23XRV 5SS

AquaEdge®
23XRV
High-Efficiency Variable Speed Screw Chiller with
Greenspeed® Intelligence and PIC III Controls
50/60 Hz
HFC-134a
Start-Up, Operation and Maintenance

Instructions
SAFETY CONSIDERATIONS
WARNING
Screw liquid chillers are designed to provide safe and
reliable service when operated within design specifica- Failure to follow these procedures may result in personal
tions. When operating this equipment, use good judg- injury or death.
ment and safety precautions to avoid damage to DO NOT USE TORCH to remove any component. System
equipment and property or injury to personnel. contains oil and refrigerant under pressure.
Be sure you understand and follow the procedures and
safety precautions contained in the machine instruc- To remove a component, wear protective gloves and gog-
tions, as well as those listed in this guide. gles and proceed as follows:
a. Shut off electrical power to unit.
b. Recover refrigerant to relieve all pressure from sys-
DANGER tem using both high-pressure and low pressure ports.
c. Traces of vapor should be displaced with nitrogen
Failure to follow these procedures will result in severe per- and the work area should be well ventilated. Refrig-
sonal injury or death. erant in contact with an open flame produces toxic
DO NOT VENT refrigerant relief devices within a build- gases.
ing. Outlet from rupture disc or relief valve must be vented d. Cut component connection tubing with tubing cutter
outdoors in accordance with the latest edition of ANSI/ and remove component from unit. Use a pan to catch
ASHRAE 15 (American National Standards Institute/ any oil that may come out of the lines and as a gage
American Society of Heating, Refrigerating, and Air-Con- for how much oil to add to the system.
ditioning Engineers). The accumulation of refrigerant in an
enclosed space can displace oxygen and cause e. Carefully unsweat remaining tubing stubs when nec-
asphyxiation. essary. Oil can ignite when exposed to torch flame.
PROVIDE adequate ventilation in accordance with ANSI/ DO NOT USE eyebolts or eyebolt holes to rig heat
ASHRAE 15, especially for enclosed and low overhead exchangers or the entire assembly.
spaces. Inhalation of high concentrations of vapor is harm- DO NOT work on high (or medium) voltage equipment
ful and may cause heart irregularities, unconsciousness, or unless you are a qualified electrician.
death. Intentional misuse can be fatal. Vapor is heavier than DO NOT WORK ON electrical components, including
air and reduces the amount of oxygen available for breath- control panels, switches, starters, or oil heater until you are
ing. Product causes eye and skin irritation. Decomposition sure ALL POWER IS OFF and no residual voltage can
products are hazardous. leak from capacitors or solid-state components.
DO NOT USE OXYGEN to purge lines or to pressurize a LOCK OPEN AND TAG electrical circuits during servic-
machine for any purpose. Oxygen gas reacts violently with ing. IF WORK IS INTERRUPTED, confirm that all cir-
oil, grease, and other common substances. cuits are deenergized before resuming work.
DO NOT USE air for leak testing. Use only refrigerant or AVOID SPILLING liquid refrigerant on skin or getting it
dry nitrogen. into the eyes. USE SAFETY GOGGLES. Wash any spills
NEVER EXCEED specified test pressures, VERIFY the from the skin with soap and water. If liquid refrigerant
allowable test pressure by checking the instruction litera- enters the eyes, IMMEDIATELY FLUSH EYES with
ture and the design pressures on the equipment nameplate. water and consult a physician.
DO NOT VALVE OFF any safety device. NEVER APPLY an open flame or live steam to a refriger-
BE SURE that all pressure relief devices are properly ant cylinder. Dangerous over pressure can result. When it is
installed and functioning before operating any machine. necessary to heat refrigerant, use only warm (110 F [43 C])
water.
RISK OF INJURY OR DEATH by electrocution. High (or
medium) voltage is present on motor leads even though the DO NOT REUSE disposable (nonreturnable) cylinders or
motor is not running. Open the power supply disconnect attempt to refill them. It is DANGEROUS AND ILLE-
before touching motor leads or terminals. GAL. 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 machine. The introduction of the wrong
refrigerant can cause machine damage or malfunction.
(Warnings continued on next page.)
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Catalog No. 04-53230011-01 Printed in U.S.A. Form 23XRV-5SS Pg 1 1016 11-14 Replaces: 23XRV-4SS
WARNING CAUTION
Operation of this equipment with refrigerants other than DO NOT leave refrigerant system open to air any longer
those cited herein should comply with ANSI/ASHRAE 15 than the actual time required to service the equipment. Seal
(latest edition). Contact Carrier for further information on circuits being serviced and charge with dry nitrogen to pre-
use of this machine with other refrigerants. vent oil contamination when timely repairs cannot be
DO NOT ATTEMPT TO REMOVE fittings, covers, etc., completed.
while machine is under pressure or while machine is run-
ning. Be sure pressure is at 0 psig (0 kPa) before breaking CAUTION
any refrigerant connection.
CAREFULLY INSPECT all relief valves, rupture discs, Chiller must be installed in an indoor environment where
and other relief devices AT LEAST ONCE A YEAR. If the ambient temperature is between 40 to 104 F (4 to 40 C)
machine operates in a corrosive atmosphere, inspect the with a relative humidity (non-condensing) of 95% or less.
devices at more frequent intervals. To ensure that electrical components operate properly and
DO NOT ATTEMPT TO REPAIR OR RECONDITION to avoid equipment damage, do not locate chiller in an area
exposed to dust, dirt, corrosive fumes, or excessive heat
any relief valve when corrosion or build-up of foreign
material (rust, dirt, scale, etc.) is found within the valve and humidity.
body or mechanism. Replace the valve.
