Control Panel

Oil Pump Contactor (2C) Control Panel

Hot Gas Bypass Relay (3C) (Optional) Control Panel

Control Transformers (T1, T2) Control Panel

Control Transformer Circuit Breakers(CB-1A, CB-1B, CB-2A, CB-2B)

Control Panel

Temperature Sensors See Fig. 3 and 9

Pressure Transducers See Fig. 3 and 10

Vaporizer Heater Contactor (6C) Control Panel

SHRINK WRAPSTRAIN RELIEF

1/8 NPTTHERMOWELL

REMOVABLETEMPERATURESENSOR

CONTRASTADJUSTMENTSCREW

Fig. 9 Control Sensors (Temperature)

Fig. 10 Control Sensors(Pressure Transducers)

Fig. 11 ICVC Contrast Adjustment

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25

1

2

43

1514

13

11 8

1

4

12

10

8

3

7

11

6

10

9

5

6

7

8

22

20

19

21

18

16

17

23

24

20

2526

4

13 8

16

17

18

19

1 2

3 7 6

225

12

11

15

16

8

9

10

148

21 20

Fig. 12 Control Center VFD Input Components

1 Input Inductor Assembly 12 Fuse, Class CC, 600V, 1A (3) 2 Capacitor Bank Assembly 13 Transformer, 3kVA 3 Pre-Charge Resistor Assembly 14 Line Sync PC Board Assembly 4 AC Contactor (3) 15 Line Sync Board Cover 5 Power Module Assembly 16 Fan, 115V (3) 6 Terminal Block, 10-Position (Extra low voltage) 17 Control Power Circuit Breaker, 600V, 15A 7 Power Module Assembly 18 Circuit Breaker, 600V 8 Fuse Block, 30A, 600V, Class CC 19 Lug, Ground, 2-600 MCM 9 Fuse, Class CC, 600V, 15A (2) 20 Inductor Overtemperature Switch (Hidden)

10 Fuse, Class CC, 600V, 5A (1) 21 Input Power Wiring Access Panel11 Fuse, Class CC, 600V, 20A (3) 22 Terminal Block (Hazardous voltage)

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

Fig. 13 Power Module Components

1 Wire Harness Assembly, Gate Driver 14 Wire Harness Assembly, DC Bus Bleeder Resistors 2 Current Feedback Device, 1000 A 15 Wire Harness Assembly, Line Sync 3 Wire Harness Assembly, Power Supply, Logic 16 Inverter Control Assembly* 4 80 W Power Supply Assembly 17 Standard I/O Option, 24 V Assembly 5 Terminal Block, 2-Position 18 Rectifier Control Assembly* 6 Cable Assembly, 40-Pin 19 AC Line I/O Assembly 7 Cable Assembly, 30-Pin 20 Connector, Terminal Block, 32-Pin 8 Wire Harness Assembly, Power Supply, Upper Gate 21 NTC Assembly 9 Inverter Power Interface Assembly 22 Internal Fan10 Wire Harness Assembly, Power Supply, Lower Gate 23 DPI Communications Interface Assembly11 Insulation Sheet 24 RS-485 Communications Assembly (VFD Gateway)12 Rectifier Power Interface Assembly 25 Wire Harness Assembly, Control Sync13 Wire Harness Assembly, Current Feedback Device 26 Cable Assembly, 20-pin

FUSEREF

FUSEDESCRIPTION

FU1 Class CC, 1A/600V



FU4 150A/600V

FU5 150A/600V

FU6 150A/600V

FU7 Class CC, 20A/600VFU8 Class CC, 20A/600V



FU11A&B Class CC, 15A/600V

A2F1 3AG SLOBLO

Door Open Door Closed

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ICVC Operation and Menus (Fig. 15-21)GENERAL

The ICVC display automatically reverts to the defaultscreen after 15 minutes if no softkey activity takes place(Fig. 15).

If a screen other than the default screen is displayed on theICVC, the name of that screen is in the upper right corner

(Fig. 16). The ICVC may be set to display either English or SI units.

Use the ICVC CONFIGURATION screen (accessed fromthe SERVICE menu) to change the units. See the ServiceOperation section, page 45.

Local Operation The PIC III can be placed in local

operating mode by pressing the softkey. The

PIC III then accepts commands from the ICVC only and

uses the Local Time Schedule to determine chiller start

and stop times.

CCN Operation The PIC III can be placed in the

CCN operating mode by pressing the softkey.

The PIC III then accepts modifications from any CCN

interface or module (with the proper authority), as well

as from the ICVC. The PIC III uses the CCN Time

Schedule to determine start and stop times.

ALARMS AND ALERTS An alarm shuts down the com-

pressor. An alert does not shut down the compressor, but inotifies the operator that an unusual condition has occurred. Analarm (*) or alert (!) is indicated in the STATUS column on theright side of the MAINSTAT display screen. See Fig. 17.

Alarms are indicated when the control center alarm light (!flashes. The primary alarm message is displayed on the defaultscreen. An additional, secondary message and troubleshootinginformation are sent to the ALARM HISTORY screen.

