19XR,XRV Hermetic Centrifugal Liquid Chillers 50/60 Hz With PIC II Controls and HFC-134a
Start-Up, Operation, and Maintenance Instructions
SAFETY CONSIDERATIONS
Centrifugal liquid chillers are designed to provide safe and reliable service when operated within design specifications. When operating this equipment, use good judgment and safety precautions to avoid damage to equipment and property or injury to personnel.
Be sure you understand and follow the procedures and safety precautions contained in the chiller instructions as well as those listed in this guide.
DO NOT VENT refrigerant relief valves within a building. Outlet from rupture disc or relief valve must be vented outdoors in accordance with the latest edition of ANSI/ASHRAE 15 (American National Standards Institute/American Society of Heating, Refrigeration, and Air Conditioning Engineers). The accumulation of refrigerant in an enclosed space can displace oxygen and cause asphyxiation.
PROVIDE adequate ventilation in accordance with ANSI/ASHRAE 15, especially for enclosed and low overhead spaces. Inhalation of high concentrations of vapor is harmful and may cause heart irregularities, unconsciousness, or death. Misuse can be fatal. Vapor is heavier than air and reduces the amount of oxygen available for breathing. Product causes eye and skin irritation. Decomposition products are hazardous.
DO NOT USE OXYGEN to purge lines or to pressurize a chiller for any purpose. Oxygen gas reacts violently with oil, grease, and other common substances.
NEVER EXCEED specified test pressures, VERIFY the allowable test pressure by checking the instruction literature and the design pressures on the equipment nameplate.
DO NOT USE air for leak testing. Use only refrigerant or dry nitrogen.
DO NOT VALVE OFF any safety device.
BE SURE that all pressure relief devices are properly installed and functioning before operating any chiller.
RISK OF INJURY OR DEATH by electrocution. High voltage is present on motor leads even though the motor is not running when a solid-state or inside-delta mechanical starter is used. Open the power supply disconnect before touching motor leads or terminals.
soap and water. If liquid refrigerant enters the eyes, IMMEDIATELY FLUSH EYES with water and consult a physician.
NEVER APPLY an open flame or live steam to a refrigerant cylinder. Dangerous over pressure can result. When it is necessary to heat refrigerant, use only warm (110 F [43 C]) water.
DO NOT REUSE disposable (nonreturnable) cylinders or attempt to refill them. It is DANGEROUS AND ILLEGAL. When cylinder is emptied, evacuate remaining gas pressure, loosen the collar and unscrew and discard the valve stem. DO NOT INCINERATE.
CHECK THE REFRIGERANT TYPE before adding refrigerant to the chiller. The introduction of the wrong refrigerant can cause damage or malfunction to this chiller.
Operation of this equipment with refrigerants other than those cited herein should comply with ANSI/ASHRAE 15 (latest edition). Contact Carrier for further information on use of this chiller with other refrigerants.
DO NOT ATTEMPT TO REMOVE fittings, covers, etc., while chiller is under pressure or while chiller is running. Be sure pressure is at 0 psig (0 kPa) before breaking any refrigerant connection.
CAREFULLY INSPECT all relief devices, rupture discs, and other relief devices AT LEAST ONCE A YEAR. If chiller operates in a corrosive atmosphere, inspect the devices at more frequent intervals.
DO NOT ATTEMPT TO REPAIR OR RECONDITION any relief device when corrosion or build-up of foreign material (rust, dirt, scale, etc.) is found within the valve body or mechanism. Replace the device.
DO NOT install relief devices in series or backwards.
USE CARE when working near or in line with a compressed spring. Sudden release of the spring can cause it and objects in its path to act as projectiles.
DO NOT STEP on refrigerant lines. Broken lines can whip about and release refrigerant, causing personal injury.
DO NOT climb over a chiller. Use platform, catwalk, or staging. Follow safe practices when using ladders.
USE MECHANICAL EQUIPMENT (crane, hoist, etc.) to lift or move inspection covers or other heavy components. Even if components are light, use mechanical equipment when there is a risk of slipping or losing your balance.
DO NOT WELD OR FLAMECUT any refrigerant line or vessel until all refrigerant (liquid and vapor) has been removed from chiller. Traces of vapor should be displaced with dry air or nitrogen and the work area should be well ventilated. Refrigerant in contact with an open flame produces toxic gases.
DO NOT USE eyebolts or eyebolt holes to rig chiller sections or the entire assembly.
DO NOT work on high-voltage equipment unless you are a qualified electrician.
DO NOT WORK ON electrical components, including control panels, switches, starters, or oil heater until you are sure ALL POWER IS OFF and no residual voltage can leak from capacitors or solid-state components.
LOCK OPEN AND TAG electrical circuits during servicing. IF WORK IS INTERRUPTED, confirm that all circuits are deenergized before resuming work.
AVOID SPILLING liquid refrigerant on skin or getting it into the eyes. USE SAFETY GOGGLES. Wash any spills from the skin with
BE AWARE that certain automatic start arrangements CAN ENGAGE THE STARTER, TOWER FAN, OR PUMPS. Open the disconnect ahead of the starter, tower fans, or pumps.
USE only repair or replacement parts that meet the code requirements of the original equipment.
DO NOT VENT OR DRAIN waterboxes containing industrial brines, liquid, gases, or semisolids without the permission of your process control group.
DO NOT LOOSEN waterbox cover bolts until the waterbox has been completely drained.
DOUBLE-CHECK that coupling nut wrenches, dial indicators, or other items have been removed before rotating any shafts.
DO NOT LOOSEN a packing gland nut before checking that the nut has a positive thread engagement.
PERIODICALLY INSPECT all valves, fittings, and piping for corrosion, rust, leaks, or damage.
PROVIDE A DRAIN connection in the vent line near each pressure relief device to prevent a build-up of condensate or rain water.
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Book |
2 |
PC 211 |
Catalog No. 531-982 |
Printed in U.S.A. |
Form 19XR-5SS |
Pg 1 |
6-01 |
Replaces: 19XR-4SS |
Tab |
5a |
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CONTENTS
Page SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . 1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
ABBREVIATIONS AND EXPLANATIONS . . . . . . . . 4,5
CHILLER FAMILIARIZATION . . . . . . . . . . . . . . . . . . . . 5-7
Chiller Information Nameplate . . . . . . . . . . . . . . . . . . . . 5
System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Motor-Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Control Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Factory-Mounted Starter or Variable
Frequency Drive (Optional). . . . . . . . . . . . . . . . . . . . . 7
Storage Vessel (Optional) . . . . . . . . . . . . . . . . . . . . . . . . 7 REFRIGERATION CYCLE . . . . . . . . . . . . . . . . . . . . . . . . . 7
MOTOR AND LUBRICATING OIL
COOLING CYCLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7,8 VFD COOLING CYCLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
LUBRICATION CYCLE . . . . . . . . . . . . . . . . . . . . . . . . . . 8,9 Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Details. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Oil Reclaim System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
•PRIMARY OIL RECOVERY MODE
•SECONDARY OIL RECOVERY METHOD
STARTING EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . 9,10
Unit-Mounted Solid-State Starter
(Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Unit-Mounted Wye-Delta Starter
(Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Unit-Mounted VFD (Optional) . . . . . . . . . . . . . . . . . . . . 10
CONTROLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-45
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
•ANALOG SIGNAL
•DISCRETE SIGNAL
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
PIC II System Components . . . . . . . . . . . . . . . . . . . . . . 11
•CHILLER VISUAL CONTROLLER (CVC)
•INTERNATIONAL CHILLER VISUAL CONTROLLER (ICVC)
•INTEGRATED STARTER MODULE (ISM)
•CHILLER CONTROL MODULE (CCM)
•OIL HEATER CONTACTOR (1C)
•OIL PUMP CONTACTOR (2C)
•HOT GAS BYPASS CONTACTOR RELAY (3C) (Optional)
•CONTROL TRANSFORMERS (T1, T2)
•OPTIONAL TRANSFORMER (T3)
CVC/ICVC Operation and Menus. . . . . . . . . . . . . . . . . 15
•GENERAL
•ALARMS AND ALERTS
•CVC/ICVC MENU ITEMS
•BASIC CVC/ICVC OPERATIONS (Using the Softkeys)
•TO VIEW STATUS
•OVERRIDE OPERATIONS
•TIME SCHEDULE OPERATION
•TO VIEW AND CHANGE SET POINTS
•SERVICE OPERATION
PIC II System Functions . . . . . . . . . . . . . . . . . . . . . . . . . 33
•CAPACITY CONTROL FIXED SPEED
•CAPACITY CONTROL VFD
•ECW CONTROL OPTION
•CONTROL POINT DEADBAND
•DIFFUSER CONTROL
•PROPORTIONAL BANDS AND GAIN
•DEMAND LIMITING
•CHILLER TIMERS
•OCCUPANCY SCHEDULE
Safety Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Page
Shunt Trip (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Default Screen Freeze . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Ramp Loading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Capacity Override . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
High Discharge Temperature Control . . . . . . . . . . . . 36
Oil Sump Temperature Control . . . . . . . . . . . . . . . . . . 36
Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Remote Start/Stop Controls . . . . . . . . . . . . . . . . . . . . . 36
Spare Safety Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Alarm (Trip) Output Contacts . . . . . . . . . . . . . . . . . . . . 37
Refrigerant Leak Detector . . . . . . . . . . . . . . . . . . . . . . . 37
Kilowatt Output. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Remote Reset of Alarms. . . . . . . . . . . . . . . . . . . . . . . . . 37
Condenser Pump Control . . . . . . . . . . . . . . . . . . . . . . . 37
Condenser Freeze Prevention . . . . . . . . . . . . . . . . . . . 38
Evaporator Freeze Protection (ICVC Only) . . . . . . . 38
Tower Fan Relay Low and High . . . . . . . . . . . . . . . . . . 38
Auto. Restart After Power Failure. . . . . . . . . . . . . . . . 38
Water/Brine Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
•RESET TYPE 1
•RESET TYPE 2
•RESET TYPE 3
Demand Limit Control Option . . . . . . . . . . . . . . . . . . . 39
Surge Prevention Algorithm
(Fixed Speed Chiller) . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Surge Prevention Algorithm with VFD . . . . . . . . . . . 40 Surge Protection VFD Units . . . . . . . . . . . . . . . . . . . . . 40 Surge Protection (Fixed Speed Chiller) . . . . . . . . . . 40
• HEAD PRESSURE REFERENCE OUTPUT Lead/Lag Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
•COMMON POINT SENSOR INSTALLATION
•CHILLER COMMUNICATION WIRING
•LEAD/LAG OPERATION
•FAULTED CHILLER OPERATION
•LOAD BALANCING
•AUTO. RESTART AFTER POWER FAILURE
Ice Build Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
•ICE BUILD INITIATION
•START-UP/RECYCLE OPERATION
•TEMPERATURE CONTROL DURING ICE BUILD
•TERMINATION OF ICE BUILD
•RETURN TO NON-ICE BUILD OPERATIONS
Attach to Network Device Control . . . . . . . . . . . . . . . 44
• ATTACHING TO OTHER CCN MODULES
Service Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
•TO ACCESS THE SERVICE SCREENS
•TO LOG OUT OF NETWORK DEVICE
•HOLIDAY SCHEDULING
START-UP/SHUTDOWN/RECYCLE
SEQUENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46,47
Local Start-Up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Shutdown Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Automatic Soft Stop Amps Threshold . . . . . . . . . . . 47
Chilled Water Recycle Mode . . . . . . . . . . . . . . . . . . . . . 47
Safety Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
BEFORE INITIAL START-UP . . . . . . . . . . . . . . . . . . 48-64
Job Data Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Equipment Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Using the Optional Storage Tank
and Pumpout System . . . . . . . . . . . . . . . . . . . . . . . . . 48
Remove Shipping Packaging . . . . . . . . . . . . . . . . . . . . 48
Open Oil Circuit Valves . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Tighten All Gasketed Joints and
Guide Vane Shaft Packing . . . . . . . . . . . . . . . . . . . . . 48
Check Chiller Tightness . . . . . . . . . . . . . . . . . . . . . . . . . 48
Refrigerant Tracer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Leak Test Chiller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Standing Vacuum Test. . . . . . . . . . . . . . . . . . . . . . . . . . . 50
2
CONTENTS (cont)
Page
Chiller Dehydration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Inspect Water Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Check Optional Pumpout Compressor
Water Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Check Relief Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Inspect Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Carrier Comfort Network Interface. . . . . . . . . . . . . . . 54
Check Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