DO NOT install relief devices in series or backwards. CONTENTS
USE CARE when working near or in line with a com- Page
pressed spring. Sudden release of the spring can cause it SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . 1,2
and objects in its path to act as projectiles. INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
SOME MODELS MAY EXCEED 85 dBA. Hearing pro- ABBREVIATIONS AND EXPLANATIONS. . . . . . . . . . 5
tection should be worn when working in the vicinity of
such chillers. 23XRV CHILLER FAMILIARIZATION . . . . . . . . . . . 5-13
Chiller Identification Nameplate . . . . . . . . . . . . . . . . . . 5
System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
CAUTION Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Failure to follow these procedures may result in personal Motor-Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
injury or damage to equipment. Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
DO NOT STEP on refrigerant lines. Broken lines can whip Control Center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
about and release refrigerant, causing personal injury. Storage Vessel (Optional) . . . . . . . . . . . . . . . . . . . . . . . 12
DO NOT climb over a machine. Use platform, catwalk, or REFRIGERATION CYCLE. . . . . . . . . . . . . . . . . . . . . 13-15
staging. Follow safe practices when using ladders. MOTOR COOLING CYCLE . . . . . . . . . . . . . . . . . . . . . . . 16
USE MECHANICAL EQUIPMENT (crane, hoist, etc.) to LUBRICATION CYCLE. . . . . . . . . . . . . . . . . . . . . . . . 16-18
lift or move inspection covers or other heavy components. Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Even if components are light, use mechanical equipment Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
when there is a risk of slipping or losing your balance. Oil Reclaim System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
BE AWARE that certain automatic start arrangements Capacity Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
CAN ENGAGE THE STARTER, TOWER FAN, OR CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-60
PUMPS. Open the disconnect ahead of the starter, tower Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
fan, and pumps. Shut off the machine or pump before ser- • ANALOG SIGNAL
vicing equipment. • DIGITAL SIGNAL
USE only repaired or replacement parts that meet the code General Controls Overview . . . . . . . . . . . . . . . . . . . . . . 18
requirements of the original equipment. PIC III System Components . . . . . . . . . . . . . . . . . . . . . 18
DO NOT VENT OR DRAIN waterboxes containing • INTERNATIONAL CHILLER VISUAL
industrial brines, liquid, gases, or semisolids without the CONTROLLER (ICVC)
permission of your process control group. • CHILLER CONTROL MODULE (CCM)
• VFD POWER MODULE
DO NOT LOOSEN waterbox cover bolts until the water- • VFD GATEWAY MODULE
box has been completely drained. • OIL HEATER CONTACTOR (1C)
DOUBLE-CHECK that coupling nut wrenches, dial indi- • OIL PUMP CONTACTOR (2C)
cators, or other items have been removed before rotating • HOT GAS BYPASS CONTACTOR RELAY (3C)
any shafts. (Optional)
DO NOT LOOSEN a packing gland nut before checking • SECOND STAGE OIL HEATER (5C)
that the nut has a positive thread engagement. • VAPORIZER HEATER CONTACTOR (6C)
• CONTROL TRANSFORMERS (T1, T2, T4)
PERIODICALLY INSPECT all valves, fittings, and piping
• EXV CONTROL MODULE (PD4-EXV)
for corrosion, rust, leaks, or damage. • AUXILIARY CONTROL MODULE (PD4-AUX1)
PROVIDE A DRAIN connection in the vent line near each • ELECTRONIC EXPANSION VALVE
pressure relief device to prevent a build-up of condensate • CONDENSER LEVEL SENSOR
or rain water.
DO NOT re-use compressor oil or any oil that has been
exposed to the atmosphere. Dispose of oil per local codes
and regulations.
2
CONTENTS (cont)
Page Page
ICVC Operation and Menus . . . . . . . . . . . . . . . . . . . . . 23 Local Start-Up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
• GENERAL Shutdown Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
• ALARMS AND ALERTS Automatic Soft Stop Amps Threshold . . . . . . . . . . . 61
• ICVC MENU ITEMS Chilled Liquid Recycle Mode . . . . . . . . . . . . . . . . . . . . 61
• BASIC ICVC OPERATIONS (Using the Softkeys) Safety Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
• TO VIEW STATUS BEFORE INITIAL START-UP. . . . . . . . . . . . . . . . . . 62-81
• OVERRIDE OPERATIONS Job Data Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
• TIME SCHEDULE OPERATION Equipment Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
• TO VIEW AND CHANGE SET POINTS Using the Optional Storage Tank
• SERVICE OPERATION and Pumpout System . . . . . . . . . . . . . . . . . . . . . . . . . 62
PIC III System Functions . . . . . . . . . . . . . . . . . . . . . . . . 45 Remove Shipping Packaging. . . . . . . . . . . . . . . . . . . . 62
• CAPACITY CONTROL Open Oil Circuit Valves . . . . . . . . . . . . . . . . . . . . . . . . . 62
• FORCED Oil Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
• NORMAL CONDITIONS Tighten All Gasketed Joints . . . . . . . . . . . . . . . . . . . . . 62
• CAPACITY INCREASE Check Chiller Tightness. . . . . . . . . . . . . . . . . . . . . . . . . 64
• CAPACITY DECREASE Refrigerant Tracer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
• ECL CONTROL OPTION Leak Test Chiller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
• CHILLED LIQUID DEADBAND Chiller Dehydration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
• PROPORTIONAL BANDS AND PROPORTIONAL Inspect Liquid Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
GAIN Inspect Refrigerant Cooling Lines. . . . . . . . . . . . . . . 71
• DEMAND LIMITING Check Optional Pumpout Compressor
• CHILLER TIMERS Liquid Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
• OCCUPANCY SCHEDULE Check Relief Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Safety Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Identify the VFD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Shunt Trip. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 • IDENTIFYING THE DRIVE BY PART NUMBER
Default Screen Freeze . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Check Control Center . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Ramp Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Input Power Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Capacity Override . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Checking the Installation. . . . . . . . . . . . . . . . . . . . . . . . 73
Compressor Minimum Speed Override . . . . . . . . . . 48 Inspect Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Vaporizer Temperature Control Ground Fault Troubleshooting . . . . . . . . . . . . . . . . . . 74