When an alarm is detected, the ICVC default screen wil

freeze (stop updating) at the time of alarm. The freeze enables

the operator to view the chiller conditions at the time of alarm

Additional information is stored in the VFD_HIST screen. The

STATUS tables will show the updated information. Once al

alarms have been cleared (by pressing the softkey)

the default ICVC screen will return to normal operation.

LOCAL

CCN

RESET

CONNECTORCNB

GROUNDWIRE

CONNECTORCN1A

OIL PUMPCONTACTOR(2C)

OIL HEATERCONTACTOR(1C)

CONTROLTRANSFORMERCIRCUITBREAKERS

CONNECTORCN2

CONNECTOR

CN3

LOW VOLTAGEFIELD WIRINGTERMINAL BLOCK

HIGHPRESSURESWITCHCABLE

24V

CONTROLTRANSFORMER(T1)

HOT GASBYPASSCONTACTOR (3C)(OPTIONAL)

VAPORIZERHEATERCONTACTOR (6C)

HAZARDOUSVOLTAGEFIELD WIRINGTERMINAL BLOCK

20V CONTROLTRANSFORMER(T2)

Fig. 14 Control Panel

a23-1628

ALERT HISTORYCONTROL TEST

CONTROL ALGORITHM STATUS

EQUIPMENT CONFIGURATIONVFD CONFIG DATA

EQUIPMENT SERVICETIME AND DATEATTACH TO NETWORK DEVICELOG OUT OF DEVICEICVC CONFIGURATION

ALARM HISTORY

23XRPIC3 SERVICE

MANUALLY STOPPED - PRESSCCN OR LOCAL TO START

11-22-04 00:0915.2 HOURS

CHL IN CHL OUT EVAP REF

CDL IN CDL OUT COND REF

OIL PRESS OILTEMP % AMPS IN

STATUS SCHEDULE SETPOINT SERVICE

59.3 58.4 62.1

76.1 85.2 84.4

0.5 130.6 0.0

PRIMARY STATUSMESSAGE

COMPRESSORON TIME

DATE TIME

SOFT KEYSMENULINE

EACH KEY'SFUNCTION IS

DEFINED BY THE MENU DESCRIPTIONON MENU LINE ABOVE

ALARM LIGHT(ILLUMINATEDWHEN POWER ON)

STOP BUTTON HOLD FOR ONE

SECOND TO STOP

BLINKSCONTINUOUSLYON FOR AN ALARM

BLINKSONCE TOCONFIRM A STOP

SECONDARYSTATUSMESSAGE

Fig. 15 ICVC Default Screen

Fig. 16 ICVC Service Screen

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ICVC MENU ITEMS To perform any of the operationsdescribed below, the PIC III must be powered up and havesuccessfully completed its self test. The self test takes placeautomatically, after power-up.

Press the softkey to view the list of menu struc-

tures: , , , and

.

The STATUS menu allows viewing and limited calibra-

tion or modification of control points and sensors, relaysand contacts, and the options board. The SCHEDULE menu allows viewing and modifica-

tion of the local and CCN Time Schedules. The SETPOINT menu allows set point adjustments,

such as the ENTERING CHILLED LIQUID and LEAV-ING CHILLED LIQUID set points.

The SERVICE menu can be used to view or modifyinformation on the ALARM HISTORY, ALERT HIS-TORY, CONTROL TEST, CONTROL ALGORITHMSTATUS, EQUIPMENT CONFIGURATION, VFDCONFIG DATA, EQUIPMENT SERVICE, TIMEAND DATE, ATTACH TO NETWORK DEVICE,LOG OUT OF DEVICE, AND ICVC CONFIGURA-TION screens.

For more information on the menu structures, refer toFig. 18.

Press the softkey that corresponds to the menu structure to

be viewed: , , , or

. To view or access parameters within any of these

menu structures, use the and softkeys

to scroll to the desired item or table. Use the soft-

key to select that item. The softkey choices that then appear de-

pend on the selected table or menu. The softkey choices and

their functions are described below.

BASIC ICVC OPERATIONS (Using the Softkeys) Toperform any of the operations described below, the PIC IIImust be powered up and have successfully completed its self

test. Press to leave the selected decision or field with-

out saving any changes.

Press to leave the selected decision or field and

save changes.

Press to scroll the cursor bar down in order to

highlight a point or to view more points below the cur-

rent screen.

Press to scroll the cursor bar up in order to

highlight a point or to view points above the current

screen.

Press to view the next screen level (high-lighted with the cursor bar), or to override (if allowable)

the highlighted point value.

Press to return to the previous screen level.

Press or to change the high-lighted point value.

TO VIEW STATUS (Fig. 17) The MAINSTAT tableshows the actual value of overall chiller status such as CON-TROL MODE, RUN STATUS, AUTO CHILLED LIQRESET, and REMOTE RESET SENSOR.

1. On the menu screen, press to view the list

of point status tables.