•MECHANICAL STARTER
•BENSHAW, INC. RediStart MICRO™ SOLID-STATE STARTER
•VFD STARTER
Oil Charge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Power Up the Controls and
Check the Oil Heater . . . . . . . . . . . . . . . . . . . . . . . . . . 55
• SOFTWARE VERSION
Software Configuration . . . . . . . . . . . . . . . . . . . . . . . . . 55
Input the Design Set Points . . . . . . . . . . . . . . . . . . . . . 55
Input the Local Occupied Schedule
(OCCPC01S) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Input Service Configurations. . . . . . . . . . . . . . . . . . . . 55
•PASSWORD
•INPUT TIME AND DATE
•CHANGE CVC/ICVC CONFIGURATION IF NECESSARY
•TO CHANGE THE PASSWORD
•TO CHANGE THE CVC/ICVC DISPLAY FROM ENGLISH TO METRIC UNITS
•CHANGE LANGUAGE (ICVC ONLY)
•MODIFY CONTROLLER IDENTIFICATION IF NECESSARY
•INPUT EQUIPMENT SERVICE PARAMETERS IF NECESSARY
•CHANGE THE BENSHAW, INC., RediStart MICRO SOFTWARE CONFIGURATION IF NECESSARY
•VERIFY VFD CONFIGURATION AND CHANGE PARAMETERS IF NECESSARY
•VFD CHILLER FIELD SET UP AND VERIFICATION
•VFD CONTROL VERIFICATION (Non-Running)
•VFD CONTROL VERIFICATION (Running)
•CONFIGURE DIFFUSER CONTROL IF NECESSARY
•MODIFY EQUIPMENT CONFIGURATION
IF NECESSARY
Perform a Control Test . . . . . . . . . . . . . . . . . . . . . . . . . . 62
• COOLER CONDENSER PRESSURE TRANSDUCER
AND WATERSIDE FLOW DEVICE CALIBRATION
Check Optional Pumpout System
Controls and Compressor. . . . . . . . . . . . . . . . . . . . . 63
High Altitude Locations . . . . . . . . . . . . . . . . . . . . . . . . . 63
Charge Refrigerant Into Chiller . . . . . . . . . . . . . . . . . . 63
•CHILLER EQUALIZATION WITHOUT A PUMPOUT UNIT
•CHILLER EQUALIZATION WITH PUMPOUT UNIT
•TRIMMING REFRIGERANT CHARGE
INITIAL START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64-66 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Dry Run to Test Start-Up Sequence . . . . . . . . . . . . . 65
Check Motor Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Check Oil Pressure and Compressor Stop . . . . . . 65 To Prevent Accidental Start-Up. . . . . . . . . . . . . . . . . . 65 Check Chiller Operating Condition . . . . . . . . . . . . . . 65 Instruct the Customer Operator . . . . . . . . . . . . . . . . . 65
•COOLER-CONDENSER
•OPTIONAL PUMPOUT STORAGE TANK AND PUMPOUT SYSTEM
•MOTOR COMPRESSOR ASSEMBLY
Page
•MOTOR COMPRESSOR LUBRICATION SYSTEM
•CONTROL SYSTEM
•AUXILIARY EQUIPMENT
•DESCRIBE CHILLER CYCLES
•REVIEW MAINTENANCE
•SAFETY DEVICES AND PROCEDURES
•CHECK OPERATOR KNOWLEDGE
•REVIEW THE START-UP, OPERATION, AND MAINTENANCE MANUAL
OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . .66,67 Operator Duties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Prepare the Chiller for Start-Up . . . . . . . . . . . . . . . . . 66
To Start the Chiller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 Check the Running System . . . . . . . . . . . . . . . . . . . . . 66 To Stop the Chiller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 After Limited Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . 66
Preparation for Extended Shutdown . . . . . . . . . . . . 66
After Extended Shutdown . . . . . . . . . . . . . . . . . . . . . . . 67 Cold Weather Operation. . . . . . . . . . . . . . . . . . . . . . . . . 67
Manual Guide Vane Operation. . . . . . . . . . . . . . . . . . . 67
Refrigeration Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
PUMPOUT AND REFRIGERANT TRANSFER PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67-71
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Operating the Optional Pumpout Unit . . . . . . . . . . . 67
• TO READ REFRIGERANT PRESSURES
Chillers with Storage Tanks . . . . . . . . . . . . . . . . . . . . . 69
•TRANSFER REFRIGERANT FROM PUMPOUT STORAGE TANK TO CHILLER
•TRANSFER REFRIGERANT FROM
CHILLER TO PUMPOUT STORAGE TANK
Chillers with Isolation Valves. . . . . . . . . . . . . . . . . . . . 70
•TRANSFER ALL REFRIGERANT TO CHILLER CONDENSER VESSEL
•TRANSFER ALL REFRIGERANT TO CHILLER COOLER VESSEL
•RETURN CHILLER TO NORMAL OPERATING CONDITIONS
GENERAL MAINTENANCE . . . . . . . . . . . . . . . . . . . .71,72 Refrigerant Properties . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Adding Refrigerant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Removing Refrigerant. . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Adjusting the Refrigerant Charge . . . . . . . . . . . . . . . 71
Refrigerant Leak Testing . . . . . . . . . . . . . . . . . . . . . . . . 71 Leak Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Test After Service, Repair, or Major Leak . . . . . . . . 71
•TESTING WITH REFRIGERANT TRACER
•TESTING WITHOUT REFRIGERANT TRACER
•TO PRESSURIZE WITH DRY NITROGEN
Repair the Leak, Retest, and Apply
Standing Vacuum Test . . . . . . . . . . . . . . . . . . . . . . . . 72
Checking Guide Vane Linkage . . . . . . . . . . . . . . . . . . 72
Trim Refrigerant Charge. . . . . . . . . . . . . . . . . . . . . . . . . 72
WEEKLY MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . 72
Check the Lubrication System . . . . . . . . . . . . . . . . . . 72
SCHEDULED MAINTENANCE . . . . . . . . . . . . . . . . 73-75
Service Ontime. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Inspect the Control Panel . . . . . . . . . . . . . . . . . . . . . . . 73
Check Safety and Operating Controls
Monthly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Changing Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Oil Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Oil Changes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
• TO CHANGE THE OIL
Refrigerant Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Oil Reclaim Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Inspect Refrigerant Float System . . . . . . . . . . . . . . . 74
3
CONTENTS (cont)
Page
Inspect Relief Valves and Piping. . . . . . . . . . . . . . . . . 74
Compressor Bearing and Gear
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Inspect the Heat Exchanger Tubes
and Flow Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
•COOLER AND FLOW DEVICES
•CONDENSER AND FLOW DEVICES
Water Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Water Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Inspect the Starting Equipment. . . . . . . . . . . . . . . . . . 75
Check Pressure Transducers . . . . . . . . . . . . . . . . . . . . 75
Optional Pumpout System Maintenance. . . . . . . . . 75
•OPTIONAL PUMPOUT COMPRESSOR OIL CHARGE
•OPTIONAL PUMPOUT SAFETY CONTROL SETTINGS
Ordering Replacement Chiller Parts . . . . . . . . . . . . . 75
TROUBLESHOOTING GUIDE . . . . . . . . . . . . . . . . 76-122
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Checking Display Messages. . . . . . . . . . . . . . . . . . . . . 76
Checking Temperature Sensors . . . . . . . . . . . . . . . . . 76
•RESISTANCE CHECK
•VOLTAGE DROP
•CHECK SENSOR ACCURACY
•DUAL TEMPERATURE SENSORS
Checking Pressure Transducers. . . . . . . . . . . . . . . . . 76
•UNITS EQUIPPED WITH CVC
•UNITS EQUIPPED WITH ICVC
•TRANSDUCER REPLACEMENT
Control Algorithms Checkout Procedure . . . . . . . . 77
Control Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Control Modules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
•RED LED (Labeled as STAT)
•GREEN LED (Labeled as COM)
Notes on Module Operation . . . . . . . . . . . . . . . . . . . . . 87
Chiller Control Module (CCM) . . . . . . . . . . . . . . . . . . . 88
•INPUTS
•OUTPUTS
Integrated Starter Module . . . . . . . . . . . . . . . . . . . . . . . 88
•INPUTS
•OUTPUTS
Replacing Defective Processor Modules . . . . . . . . 88
• INSTALLATION
Solid-State Starters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
•TESTING SILICON CONTROL RECTIFIERS IN BENSHAW, INC. SOLID-STATE STARTERS
•SCR REMOVAL/INSTALLATION
Physical Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123,124
INITIAL START-UP CHECKLIST FOR 19XR, XRV HERMETIC CENTRIFUGAL
LIQUID CHILLER . . . . . . . . . . . . . . . . . . . .CL-1 to CL-16
INTRODUCTION
Prior to initial start-up of the 19XR unit, those involved in the start-up, operation, and maintenance should be thoroughly familiar with these instructions and other necessary job data. This book is outlined to familiarize those involved in the startup, operation and maintenance of the unit with the control system before performing start-up procedures. Procedures in this manual are arranged in the sequence required for proper chiller start-up and operation.
This unit uses a microprocessor control system. Do not short or jumper between terminations on circuit boards or modules; control or board failure may result.
Be aware of electrostatic discharge (static electricity) when handling or making contact with circuit boards or module connections. Always touch a chassis (grounded) part to dissipate body electrostatic charge before working inside control center.
Use extreme care when handling tools near boards and when connecting or disconnecting terminal plugs. Circuit boards can easily be damaged. Always hold boards by the edges and avoid touching components and connections.
This equipment uses, and can radiate, radio frequency energy. If not installed and used in accordance with the instruction manual, it may cause interference to radio communications. It has been tested and found to comply with the limits for a Class A computing device pursuant to Subpart J of Part 15 of FCC Rules, which are designed to provide reasonable protection against such interference when operated in a commercial environment. Operation of this equipment in a residential area is likely to cause interference, in which case the user, at his own expense, will be required to take whatever measures may be required to correct the interference.
Always store and transport replacement or defective boards in anti-static shipping bag.
ABBREVIATIONS AND EXPLANATIONS
Frequently used abbreviations in this manual include:
CCM |
— Chiller Control Module |
CCN |
— Carrier Comfort Network |
CCW |
— Counterclockwise |
CVC |
— Chiller Visual Controller |
CW |
— Clockwise |
ECDW |
— Entering Condenser Water |
ECW |
— Entering Chilled Water |
EMS |
— Energy Management System |
HGBP |
— Hot Gas Bypass |
I/O |
— Input/Output |
ICVC |
— International Chiller Visual Controller |
ISM |
— Integrated Starter Module |
LCD |
— Liquid Crystal Display |
LCDW |
— Leaving Condenser Water |
LCW |
— Leaving Chilled Water |
LED |
— Light-Emitting Diode |
OLTA |
— Overload Trip Amps |
PIC II |
— Product Integrated Controls II |
RLA |
— Rated Load Amps |
SCR |
— Silicon Controlled Rectifier |
SI |
— International System of Units |
TXV |
— Thermostatic Expansion Valve |
VFD |
— Variable Frequency Drive |
Words printed in all capital letters or in italics may be viewed on the Chiller Visual Controller/International Chiller Visual Controller (CVC/ICVC) (e.g., LOCAL, CCN, ALARM, etc.).
Words printed in both all capital letters and italics can also be viewed on the CVC/ICVC and are parameters (e.g., CONTROL MODE, COMPRESSOR START RELAY, ICE BUILD OPTION, 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 CVC/ICVC control panel (e.g., ENTER ,
EXIT , INCREASE , QUIT , etc.).
4
Factory-installed additional components are referred to as options in this manual; factory-supplied but field-installed additional components are referred to as accessories.
The chiller software part number of the 19XR unit is located on the back of the CVC/ICVC.
CHILLER FAMILIARIZATION (Fig. 1 and 2)
Chiller Information Nameplate — The information nameplate is located on the right side of the chiller control panel.
System Components — The components include the cooler and condenser heat exchangers in separate vessels, motor-compressor, lubrication package, control panel, and motor starter. All connections from pressure vessels have external threads to enable each component to be pressure tested with a threaded pipe cap during factory assembly.
Cooler — This vessel (also known as the evaporator) is located underneath the compressor. The cooler is maintained at lower temperature/pressure so evaporating refrigerant can remove heat from water flowing through its internal tubes.
Condenser — The condenser operates at a higher temperature/pressure than the cooler and has water flowing
through its internal tubes in order to remove heat from the refrigerant.
Motor-Compressor — This component maintains system temperature and pressure differences and moves the heatcarrying refrigerant from the cooler to the condenser.
Control Panel — The control panel is the user interface for controlling the chiller. It regulates the chiller’s capacity as required to maintain proper leaving chilled water temperature. The control panel:
•registers cooler, condenser, and lubricating system pressures
•shows chiller operating condition and alarm shutdown conditions
•records the total chiller operating hours
•sequences chiller start, stop, and recycle under microprocessor control
•displays status of motor starter
•provides access to other CCN (Carrier Comfort Network) devices and energy management systems
•Languages pre-installed at factory include: English, Chinese, Japanese, and Korean (ICVC only).
•International language translator (ILT) is available for conversion of extended ASCII characters (ICVC only).