COMPRESSOR ON. . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Carrier Comfort Network® Interface . . . . . . . . . . . . . 75
Oil Sump Temperature Control Power Up the Controls and Check the
COMPRESSOR OFF. . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Oil Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Oil Sump Temperature Control Software Configuration . . . . . . . . . . . . . . . . . . . . . . . . . 75
COMPRESSOR ON. . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Input the Design Set Points . . . . . . . . . . . . . . . . . . . . . 75
Remote Start/Stop Contacts. . . . . . . . . . . . . . . . . . . . . 52 Input the Local Occupancy Schedule
Spare Safety and Spare Temperature Inputs . . . . 52 (OCCPC01S) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Spare Alarm Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Input Service Configurations. . . . . . . . . . . . . . . . . . . . 75
Refrigerant Leak Detector . . . . . . . . . . . . . . . . . . . . . . . 52 • PASSWORD
4 to 20 mA Kilowatt Output. . . . . . . . . . . . . . . . . . . . . . 52 • INPUT TIME AND DATE
Remote Reset of Alarms . . . . . . . . . . . . . . . . . . . . . . . . 52 • CHANGE ICVC CONFIGURATION IF NECESSARY
Condenser Pump Control . . . . . . . . . . . . . . . . . . . . . . . 53 • TO CHANGE THE PASSWORD
Condenser Freeze Prevention . . . . . . . . . . . . . . . . . . . 53 • TO CHANGE THE ICVC DISPLAY FROM ENGLISH
Tower Fan Relay Low and High . . . . . . . . . . . . . . . . . 53 TO METRIC UNITS
Auto. Restart After Power Failure . . . . . . . . . . . . . . . 53 • MODIFY CONTROLLER IDENTIFICATION
Fast Power Source Transfers . . . . . . . . . . . . . . . . . . . 53 IF NECESSARY
Liquid/Brine Temperature Reset . . . . . . . . . . . . . . . . 53 • INPUT EQUIPMENT SERVICE PARAMETERS
• RESET TYPE 1 IF NECESSARY
• RESET TYPE 2 • MODIFY EQUIPMENT CONFIGURATION
• RESET TYPE 3 IF NECESSARY
Demand Limit Control Option . . . . . . . . . . . . . . . . . . . 54 Perform a Control Test . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Hot Gas Bypass (Optional) Algorithm . . . . . . . . . . . 54 Pressure Transducer and Optional Flow
Head Pressure Output Reference . . . . . . . . . . . . . . . 54 Device Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Lead/Lag Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 • ZERO POINT CALIBRATION
• COMMON POINT SENSOR INSTALLATION • HIGH END CALIBRATION
• CHILLER COMMUNICATION WIRING Check Optional Pumpout System
• LEAD/LAG OPERATION Controls and Compressor . . . . . . . . . . . . . . . . . . . . 79
• FAULTED CHILLER OPERATION High Altitude Locations . . . . . . . . . . . . . . . . . . . . . . . . . 79
• LOAD BALANCING Charge Refrigerant Into Chiller . . . . . . . . . . . . . . . . . . 79
• AUTO. RESTART AFTER POWER FAILURE • CHILLER EQUALIZATION WITHOUT A
Attach to Network Device Control . . . . . . . . . . . . . . . 58 PUMPOUT UNIT
• ATTACHING TO OTHER CCN MODULES • CHILLER EQUALIZATION WITH PUMPOUT UNIT
Service Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 • CHILLER SHIPPED WITH HOLDING CHARGE
• TO ACCESS THE SERVICE SCREENS • TRIMMING REFRIGERANT CHARGE
• TO LOG OUT OF DEVICE
• HOLIDAY SCHEDULING INITIAL START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . .82,83
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
START-UP/SHUTDOWN/RECYCLE Check Oil Pressure and Compressor Stop . . . . . . 82
SEQUENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-62 To Prevent Accidental Start-Up . . . . . . . . . . . . . . . . . 82
3
CONTENTS (cont) Oil Strainers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Page Page
Check Chiller Operating Condition . . . . . . . . . . . . . . 82 VFD Refrigerant Strainer . . . . . . . . . . . . . . . . . . . . . . . . 91
Instruct the Customer Operator . . . . . . . . . . . . . . . . . 82 Vaporizer Refrigerant Return Line Orifice . . . . . . . 91
• COOLER-CONDENSER Compressor Inlet Bearing Oil Orifice . . . . . . . . . . . . 92
• OPTIONAL PUMPOUT STORAGE TANK AND Inspect Condenser Refrigerant Float System . . . . 92
PUMPOUT SYSTEM Inspect Variable Frequency Drive . . . . . . . . . . . . . . . 94
• COMPRESSOR ASSEMBLY Inspect Relief Valves and Piping . . . . . . . . . . . . . . . . 94
• COMPRESSOR LUBRICATION SYSTEM Compressor Bearing Maintenance . . . . . . . . . . . . . . 94
• CONTROL SYSTEM Compressor Rotor Check . . . . . . . . . . . . . . . . . . . . . . . 94
• AUXILIARY EQUIPMENT Motor Insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
• DESCRIBE CHILLER CYCLES Inspect the Heat Exchanger Tubes . . . . . . . . . . . . . . 94
• REVIEW MAINTENANCE • COOLER
• SAFETY DEVICES AND PROCEDURES • CONDENSER
• CHECK OPERATOR KNOWLEDGE Water/Brine Leaks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
• REVIEW THE START-UP, OPERATION AND Water/Brine Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . 95
MAINTENANCE MANUAL Inspect the Control Center . . . . . . . . . . . . . . . . . . . . . . 95
Recalibrate Pressure Transducers . . . . . . . . . . . . . . 95
OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . 83-85
Operator Duties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 Optional Pumpout System Maintenance. . . . . . . . . 95
Prepare the Chiller for Start-Up. . . . . . . . . . . . . . . . . . 83 • OPTIONAL PUMPOUT COMPRESSOR
OIL CHARGE
To Start The Chiller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Check the Running System . . . . . . . . . . . . . . . . . . . . . 83 • OPTIONAL PUMPOUT SAFETY
To Stop the Chiller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 CONTROL SETTINGS
Ordering Replacement Chiller Parts . . . . . . . . . . . . . 96
• FAILURE TO STOP
After Limited Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . 84 TROUBLESHOOTING GUIDE . . . . . . . . . . . . . . . . 96-144
Preparation for Extended Shutdown. . . . . . . . . . . . . 84 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
After Extended Shutdown . . . . . . . . . . . . . . . . . . . . . . . 84 Checking Display Messages . . . . . . . . . . . . . . . . . . . . 97
Cold Weather Operation . . . . . . . . . . . . . . . . . . . . . . . . . 84 Checking Temperature Sensors . . . . . . . . . . . . . . . . . 97
Refrigeration Log. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 • RESISTANCE CHECK
• VOLTAGE DROP
PUMPOUT AND REFRIGERANT TRANSFER
PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86-89 • CHECK SENSOR ACCURACY
Preparation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 • DUAL MOTOR TEMPERATURE SENSORS
Checking Pressure Transducers . . . . . . . . . . . . . . . . 97
Operating the Optional Pumpout Unit . . . . . . . . . . . 86