MENU

STATUS SCHEDULE SETPOINT

SERVICE

STATUS SCHEDULE SETPOINT

SERVICE

NEXT PREVIOUS

SELECT

QUIT

ENTER

NEXT

PREVIOUS

SELECT

EXIT

INCREASE DECREASE

STATUS

23XRPIC3 MAINSTAT POINT STATUS

Reset

Tripout 0.0 min No Alarm Stop CONTRL Open C 0.0 ^F50.0 F55.7 F

Run StatusStart Inhibit TimerOccupied?System Alert/AlarmChiller Start/StopRemote Start ContactTemperature ResetControl PointChilled Liquid Temp

Control Mode

Fig. 17 Example of MAINSTAT Screen

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2. Press or to highlight the desired

status table. The list of tables is:

MAINSTAT Overall chiller status STARTUP Status required to perform start-up of

chiller COMPRESS Status of sensors related to the

compressor HEAT_EX Status of sensors related to the heat

exchangers POWER Status of motor input power VFD_STAT Status of the variable frequency

drive ICVC_PSWD Service menu password forcing

access screen

3. Press to view the desired point status table.

4. On the point status table, press or

until the desired point is displayed on the

screen.

OVERRIDE OPERATIONS

To Override a Value or Status

1. From any point status screen, press or

to highlight the desired value.

2. Press to select the highlighted value. Then:

For Discrete Points Press or to

select the desired state.

For Analog Points Press or

to select the desired value.

3. Press to register the new value.

NOTE: When overriding or changing metric values, it is necessary to hold down the softkey for a few seconds in order tosee a value change, especially on kilopascal values.

To Remove an Override1. On the point status table press o

to highlight the desired value.

2. Press to access the highlighted value.

3. Press to remove the override and return

the point to the PIC IIIs automatic control.

Override Indication An override value is indicated bySUPVSR, SERVC, or BEST flashing next to the poinvalue on the STATUS table.

NEXT PREVIOUS

SELECT

NEXT

PREVIOUS

NEXT

PREVIOUS

SELECT

YES NO

YES NO ENTER EXIT

INCREASE

DECREASE

ENTER

NEXT

PREVIOUS

SELECT

RELEASE

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CCN LOCAL RESET MENU

DEFAULT SCREEN

Start Chiller In CCN Control

Start Chiller in Local Control

Clear Alarms

STATUS SCHEDULE SETPOINT SERVICE

(SOFTKEYS)

AccessMain Menu

List theStatusTables

Display The Setpoint Table

List the Service Tables

OCCPC01S LOCAL TIME SCHEDULE OCCPC02S ICE BUILD TIMESCHEDULE OCCPC03S CCN TIME SCHEDULE

List the Schedules

NEXT PREVIOUS SELECT EXIT

ALARM HISTORYALERT HISTORYCONTROL TESTCONTROL ALGORITHM STATUSEQUIPMENT CONFIGURATIONVFD CONFIG DATAEQUIPMENT SERVICETIME AND DATEATTACH TO NETWORK DEVICELOG OUT OF DEVICEICVC CONFIGURATION

SEE FIGURE 19

Base Demand Limit LCL Setpoint ECL Setpoint Ice Build Setpoint Tower Fan High Setpoint

EXITSELECTPREVIOUSNEXT

Select a Schedule

12345678

Override

ENABLE DISABLE

EXITSELECTPREVIOUSNEXT

Select a Time Period/Override

Modify a Schedule Time

ENTER EXIT

INCREASE DECREASE ENTER EXIT (ANALOG VALUES)

(DISCRETE VALUES)

Add/Eliminate a Day

1

Select a StatusTable


STARTON STOPOFFRELEASE ENTER

EXITNEXT PREVIOUS SELECT

ENTERENABLE DISABLE QUIT

DECREASEINCREASE ENTERRELEASE

Select a Modification Point

Modify a Discrete Point

Modify an AnalogPoint

Modify Control Options

MAINSTAT STARTUP COMPRESS HEAT_EX POWER VFD_STAT ICVC_PWD

Modify the Setpoint

DECREASEINCREASE QUIT ENTER


Select the Setpoint

(ENTER A 4-DIGIT PASSWORD)1 1 1

Fig. 18 23XRV ICVC Menu Structure

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SERVICE TABLE

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

Thermistors

Pressure Transducers Pumps Discrete Outputs Oil Reclaim Output Head Pressure Output Pumpdown/Lockout Terminate Lockout

CONTINUEDON NEXT PAGE


CONTROL TEST

ALARM HISTORY

List the Control Tests

List the Control Algorithm Status Tables CAPACITY (Capacity Control) OVERRIDE (Override Status) LL_MAINT (Lead Lag Status) VFD_HIST(VFD Alarm History) CUR ALRM (Chiller Alarm History)WSMCHLRE (Water System Manager)OCCDEFCM (Time Schedule Status)


Select a Table

NET_OPTBRODEF OCCEFCS HOLIDAYS CONSUME RUNTIME

(ANALOG VALUES)

(DISCRETE VALUES)

Select a Parameter


Modify a Parameter


DECREASEINCREASE ENTERQUIT


Select a Table

EQUIPMENT CONFIGURATION List the Equipment Configuration Tables

CAPACITY (Capacity Control Algorithm) OVERRIDE (Override Status) LL_MAINT (LEADLAG Status) WSMDEFME (Water System Manager Control Status)

Maintenance Table Data


Data Select Table

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

OCCDEFM (Time Schedule Status)