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19XRV 52 51 |
473 |
DG H 64 – |
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19XR- — High Efficiency Hermetic |
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Centrifugal Liquid Chiller |
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19XRV — High Efficiency Hermetic |
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Centrifugal Liquid Chiller with |
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Special Order Indicator |
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Variable Frequency Drive |
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– — Standard |
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Unit-Mounted |
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S — Special Order |
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Cooler Size |
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Motor Voltage Code |
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Code Volts-Phase-Hertz |
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10-12 (Frame 1 XR) |
55-57 (Frame 5 XR) |
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60 |
— 200-3-60 |
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15-17 (Frame 1 XR) |
5F (Frame 5 XR) |
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61 |
— 230-3-60 |
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20-22 (Frame 2 XR) |
5G (Frame 5 XR) |
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62 |
— 380-3-60 |
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30-32 (Frame 3 XR) |
5H (Frame 5 XR) |
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63 |
— 416-3-60 |
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35-37 (Frame 3 XR) |
60-62 (Frame 6 XR) |
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64 |
— 460-3-60 |
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40-42 (Frame 4 XR) |
65-67 (Frame 6 XR) |
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65 |
— 575-3-60 |
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45-47 (Frame 4 XR) |
70-72 (Frame 7 XR) |
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66 |
— 2400-3-60 |
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50-52 (Frame 5 XR) |
75-77 (Frame 7 XR) |
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67 |
— 3300-3-60 |
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5A (Frame 5 XR) |
80-82 (Frame 8 XR) |
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68 |
— 4160-3-60 |
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5B (Frame 5 XR) |
85-87 (Frame 8 XR) |
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69 |
— 6900-3-60 |
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5C (Frame 5 XR) |
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50 |
— 230-3-50 |
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51 |
— 346-3-50 |
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52 |
— 400-3-50 |
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53 |
— 3000-3-50 |
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Condenser Size |
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54 |
— 3300-3-50 |
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55 |
— 6300-3-50 |
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10-12 (Frame 1 XR) |
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15-17 (Frame 1 XR) |
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Motor Efficiency Code |
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20-22 (Frame 2 XR) |
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30-32 (Frame 3 XR) |
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H — High Efficiency |
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35-37 (Frame 3 XR) |
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S — Standard Efficiency |
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40-42 (Frame 4 XR) |
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45-47 (Frame 4 XR) |
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Motor Code |
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50-52 (Frame 5 XR) |
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55-57 (Frame 5 XR) |
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BD |
CD |
DB |
EH |
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60-62 (Frame 6 XR) |
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BE |
CE |
DC |
EJ |
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65-67 (Frame 6 XR) |
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BF |
CL |
DD |
EK |
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70-72 (Frame 7 XR) |
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BG |
CM |
DE |
EL |
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75-77 (Frame 7 XR) |
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BH |
CN |
DF |
EM |
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80-82 (Frame 8 XR) |
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CP |
DG |
EN |
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85-87 (Frame 8 XR) |
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CQ |
DH |
EP |
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DJ |
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Compressor Code |
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(First Digit Indicates Compressor Frame Size)* |
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*Second digit will be a letter (example 4G3) |
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on units equipped with split ring diffuser. |
MODEL NUMBER NOMENCLATURE |
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27 99 |
Q |
59843 |
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Week of Year
Year of Manufacture
Unique Number
Place of Manufacture
SERIAL NUMBER BREAKDOWN
Fig. 1 — 19XR Identification
5
FRONT VIEW
1
2
3
4
5
17 |
6 |
16
7
8
15 14
13
12
11 |
9 |
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10 |
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LEGEND
1— Guide Vane Actuator
2— Suction Elbow
3— Chiller Visual Controller/ International Chiller Visual Control (CVC/ICVC)
4— Chiller Identification Nameplate
5— Cooler, Auto Reset Relief Valves
6— Cooler Pressure Transducer
7— Condenser In/Out Temperature Thermistors
8— Condenser Waterflow Device (ICVC Inputs available)
9— Cooler In/Out Temperature Thermistors
10— Cooler Waterflow Device (ICVC Inputs available)
11— Refrigerant Charging Valve
12— Typical Flange Connection
13— Oil Drain Charging Valve
14— Oil Level Sight Glasses
15— Refrigerant Oil Cooler (Hidden)
16— Auxiliary Power Panel
17— Compressor Motor Housing
REAR VIEW
18 19 20 21 22
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LEGEND |
34 |
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18 |
— Condenser Auto. Reset Relief Valves |
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23 |
19 |
— Compressor Motor Circuit Breaker |
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20 |
— Solid-State Starter Control Display |
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21 |
— Unit-Mounted Starter (Optional) |
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Solid-State Starter Shown |
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22 |
— Motor Sight Glass |
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23 |
— Cooler Return-End Waterbox Cover |
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24 |
— ASME Nameplate (One Hidden) |
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25 |
— Typical Waterbox Drain Port |
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26 |
— Condenser Return-End Waterbox Cover |
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27 |
— Refrigerant Moisture/Flow Indicator |
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28 |
— Refrigerant Filter/Drier |
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29 |
— Liquid Line Isolation Valve (Optional) |
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30 |
— Linear Float Valve Chamber |
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31 |
— Vessel Take-Apart Connector |
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32 |
— Discharge Isolation Valve (Optional) |
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33 |
— Pumpout Valve |
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34 |
— Condenser Pressure Transducer |
33 |
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24 |
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32 |
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28 27 |
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31 |
30 |
29 |
26 |
25 |
24 |
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Fig. 2 — Typical 19XR Components
6
Factory-Mounted Starter or Variable Frequency Drive (Optional) — The starter allows for the proper start and disconnect of electrical energy for the com- pressor-motor, oil pump, oil heater, and control panel.
Storage Vessel (Optional) — There are 2 sizes of storage vessels available. The vessels have double relief valves, a magnetically-coupled dial-type refrigerant level gage, a one-inch FPT drain valve, and a 1/2-in. male flare vapor connection for the pumpout unit.
NOTE: If a storage vessel is not used at the jobsite, factoryinstalled isolation valves on the chiller may be used to isolate the chiller charge in either the cooler or condenser. An optional pumpout system is used to transfer refrigerant from vessel to vessel.
REFRIGERATION CYCLE
The compressor continuously draws refrigerant vapor from the cooler at a rate set by the amount of guide vane opening or compressor speed (19XRV only). 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]). The energy required for boiling is obtained from the water flowing through the cooler tubes. With heat energy removed, the water becomes cold enough to use in an air conditioning circuit or for process liquid cooling.
After taking heat from the water, the refrigerant vapor is compressed. Compression adds still more heat energy, and the
refrigerant is quite warm (typically 98 to 102 F [37 to 40 C]) when it is discharged from the compressor into the condenser.
Relatively cool (typically 65 to 90 F [18 to 32 C]) water flowing into the condenser tubes removes heat from the refrigerant and the vapor condenses to liquid.
The liquid refrigerant passes through orifices into the FLASC (Flash Subcooler) chamber (Fig. 3). Since the FLASC chamber is at a lower pressure, part of the liquid refrigerant flashes to vapor, thereby cooling the remaining liquid. The FLASC vapor is recondensed on the tubes which are cooled by entering condenser water. The liquid drains into a float chamber between the FLASC chamber and cooler. Here a float valve forms a liquid seal to keep FLASC chamber vapor from entering the cooler. When liquid refrigerant passes through the valve, some of it flashes to vapor in the reduced pressure on the cooler side. In flashing, it removes heat from the remaining liquid. The refrigerant is now at a temperature and pressure at which the cycle began.
MOTOR AND LUBRICATING OIL
COOLING CYCLE
The motor and the lubricating oil are cooled by liquid refrigerant taken from the bottom of the condenser vessel (Fig. 3). Refrigerant flow is maintained by the pressure differential that exists due to compressor operation. After the refrigerant flows past an isolation valve, an in-line filter, and a sight glass/moisture indicator, the flow is split between the motor cooling and oil cooling systems.
Fig. 3 — Refrigerant Motor Cooling and Oil Cooling Cycles
7
Flow to the motor cooling system passes through an orifice and into the motor. Once past the orifice, the refrigerant is directed over the motor by a spray nozzle. The refrigerant collects in the bottom of the motor casing and is then drained back into the cooler through the motor refrigerant drain line. An orifice (in the motor shell) maintains a higher pressure in the motor shell than in the cooler. The motor is protected by a temperature sensor imbedded in the stator windings. An increase in motor winding temperature past the motor override
set point overrides the temperature capacity control to hold, and if the motor temperature rises 10° F (5.5° C) above this set
point, closes the inlet guide vanes. If the temperature rises above the safety limit, the compressor shuts down.
Refrigerant that flows to the oil cooling system is regulated by thermostatic expansion valves (TXVs). The TXVs regulate flow into the oil/refrigerant plate and frame-type heat exchanger (the oil cooler in Fig. 3). The expansion valve bulbs control oil temperature to the bearings. The refrigerant leaving the oil cooler heat exchanger returns to the chiller cooler.
VFD COOLING CYCLE
The unit-mounted variable frequency drive (VFD) is cooled in a manner similar to the motor and lubricating oil cooling cycle (Fig. 3).
If equipped with a unit-mounted VFD, the refrigerant line that feeds the motor cooling and oil cooler also feeds the heat exchanger on the unit-mounted VFD. Refrigerant is metered through a thermostatic expansion valve (TXV). To maintain proper operating temperature in the VFD, the TXV bulb is mounted to the heat exchanger to regulate the flow of refrigerant. The refrigerant leaving the heat exchanger returns to the cooler.
LUBRICATION CYCLE
Summary — The oil pump, oil filter, and oil cooler make up a package located partially in the transmission casing of the compressor-motor assembly. The oil is pumped into a filter assembly to remove foreign particles and is then forced into an oil cooler heat exchanger where the oil is cooled to proper operational temperatures. After the oil cooler, part of the flow is directed to the gears and the high speed shaft bearings; the remaining flow is directed to the motor shaft bearings. Oil drains into the transmission oil sump to complete the cycle (Fig. 4).
Details — Oil is charged into the lubrication system through a hand valve. Two sight glasses in the oil reservoir permit oil level observation. Normal oil level is between the middle of the upper sight glass and the top of the lower sight glass when the compressor is shut down. The oil level should be visible in at least one of the 2 sight glasses during operation. Oil sump temperature is displayed on the CVC/ICVC (Chiller Visual Controller/International Chiller Visual Controller) default screen. During compressor operation, the oil sump temperature ranges between 125 to 150 F (52 to 66 C).
The oil pump suction is fed from the oil reservoir. An oil pressure relief valve maintains 18 to 25 psid (124 to172 kPad) differential pressure in the system at the pump discharge. This differential pressure can be read directly from the CVC/ICVC default screen. The oil pump discharges oil to the oil filter assembly. This filter can be closed to permit removal of the filter without draining the entire oil system (see Maintenance sections, pages 71 to 75, for details). The oil is then piped to the oil
cooler heat exchanger. The oil cooler uses refrigerant from the condenser as the coolant. The refrigerant cools the oil to a temperature between 120 and 140 F (49 to 60 C).
As the oil leaves the oil cooler, it passes the oil pressure transducer and the thermal bulb for the refrigerant expansion valve on the oil cooler. The oil is then divided. Part of the oil flows to the thrust bearing, forward pinion bearing, and gear spray. The rest of the oil lubricates the motor shaft bearings and the rear pinion bearing. The oil temperature is measured in the bearing housing as it leaves the thrust and forward journal bearings. The oil then drains into the oil reservoir at the base of the compressor. The PIC II (Product Integrated Control II) measures the temperature of the oil in the sump and maintains the temperature during shutdown (see Oil Sump Temperature Control section, page 36). This temperature is read on the CVC/ICVC default screen.
During the chiller start-up, the PIC II energizes the oil pump and provides 45 seconds of pre-lubrication to the bearings after pressure is verified before starting the compressor. During shutdown, the oil pump will run for 60 seconds to postlubricate after the compressor shuts down. The oil pump can also be energized for testing purposes during a Control Test.
Ramp loading can slow the rate of guide vane opening to minimize oil foaming at start-up. If the guide vanes open quickly, the sudden drop in suction pressure can cause any refrigerant in the oil to flash. The resulting oil foam cannot be pumped efficiently; therefore, oil pressure falls off and lubrication is poor. If oil pressure falls below 15 psid (103 kPad) differential, the PIC II will shut down the compressor.
If the controls are subject to a power failure that lasts more than 3 hours, the oil pump will be energized periodically when the power is restored. This helps to eliminate refrigerant that has migrated to the oil sump during the power failure. The controls energize the pump for 60 seconds every 30 minutes until the chiller is started.
Oil Reclaim System — The oil reclaim system returns oil lost from the compressor housing back to the oil reservoir by recovering the oil from 2 areas on the chiller. The guide vane housing is the primary area of recovery. Oil is also recovered by skimming it from the operating refrigerant level in the cooler vessel.
PRIMARY OIL RECOVERY MODE — Oil is normally recovered through the guide vane housing on the chiller. This is possible because oil is normally entrained with refrigerant in the chiller. As the compressor pulls the refrigerant up from the cooler into the guide vane housing to be compressed, the oil normally drops out at this point and falls to the bottom of the guide vane housing where it accumulates. Using discharge gas pressure to power an eductor, the oil is drawn from the housing and is discharged into the oil reservoir.
SECONDARY OIL RECOVERY METHOD — The secondary method of oil recovery is significant under light load conditions, when the refrigerant going up to the compressor suction does not have enough velocity to bring oil along. Under these conditions, oil collects in a greater concentration at the top level of the refrigerant in the cooler. This oil and refrigerant mixture is skimmed from the side of the cooler and is then drawn up to the guide vane housing. There is a filter in this line. Because the guide vane housing pressure is much lower than the cooler pressure, the refrigerant boils off, leaving the oil behind to be collected by the primary oil recovery method.
8
REAR MOTOR |
FWD MOTOR |
OIL SUPPLY TO |
BEARING |
BEARING |
FORWARD HIGH |
|
LABYRINTH |
SPEED BEARING |
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GAS LINE |
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MOTOR |
COOLING LINE |
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ISOLATION |
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VALVE |
TXV BULB |
PRESSURE |
ISOLATION |
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OIL |
FILTER |
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PUMP |
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TRANSDUCER |
VALVE |
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OIL |
SIGHT |
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OIL |
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OIL PUMP |
HEATER |
GLASS |
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COOLER |
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EDUCTOR FILTER |
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MOTOR |
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||
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SIGHT GLASS |
ISOLATION |
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VALVE |
OIL SKIMMER LINE
Fig. 4 — Lubrication System
STARTING EQUIPMENT
The 19XR requires a motor starter to operate the centrifugal hermetic compressor motor, the oil pump, and various auxiliary equipment. The starter is the main field wiring interface for the contractor.