Chillers with Storage Tanks . . . . . . . . . . . . . . . . . . . . . 87 • COOLER CONDENSER PRESSURE TRANSDUCER
• TRANSFER REFRIGERANT FROM PUMPOUT AND OPTIONAL WATER SIDE PRESSURE TRANS-
DUCER CALIBRATION
STORAGE TANK TO CHILLER
• TRANSFER REFRIGERANT FROM CHILLER TO • TRANSDUCER REPLACEMENT
PUMPOUT STORAGE TANK Control Algorithms Checkout Procedure . . . . . . . . 98
• CHILLERS WITH ISOLATION VALVES Control Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
• DISTILLING THE REFRIGERANT Control Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
• RED LED (Labeled as STAT)
GENERAL MAINTENANCE . . . . . . . . . . . . . . . . . . . 89,90 • GREEN LED (Labeled as COM)
Refrigerant Properties. . . . . . . . . . . . . . . . . . . . . . . . . . . 89 Notes on Module Operation . . . . . . . . . . . . . . . . . . . . 119
Adding Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 Chiller Control Module (CCM) . . . . . . . . . . . . . . . . . . 119
Removing Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 Replacing Defective ICVC Modules . . . . . . . . . . . . . 120
Adjusting the Refrigerant Charge . . . . . . . . . . . . . . . 89 • INSTALLATION
Refrigerant Leak Testing . . . . . . . . . . . . . . . . . . . . . . . . 89 Gateway Status LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Refrigerant Leak Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 • DRIVE STATUS INDICATOR
Test After Service, Repair, or Major Leak . . . . . . . . 89 • MS STATUS INDICATOR
• REFRIGERANT TRACER • NET A STATUS INDICATOR
• TO PRESSURIZE WITH DRY NITROGEN • NET B STATUS INDICATOR
Repair the Refrigerant Leak, Retest, and Apply • PD4 EXV BOARD (P COMPRESSOR ONLY)
Standing Vacuum Test . . . . . . . . . . . . . . . . . . . . . . . . 90 • PD4 AUX BOARD (P COMPRESSOR ONLY)
Trim Refrigerant Charge. . . . . . . . . . . . . . . . . . . . . . . . . 90 • EXV TROUBLESHOOTING
WEEKLY MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . 90 Physical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Check the Lubrication System . . . . . . . . . . . . . . . . . . 90 APPENDIX A — ICVC PARAMETER INDEX . . 145-152
SCHEDULED MAINTENANCE . . . . . . . . . . . . . . . . 90-96 APPENDIX B — MAINTENANCE SUMMARY
Service Ontime . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 AND LOG SHEETS . . . . . . . . . . . . . . . . . . . . . . . 153-156
Inspect the Control Center . . . . . . . . . . . . . . . . . . . . . . 90 APPENDIX C — BACNET COMMUNICATION
Check Safety and Operating Controls OPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157-163
Monthly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Changing Oil and Oil Filter . . . . . . . . . . . . . . . . . . . . . . 90 INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
• CHANGING OIL INITIAL START-UP CHECKLIST FOR 23XRV
Oil Specification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 VARIABLE SPEED SCREW CHILLER
Oil Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 WITH GREENSPEED
Refrigerant Filter/Drier . . . . . . . . . . . . . . . . . . . . . . . . . . 91 INTELLIGENCE . . . . . . . . . . . . . . . . . . . . . . .CL-1 to CL-10
4
INTRODUCTION ABBREVIATIONS AND EXPLANATIONS
Frequently used abbreviations in this manual include:
CAUTION CCM — Chiller Control Module
CCN — Carrier Comfort Network®
This unit uses a microprocessor control system. Do not CCW — Counterclockwise
short or jumper between terminations on circuit boards or CSM — Chillervisor System Manager
modules; control or board failure may result. CW — Clockwise
DPI — LF2 VFD Drive Peripheral Interface Board
Be aware of electrostatic discharge (static electricity) when ECDL — Entering Condenser Liquid
handling or making contact with circuit boards or module ECL — Entering Chilled Liquid
EMS — Energy Management System
connections. Always touch a chassis (grounded) part to EXV — Electronic Expansion Valve
dissipate body electrostatic charge before working inside HGBP — Hot Gas Bypass
control center. ICVC — International Chiller Visual Controller
IGBT — Insulated Gate Bipolar Transistor
Use extreme care when handling tools near boards and I/O — Input/Output
when connecting or disconnecting terminal plugs. Circuit KAIC — Kiloamps Interrupt Capacity
boards can easily be damaged. Always hold boards by the LCD — Liquid Crystal Display
edges and avoid touching components and connections. LCDL — Leaving Condenser Liquid
LCL — Leaving Chilled Liquid
This equipment uses, and can radiate, radio frequency LED — Light-Emitting Diode
energy. If not installed and used in accordance with the LEI — Local Equipment Interface Translator
LF2 — Reliance LiquiFlo™ 2 VFD with Active
instruction manual, it may cause interference to radio com- Rectifier
munications. The chiller control boards have been tested OIM — Reliance Operator Interface Module
and found to comply with the limits for a Class A comput- OLTA — Overload Trip Amps
ing device pursuant to International Standard in North PIC III — Product Integrated Control III
RLA — Rated Load Amps
America EN 61000-2/3 which are designed to provide rea- RS485 — Communications Type used by ICVC and
sonable protection against such interference when operated CCM
in a commercial environment. Operation of this equipment SCR — Silicon Controlled Rectifier
in a residential area is likely to cause interference, in which SI — International System of Units
SIO — Sensor Input/Output
case the user, at his own expense, will be required to take TB1 — Control Center Terminal Block 1
whatever measures may be required to correct the interfer- TB2 — Control Center Terminal Block 2
ence. VFD — Variable Frequency Drive
VFG — Variable Frequency Gateway Module
Always store and transport replacement or defective boards
in anti-static shipping bag. Words printed in all capital letters or in italics may be
viewed on the International Chiller Visual Controller (ICVC)
Prior to initial start-up of the 23XRV chiller, those involved (e.g., LOCAL, CCN, ALARM, etc.).
in the start-up, operation, and maintenance should be thorough- Words printed in both all capital letters and italics can also
ly familiar with these instructions and other necessary job data. be viewed on the ICVC and are parameters (e.g., CONTROL
This book is outlined to familiarize those involved in the start- MODE, COMPRESSOR START RELAY, etc.) with associated
up, operation and maintenance of the unit with the control sys- values (e.g., modes, temperatures, percentages, pressures, on,
tem before performing start-up procedures. Procedures in this off, etc.).
manual are arranged in the sequence required for proper chiller
start-up and operation. Words printed in all capital letters and in a box represent
softkeys on the ICVC control center (e.g., ENTER , EXIT ,
INCREASE , QUIT , etc.).