Select a Test

ALERT HISTORY

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

Display Alert History

ALERT HISTORY

Fig. 19 23XRV Service Menu Structure

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SERVICE MENU CONTINUEDFROM PREVIOUS PAGE

Select a Service Table

Select a Service Table Parameter


Modify a Service Table Parameter

(ANALOG VALUES)

(DISCRETE VALUES)

TIME AND DATE

Display Time and Date Table: To Modify Current Time Day of Week

Current Date Holiday TodayATTACH TO NETWORK DEVICE

DECREASEINCREASE


DECREASEINCREASE ENTERQUIT

Select a Device

ATTACHNEXT PREVIOUS SELECT

Modify Device Address

EXITINCREASE DECREASE ENTER

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

Default ScreenMENURESETCCN LOCAL

LOG OUT OF DEVICE

List Network Devices Local Device 1 Device 2 Device 3 Device 4

Device 5

Device 6 Device 7 Device 8

Service Tables: OPTIONS SETUP1 SETUP2 LEADLAG RAMP_DEM TEMP_CTL

EQUIPMENT SERVICE

VFD CONFIG DATA

Service Tables:VFD CONFIG PASSWORD VFD_CONF

(ENTER A 4-DIGIT PASSWORD)4 4 4 4

ICVC CONFIGURATION

EXITINCREASE DECREASE ENTER

ICVC Configuration Table

To Modify ICVC CCN Address

English (US IMP) or S.I. Metric Units Password

To View ICVC Software Version (last 2 digits of part number indicate software version)

Attach To Any Device

(ANALOG VALUES)ENTER EXIT

ENTER EXITNOYES (DISCRETE VALUES)

LID Language

Baud Rate

Fig. 19 23XRV Service Menu Structure (cont)

LEGEND

CCN Carrier Comfort NetworkICVC International Chiller Visual

ControllerIMP ImperialVFD Variable Frequency DrivePIC III Product Integrated Control III

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TIME SCHEDULE OPERATION (Fig. 20)

1. On the Menu screen, press .

2. Press or to highlight the de-

sired schedule.

OCCPC01S LOCAL Time ScheduleOCCPC02S ICE Build Schedule

OCCPC03S CCN Time Schedule

3. Press to view the desired time schedule.

4. Press or to highlight the de-

sired period or override to change.

5. Press to access the highlighted period or

override.

6. a Press or to change the

time values. Override values are in one-hour

increments, up to 4 hours.

b. Press to select days in the day-of-week

fields. Press to eliminate days from the

period.

7. Press to register the values and to move hori

zontally (left to right) within a period.

8. Press to leave the period or override.

9. Either return to Step 4 to select another period or over

ride, or press again to leave the current time

schedule screen and save the changes.

10. The Holiday Designation (HOLIDAYS table) may befound in the Service Operation section, page 45. Themonth, day, and duration for the holiday must beassigned. The TIME BROADCAST ENABLE func-tion in the BRODEF screen also must be enabled forholiday periods to function.

TO VIEW AND CHANGE SET POINTS (Fig. 21)

1. To view the SETPOINT table, from the MENU screen

press .

SCHEDULE

NEXT PREVIOUS

SELECT

NEXT PREVIOUS

SELECT

INCREASE DECREASE

ENABLE

DISABLE

ENTER

EXIT

EXIT

SETPOINT

23XRPIC3 SETPOINT SELECTSETPOINT

Base Demand Limit

Control Point Source

LCL Setpoint ECL SetpointIce Build SetpointTower Fan High Setpoint

100%

50.0 F

60.0 F40.0 F

75 F

Fig. 21 Example of Set Point Screen

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23XRPIC3

Fig. 20 Example of Time ScheduleOperation Screen

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2. There are 5 set points on this screen: BASE DEMANDLIMIT, LCL SETPOINT (leaving chilled liquid setpoint), ECL SETPOINT (entering chilled liquid setpoint), ICE BUILD SETPOINT and TOWER FANHIGH SETPOINT. Only one of the CONTROLPOINT SOURCES (LCL or ECL) can be active at onetime. The control point source that is active is deter-mined from the TEMP_CTL screen. See the ServiceOperation section, page 45.

3. Press or to highlight the desired

set point entry.

4. Press to modify the highlighted set point.

5. Press or to change the

selected set point value.

6. Press to save the changes and return to the

previous screen.

SERVICE OPERATION To view the menu-driven pro-grams available for Service Operation, see Service Operationsection, page 45. For examples of ICVC display screens, seeTable 3.

Table 3 ICVC Display Data

1. Only 12 lines of information appear on the ICVC screen at any one

time. Press the or softkey to highlight a point

or to view items below or above the current screen. Double-click the

softkey to page forward; double-click the

softkey to page back.

2. To access the information shown in Examples 9 through 23, enter

your 4-digit password after pressing the softkey. If no

softkeys are pressed for 15 minutes, the ICVC automatically logs off

(to prevent unrestricted access to PIC III controls) and reverts to the

default screen. If this happens, you must re-enter your password to

access the tables shown in Examples 9 through 23.