See Carrier Specification Z-415 for specific starter requirements, Z-416 for free-standing VFD requirements and Z-417 for unit-mounted VFD requirements. All starters must meet these specifications in order to properly start and satisfy mechanical safety requirements. Starters may be supplied as separate, free-standing units or may be mounted directly on the chiller (unit mounted) for low voltage units only.
Three separate circuit breakers are inside the starter. Circuit breaker CB1 is the compressor motor circuit breaker. The disconnect switch on the starter front cover is connected to this breaker. Circuit breaker CB1 supplies power to the compressor motor.
The main circuit breaker (CB1) on the front of the starter disconnects the main motor current only. Power is still energized for the other circuits. Two more circuit breakers inside the starter must be turned off to disconnect power to the oil pump, PIC II controls, and oil heater.
Circuit breaker CB2 supplies power to the control panel, oil heater, and portions of the starter controls.
Circuit breaker CB3 supplies power to the oil pump. Both CB2 and CB3 are wired in parallel with CB1 so that power is supplied to them if the CB1 disconnect is open.
All starters must include a Carrier control module called the Integrated Starter Module (ISM), excluding the Benshaw
solid-state starters. This module controls and monitors all aspects of the starter. See the Controls section on page 10 for additional ISM information. All starter replacement parts are supplied by the starter manufacturer excluding the ISM (contact Carrier’s Replacement Component Division [RCD]).
Unit-Mounted Solid-State Starter (Optional) —
The 19XR chiller may be equipped with a solid-state, reducedvoltage starter (Fig. 5 and 6). This starter’s primary function is to provide on-off control of the compressor motor. This type of starter reduces the peak starting torque, reduces the motor inrush current, and decreases mechanical shock. This capability is summed up by the phrase “soft starting.” The solid-state starter is available as a 19XR option (factory supplied and installed). The solid-state starters manufacturer name is located inside the starter access door.
A solid-state, reduced-voltage starter operates by reducing the starting voltage. The starting torque of a motor at full voltage is typically 125% to 175% of the running torque. When the voltage and the current are reduced at start-up, the starting torque is reduced as well. The object is to reduce the starting voltage to just the voltage necessary to develop the torque required to get the motor moving. The voltage is reduced by silicon controlled rectifiers (SCRs). The voltage and current are then ramped up in a desired period of time. Once full voltage is reached, a bypass contactor is energized to bypass the SCRs.
When voltage is supplied to the solid-state circuitry (CB1 is closed), the heat sinks in the starter as well as the wires leading to the motor and the motor terminal are at line voltage. Do not touch the heat sinks, power wiring, or motor terminals while voltage is present or serious injury will result.
9
7
1
2
3
4
6
5
LEGEND
1— RediStart MICRO™ Input/Output Card
2— Fuses 1-4 (Hidden, not depicted)
3— Circuit Breaker 2 (CB2): Machine Control and Heater Power
4— Circuit Breaker 3 (CB3): Oil Pump Power
5— RediStart MICRO Central Processing Unit Card (CPU)
6— RediStart MICRO Power Card (hidden, not depicted)
7— RediStart MICRO Bypass Card (hidden, not depicted)
Fig. 5 — Solid-State Starter Box,
Internal View
Fig. 6 — Typical Starter External View
(Solid-State Starter Shown)
There is a display on the front of the Benshaw, Inc., solidstate starters that is useful for troubleshooting and starter checkout. The display indicates:
•voltage to the SCRs
•SCR control voltage
•power indication
•proper phasing for rotation
•start circuit energized
•over-temperature
•ground fault
•current unbalance
•run state
•software configuration
The starter is further explained in the Check Starter and Troubleshooting Guide sections, pages 54 and 76.
Unit-Mounted Wye-Delta Starter (Optional) —
The 19XR chiller may be equipped with a wye-delta starter mounted on the unit. This starter is used with low-voltage motors (under 600 v). It reduces the starting current inrush by connecting each phase of the motor windings into a wye configuration. This occurs during the starting period when the motor is accelerating up to speed. Once the motor is up to speed, the starter automatically connects the phase windings into a delta configuration. Starter control, monitoring, and motor protection is provided by Carrier’s Integrated Starter Module (ISM).
Unit-Mounted VFD (Optional) — The 19XRV unit will be equipped with a variable frequency drive motor controller mounted on the unit. See Fig. 7 and 8. This VFD is used with low voltage motors between 380 and 480 VAC. It reduces the starting current inrush by controlling the voltage and frequency to the compressor motor. Once the motor has accelerated to minimum speed the PIC II modulates the compressor speed and guide vane position to control chilled water temperature. The VFD is further explained in the Controls section and Troubleshooting Guide section, pages 10 and 76.
There is a separate display located on the unit-mounted VFD. Operational parameters and fault codes are displayed relative to the drive. Refer to specific drive literature along with troubleshooting sections. The display is also the interface for entering specific chiller operational parameters. These parameters have been preprogrammed at the factory. An adhesive backed label on the inside of the drive has been provided for verification of the specific job parameters. See Initial Start-Up Checklist section for details.
CONTROLS
Definitions
ANALOG SIGNAL — An analog signal varies in proportion to the monitored source. It quantifies values between operating limits. (Example: A temperature sensor is an analog device because its resistance changes in proportion to the temperature, generating many values.)
DISCRETE SIGNAL — A discrete signal is a 2-position representation of the value of a monitored source. (Example: A switch produces a discrete signal indicating whether a value is above or below a set point or boundary by generating an on/off, high/low, or open/closed signal.)
10
ENTER |
OPTIONAL |
METER |
PACKAGE |
|
RUNNING |
AUTO |
Forward |
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SPEED |
MAN |
Reverse |
||
VOLTS |
REMOTE |
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AMPS |
JOG |
PROGRAM |
RUN |
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Hz |
AUTO |
JOB |
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||||
Kw |
FORWARD |
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TORQUE |
REVERSE |
ENTER |
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Password |
PROGRAM |
|||
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MANUAL RESET
Fig. 7 — Variable Frequency Drive (VFD)
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+ DC BUS BAR |
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MEASUREMENT |
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- POINT |
INTEGRATED |
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STARTER |
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MODULE |
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(ISM) |
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INITIAL DC BUS |
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MEASUREMENT |
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POINT |
OIL PUMP |
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+ DANGER - |
DISCONNECT |
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HIGH VOLTAGE |
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CONTROL |
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AUTO Forward |
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SPEED |
RUNNING |
MAN Reverse |
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VOLTS |
REMOTE |
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AMPS |
JOG |
RUN |
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AND OIL |
|
Hz |
AUTO |
JOB |
LINE |
Kw |
FORWARD |
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TORQUE REVERSE |
ENTER |
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Password PROGRAM |
||||
HEATER |
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DISCONNECT |
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VFD |
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MODULE |
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LOAD |
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COOLING LINES |
COMPRESSOR |
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MOTOR |
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DISCONNECT |
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TXV |
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Fig. 8 — Variable Frequency Drive (VFD) Starter Internal View
General — The 19XR hermetic centrifugal liquid chiller contains a microprocessor-based control center that monitors and controls all operations of the chiller (see Fig. 9). The microprocessor control system matches the cooling capacity of the chiller to the cooling load while providing state-of-the-art chiller protection. The system controls cooling load within the set point plus the deadband by sensing the leaving chilled water or brine temperature and regulating the inlet guide vane via a mechanically linked actuator motor. The guide vane is a variable flow pre-whirl assembly that controls the refrigeration effect in the cooler by regulating the amount of refrigerant vapor flow into the compressor. An increase in guide vane opening increases capacity. A decrease in guide vane opening decreases capacity. The microprocessor-based control center protects the chiller by monitoring the digital and analog inputs and executing capacity overrides or safety shutdowns, if required.
PIC II System Components — The chiller control system is called the PIC II (Product Integrated Control II). See Table 1. The PIC II controls the operation of the chiller by monitoring all operating conditions. The PIC II can diagnose a problem and let the operator know what the problem is and what to check. It promptly positions the guide vanes to maintain leaving chilled water temperature. It can interface with auxiliary equipment such as pumps and cooling tower fans to turn them on when required. It continually checks all safeties to prevent any unsafe operating condition. It also regulates the oil heater while the compressor is off and regulates the hot gas bypass valve, if installed. The PIC II controls provide critical protection for the compressor motor and controls the motor starter.
11
FITTING (HIDDEN) |
PANEL |
ACTUATOR CABLE |
PANEL |
CABLE |
WATER |
|
SENSOR |
WATER |
CABLES |
|
|
SENSOR |
|
CABLES |
COOLER |
|
PRESSURE |
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TRANSDUCER |
|
CONNECTION |
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CONDENSER |
SCHRADER |
CONDENSER |
DISCHARGE |
COMPRESSOR |
MOTOR WINDING |
PRESSURE |
FITTING (HIDDEN) |
SERVICE |
ISOLATION |
DISCHARGE |
TEMPERATURE |
CABLE |
CONDENSER |
VALVE |
VALVE |
ELBOW JOINTS |
CABLE |
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PRESSURE |
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(OPTIONAL) |
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TRANSDUCER |
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CONNECTION |
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TOP VIEW
COMPRESSOR DETAIL
Fig. 9 — 19XR Controls and Sensor Locations
12
The PIC II can interface with the Carrier Comfort Network (CCN) if desired. It can communicate with other PIC I or PIC II equipped chillers and other CCN devices.
The PIC II consists of 3 modules housed inside 3 major components. The component names and corresponding control voltages are listed below (also see Table 1):
•control panel
—all extra low-voltage wiring (24 v or less)
•power panel
—230 or 115 v control voltage (per job requirement)
—up to 600 v for oil pump power
•starter cabinet
—chiller power wiring (per job requirement)
Table 1 — Major PIC II Components and
Panel Locations*
PIC II COMPONENT |
PANEL LOCATION |
Chiller Visual Controller (CVC/ICVC) and |
Control Panel |
Display |
|
Integrated Starter Module (ISM) |
Starter Cabinet |
Chiller Control Module (CCM) |
Control Panel |
Oil Heater Contactor (1C) |
Power Panel |
Oil Pump Contactor (2C) |
Power Panel |
Hot Gas Bypass Relay (3C) (Optional) |
Power Panel |
Control Transformers (T1, T2) |
Power Panel |
Temperature Sensors |
See Fig. 9. |
Pressure Transducers |
See Fig. 9. |
*See Fig. 8-13. |
|
CHILLER VISUAL CONTROLLER (CVC) — The CVC is the “brain” of the PIC II. This module contains all the operating software needed to control the chiller. The CVC is mounted to the control panel (Fig. 12) and is the input center for all local chiller set points, schedules, configurable functions, and options. The CVC has a stop button, an alarm light, four buttons for logic inputs, and a backlight display. The backlight will automatically turn off after 15 minutes of non-use. The functions of the four buttons or “softkeys” are menu driven and are shown on the display directly above the softkeys.
The viewing angle of the CVC can be adjusted for optimum viewing. Remove the 2 bolts connecting the control panel to the brackets attached to the cooler. Place them in one of the holes to pivot the control panel forward to backward to change the viewing angle. See Fig. 12. To change the contrast of the display, access the adjustment on the back of the CVC. See Fig. 12.
INTERNATIONAL CHILLER VISUAL CONTROLLER (ICVC) — Incorporates all of the functions and operating software of the CVC with the added feature of 4 factory programmed languages:
English (default) Chinese Japanese Korean
NOTE: Pressing any one of the four softkey buttons will activate the backlight display without implementing a softkey function.
INTEGRATED STARTER MODULE (ISM) — This module is located in the starter cabinet. This module initiates commands from the CVC/ICVC for starter functions such as starting and stopping the compressor, condenser, chilled water pumps, tower fan, spare alarm contacts, and the shunt trip. The ISM monitors starter inputs such as line voltage, motor current,
ground fault, remote start contact, spare safety, condenser high pressure, oil pump interlock, starter 1M, and run contacts. The ISM contains logic capable of safety shutdown. It shuts down the chiller if communications with the CVC/ICVC are lost. The ISM can also act as the interface for PIC II to the VFD controller.
CHILLER CONTROL MODULE (CCM) — This module is located in the control panel. The CCM provides the input and outputs necessary to control the chiller. This module monitors refrigerant pressure, entering and leaving water temperatures, and outputs control for the guide vane actuator, oil heaters, and oil pump. The CCM is the connection point for optional demand limit, chilled water reset, remote temperature reset, refrigerant leak sensor and motor kilowatt output.
OIL HEATER CONTACTOR (1C) — This contactor is located in the power panel (Fig. 13) and operates the heater at either 115 or 230 v. It is controlled by the PIC II to maintain oil temperature during chiller shutdown. The XR4 with split ring diffuser has a line voltage oil heater. Refer to the control panel wiring schematic.
OIL PUMP CONTACTOR (2C) — This contactor is located in the power panel. It operates all 200 to 575-v oil pumps. The PIC II energizes the contactor to turn on the oil pump as necessary.
HOT GAS BYPASS CONTACTOR RELAY (3C) (Optional) — This relay, located in the power panel, controls the opening of the hot gas bypass valve. The PIC II energizes the relay during low load, high lift conditions.
CONTROL TRANSFORMERS (T1, T2) — These transformers convert incoming control voltage to 24 vac power for the 3 power panel contactor relays, CCM, and CVC/ICVC.
OPTIONAL TRANSFORMER (T3) — This transformer provides control power to Dataport™/DataLINK™ modules.