Factory-installed additional components are referred to as
options in this manual; factory-supplied but field-installed ad-
ditional components are referred to as accessories.
The chiller software part number of the 23XRV unit is lo-
cated on the back of the ICVC.
23XRV CHILLER FAMILIARIZATION

(FIG. 1-7)
Chiller Identification Nameplate — The chiller
identification nameplate is located on the right side of the
chiller control center.
System Components — The components include
cooler and condenser, heat exchangers in separate vessels,
motor-compressor, lubrication system, control center, and
optional economizer.
5
23XRV 40 42 N R V AA 5 0 S
S – Special
23XRV – High Efficiency Compressor Option

Variable Speed Screw Chiller 0 – Full Load Optimized
Cooler Size* 1 – Part Load Optimized
A1-A6
B1-B6 Voltage Code
30-32 3 – 380-3-60
35-37 4 – 416-3-60
40-42 5 – 460-3-60
45-47 7 – 575-3-60 (Q and R compressors only)
50-52 9 – 380/415-3-50
55-57
Condenser Size* Drive Code**
A1-A6 AA – LF-2, 440 Amps In, 442 Amps Out
B1-B6 BA – LF-2, 520 Amps In, 442 Amps Out
30-32 CC – LF-2, 608 Amps In, 608 Amps Out
35-37 EC – Std Tier, 575-v, 389 Amps In, 389 Amps Out
40-42 EF – Std Tier, 575-v, 469 Amps In, 469 Amps Out
45-47 R2 – Std Tier, 230 Amps In, 230 Amps Out
Economizer Option
E – With Economizer Motor Code
N – No Economizer H S
Compressor Code† J T
P P U
Q Q V
R R X
* First number denotes frame size.

† Only H and J motors are used with P compressors. Only type
V motors are used with Q compressors.
**Maximum limits only. Additional application limits apply that
may reduce these ampacities.
A23-1678
 Fig. 1 — Model Number Identification
1016 6
20 1 2
19 3 1 — Discharge Pipe
2 — Variable Frequency Drive
4 3 — Cooler Relief Valve
18 5 4 — Compressor Discharge Pipe
6 5 — International Chiller Visual Controller (ICVC)
17 6 — Refrigerant Charging Valve
7 — ASME Nameplate, Evaporator
7 8 — Condenser Relief Valves
16 8 9 — Tubesheet Mounting Brackets
9 10 — Condenser
11 — ASME Nameplate, Condenser
10 12 — Level Sensing Chamber
13 — Condenser Refrigerant Pumpout Valve
14 — Refrigerant Strainer
11 15 — Cooler Inlet Isolation Valve
16 — Motor Cooling Isolation Valve
17 — Motor Cooling Sight Glass
18 — Motor Cooling Supply Line
19 — Motor Cooling Line Filter Drier (Hidden)
20 — VFD Disconnect
12
a23-1691
13
14
15
21 — Vaporizer
22 — Tubesheet Mounting Brackets
23 — Oil Sump Heater (Hidden)
37 24 — Vaporizer Drain Sight Glass
25 — Oil Sump
26 — Oil Sump Sight Glass
36 27 — Oil Charging Drain Valve (Hidden)
28 — Strainer Housing Sight Glass
29 — Oil Pump Inlet Strainer
21 30 — Oil Filter Assembly
35 22 31 — Oil Pump
32 — Typical Waterbox Drain Coupling (Hidden)
33 — Condenser Supply/Return End Waterbox
34 34 — Oil Reclaim Actuator
35 — Cooler Supply/Return End Waterbox
36 — Vaporizer Sight Glass
37 — Hot Gas Bypass Line (Option)
33
24 23
26 25
a23-1692
27
28
29
32 31 30
43 38 — Discharge Isolation Valve Assembly (Option or

Accessory)
39 — Machine Electrical Data Nameplate
40 — Main EXV
41 — Economizer Gas EXV (Option)
42 38 42 — Economizer (Option)
43 — Economizer Muffler (Hidden)
41
40
39
Fig. 2 — Typical 23XRV Components (Units with P Compressor)
7
1 4 1 — Motor Terminal Cover Plate
2 3
21 2 — Variable Frequency Drive
3 — International Chiller Visual Controller (ICVC)
4 — Discharge Pipe Relief Valve
5
5 — Condenser
6 — Oil Reclaim Actuator
20 7 — Vaporizer Sight Glass
8 — Oil Filter Assembly (Hidden)
9 — Vaporizer
6 10 — Oil Charging/Drain Valve
11 — Oil Sump
7 12 — Condenser Refrigerant Pumpout Valve
13 — Condenser Float Chamber
14 — Cooler Inlet Isolation Valve
8 15 — ASME Nameplate, Economizer (Hidden)
16 — Filter Drier
9 17 — Oil Sump Heater
10 18 — Condenser Supply/Return End Waterbox
11 19 — Cooler Supply/Return End Waterbox
12
20 — Motor Cooling Supply Line
13
21 — VFD Disconnect
14
19 15
16
18 17 a23-1658
22 23
22 — Discharge Pipe
23 — Compressor Discharge Check Valve Access Cover
24 24 — Condenser Relief Valves
25 — Refrigerant Charging Valves
25 26 — Cooler Relief Valve
27 — Tubesheet Mounting Brackets
26 28 — Typical Waterbox Drain Coupling
30 — Oil Pump
33 — Discharge Isolation Valve (Option or Accessory)
34 — Refrigeration Machine Nameplate
37 — Filter Drier Isolation Valve with Schrader Valve
38 — Economizer
41
40 39 40 — Motor Cooling Isolation Valve
41 — Vaporizer Drain Sight Glass
38 37
36
35 34 27
28 a23-1659
33 32 29
31 30
44 45
43
42 42 — VFD Cold Plate Refrigeration Inlet Connection
46 (Outlet Hidden)
43 — VFD Cold Plate Solenoid
44 — Compressor Nameplate
47
45 — Compressor Lubrication Block
46 — Economizer Muffler
47 — Vaporizer Condenser Gas Isolation Valve
48 — Hot Gas Bypass Isolation and Trim Valve
49 — VFD Cooling Refrigerant Strainer
50 — Cooler Refrigerant Pumpout Valve
51 — ASME Nameplate, Cooler
48
49
50
a23-1660
51
Fig. 3 — Typical 23XRV Components (Units with Q Compressor)
8
4 1 — Motor Terminal Cover Plate
1 2 3 2 — Variable Frequency Drive
21 3 — International Chiller Visual Controller (ICVC)
4 — Discharge Pipe Relief Valve
5 5 — Condenser
6 — Oil Reclaim Actuator
7 — Vaporizer Sight Glass
20 8 — Oil Filter Assembly (Hidden)