3. Terms in the Description column of these tables are listed as theyappear on the ICVC screen.

4. The ICVC may be configured in English or Metric (SI) units using theICVC CONFIGURATION screen. See the Service Operation section,

page 45, for instructions on making this change.5. The items in the Reference Point Name column do not appear on the

ICVC screen. They are data or variable names used in CCN, BuildingSystems Interface (BSI) or Local Equipment Interface (LEI) Modulesoftware (optional). They are listed in these tables as a convenienceto the operator if it is necessary to cross reference CCN/BSI docu-mentation or use CCN/BSI programs. For more information, see theCCN literature.

6. Reference Point Names shown in these tables in all capital letterscan be read by CCN and BSI software. Of these capitalized names,those preceded by a dagger can also be changed (that is, written to)

by the CCN, BSI, LEI, and the ICVC. Capitalized Reference PointNames preceded by two asterisks can be changed only from theICVC. Reference Point Names in lower case type can be viewed byCCN or BSI only by viewing the whole table.

7. Alarms and Alerts: An asterisk in the far right field of a ICVC statusscreenindicates that the chiller is in an alarm state; an exclamationpoint in the far right field of the ICVC screen indicates an alert state.The asterisk (or exclamation point) indicates that the value on thatline has exceeded (or is approaching) a limit. For more information onalarms and alerts, see the Alarms and Alerts section, page 15.

8. Index of all ICVC Parameters is shown in Appendix A.

LEGEND

EXAMPLE 1 ICVC DEFAULT SCREEN

The following data is displayed in the ICVC Default screen.

*The Evaporator Refrigerant Temperature displayed is the smaller value of EVAP REFRIG LIQUID TEMP or CALC EVAP SAT TEMP.

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

NEXT PREVIOUS

SELECT

INCREASE DECREASE

ENTER

IMPORTANT: The following notes apply to all Table 3 examples.

NEXT PREVIOUS

NEXT PREVIOUS

SERVICE

1CR Control RelayCCN Carrier Comfort NetworkCHL Chilled LiquidCR Control RelayCT Current TransformerI2T Motor OverloadICVC International Chiller Visual ControllerECL Entering Chilled LiquidHGBP Hot Gas BypassLCL Leaving Chilled LiquidLRA Locked Rotor AmpsmA MilliampsP PressureT TemperatureVFD Variable Frequency DriveWSM Liquid System Manager F Temperature in Degrees Fahrenheit

F Temperature Difference in Degrees Fahrenheit

DESCRIPTION RANGE UNITSREFERENCE POINT NAME

(ALARM HISTORY)DISPLAY

(PRIMARY MESSAGE)(SECONDARY MESSAGE)

(DATE AND TIME)Compressor Ontime 0-500000.0 HOURS C_HRSEntering Chilled Liquid 40-245 F (C) ECL CHL INLeaving Chilled Liquid 40-245 F (C) LCL CHL OUTEvaporator Refrigerant Temperature* 40-245 F (C) ERT_EST EVAP REFEntering Condenser Liquid 40-245 F (C) ECDL CDL INLeaving Condenser Liquid 40-245 F (C) LCDL CDL OUTCondenser Refrigerant Temperature 40-245 F (C) CRT COND REFOil Pressure Delta P 6.7-425 PSI (kPa) OIL_PD OILPRESSOil Sump Temp 40-245 F (C) OILT OIL TEMPPercent Line Current 0-999 % AMPS_P % AMPS INCCN 0-1 CCNLOCAL 0-1 LOCALRESET 0-1 RESET

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Table 3 ICVC Display Data (cont)

EXAMPLE 2 MAINTSTAT DISPLAY SCREEN

To access this display from the ICVC defaultscreen:

1. Press .

2. Press ( will be highlighted).

3. Press .

NOTES:1. Numbers in parentheses indicate the equivalent CCN BEST++ programming LEI or BACnet Translator use.2. Off (0), Local (1), CCN (2), Reset (3)3. Timeout (0), Ready (1), Recycle (2), Startup (3), Running (4), Demand (5), Ramping (6), Auto Restart (7), Override (8), Tripout (9), Control Tes

(10), Lockout (11), Pumpdown (12), Prestart (13)4. Normal (0), Alert (1), Alarm (2).5. All variables with capital letter point names are available for CCN read operation.

Those shown with (*) support write operations for all CCN and LEI devices.Those shown with () shall support one time write operations for the ICVC only when the value is initially zero.Those shown with (**) shall support write operations for the ICVC only.

EXAMPLE 3 STARTUP DISPLAY SCREEN


1. Press .

2. Press .3. Scroll down to highlight .

4. Press .

NOTE: All variables with CAPITAL LETTER point names are available for CCN read operation.Those shown with (**) shall support write operations for the ICVC only.