Fig. 10 — Control Sensors (Temperature)
Fig. 11 — Control Sensors
(Pressure Transducers, Typical)
13
Fig. 12 — Control Panel
Fig. 13 — Power Panel
14
CVC/ICVC Operation and Menus (Fig. 14-20)
GENERAL
•The CVC/ICVC display automatically reverts to the default screen after 15 minutes if no softkey activity takes place and if the chiller is not in the pumpdown mode (Fig. 14).
•If a screen other than the default screen is displayed on the CVC/ICVC, the name of that screen is in the upper right corner (Fig. 15).
•The CVC/ICVC may be set to display either English or SI units. Use the CVC/ICVC configuration screen (accessed from the Service menu) to change the units. See the Service Operation section, page 45.
•Local Operation — The PIC II can be placed in local operating mode by pressing the LOCAL softkey. The PIC II then accepts commands from the CVC/ICVC only and uses the Local Time Schedule to determine chiller start and stop times.
•CCN Operation — The PIC II can be placed in the CCN operating mode by pressing the CCN softkey. The PIC II then accepts modifications from any CCN interface or module (with the proper authority), as well as from the CVC/ICVC. The PIC II uses the CCN time schedule to determine start and stop times.
ALARMS AND ALERTS — An alarm shuts down the compressor. An alert does not shut down the compressor, but it notifies the operator that an unusual condition has occurred. An alarm (*) or alert (!) is indicated on the STATUS screens on the far right field of the CVC/ICVC display screen.
Alarms are indicated when the control center alarm light (!) flashes. The primary alarm message is displayed on the default screen. An additional, secondary message and troubleshooting information are sent to the ALARM HISTORY table.
When an alarm is detected, the CVC/ICVC default screen will freeze (stop updating) at the time of alarm. The freeze enables the operator to view the chiller conditions at the time of alarm. The STATUS tables will show the updated information.
Once all alarms have been cleared (by pressing the RESET softkey), the default CVC/ICVC screen will return to normal operation.
CVC/ICVC MENU ITEMS — To perform any of the operations described below, the PIC II must be powered up and have successfully completed its self test. The self test takes place automatically, after power-up.
Press the MENU softkey to view the list of menu structures: STATUS , SCHEDULE , SETPOINT , and SERVICE .
•The STATUS menu allows viewing and limited calibration or modification of control points and sensors, relays and contacts, and the options board.
•The SCHEDULE menu allows viewing and modification of the local and CCN time schedules and Ice Build time schedules.
•The SETPOINT menu allows set point adjustments, such as the entering chilled water and leaving chilled water set points.
•The SERVICE menu can be used to view or modify information on the Alarm History, Control Test, Control Algorithm Status, Equipment Configuration, ISM Starter Configuration data, Equipment Service, Time and Date, Attach to Network Device, Log Out of Network Device, and CVC/ICVC Configuration screens.
For morePRIMARYinformationSTATUS |
on theCOMPRESSORmenu structures,DATE referTIMEto |
Fig. 17. MESSAGE |
ON TIME |
SECONDARY |
|
|
|
|
|
STATUS |
RUNNING TEMP CONTROL |
01-01-95 11:48 |
|||
MESSAGE |
|||||
LEAVING CHILLED WATER |
28.8 HOURS |
||||
ALARM LIGHT |
CHW IN |
CHW OUT |
EVAP REF |
||
55.1 |
|
44.1 |
40.7 |
||
(ILLUMINATED |
|
||||
CDW IN |
CDW OUT |
COND REF |
|||
WHEN POWER ON) |
|||||
85.0 |
|
95.0 |
98.1 |
||
• BLINKS CONTINUOUSLY |
|
||||
OIL PRESS |
OIL TEMP |
AMPS % |
|||
ON FOR AN ALARM |
21.8 |
132.9 |
93 |
||
• BLINKS ONCE TO |
|||||
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|
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|
||
CONFIRM A STOP |
CCN |
LOCAL |
RESET |
MENU |
|
STOP BUTTON |
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• HOLD FOR ONE |
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|
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SECOND TO STOP |
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SOFT KEYS |
MENU |
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EACH KEY'S FUNCTION IS |
||
LINE |
||
DEFINED BY THE MENU DESCRIPTION |
||
ON MENU LINE ABOVE |
|
Fig. 14 — CVC/ICVC Default Screen
19XR_II |
SERVICE |
ALARM HISTORY
CONTROL TEST
CONTROL ALGORITHM STATUS
EQUIPMENT CONFIGURATION
ISM (STARTER) CONFIGURATION DATA
EQUIPMENT SERVICE
TIME AND DATE
ATTACH TO NETWORK DEVICE
LOG OUT OF DEVICE
CVC CONFIGURATION
Fig. 15 — CVC/ICVC Service Screen
Press the softkey that corresponds to the menu structure to be viewed: STATUS SCHEDULE , SETPOINT , or
SERVICE . To view or change parameters within any of these menu structures, use the NEXT and PREVIOUS softkeys to scroll down to the desired item or table. Use the SELECT softkey to select that item. The softkey choices that then appear depend on the selected table or menu. The softkey choices and their functions are described below.
BASIC CVC/ICVC OPERATIONS (Using the Softkeys) — To perform any of the operations described below, the PIC II must be powered up and have successfully completed its self test.
15
•Press QUIT to leave the selected decision or field without saving any changes.
•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.
•Press SELECT to view the next screen level (highlighted with the cursor bar), or to override (if allowable) the highlighted point value.
•Press EXIT to return to the previous screen level.
•Press INCREASE or DECREASE to change the highlighted point value.
TO VIEW STATUS (Fig. 16) — The status table shows the actual value of overall chiller status such as CONTROL MODE, RUN STATUS, AUTO CHILLED WATER RESET, and REMOTE RESET SENSOR.
1.On the menu screen, press STATUS to view the list of point status tables.
2.Press NEXT or PREVIOUS 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
•ISM_STAT — Status of motor starter
•CVC_PSWD — Service menu password forcing access screen
•ICVC_PSWD — Service menu password forcing access screen
3.Press SELECT to view the desired point status table.
4. On the point status table, press NEXT or PREVIOUS until the desired point is displayed on the screen.
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19XR_II MAINSTAT |
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POINT STATUS |
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Control Mode |
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OFF |
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Run Status |
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Ready |
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Start Inhibit Timer |
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0.0 Min |
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Occupied? |
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NO |
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System Alert/Alarm |
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NORMAL |
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Chiller Start/Stop |
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STOP |
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Remote Start Contact |
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Open |
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Temperature Reset |
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0.0 F |
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Control Point |
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44.0 F |
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Chilled Water Temp |
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44.6 F |
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Active Demand Limit |
100% |
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Average Line Current |
0.0% |
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Fig. 16 — Example of Status Screen
OVERRIDE OPERATIONS
To Override a Value or Status
1.From any point status screen, press NEXT or PREVIOUS to highlight the desired value.
2.Press SELECT to select the highlighted value. Then:
16
• |
DEFAULT SCREEN |
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CCN |
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LOCAL |
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RESET |
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MENU |
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(SOFTKEYS) |
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Start Chiller In CCN Control |
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Start Chiller in Local Control |
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Clear Alarms |
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Access Main Menu |
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STATUS |
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SCHEDULE |
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SETPOINT |
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SERVICE |
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1 1 1 1 |
(ENTER A 4-DIGIT PASSWORD) (VALUES SHOWN AT FACTORY DEFAULT) |
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List the |
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Status Tables |
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List the Service Tables |
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Display The Setpoint Table |
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•MAINSTAT
•STARTUP
• COMPRESS |
List the Schedules |
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• HEAT_EX |
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• Base Demand Limit |
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• LCW Setpoint |
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• POWER |
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• ECW Setpoint |
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• ISM_STAT |
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• Ice Build Setpoint |
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• CVC_PSWD |
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• Tower Fan High Setpoint |
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Select a Status Table |
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Select the Setpoint |
NEXT |
PREVIOUS |
SELECT |
EXIT |
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NEXT |
PREVIOUS |
SELECT |
EXIT |
Select a Modification Point |
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Modify the Setpoint |
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INCREASE |
DECREASE |
QUIT |
ENTER |
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NEXT |
PREVIOUS |
SELECT |
EXIT |
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Modify a Discrete Point |
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START |
STOP |
RELEASE |
ENTER |
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ON |
OFF |
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Modify an Analog Point |
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• OCCPC01S – LOCAL TIME SCHEDULE |
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INCREASE |
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RELEASE |
ENTER |
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• OCCPC02S – |
ICE BUILD TIME SCHEDULE |
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Modify Control Options |
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• OCCPC03S – CCN TIME SCHEDULE |
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ENABLE |
DISABLE |
QUIT |
ENTER |
Select a Schedule |
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NEXT |
PREVIOUS |
SELECT |
EXIT |
1
2
3
4
5
6
7
8 Override
Select a Time Period/Override
NEXT |
PREVIOUS |
Modify a Schedule Time |
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INCREASE |
DECREASE |
Add/Eliminate a Day |
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ENABLE |
DISABLE |
SELECT |
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(ANALOG VALUES) |
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EXIT |
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(DISCRETE VALUES) |
ENTER |
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EXIT |
ALARM HISTORY
CONTROL TEST
CONTROL ALGORITHM STATUS
EQUIPMENT CONFIGURATION
ISM (STARTER) CONFIG DATA
EQUIPMENT SERVICE
TIME AND DATE
ATTACH TO NETWORK DEVICE
LOG OUT OF DEVICE
CVC CONFIGURATION
ICVC CONFIGURATION
NEXT |
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PREVIOUS |
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SELECT |
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EXIT |
SEE FIGURE 18
Fig. 17 — 19XR Chiller Display Menu Structure (CVC/ICVC)
17
•SERVICE TABLE
NEXT |
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PREVIOUS |
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SELECT |
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EXIT |
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ALARM HISTORY |
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Display Alarm History |
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(The table holds up to 25 alarms and |
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alerts with the most recent alarm |
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at the top of the screen.) |
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CONTROL TEST |
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List the Control Tests |
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• CCM Thermistors |
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CONTROL ALGORITHM STATUS |
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• CCM Pressure Transducers |
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• Pumps |
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• Discrete Outputs |
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List the Control Algorithm Status Tables |
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• Guide Vane Actuator |
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• CAPACITY (Capacity Control) |
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• Diffuser Actuator |
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• OVERRIDE (Override Status) |
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• Pumpdown/Lockout |
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• LL_MAINT (Lead Lag Status) |
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• Terminate Lockout |
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• ISM_HIST (ISM Alarm History) |
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Select a Test |
• Guide Vane Calibration |
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• LOADSHED |
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• WSMDEFME (Water System Manager Control Status) |
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NEXT |
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PREVIOUS |
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SELECT |
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EXIT |
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• OCCDEFCM (Time Schedule Status) |
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Select a Table |
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NEXT |
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PREVIOUS |
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SELECT |
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EXIT |
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OCCDEFM (Time |
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Schedule Status) |
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• CAPACITY (Capacity Control Algorithm) |
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Data Select Table |
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• OVERRIDE (Override Status) |
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NEXT |
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SELECT |
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EXIT |
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• LL_MAINT (LEADLAG Status) |
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• WSMDEFM2 (Water System Manager Control Status) |
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OCCPC01S (Local Status) |
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OCCPC02S (CCN, ICE BUILD Status) |
Maintenance Table Data |
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OCCPC03S (CCN Status) |
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EQUIPMENT CONFIGURATION |
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List the Equipment Configuration Tables |
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• NET_OPT |
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• BRODEF |
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• OCCEFCS |
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• HOLIDAYS |
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• CONSUME |
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• RUNTIME |
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Select a Table |
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NEXT |
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PREVIOUS |
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SELECT |
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EXIT |
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Select a Parameter |
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NEXT |
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EXIT |
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ICVC CONFIGURATION |
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Modify a Parameter |
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INCREASE |
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DECREASE |
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QUIT |
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ENTER |
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ENABLE |
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DISABLE |
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QUIT |
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ENTER |
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CONTINUED |
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SELECT (USE ENTER) TO SCROLL DOWN |
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ON NEXT PAGE |
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LID LANGUAGE |
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INCREASE |
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DECREASE |
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ENTER |
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EXIT |
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Fig. 18 — 19XR Service Menu Structure
18
SERVICE MENU CONTINUED
FROM PREVIOUS PAGE
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ISM (STARTER) CONFIG DATA |
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EQUIPMENT SERVICE |
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4 4 4 4 (ENTER A 4-DIGIT PASSWORD) |
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(VALUES SHOWN AT FACTORY DEFAULT) |
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Service Tables: |
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• OPTIONS |
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Service Tables: |
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• SETUP1 |
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• ISM (STARTER) CONFIG PASSWORD |
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• SETUP2 |
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• ISM_CONF |
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• LEADLAG |
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• RAMP_DEM |
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• TEMP_CTL |
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Select a Service Table |
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NEXT |
PREVIOUS |
SELECT |
EXIT |
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Select a Service Table Parameter |
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NEXT |
PREVIOUS |
SELECT |
EXIT |
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Modify a Service Table Parameter |
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INCREASE |
DECREASE |
QUIT |
ENTER |
(ANALOG VALUES) |
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ENABLE |
DISABLE |
QUIT |
ENTER |
(DISCRETE VALUES) |
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TIME AND DATE |
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Display Time and Date Table: |
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• To Modify — Current Time |
— Day of Week |
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ATTACH TO NETWORK DEVICE |
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— Current Date |
— Holiday Today |
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INCREASE |
DECREASE |
ENTER |
EXIT |
(ANALOG VALUE) |
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List Network Devices |
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YES |
NO |
ENTER |
EXIT |
(DISCRETE VALUE) |
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• Local |
• Device 6 |
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• Device 1 |
• Device 7 |
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• Device 2 |
• Device 8 |
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• Device 3 |
• Device 9 |
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• Device 4 |
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• Device 5 |
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Select a Device |
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NEXT |
PREVIOUS |
SELECT |
ATTACH |
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Modify Device Address |
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INCREASE |
DECREASE |
ENTER |
EXIT |
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• Use to attach CVC to another CCN network or device |
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• Attach to "LOCAL" to enter this machine |
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• To upload new tables |
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LOG OUT OF DEVICE |
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Default Screen |
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CCN |
LOCAL |
RESET |
MENU |
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CVC CONFIGURATION
CVC Configuration Table |
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INCREASE |
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DECREASE |
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ENTER |
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EXIT |
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• To Modify — CVC CCN Address |
• To View — CVC Software Version |
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— English (U.S. IMP.) or S.I. Metric Units |
(last 2 digits of part number |
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— Password |
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indicate software version) |
LEGEND
CCN — Carrier Comfort Network
CVC — Chiller Visual Controller
ICVC — International Chiller Visual Controller
ISM — Integrated Starter Module
PIC II — Product Integrated Control II
Fig. 18 — 19XR Service Menu Structure (cont)
19
For Discrete Points — Press START or STOP to select the desired state.