9 — Vaporizer
10 — Oil Charging/Drain Valve
6 11 — Oil Sump
12 — Condenser Refrigerant Pumpout Valve
7 13 — Condenser Float Chamber
14 — Cooler Inlet Isolation Valve
15 — ASME Nameplate, Economizer (Hidden)
8 16 — Filter Drier
17 — Oil Sump Heater
9 18 — Condenser Supply/Return End Waterbox
10 19 — Cooler Supply/Return End Waterbox
11 20 — Motor Cooling Supply Line
12 21 — VFD Disconnect
13
14
19 15
16
17 a23-1548
18
22
23 22 — Discharge Pipe
24 23 — Compressor Discharge Check Valve Access Cover
25
24 — Condenser Relief Valves
25 — Refrigerant Charging Valves
26 — Cooler Relief Valve
26 27 — Tubesheet Mounting Brackets
28 — Typical Waterbox Drain Coupling
30 — Oil Pump
33 — Discharge Isolation Valve (Option or Accessory)
34 — Refrigeration Machine Nameplate
37 — Filter Drier Isolation Valve with Schrader Valve
38 — Economizer
41 40 39 38 40 — Motor Cooling Isolation Valve
37 41 — Vaporizer Drain Sight Glass
36 35 34
27
33 28
32 31 a23-1549
30 29
45
42 43 44
42 — VFD Cold Plate Refrigeration Inlet Connection
(Outlet Hidden)
46 43 — VFD Cold Plate Solenoid
47 44 — Compressor Nameplate
45 — Compressor Lubrication Block
46 — Economizer Muffler
47 — Vaporizer Condenser Gas Isolation Valve
48 — Hot Gas Bypass Isolation and Trim Valve
49 — VFD Cooling Refrigerant Strainer
50 — Cooler Refrigerant Pumpout Valve
51 — ASME Nameplate, Cooler
48
49
50
a23-1550
51
Fig. 4 — Typical 23XRV Components (Units with R Compressor)
9
12 13 1 — Compressor Motor Winding Temperature (Hidden)
1 2 — Vaporizer Temperature
3 — Evaporator Liquid Temperature
11 4 — Oil Sump Temperature
5 — Oil Sump Pressure
6 — Supply Oil Pressure
a23-1695 7 — Condenser Liquid Temperature (Hidden)
10 8 — Condenser Liquid Flow (Optional)
9 — Evaporator Liquid Flow (Optional)
10 — Evaporator Liquid Temperature (Hidden)
11 — Compressor Discharge Temperature
12 — Compressor Discharge Pressure
13 — Compressor Discharge High Pressure Switch
8
3
2
4 a23-1695
5
6
7
14 14 — Inductor Temperature Switch (Inside VFD Enclosure)

15 — VFD Rectifier Temperature (Inside Power Module)
15 16 — VFD Heat Sink Temperature (Inside VFD Enclosure)
16 17 — VFD Inverter Temperature (Inside Power Module)
18 — Evaporator Pressure
17 19 — Condenser Pressure
22 20 — Condenser Liquid Level Sensor
21 21 — Economizer Pressure (Optional)
22 — Economizer Temperature (Optional)
18
19
20
Fig. 5 — Typical 23XRV Installation — Sensor Locations (Units with P Compressor)
10
4 5
3
2
1
6 — Compressor Motor Winding Temperature (Hidden)
7 — Evaporator Refrigerant Liquid Temperature (Hidden)
8 — Condenser Liquid Temperature
9 — Condenser Liquid Flow (Optional)
9
7
8
a23-1661
13
10 11 12
14 10 — Inductor Temperature Switch (Inside VFD Enclosure)
11 — VFD Rectifier Temperature (Inside Power Module)
12 — VFD Cold Plate Temperature (Inside VFD Enclosure)
13 — VFD Inverter Temperature (Inside Power Module)
14 — Humidity Sensor (Inside VFD Enclosure)
15 — Oil Pressure Leaving Filter (Hidden)
15 16 — Oil Sump Pressure (Hidden)
17 — Oil Sump Temperature (Hidden)
18 — Vaporizer Temperature
19 — Evaporator Liquid Temperature
16
17
20
a23-1662
19
18
Fig. 6 — Typical 23XRV Installation — Sensor Locations (Units with Q Compressor)

6
4 5
2 3
6 — Compressor Motor Winding Temperature (Hidden)
7 — Evaporator Refrigerant Liquid Temperature (Hidden)
8 — Condenser Liquid Temperature
9 — Condenser Liquid Flow (Optional)
7 a23-1551
8
10 — Inductor Temperature Switch (Inside VFD Enclosure)
12 13
10 11 11 — VFD Rectifier Temperature (Inside Power Module)
12 — VFD Cold Plate Temperature (Inside VFD Enclosure)
13 — VFD Inverter Temperature (Inside Power Module)
14 14 — Humidity Sensor (Inside VFD Enclosure)
15 — Oil Pressure Leaving Filter (Hidden)
16 — Oil Sump Pressure (Hidden)
17 — Oil Sump Temperature (Hidden)
18 — Vaporizer Temperature
15 19 — Evaporator Liquid Temperature
a23-1552
20 16
17
19
18
Fig. 7 — Typical 23XRV Installation — Sensor Locations (Units with R Compressor)
11
Cooler — The cooler (also known as the evaporator) is • records the total chiller operating hours, starts, and the
maintained at low temperature/pressure so that evaporating number of hours the chiller has been currently running
refrigerant can remove heat from the liquid flowing through its • sequences chiller start, stop, and recycle under microproces-
internal tubes. sor control
• provides access to other Carrier Comfort Network® devices
Condenser — This vessel is located underneath the • provides machine protection
compressor. The condenser operates at a higher temperature/
pressure than the cooler and has liquid flowing through its Storage Vessel (Optional) — Two sizes of storage
internal tubes to remove heat from the refrigerant. vessels are available. The vessels have double relief valves,
a magnetically coupled dial-type refrigerant level gage, a
Motor-Compressor — The motor-compressor main- 1-in. FPT drain valve, and a 1/2-in. male flare vapor connection
tains system temperature/pressure differences and moves the for the pumpout unit. A 30-in.-0-400 psi (–101-0-2750 kPa)
heat carrying refrigerant from the cooler to the condenser. See gage is also supplied with each unit.