MENU

STATUS MAINSTAT

SELECT

DESCRIPTION STATUS UNITS POINT

Control Mode NOTE 2 NOTE 2 MODERun Status NOTE 3 NOTE 3 STATUS

Start Inhibit Timer 0-15 min T_STARTOccupied ? 0/1 NO/YES OCCSystem Alert/Alarm 0-2 NOTE 4 SYS_ALM*Chiller Start/Stop 0/1 STOP/START CHIL_S_S*Remote Start Contact 0/1 OPEN/CLOSE REMCONTemperature Reset 30-30 ^ F (^ C) T_RESET*Control Point 10-65 F ( C) LCW_STPTChilled Liquid Temp 40-245 F ( C) CHL_TMP*Active Demand Limit 40-100 % DEM_LIMPercent Line Current 0.0-9999 % LN AMPS_PPercent Line Kilowatts 0.0-9999 % LINE KW_PAuto Demand Limit Input 4-20 mA AUTODEMAuto Chilled Liq Reset 4-20 mA AUTORESRemote Reset Sensor 40-245 F (C) R_RESET

Total Compressor Starts 0-99999 C_STARTSStarts in 12 Hours 0-8 STARTS

Compressor Ontime 0-500000.0 HOURS C_HRS**Service Ontime 0-32767.0 HOURS S_HRSIce Build Contact 0/1 OPEN/CLOSE ICE_CON

Refrigerant Leak Sensor PPM 0.0-9999.0 mA REF_LEAKEmergency Stop 0/1 ENABLE/EMSTOP EMSTOP

MENU

STATUSSTARTUP

SELECT


**Chilled Liquid Pump 0-1 OFF/ON CHLPChilled Liquid Flow 0-1 NO/YES CHL_FLOW

**Condenser Liquid Pump 0-1 OFF/ON CDPCondenser Liquid Flow 0-1 NO/YES CDL_FLOWOil Pump Relay 0-1 OFF/ON OILR

Oil Reclaim Output 0-100.0 %(4 to 20mA) OIL_MA**Oil Pressure Delta P 6.7-200 PSI (kPa) OILPD

Oil Sump Temp 40.0-245.0 F ( C) OILTVaporizer Temp 40.0-245.0 F ( C) VAP_TEMPVFD Start 0-1 NO/YES VFDSTARTStart Complete 0-1 FALSE/TRUE START_OKStop Complete 0-1 FALSE/TRUE STOP_OK

VFD Speed Output 0.0-100.0 % VFD_OUT

Comp Motor RPM 0-300000 RPM CPR_RPM Comp Motor Frequency 0-10000 Hz VFD_FREQ Comp Maximum Speed 0-101 Hz MAXSPEED Comp Minimum Speed 0-100 % MINSPEED**Tower Fan Relay Low 0-1 OFF/ON TFR_LOW**Tower Fan Relay High 0-1 OFF/ON TFR_HIGH

Spare Safety Input 0-1 ALARM/NORMAL SAFETYShunt Trip Relay 0-1 OFF/ON TRIPR

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EXAMPLE 4 COMPRESS DISPLAY SCREEN

To access this display from the ICVC default screen:

1. Press .

2. Press .

3. Scroll down to highlight .

4. Press .

NOTE: All variables with CAPITAL LETTER point names are available for CCN read operation;those with (**) shall support write operations for ICVC only.

EXAMPLE 5 HEAT_EX DISPLAY SCREEN


1. Press .

2. Press .


4. Press .

NOTE: All variables with CAPITAL LETTER point names are available for CCN read operation;those with (**) shall support write operations for ICVC only.

MENU

STATUS

COMPRESS

SELECT


Actual VFD Speed 0-115 % VFD_ACT

Compressor Motor RPM 0-300000 RPM CPR_RPMCompressor Motor Frequency 0-10000 Hz VFD_FREQ Compressor Maximum Speed 0-101 Hz MAXSPEED

Compressor Minimum Speed 0-100 % MINSPEEDVFD Delta 2-2 % VFDDELTA

**Target VFD Speed 0-100 % VFD_TRGVFD Speed Output 0-100 % VFD_OUTOil Pump Relay 0/1 OFF/ON OILR**Oil Pressure Delta P 6.7-420 PSI (kPa) OILPDOil Sump Temp 40-245 F ( C) OILTVaporizer Temperature 40-245 F ( C) VAP_TEMPOil Heater Relay 0/1 OFF/ON OILHEATVaporizer Heater 0/1 OFF/ON VAP_HEATComp Motor Winding Temp 40-245 F ( C) MTRWCompDischarge Temp 40-245 F ( C) CMPDDischarge Superheat 20-999 ^F (^C) SUPRHEATStall Protection Counts 0-5 SPCSpare Temperature 1 40-245 F ( C) SPARE_T1Spare Temperature 2 40-245 F ( C) SPARE_T2

MENU

STATUS

HEAT_EX

SELECT


**Chilled Liquid Delta P 6.7-420 PSI (kPa) CHLPDEntering Chilled Liquid 40-245 F ( C) ECLLeaving Chilled Liquid 40-245 F ( C) LCLChilled Liquid Delta T 40-245 ^F (^C) CHL_DTChill Liq Pulldown/Min 20-20 ^F (^C) CHL_PULLCalc Evap Sat Temp 40-245 F ( C) ERT

**Evaporator Pressure 6.7-420 PSI (kPa) ERPEvap Refrig Liquid Temp 40-245 F ( C) ESTEvaporator Approach 0-99 ^F (^C) EVAP_APP