For Analog Points — Press INCREASE or DECREASE to select the desired value.
3. Press ENTER 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 to see a value change, especially on kilopascal values.
To Remove an Override
1. On the point status table press NEXT or PREVIOUS to highlight the desired value.
2.Press SELECT to access the highlighted value.
3.Press RELEASE to remove the override and return the point to the PIC II’s automatic control.
Override Indication — An override value is indicated by “SUPVSR,” “SERVC,” or “BEST” flashing next to the point value on the STATUS table.
TIME SCHEDULE OPERATION (Fig. 19)
1.On the Menu screen, press SCHEDULE .
2.Press NEXT or PREVIOUS to highlight the desired schedule.
OCCPC01S — LOCAL Time Schedule
OCCPC02S — ICE BUILD Time Schedule
OCCPC03S — CCN Time Schedule
3.Press SELECT to view the desired time schedule.
4.Press NEXT or PREVIOUS to highlight the desired period or override to change.
5.Press SELECT to access the highlighted period or override.
6.a. Press INCREASE or DECREASE to change the time values. Override values are in one-hour
increments, up to 4 hours.
b.Press ENABLE to select days in the day-of-week
fields. Press DISABLE to eliminate days from the period.
Fig. 19 — Example of Time Schedule
Operation Screen
20
7.Press ENTER to register the values and to move horizontally (left to right) within a period.
8.Press EXIT to leave the period or override.
9.Either return to Step 4 to select another period or override, or press EXIT again to leave the current time schedule screen and save the changes.
10.The Holiday Designation (HOLIDEF table) may be found in the Service Operation section, page 45. The month, day, and duration for the holiday must be assigned. The Broadcast function in the BRODEF table also must be enabled for holiday periods to function.
TO VIEW AND CHANGE SET POINTS (Fig. 20)
1.To view the SETPOINT table, from the MENU screen press SETPOINT .
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19XR_II |
SETPOINT |
SETPOINT SELECT |
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Base Demand Limit |
100% |
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Control Point |
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LCW Setpoint |
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50.0 F |
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ECW Setpoint |
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60.0 F |
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ICE BUILD Setpoint |
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40.0 F |
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Tower Fan High Setpoint |
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85.0 F |
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Fig. 20 — Example of Set Point Screen
2.There are 5 set points on this screen: BASE DEMAND LIMIT, LCW SETPOINT (leaving chilled water set point), ECW SETPOINT (entering chilled water set point), ICE BUILD SETPOINT, and TOWER FAN HIGH SETPOINT. Only one of the chilled water set points can be active at one time. The set point that is active is determined from the SERVICE menu. See the Service Operation section, page 45. The ice build (ICE BUILD) function is also activated and configured from the SERVICE menu.
3. Press NEXT or PREVIOUS to highlight the desired set point entry.
4.Press SELECT to modify the highlighted set point.
5.Press INCREASE or DECREASE to change the selected set point value.
6.Press ENTER to save the changes and return to the previous screen.
SERVICE OPERATION — To view the menu-driven programs available for Service Operation, see Service Operation section, page 45. For examples of CVC/ICVC display screens, see Table 2.
21
Table 2 — CVC/ICVC Display Data
IMPORTANT: The following notes apply to all Table 2 examples.
1.Only 12 lines of information appear on the chiller display screen at any one time. Press the NEXT or PREVIOUS softkey to highlight a point or to view items below or above the current screen. Press the NEXT softkey twice to page forward; press the PREVIOUS softkey twice to page back.
2.To access the information shown in Examples 10 through 22, enter your 4-digit password after pressing the SERVICE softkey. If no softkeys are pressed for 15 minutes, the CVC/ICVC automatically logs off (to prevent unrestricted access to PIC II controls) and reverts to the default screen. If this happens, you must re-enter your password to access the tables shown in Examples 10 through 22.
3.Terms in the Description column of these tables are listed as they appear on the chiller display screen.
4.The CVC/ICVC may be configured in English or Metric (SI) units using the CVC/ICVC 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 chiller display screen. They are data or variable names used in CCN or Building Supervisor (BS) software. They are listed in these tables as a convenience to the operator if it is necessary to cross reference CCN/BS documentation or use CCN/BS programs. For more information, see the 19XR CCN literature.
6.Reference Point Names shown in these tables in all capital letters can be read by CCN and BS software. Of these capitalized names, those preceded by a dagger can also be changed (that is, written to) by the CCN, BS, and the CVC/ICVC. Capitalized Reference Point Names preceded by two asterisks can be changed only from the CVC/ICVC. Reference Point Names in lower case type can be viewed by CCN or BS only by viewing the whole table.
7.Alarms and Alerts: An asterisk in the far right field of a CVC/ ICVC status screen indicates that the chiller is in an alarm state; an exclamation point in the far right field of the CVC/ICVC screen indicates an alert state. The asterisk (or exclamation point) indicates that the value on that line has exceeded (or is approaching) a limit. For more information on alarms and alerts, see the Alarms and Alerts section, page 15.
LEGEND
CCN — Carrier Comfort Network
CHW — Chilled Water
CHWR — Chilled Water Return
CHWS — Chilled Water Supply
CVC — Chiller Visual Controller
CT — Current Transformer
ECW — Entering Chilled Water
HGBP — Hot Gas Bypass
ICVC — International Chiller Visual Controller
ISM — Integrated Starter Module
LCW — Leaving Chilled Water
LRA — Locked Rotor Amps
mA — Milliamps
P — Pressure
PIC II — Product Integrated Controls II
SS — Solid State
T — Temperature
VFD — Variable Frequency Drive
WSM — Water System Manager
EXAMPLE 1 — CHILLER DISPLAY DEFAULT SCREEN
The following data is displayed in the Default screen.
DESCRIPTION |
STATUS |
UNITS |
REFERENCE POINT NAME |
DISPLAY |
|
(ALARM HISTORY) |
|||||
|
|
|
|
||
(PRIMARY MESSAGE) |
|
|
|
|
|
(SECONDARY MESSAGE) |
|
|
|
|
|
(DATE AND TIME) |
|
|
|
|
|
Compressor Ontime |
0-500000.0 |
HOURS |
C_HRS |
|
|
Entering Chilled Water |
–40-245 |
DEG F |
ECW |
CHW IN |
|
Leaving Chilled Water |
–40-245 |
DEG F |
LCW |
CHW OUT |
|
Evaporator Temperature |
–40-245 |
DEG F |
ERT |
EVAP REF |
|
Entering Condenser Water |
–40-245 |
DEG F |
ECDW |
CDW IN |
|
Leaving Condenser Water |
–40-245 |
DEG F |
LCDW |
CDW OUT |
|
Condenser Temperature |
–40-245 |
DEG F |
CRT |
COND REF |
|
Oil Pressure |
0-420 |
PSI |
OILPD |
OILPRESS |
|
Oil Sump Temp |
40-245 |
DEG F |
OILT |
OIL TEMP |
|
Average Line Current |
0-999 |
% |
AMPS_% |
AMPS% |
|
|
0-1 |
|
CCN |
|
|
|
0-1 |
|
LOCAL |
|
|
|
0-1 |
|
RESET |
|
NOTE: The last three entries are used to indicate operating mode to the PIC II. These values may be forced by the CVC/ICVC only.
22
|
|
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|
|
|
|
Table 2 — CVC/ICVC Display Data (cont) |
|
|
|
|
|
|
|
|
|
EXAMPLE 2 — MAINTSTAT DISPLAY SCREEN |
|
|
To access this display from the CVC/ICVC default screen: |
|
|
|||||||
1. |
Press |
|
. |
|
|
|
|
|
|
MENU |
|
|
|
||||||
2. |
Press |
|
( |
|
will be highlighted). |
|
|
||
STATUS |
MAINSTAT |
|
|
||||||
3. |
Press |
|
. |
|
|
|
|||
SELECT |
|
|
|
||||||
|
|
|
|
|
|
|
|
|
|
|
|
DESCRIPTION |
STATUS |
UNITS |
POINT |
||||
|
Control Mode |
NOTE 1 |
NOTE 1 |
MODE |
|||||
|
Run Status |
NOTE 2 |
NOTE 2 |
STATUS |
|||||
|
Start Inhibit Timer |
0-15 |
min |
T_START |
|||||
|
Occupied? |
0/1 |
NO/YES |
OCC |
|||||
|
System Alert/Alarm |
0-2 |
NOTE 3 |
SYS_ALM |
|||||
*Chiller Start/Stop |
0/1 |
STOP/START |
CHIL_S_S |
||||||
*Remote Start Contact |
0/1 |
OPEN/CLOSE |
REMCON |
||||||
|
Temperature Reset |
–30-30 |
DEG F |
T_RESET |
|||||
*Control Point |
10-120 |
DEG F |
LCW_STPT |
||||||
|
Chilled Water Temp |
–40-245 |
DEG F |
CHW_TMP |
|||||
*Active Demand Limit |
40-100 |
% |
DEM_LIM |
||||||
|
Average Line Current |
0-999 |
% |
%_AMPS |
|||||
|
Motor Percent Kilowatts |
0-999 |
% |
KW_P |
|||||
|
Auto Demand Limit Input |
4-20 |
mA |
AUTODEM |
|||||
|
Auto Chilled Water Reset |
4-20 |
mA |
AUTORES |
|||||
|
Remote Reset Sensor |
–40-245 |
DEG F |
R_RESET |
|||||
|
Total Compressor Starts |
0-99999 |
|
c_starts |
|||||
|
Starts in 12 Hours |
0-8 |
|
STARTS |
|||||
|
Compressor Ontime |
0-500000.0 |
HOURS |
c_hrs |
|||||
*Service Ontime |
0-32767 |
HOURS |
S_HRS |
||||||
|
Ice Build Contact |
0-1 |
OPEN/CLOSE |
ICE_CON |
|||||
|
Refrigerant Leak Sensor |
0-20 |
mA |
REF_LEAK |
NOTES:
1.Reset, Off, Local, CCN
2.Timeout, Ready, Recycle, Prestart, Start-up, Ramping, Running, Demand, Override, Shutdown, Trippout, Pumpdown, Lockout
3.Normal, Alert, Alarm
4.All variables with capital letter point names are available for CCN read operation. Those shown with (*) support write operations for all CCN devices.
EXAMPLE 3 — STARTUP DISPLAY SCREEN
To access this display from the CVC/ICVC default screen:
1.Press MENU .
2.Press STATUS .
3.Scroll down to highlight STARTUP .
4.Press SELECT .
DESCRIPTION |
STATUS |
UNITS |
POINT |
Actual Guide Vane Pos |
0-100 |
% |
GV_ACT |
**Chilled Water Pump |
0-1 |
OFF/ON |
CHWP |
Chilled Water Flow |
0-1 |
NO/YES |
CHW_FLOW |
**Condenser Water Pump |
0-1 |
OFF/ON |
CDP |
Condenser Water Flow |
0-1 |
NO/YES |
CDW_FLOW |
Oil Pump Relay |
0-1 |
OFF/ON |
OILR |
**Oil Pump Delta P |
–6.7-200 |
^PSI |
OILPD |
Compressor Start Relay |
0-1 |
OFF/ON |
CMPR |
Compressor Start Contact |
0-1 |
OPEN/CLOSED |
CR_AUX |
Starter Trans Relay |
0-1 |
OFF/ON |
CMPTRANS |
Compressor Run Contact |
0-1 |
OPEN/CLOSED |
RUN_AUX |
**Tower Fan Relay Low |
0-1 |
OFF/ON |
TFR_LOW |
**Tower Fan Relay High |
0-1 |
OFF/ON |
TFR_HIGH |
Starter Fault |
0-1 |
ALARM/NORMAL |
STR_FLT |
Spare Safety Input |
0-1 |
ALARM/NORMAL |
SAFETY |
Shunt Trip Relay |
0-1 |
OFF/ON |
TRIPR |
ISM Fault Status |
0-255 |
|
STRSTAT |
NOTE: All variables with CAPITAL LETTER point names are available for CCN read operation. Those shown with (**) shall support write operations for the CVC/ICVC only.
23
Table 2 — CVC/ICVC Display Data (cont)
EXAMPLE 4 — COMPRESS DISPLAY SCREEN
To access this display from the CVC/ICVC default screen:
1.Press MENU .
2.Press STATUS .