Fig. 8.
NOTE: If a storage vessel is not used at the jobsite, factory-
Muffler — The muffler provides acoustical attenuation. A installed optional isolation valves may be used to isolate the
check valve just downstream of the muffler prevents reverse chiller charge in either the cooler or condenser. An optional
compressor rotation during shutdown. pumpout compressor system is used to transfer refrigerant
from vessel to vessel.
Control Center — The control center is the user inter-
face for controlling the chiller and regulating the chiller’s
capacity to maintain the proper chilled liquid temperature. See
Fig. 9. The control center:
• registers cooler, condenser, and lubricating system pressures
• shows chiller operating condition and alarm shutdown
conditions
DISCHARGE
COMPRESSOR LUBRICATION BLOCK MOTOR TERMINAL

ACCESS COVER
MOTOR TERMINALS ECONOMIZER
PORT
MOTOR
COOLING
INLET
FLANGE
MOTOR COOLING
DRAIN
a23-1619
Fig. 8 — Compressor (Typical, R Compressor Shown)
12
STANDARD
65 KAIC
CIRCUIT
BREAKER
OPTIONAL
100 KAIC
CIRCUIT BREAKER
(HANDLE SHIPPED
LOOSE INSIDE OF
CONTROL CENTER
FOR FIELD
INSTALLATION)
a23-1620
Fig. 9 — Standard and 100-KAIC Circuit Breaker Control Center (R Compressor Shown)
REFRIGERATION CYCLE which forms a liquid seal to keep FLASC chamber vapor from
entering the cooler.
The compressor continuously draws refrigerant vapor from
the cooler. As the compressor suction reduces the pressure in Heat exchanger frame sizes A and B incorporate a sensible
the cooler, the remaining refrigerant boils at a fairly low tem- subcooler instead of the FLASC, and the liquid seal and throt-
perature (typically 38 to 42 F [3 to 6 C]). The energy required tle level control are performed by an electronic expansion
for boiling is obtained from the liquid flowing through the valve instead of a float valve. See Fig. 11.
cooler tubes. With heat energy removed, the liquid becomes An optional economizer can be installed between the
cold enough for use in an air-conditioning circuit or process condenser and cooler. Pressure in this chamber is intermediate
liquid cooling. between condenser and cooler pressures. At this lower pres-
After absorbing heat from the chilled liquid, the refrigerant sure, some of the liquid refrigerant flashes to gas, cooling the
vapor is compressed. Compression adds still more energy, and remaining liquid. For heat exchanger frame sizes 3-5, an in-line
the refrigerant is quite warm (typically 90 to 130 F [32 to orifice on the economizer drain flange meters the refrigerant
54 C]) when it is discharged from compressor into condenser. liquid into the cooler. For size A and B heat exchangers, the
flash gas to the compressor is produced in a brazed plate heat
Relatively cool (typically 65 to 85 F [18 to 29 C]) liquid exchanger where some of the condenser liquid prior to throt-
flowing into the condenser tubes removes heat from the refrig- tling is diverted through the economizer electronic expansion
erant and the vapor condenses to liquid, refrigerant. valve (EXV). The EXV control logic is based on economizer
For heat exchangers frame sizes 3-5, the liquid refrigerant in saturated temperature, superheat and compressor speed. The
the condenser passes through orifices into the FLASC (Flash flash gas, having absorbed heat, is returned directly to the com-
Subcooler) chamber (Fig. 10). Since the FLASC chamber is at pressor at a point after suction cutoff (Fig. 12 and 13). Here it is
a lower pressure, part of the liquid refrigerant flashes to vapor, mixed with gas from the suction cut-off point to produce an in-
thereby cooling the remaining liquid. The FLASC vapor is re- crease in the mass flow of refrigerant transported and com-
condensed on the tubes which are cooled by entering condens- pressed without either an increase in suction volume or a
er liquid. The liquid then passes through a float valve assembly change in suction temperature.
13
REFRIGERANT
VAPOR
REFRIGERANT
LIQUID
REFRIGERANT
a23-1668 LIQUID/VAPOR
Fig. 10 — Refrigerant Flow Schematic, Q and R Compressors (Without Optional Flash Economizer)
a23-1727
Fig. 11 — Refrigerant Flow Schematic, P Compressor (Without Optional Economizer)
14
REFRIGERANT
VAPOR
REFRIGERANT
LIQUID
REFRIGERANT
LIQUID/VAPOR
a23-1669
Fig. 12 — Refrigerant Flow Schematic, Q and R Compressors (With Optional Flash Economizer)
a23-1728
Fig. 13 — Refrigerant Flow Schematic, P Compressor (With Optional Economizer)
15
MOTOR COOLING CYCLE During operation, the oil level should always be visible in the
oil sump sight glass. Approximately 10 gal. (37.9 L) of oil is
For Q and R compressors, one half of the motor is cooled by charged into the sump.