**Condenser Liquid Delta P 6.7-420 PSI (kPa) CDLPDEntering Cond Liquid 40-245 F ( C) ECDLLeaving Cond Liquid 40-245 F ( C) LCDLCondenser Refrig Temp 40-245 F ( C) CRT

**Condenser Pressure 6.7-420 PSI (kPa) CRPCondenser Approach 0-99 ^F (^C) COND_APPVaporizer Temp 40-245 F ( C) VAP_TEMPReclaim Delta T 500-500 ^F (^C) R_DELTAOil Reclaim Output 0-100 % OIL_MAVFD Coolant Flow 0-100 % VFD_FOUTHot Gas Bypass Relay 0/1 OFF/ON HGBYPASSActive Delta P 0-200 PSI (kPa) DP_AActive Delta T 0-200 ^F (^C) DT_AHGBP Delta T 0-200 ^F (^C) DT_CHead Pressure Reference 0-100 % HPR

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EXAMPLE 6 POWER DISPLAY SCREEN


1. Press .

2. Press .


4. Press .

NOTE: All variables with CAPITAL LETTER point names are available for CCN read operation.

MENU

STATUS

POWER

SELECT


Percent Line Current 0-999 % LNAMPS_P

Average Line Current 0-99999 AMPS LNAMPS_APercent Line Voltage 0-999 % LNVOLT_PAverage Line Voltage 0-99999 VOLTS LNVOLT_ALine Power Factor 0.0-2.0 LINE_PFLine Kilowatts 0-99999 KW LINE_KWPercent Line Kilowatts 0-99999 % LINEKW_P

Percent Load Current 0-99999 % LDAMPS_P

Average Load Current 0-99999 AMPS LDAMPS_AMotor Power Factor 0.0-2.0 MOTOR_PFMotor Kilowatts 0-99999 KW MOTOR_KWPercent Motor Kilowatts 0-99999 % MOTORKWP

Motor Kilowatt-Hours 0-99999 KWH MOTORKWHDemand Kilowatts 0-99999 KW DEM_KWLine Current Phase 1 (R) 0-99999 AMPS LN_AMPS1Line Current Phase 2 (S) 0-99999 AMPS LN_AMPS2Line Current Phase 3 (T) 0-99999 AMPS LN_AMPS3Load Current Phase 1 (U) 0-99999 AMPS LD_AMPS1Load Current Phase 2 (V) 0-99999 AMPS LD_AMPS2Load Current Phase 3 (W) 0-99999 AMPS LD_AMPS3

Line Voltage Phase 1 (RS) 0-99999 VOLTS LN_VOLT1Line Voltage Phase 2 (ST) 0-99999 VOLTS LN_VOLT2Line Voltage Phase 3 (TR) 0-99999 VOLTS LN_VOLT3Ground Fault Current 0-999 AMPS GF_AMPSLine Frequency 0-99 HZ LINEFREQRectifier Overload 0-100 % RECT_OV

Inverter Overload 0-100 % INV_OV

Motor Overload 0-100 % MOTOR_OV

Line Current Imbalance 0-100 % LN_IMB_I

Motor Current Imbalance 0-100 % MT_IMB_I

Line Voltage Imbalance 0-100 % LN_IMB_V

Line Active Current 0-99999 AMPS AMPS_ACTLine Reactive Current 0-99999 AMPS AMPS_RELine Active Voltage 0-99999 VOLTS VOLT_ACTLine Reactive Voltage 0-99999 VOLTS VOLT_REDC Bus Voltage Reference 0-99999 VOLTS BUS_REFDC Bus Voltage 0-99999 VOLTS BUS_VOLT

Flux Current 0-99999 AMPS FLUXAMPSTorque Current 0-99999 AMPS TORQAMPSInverter Temperature 0-300 F ( C) INV_TEMPRectifier Temperature 0-300 F ( C) REC_TEMPVFD Enclosure Temperature 0-300 F ( C) VFD_ENCLVFD Cold Plate Temperature 0-300 F ( C) CP_TEMPHumidity Sensor Input 0.0-5.0 VOLTS HUMID_SRRelative Humidity 0-100 % HUMIDITY

VFD Coolant Flow 0-100 % VFD_FOUT

Actual VFD Speed 0-100 % VFD_ACT

Comp Motor RPM 0-300000 RPM CPR_RPMComp Motor Frequency 0-10000 Hz VFD_FREQ

Comp Maximum Speed 0-101 Hz MAXSPEEDComp Minimum Speed 0-100 % MINSPEED

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EXAMPLE 7 VFD

VFD_STAT SCREEN


1. Press .

2. Press .


4. Press .

NOTE: All variables with CAPITAL LETTER point names are available for CCN read operation.

EXAMPLE 8 ICVC PWDTo access this display from the ICVC defaultscreen:

1. Press .

2. Press


NOTE: The Disable Service Password parameter supports the service tool password disable access. It will only allow forcing with the service toolfor a one time bypass of both the service menu and the VFD config data table. Exit from the service menu reverts to normal password operation.Those with (**) shall support write operations for ICVC only.

The Reset Alarm? and CCN mode? parameters support write operations from CCN and LEI devices when the Remote Reset Option is enabled.