3.Scroll down to highlight COMPRESS .
4.Press SELECT .
DESCRIPTION |
STATUS |
UNITS |
POINT |
Actual Guide Vane Pos |
0-100 |
% |
GV_ACT |
Guide Vane Delta |
0-100 |
% |
GV_DELTA |
**Target Guide Vane Pos |
0-100 |
% |
GV_TRG |
Oil Sump Temp |
–40-245 |
DEG F |
OILT |
**Oil Pump Delta P |
–6.7-200 |
^PSI |
OILPD |
Comp Discharge Temp |
–40-245 |
DEG F |
CMPD |
Comp Thrust Brg Temp |
–40-245 |
DEG F |
MTRB |
Comp Motor Winding Temp |
–40-245 |
DEG F |
MTRW |
Spare Temperature 1 |
–40-245 |
DEG F |
SPARE1 |
Spare Temperature 2 |
–40-245 |
DEG F |
SPARE2 |
Oil Heater Relay |
0/1 |
OFF/ON |
OILH |
Diffuser Actuator |
0-100 |
% |
DIFF_ACT |
**Target VFD Speed |
0-100 |
% |
VFD_OUT |
**Actual VFD Speed |
0-110 |
% |
VFD_ACT |
Surge Protection Counts |
0-5 |
|
SPC |
NOTE: All variables with CAPITAL LETTER point names are available for CCN read operation. Those shown with (**) shall support write operations for the CVC/ICVC only.
EXAMPLE 5 — HEAT_EX DISPLAY SCREEN
To access this display from the CVC/ICVC default screen:
1.Press MENU .
2.Press STATUS .
3.Scroll down to highlight HEAT_EX .
4.Press SELECT .
DESCRIPTION |
STATUS |
UNITS |
POINT |
**Chilled Water Delta P |
–6.7-420 |
PSI |
CHW_PD |
Entering Chilled Water |
–40-245 |
DEG F |
ECW |
Leaving Chilled Water |
–40-245 |
DEG F |
LCW |
Chilled Water Delta T |
–6.7-420 |
^F |
CHW_DT |
Chill Water Pulldown/Min |
–20-20 |
^F |
CHW_PULL |
Evaporator Refrig Temp |
–40-245 |
DEG F |
ERT |
**Evaporator Pressure |
–6.7-420 |
PSI |
ERP |
Evaporator Approach |
0-99 |
^F |
EVAP_APP |
**Condenser Water Delta P |
–6.7-420 |
PSI |
COND_PD |
Entering Condenser Water |
–40-245 |
DEG F |
ECDW |
Leaving Condenser Water |
–40-245 |
DEG F |
LCDW |
Condenser Refrig Temp |
–40-245 |
DEG F |
CRT |
**Condenser Pressure |
–6.7-420 |
PSI |
CRP |
Condenser Approach |
0-99 |
^F |
COND_APP |
Hot Gas Bypass Relay |
0/1 |
OFF/ON |
HGBR |
Surge / HGBP Active? |
0/1 |
NO/YES |
SHG_ACT |
Active Delta P |
0-200 |
PSI |
dp_a |
Active Delta T |
0-200 |
DEG F |
dt_a |
Surge / HGBP Delta T |
0-200 |
DEG F |
dt_c |
Head Pressure Reference |
0-100 |
% |
hpr |
Evaporator Saturation Temp |
–40-245 |
^F |
EST |
(ICVC only) |
|
|
|
NOTE: All variables with CAPITAL LETTER point names are available for CCN read operation. Those shown with (**) shall support write operations for the CVC/ICVC only.
24
Table 2 — CVC/ICVC Display Data (cont)
EXAMPLE 6 — POWER DISPLAY SCREEN
To access this display from the CVC/ICVC default screen:
1.Press MENU .
2.Press STATUS .
3.Scroll down to highlight POWER .
4.Press SELECT .
DESCRIPTION |
STATUS |
UNITS |
POINT |
Average Line Current |
0-999 |
% |
%_AMPS |
Actual Line Current |
0-99999 |
AMPS |
AMP_A |
Average Line Voltage |
0-999 |
% |
VOLT_P |
Actual Line Voltage |
0-99999 |
VOLTS |
VOLT_A |
Power Factor |
0.0-1.0 |
|
PF |
Motor Kilowatts |
0-99999 |
kW |
KW_A |
**Motor Kilowatt-Hours |
0-99999 |
kWH |
KWH |
Demand Kilowatts |
0-99999 |
kWH |
DEM_KWH |
Line Current Phase 1 |
0-99999 |
AMPS |
AMPS_1 |
Line Current Phase 2 |
0-99999 |
AMPS |
AMPS_2 |
Line Current Phase 3 |
0-99999 |
AMPS |
AMPS_3 |
Line Voltage Phase 1 |
0-99999 |
VOLTS |
VOLTS_1 |
Line Voltage Phase 2 |
0-99999 |
VOLTS |
VOLTS_2 |
Line Voltage Phase 3 |
0-99999 |
VOLTS |
VOLTS_3 |
Ground Fault Phase 1 |
0-999 |
AMPS |
GF_1 |
Ground Fault Phase 2 |
0-999 |
AMPS |
GF_2 |
Ground Fault Phase 3 |
0-999 |
AMPS |
GF_3 |
Frequency |
0-99 |
Hz |
FREQ |
I2T Sum Heat-Phase 1 |
0-200 |
% |
HEAT1SUM |
I2T Sum Heat-Phase 2 |
0-200 |
% |
HEAT2SUM |
I2T Sum Heat-Phase 3 |
0-200 |
% |
HEAT3SUM |
NOTES:
1.All variables with CAPITAL LETTER point names are available for CCN read operation.
2.Those shown with (**) shall support write operations for CVC/ICVC only.
EXAMPLE 7 — ISM_STAT DISPLAY SCREEN
To access this display from the CVC/ICVC default screen:
1.Press MENU .
2.Press STATUS .
3.Scroll down to highlight ISM_STAT .
4.Press SELECT .
DESCRIPTION |
STATUS |
UNITS |
POINT |
ISM Fault Status |
0-223 |
|
ISMFLT |
Single Cycle Dropout |
0-1 |
NORMAL/ALARM |
CYCLE_1 |
Phase Loss |
0-1 |
NORMAL/ALARM |
PH_LOSS |
Overvoltage |
0-1 |
NORMAL/ALARM |
OV_VOLT |
Undervoltage |
0-1 |
NORMAL/ALARM |
UN_VOLT |
Current Imbalance |
0-1 |
NORMAL/ALARM |
AMP_UNB |
Voltage Imbalance |
0-1 |
NORMAL/ALARM |
VOLT_UNB |
Overload Trip |
0-1 |
NORMAL/ALARM |
OVERLOAD |
Locked Rotor Trip |
0-1 |
NORMAL/ALARM |
LRATRIP |
Starter LRA Trip |
0-1 |
NORMAL/ALARM |
SLRATRIP |
Ground Fault |
0-1 |
NORMAL/ALARM |
GRND_FLT |
Phase Reversal |
0-1 |
NORMAL/ALARM |
PH_REV |
Frequency Out of Range |
0-1 |
NORMAL/ALARM |
FREQFLT |
ISM Power on Reset |
0-1 |
NORMAL/ALARM |
ISM_POR |
Phase 1 Fault |
0-1 |
NORMAL/ALARM |
PHASE_1 |
Phase 2 Fault |
0-1 |
NORMAL/ALARM |
PHASE_2 |
Phase 3 Fault |
0-1 |
NORMAL/ALARM |
PHASE_3 |
1CR Start Complete |
0-1 |
FALSE/TRUE |
START_OK |
1M Start/Run Fault |
0-1 |
NORMAL/ALARM |
1M_FLT |
2M Start/Run Fault |
0-1 |
NORMAL/ALARM |
2M_FLT |
Pressure Trip Contact |
0-1 |
NORMAL/ALARM |
PRS_RIP |
Starter Fault |
0-1 |
NORMAL/ALARM |
STRT_FLT |
Motor Amps Not Sensed |
0-1 |
NORMAL/ALARM |
NO_AMPS |
Starter Acceleration Fault |
0-1 |
NORMAL/ALARM |
ACCELFLT |
High Motor Amps |
0-1 |
NORMAL/ALARM |
HIGHAMPS |
1CR Stop Complete |
0-1 |
FALSE/TRUE |
STOP_OK |
1M/2M Stop Fault |
0-1 |
NORMAL/ALARM |
1M2MSTOP |
Motor Amps When Stopped |
0-1 |
NORMAL/ALARM |
AMPSTOP |
Hardware Failure |
0-1 |
NORMAL/ALARM |
HARDWARE |
NOTE: All variables with CAPITAL LETTER point names are available for CCN read operation.
25
Table 2 — CVC/ICVC Display Data (cont)
EXAMPLE 8 — CVC/ICVC_PSWD DISPLAY SCREEN
To access this display from the CVC/ICVC default screen:
1.Press MENU .
2.Press STATUS .
3. |
Scroll down to highlight |
CVC |
.or |
ICVC |
|
|
|
|||
4. |
Press |
|
. |
|
|
|
|
|
|
|
SELECT |
|
|
|
|
|
|
||||
|
|
|
|
|
|
|
|
|
|
|
|
|
DESCRIPTION |
|
|
|
STATUS |
UNITS |
POINT |
||
|
Disable Service Password |
|
|
0-1 |
DSABLE/ENABLE |
PSWD_DIS |
||||
**Remote Reset Option |
|
|
0-1 |
DSABLE/ENABLE |
RESETOPT |
|||||
|
Reset Alarm? |
|
|
0-1 |
NO/YES |
REMRESET |
||||
|
CCN Mode? |
|
|
0-1 |
NO/YES |
REM_CCN |
NOTE: All variables with CAPITAL LETTER point names are available for CCN read operation. Those shown with (**) shall support write operations for the CVC/ICVC only.
EXAMPLE 9 — SETPOINT DISPLAY SCREEN
To access this display from the CVC/ICVC default screen:
1.Press MENU .
2.Press SETPOINT .
3.Press SELECT .
DESCRIPTION |
STATUS |
UNITS |
POINT |
DEFAULT |
Base Demand Limit |
40-100 |
% |
DLM |
100 |
Control Point |
|
|
|
|
ECW Setpoint |
15-120 |
DEG F |
ecw_sp |
60.0 |
LCW Setpoint |
10-120 |
DEG F |
lcw_sp |
50.0 |
Ice Build Setpoint |
15-60 |
DEG F |
ice_sp |
40.0 |
Tower Fan High Setpoint |
55-105 |
DEG F |
tf2_sp |
75 |
NOTE: All variables are available for CCN read operation; forcing shall not be supported on setpoint screens.
EXAMPLE 10 — CAPACITY DISPLAY SCREEN
To access this display from the CVC/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 CAPACITY .
6.Press SELECT .
DESCRIPTION |
STATUS |
UNITS |
POINT |
Entering Chilled Water |
–40-245 |
DEG F |
ECW |
Leaving Chilled Water |
–40-245 |
DEG F |
LCW |
Capacity Control |
|
|
|
Control Point |
10-120 |
DEG F |
ctrlpt |
Control Point Error |
–99-99 |
^F |
cperr |
ECW Delta T |
–99-99 |
^F |
ecwdt |
ECW Reset |
–99-99 |
^F |
ecwres |
LCW Reset |
–99-99 |
^F |
lcwres |
Total Error + Resets |
–99-99 |
^F |
error |
Guide Vane Delta |
–2-2 |
% |
gvd |
Target Guide Vane Pos |
0-100 |
% |
GV_TRG |
Actual Guide Vane Pos |
0-100 |
% |
GV_ACT |
Target VFD Speed |
0-100 |
% |
VFD_IN |
Actual VFD Speed |
0-100 |
% |
VFD_ACT |
VFD Gain |
0.1-1.5 |
|
vfd_gain |
Demand Limit Inhibit |
0-100 |
% |
DEM_INH |
Amps/kW Ramp |
0-100 |
% |
DMD_RAMP |
VFD Load Factor |
0-200 |
|
VFD_LF |
NOTE: All variables with CAPITAL LETTER point names are available for CCN read operation; forcing shall not be supported on maintenance screen.
26
Table 2 — CVC/ICVC Display Data (cont)
EXAMPLE 11 — OVERRIDE DISPLAY SCREEN
To access this display from the CVC/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 .
6.Press SELECT .
DESCRIPTION |
STATUS |
UNITS |
POINT |
Comp Motor Winding Temp |
–40-245 |
DEG F |
MTRW |
Comp Motor Temp Override |
150-200 |
DEG F |
mt_over |
Condenser Pressure |
0-420 |
PSI |
CRP |
Cond Press Override |
90-180 |
PSI |
cp_over |
Evaporator Refrig Temp |
–40-245 |
DEG F |
ERT |
Evap Ref Override Temp |
2-45 |
DEG F |
rt_over |
Comp Discharge Temp |
–40-245 |
DEG F |
CMPD |
Comp Discharge Alert |
125-200 |
DEG F |
cd_alert |
Comp Thrust Brg Temp |
–40-245 |
DEG F |
MTRB |
Comp Thrust Brg Alert |
165-185 |
DEG F |
tb_alert |
Actual Superheat |
–20-99 |
^F |
SUPRHEAT |
Superheat Required |
6-99 |
^F |
SUPR_REQ |
Condenser Refrig Temp |
–40-245 |
DEG F |
CRT |
NOTE: All variables with CAPITAL LETTER point names are available for CCN read operation; forcing shall not be supported on maintenance screens.