VFD Fault Code 0-272 VFD_FLTSingle Cycle Dropout 0-1 NORMAL/ALARM CYCLE_1Line Current Imbalance 0-1 NORMAL/ALARM LINEIM_ILine Voltage Imbalance 0-1 NORMAL/ALARM LINEIM_VLine Phase Reversal 0-1 NORMAL/ALARM PH_REVHigh Line Voltage 0-1 NORMAL/ALARM HI_VOLTLow Line Voltage 0-1 NORMAL/ALARM LOW_VOLTHigh DC Bus Voltage 0-1 NORMAL/ALARM HI_DCBUSLow DC Bus Voltage 0-1 NORMAL/ALARM LO_DCBUSMotor Current Imbalance 0-1 NORMAL/ALARM MOTIM_IMotor Overload 0-1 NORMAL/ALARM MOTOR_OVRectifier Overcurrent 0-1 NORMAL/ALARM RECT_OIRectifier Overtemp 0-1 NORMAL/ALARM RECT_OTRectifier Power Fault 0-1 NORMAL/ALARM RECT_PUInverter Overcurrent 0-1 NORMAL/ALARM INV_OIInverter Overtemp 0-1 NORMAL/ALARM INV_OTInverter Power Fault 0-1 NORMAL/ALARM INV_PUGround Fault 0-1 NORMAL/ALARM GRND_FLT

Frequency Fault 0-1 NORMAL/ALARM FREQFLTVFD Power on Reset 0-1 NORMAL/ALARM VFD_PORStart Complete 0-1 FALSE/TRUE START_OKStop Complete 0-1 FALSE/TRUE STOP_OKCondenser High Pressure 0-1 NORMAL/ALARM PRS_TRIPMotor Amps Not Sensed 0-1 NORMAL/ALARM NO_AMPSStart Acceleration Fault 0-1 NORMAL/ALARM ACCELFLTStop Fault 0-1 NORMAL/ALARM AMPSTOPVFD Start Inhibit 0-1 NORMAL/ALARM STRT_INHVFD Checksum Error 0-1 NORMAL/ALARM CHECKSUMVFD Comm Fault 0-1 NORMAL/ALARM VFD_COMMVFD Fault 0-1 NORMAL/ALARM VFDFAULTVFD Gateway Version # 0-255 VFG_VERVFD Inverter Version # 0-1000 INV_VERVFD Rectifier Version # 0-1000 REC_VER

MENU

STATUS

VFD_STAT

SELECT


Disable Service Password 0-1 DS/ENABLE PSWD_DIS**Remote Reset Option 0-1 DS/ENABLE RESETOPTReset Alarm ? 0-1 NO/YES REMRESETCCN Mode ? 0-1 NO/YES REM_CCN

MENU

STATUS

ICVC_PWD

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EXAMPLE 9 SETPOINT DISPLAY SCREEN


1. Press .

2. Press (Base Demand Limit will be highlighted).

3. Press .

NOTE: No variables are available for CCN read operation; forcing shall not be supported on setpoint screens.

EXAMPLE 10 CAPACITY DISPLAY SCREEN


1. Press .

2. Press .


4. Press .


NOTE: All variables with CAPITAL LETTER point names are available for CCN read operation;forcing shall not be supported on maintenance screens.

DESCRIPTION STATUS UNITS POINT DEFAULT

Base Demand Limit 40-100 % DLM 100Control Point SourceLCL Setpoint 10-60 F (-12.2-15.6 C) F ( C) lcl_sp 50.0 F (10.0 C)

ECL Setpoint 15-65 F (-9.4-18.3 C) F ( C) ecl_sp 60.0 F (15.6 C)Ice Build Setpoint 15-60 F (-9.4-15.6 C) F ( C) ice_sp 40 F (4.4 C)Tower Fan High Setpoint 55-105 F (13-41 C) F ( C) TFH_sp 75 F (23.9 C)


Entering Chilled Liquid 40-245 F (C) ECLLeaving Chilled Liquid 40-245 F (C) LCLCapacity ControlControl Point 10-65 F (C) ctrlptControl Point Error 99-99 ^F (^C) cperrECL Delta T 99-99 ^F (^C) ecldtECL Reset 99-99 ^F (^C) eclresLCL Reset 99-99 ^F (^C) lclresTotal Error + Resets 99-99 ^F (^C) errorCap Delta 2-2 % capdeltaVFD Delta 2-2 % vfddeltaTarget VFD Speed 0-100 % VFD_TRGActual VFD Speed 0-110 % VFD_ACTComp Motor RPM 0-300000 RPM CPR_RPMComp Motor Frequency 0-10000 Hz VFD_FREQComp Maximum Speed 0-101 Hz MAXSPEEDComp Minimum Speed 0-100 % MINSPEEDVFD Speed Output 0-110 % VFD_OUTVFD Gain 0.1-1.5 vfd_gain

Demand Limit Inhibit 0.2-1 % DEM_INHAmps/kW Ramp 0-100 % RAMP_LMT

MENU

SETPOINT

SELECT

MENU

SERVICE


SELECT

CAPACITY

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