EXAMPLE 12 — LL_MAINT DISPLAY SCREEN
To access this display from the CVC/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 LL_MAINT.
6.Press SELECT .
DESCRIPTION |
STATUS |
UNITS |
POINT |
LeadLag Control |
|
|
|
LEADLAG: Configuration |
NOTE 1 |
|
leadlag |
Current Mode |
NOTE 2 |
|
llmode |
Load Balance Option |
0/1 |
DSABLE/ENABLE |
loadbal |
LAG START Time |
2-60 |
MIN |
lagstart |
LAG STOP Time |
2-60 |
MIN |
lagstop |
Prestart Fault Time |
2-30 |
MIN |
preflt |
Pulldown: Delta T / Min |
x.xx |
^F |
pull_dt |
Satisfied? |
0/1 |
NO/YES |
pull_sat |
LEAD CHILLER in Control |
0/1 |
NO/YES |
leadctrl |
LAG CHILLER: Mode |
NOTE 3 |
|
lagmode |
Run Status |
NOTE 4 |
|
lagstat |
Start/Stop |
NOTE 5 |
|
lag_s_s |
Recovery Start Request |
0/1 |
NO/YES |
lag_rec |
STANDBY CHILLER: Mode |
NOTE 3 |
|
stdmode |
Run Status |
NOTE 4 |
|
stdstat |
Start/Stop |
NOTE 5 |
|
Std_s_s |
Recovery Start Request |
0/1 |
NO/YES |
std_rec |
Spare Temperature 1 |
–40-245 |
DEG F |
SPARE_1 |
Spare Temperature 2 |
–40-245 |
DEG F |
SPARE_2 |
NOTES:
1.DISABLE, LEAD, LAG, STANDBY, INVALID
2.DISABLE, LEAD, LAG, STANDBY, RECOVERY, CONFIG
3.Reset, Off, Local, CCN
4.Timeout, Ready, Recycle, Prestart, Startup, Ramping, Running, Demand, Override, Shutdown, Trippout, Pumpdown, Lockout
5.Stop, Start, Retain
6.All variables with CAPITAL LETTER point names are available for CCN read operation; forcing shall not be supported on maintenance screens.
27
Table 2 — CVC/ICVC Display Data (cont)
EXAMPLE 13 — ISM_HIST DISPLAY SCREEN
To access this display from the CVC/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 ISM_HIST .
6.Press SELECT .
DESCRIPTION |
STATUS |
UNITS |
POINT |
ISM FAULT HISTORY |
|
|
|
Values At Last Fault: |
|
|
|
Line Current Phase 1 |
0-99999 |
AMPS |
AMPS_1F |
Line Current Phase 2 |
0-99999 |
AMPS |
AMPS_2F |
Line Current Phase 3 |
0-99999 |
AMPS |
AMPS_3F |
Line Voltage Phase 1 |
0-99999 |
VOLTS |
VOLTS_1F |
Line Voltage Phase 2 |
0-99999 |
VOLTS |
VOLTS_2F |
Line Voltage Phase 3 |
0-99999 |
VOLTS |
VOLTS_3F |
Ground Fault Phase 1 |
0-999 |
AMPS |
GF_1F |
Ground Fault Phase 2 |
0-999 |
AMPS |
GF_2F |
Ground Fault Phase 3 |
0-999 |
AMPS |
GF_3F |
I2T Sum Heat-Phase 1 |
0-200 |
% |
HEAT1SUMF |
I2T Sum Heat-Phase 2 |
0-200 |
% |
HEAT2SUMF |
I2T Sum Heat-Phase 3 |
0-200 |
% |
HEAT3SUMF |
Phase 1 Faulted? |
0/1 |
NO/YES |
PH1_FLT |
Phase 2 Faulted? |
0/1 |
NO/YES |
PH2_FLT |
Phase 3 Faulted? |
0/1 |
NO/YES |
PH3_FLT |
Line Frequency |
0-99 |
Hz |
FREQ_ F |
ISM Fault Status |
0-9999 |
|
ISM_STAT |
NOTE: All variables with CAPITAL LETTER point names are available for CCN read operation; forcing shall not be supported on maintenance screens.
EXAMPLE 14 — WSMDEFME DISPLAY SCREEN
To access this display from the CVC/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 .
6.Press SELECT .
DESCRIPTION |
STATUS |
UNITS |
POINT |
WSM Active? |
0/1 |
NO/YES |
WSMSTAT |
Chilled Water Temp |
0.0-99.9 |
DEG F |
CHWTEMP |
Equipment Status |
0/1 |
OFF/ON |
CHLRST |
Commanded State |
XXXXXXXX |
TEXT |
CHLRENA |
CHW setpt Reset Value |
0.0-25.0 |
DEG F |
CHWRVAL |
Current CHW Set Point |
0.0-99.9 |
DEG F |
CHWSTPT |
NOTE: All variables with CAPITAL LETTER point names are available for CCN read operation; forcing shall not be supported on maintenance screens.
28
Table 2 — CVC/ICVC Display Data (cont)
EXAMPLE 15 — NET_OPT DISPLAY SCREEN
To access this display from the CVC/ICVC default screen:
1.Press MENU .
2.Press SERVICE .
3.Scroll down to highlight EQUIPMENT CONFIGURATION .
4.Press SELECT .
5.Scroll down to highlight NET_OPT .
6.Press SELECT .
DESCRIPTION |
STATUS |
UNITS |
POINT |
DEFAULT |
Loadshed Function |
|
|
|
|
Group Number |
0-99 |
|
ldsgrp |
0 |
Demand Limit Decrease |
0-60 |
% |
ldsdelta |
20 |
Maximum Loadshed Time |
0-120 |
MIN |
maxldstm |
60 |
CCN Occupancy Config: |
|
|
|
|
Schedule Number |
3-99 |
|
occpcxxe |
3 |
Broadcast Option |
0-1 |
DSABLE/ENABLE |
occbrcst |
DSABLE |
Alarm Configuration |
|
|
|
|
Re-Alarm Time |
0-1440 |
MIN |
|
30 |
Alarm Routing |
0-1 |
|
|
10000000 |
NOTE: No variables are available for CCN read or write operation.
EXAMPLE 16 — ISM_CONF DISPLAY SCREEN
To access this display from the CVC/ICVC default screen:
1.Press MENU .
2.Press SERVICE .
3.Scroll down to highlight ISM (STARTER) CONFIG DATA .
4.Press SELECT .
5.Enter password (4444 Factory Default).
6.Scroll down to highlight ISM_CONF .
7.Press SELECT .
DESCRIPTION |
STATUS |
UNITS |
POINT |
DEFAULT |
Starter Type |
0-2 |
|
starter |
1 |
(0 = Full, 1 = Red, 2 = SS/VFD) |
|
|
|
|
Motor Rated Line Voltage |
200-13200 |
VOLTS |
v_fs |
460 |
Volt Transformer Ratio:1 |
1-35 |
|
vt_rat |
1 |
Overvoltage Threshold |
105-115 |
% |
overvolt |
115 |
Undervoltage Threshold |
85-95 |
% |
undvolt |
85 |
Over/Under Volt Time |
1-10 |
SEC |
uvuntime |
5 |
Voltage % Imbalance |
1-10 |
% |
v_unbal |
10 |
Voltage Imbalance Time |
1-10 |
SEC |
v_time |
5 |
Motor Rated Load Amps |
10-5000 |
AMPS |
a_fs |
200 |
Motor Locked Rotor Trip |
100-60000 |
AMPS |
motor_lr |
1000 |
Locked Rotor Start Delay |
1-10 |
cycles |
lrdelay |
5 |
Starter LRA Rating |
100-60000 |
AMPS |
start_lr |
2000 |
Motor Current CT Ratio:1 |
3-1000 |
|
ct_turns |
100 |
Current % Imbalance |
5-40 |
% |
c_unbal |
15 |
Current Imbalance Time |
1-10 |
SEC |
c_time |
5 |
Grnd Fault CT’s? |
0-1 |
NO/YES |
gf_phase |
YES |
Ground Fault CT Ratio:1 |
150 |
|
gf_ctr |
150 |
Ground Fault Current |
1-25 |
AMPS |
gf_amps |
15 |
Ground Fault Start Delay |
1-20 |
cycles |
gf_delay |
10 |
Ground Fault Persistence |
1-10 |
cycles |
gf_pers |
5 |
Single Cycle Dropout |
0/1 |
DSABLE/ENABLE |
cycdrop |
DSABLE |
Frequency = 60 Hz? (No = 50) |
0/1 |
NO/YES |
freq |
YES |
Line Frequency Faulting |
0/1 |
DSABLE/ENABLE |
freq_en |
DSABLE |
29
Table 2 — CVC/ICVC Display Data (cont)
EXAMPLE 17 — OPTIONS DISPLAY SCREEN
To access this display from the CVC/ICVC default screen:
1.Press MENU .
2.Press SERVICE .
3.Scroll down to highlight EQUIPMENT SERVICE .
4.Press SELECT .
5.Scroll down to highlight OPTIONS .
6.Press SELECT .
DESCRIPTION |
STATUS |
UNITS |
POINT |
DEFAULT |
Auto Restart Option |
0/1 |
DSABLE/ENABLE |
start |
DSABLE |
Remote Contacts Option |
0/1 |
DSABLE/ENABLE |
r_contact |
DSABLE |
Soft Stop Amps Threshold |
40-100 |
% |
softstop |
100 |
Surge / Hot Gas Bypass |
|
|
|
|
Surge Limit/HGBP Option |
0/1 |
|
srg_hgbp |
0 |
Select: Surge=0, HGBP=1 |
|
|
|
|
Min. Load Point (T1,P1) |
|
|
|
|
Surge/HGBP Delta T1 |
0.5-20 |
^F |
hgb_dt1 |
1.5 |
Surge/HGBP Delta P1 |
30-170 |
PSI |
hgb_dp1 |
50 |
Full Load Point (T2,P2) |
|
|
|
|
Surge/HGBP Delta T2 |
0.5-20 |
^F |
hbg_dt2 |
10 |
Surge/HGBP Delta P2 |
50-170 |
PSI |
hgb_dp2 |
85 |
Surge/HGBP Deadband |
0.5-3 |
^F |
hbg_db |
1 |
Surge Protection |
|
|
|
|
Surge Delta% Amps |
5-20 |
% |
surge_a |
10 |
Surge Time Period |
7-10 |
MIN |
surge_t |
8 |
Ice Build Control |
|
|
|
|
Ice Build Option |
0/1 |
DSABLE/ENABLE |
ibopt |
DSABLE |
Ice Build Termination |
0-2 |
|
ibterm |
0 |
0=Temp, 1=Contacts, 2=Both |
|
|
|
|
Ice Build Recycle |
0/1 |
DSABLE/ENABLE |
ibrecyc |
DSABLE |
Refrigerant Leak Option |
0/1 |
DSABLE/ENABLE |
|
DSABLE |
Refrigerant Leak Alarm mA |
4-20 |
mA |
REF_LEAK |
20 |
Head Pressure Reference |
|
|
|
|
Delta P at 0% (4mA) |
20-60 |
PSI |
HPDPO |
25 |
Delta P at 100% (20mA) |
20-60 |
PSI |
HPDP100 |
35 |
Minimum Output |
0-100 |
% |
HPDPMIN% |
0 |
NOTE: No variables are available for CCN read or write operation.
EXAMPLE 18 — SETUP1 DISPLAY SCREEN
To access this display from the CVC/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 .
6.Press SELECT .
DESCRIPTION |
STATUS |
UNITS |
POINT |
DEFAULT |
Comp Motor Temp Override |
150-200 |
DEG F |
mt_over |
200 |
Cond Press Override |
90-165 |
PSI |
cp_over |
125 |
Comp Discharge Alert |
125-200 |
DEG F |
cd_alert |
200 |
Comp Thrust Brg Alert |
165-185 |
DEG F |
tb_alert |
175 |
Chilled Medium |
0/1 |
WATER/BRINE |
medium |
WATER |
Chilled Water Deadband |
.5-2.0 |
^F |
cw _db |
1.0 |
Evap Refrig Trippoint |
0.0-40.0 |
DEG F |
ert_trip |
33 |
Refrig Override Delta T |
2.0-5.0 |
^F |
ref_over |
3 |
Condenser Freeze Point |
–20 - 35 |
DEG F |
cdfreeze |
34 |
Evap Flow Delta P Cutout |
0.5 - 50.0 |
PSI |
evap_cut |
5.0 |
Cond Flow Delta P Cutout |
0.5 - 50.0 |
PSI |
cond_cut |
5.0 |
Water Flow Verify Time |
0.5-5 |
MIN |
wflow_t |
5 |
Oil Pressure Verify Time |
15-300 |
SEC |
oilpr_t |
40 |
Recycle Control |
|
|
|
|
Restart Delta T |
2.0-10.0 |
DEG F |
rcycr_dt |
5 |
Shutdown Delta T |
0.5-4.0 |
DEG F |
rcycs_dt |
1 |
SPARE ALERT/ALARM ENABLE |
|
|
|
|
Disable=0, Lo=1/3, Hi=2/4 |
|
|
|
|
Spare Temp #1 Enable |
0-4 |
|
sp1_en |
0 |
Spare Temp #1 Limit |
–40-245 |
DEG F |
sp1_lim |
245 |
Spare Temp #2 Enable |
0-4 |
|
sp2_ en |
0 |
Spare Temp #2 Limit |
–40-245 |
DEG F |
sp2_ lim |
245 |
NOTE: No variables are available for CCN read or write operation; forcing shall not be supported on service screens.
30