suction gas while the other half is cooled by liquid refrigerant
taken from the bottom of the condenser vessel. The P compres- Oil from the compressor bearing drain is drained directly
sor has two spray nozzles that cool the motor by injecting liq- into the oil sump. Refrigerant is driven from the oil as it flows
uid refrigerant. The flow of liquid refrigerant is maintained by around the oil sump heater and into the strainer housing. The
the pressure differential that exists due to compressor opera- oil pump draws the oil through a strainer and forces it through
tion. The refrigerant flows through an isolation valve, in-line an oil filter.
filter/drier, and a sight glass/moisture indicator (dry-eye), into The filter housing is capable of being isolated by upstream
the motor through the motor spray nozzle. See Fig. 10-13. and downstream valves to permit filter replacement. An oil
pressure regulator valve directs excessive oil back into the oil
 IMPORTANT: To avoid adverse effects on chiller oper- sump. Oil supplied to the compressor is monitored by an oil
ation, consideration must be made to condenser water pressure sensor. The OIL PRESSURE DELTA P value is equal
temperature control. Consult the Chiller Builder for to the difference between the oil pressure leaving the filter and
required steady state operational limits. Inverted start the oil sump pressure. It is read directly from the ICVC (Inter-
conditions are acceptable for short durations; generally, national Chiller Visual Controller) default screen.
for periods exceeding 5 minutes, special control strat- Oil is supplied to the compressor through two separate
egy solutions are to be used to allow the chiller to build inlets. One inlet leads to the suction bearings, the other leads to
minimum refrigerant pressure differential (and thereby the discharge bearings. Most of the oil drains back into the
adequate equipment cooling). sump while a small amount is used to lubricate the rotors.
Rotor lubrication oil leaves the compressor mixed with the
The motor spray nozzle is orificed to control refrigerant compressed discharge refrigerant vapor.
flow through the gaps between the rotor and stator. The refrig- The oil sump contains temperature and pressure sensors and
erant collects in the bottom of the motor casing and then drains an oil heater. (In some cases a two-stage heater is supplied,
into the cooler through the motor cooling drain line. with 500 W for the first stage and 1000 W for the second
The motor is protected by a temperature sensor and a stage.) The oil sump is vented to the compressor suction to
temperature switch embedded in the stator windings. COMP minimize the amount of refrigerant absorbed by the oil. The
MOTOR WINDING TEMP temperatures above the COMP OIL SUMP TEMPERATURE is measured and displayed on the
MOTOR TEMP OVERRIDE threshold (see Capacity Override ICVC default screen and the COMPRESS screen. The oil
section, page 48) will override the chilled liquid temperature sump pressure is used to calculate the OIL PRESSURE DELTA
capacity control to hold. If the motor temperature rises 10° F P value.
(5.5 C) above this threshold, the compressor will unload. If the Operating OIL PRESSURE DELTA P must be at least
COMP MOTOR WINDING TEMP rises above the 220 F 18 psid (124 kPa) after the OIL PRESS VERIFY TIME has
(104.4 C) safety limit, the compressor will shut down. elapsed. Under normal full load conditions, oil pressure is
typically 20 to 28 psid (138 to 193 kPa). If sufficient oil pres-
LUBRICATION CYCLE sure is not established or maintained the chiller will shut down.
An oil pressure delta P sensor fault will be declared if the OIL
Summary — The 23XRV chiller requires an oil pump. Oil PRESSURE DELTA P is not less than 4 psid (27.6 kPa) prior to
flow is provided by a magnetically coupled, motor-driven oil start-up.
pump. Oil flows through the oil filter into the compressor ro- If the oil pressure falls below the values specified in Table 1
tors and bearings. The cycle is referred to as a “low side” oil during start-up, the PIC III control will shut down the chiller.
system. See Fig. 14.
Table 1 — Oil Pressure Requirements
Details — The oil system:
• lubricates the roller bearings which support the male MINIMUM START-UP OIL
PRESSURE REQUIREMENT
and female rotors, and the ball bearings of the 23XRV TIME
(SEC) HFC-134A
compressor.
• lubricates the male and female rotors. PSID KPA
BEFORE OIL PUMP ON <4 27.6
Oil is charged into the system through a hand valve located
AFTER OIL PRESS VERIFY
on the bottom of the oil sump. Sight glasses on the oil sump TIME
18 124
permit oil level observation. When the compressor is shut DURING START/RUN 15 103
down, an oil level should be visible in the oil sump sight glass.
1016 16
COMPRESSOR OIL SUPPLY
TO COMPRESSOR
SUCTION
COMPRESSOR OIL
DRAIN
CONDENSER
ISOLATION
VALVE
COOLER
MIST ACTUATED BALL

ELIMINATOR VALVE ORIFICE
VAPORIZER SIGHT GLASS
EXTERNAL OIL HEATER

SIGHT GLASS MIST ELIMINATOR
OIL PUMP
ISOLATION
OIL SIGHT GLASS VALVE
SUMP
OIL FILTER
HEATER
A23-1643 ISOLATION SERVICE
VALVE VALVE PUMP
PRESSURE
REGULATOR STRAINER OIL FILTER
VALVE ISOLATION
VALVE
OIL REFRIGERANT OIL/REFRIGERANT MIXTURE
Fig. 14 — Oil Flow Schematic
Oil Reclaim System — The oil reclaim system recovers The viscosity of the compressor oil is significantly reduced
oil from the cooler, removes the refrigerant, filters and returns when it absorbs refrigerant. A combination of heat and low
the oil back to the compressor. One or more oil reclaim nozzles pressure is used to vaporize the refrigerant that has been
are positioned along the length of the cooler to draw the oil and absorbed by the oil mixture reclaimed from the cooler.
refrigerant mixture from the surface of the refrigerant level. Condenser gas is used to warm the refrigerant and oil mixture
The mixture passes through an oil reclaim modulating valve in the vaporizer. Warm refrigerant is bled from the top of the
and into the vaporizer. The flow of refrigerant and oil is regu- condenser, directed through a row of tubes that line the bottom
lated to prevent the vaporizer from becoming overloaded with of the vaporizer, and discharged into the cooler. A 1500 W
liquid refrigerant. The modulating valve position is adjusted in surface mounted electric heater provides supplemental heat to
accordance with the difference between the VAPORIZER the vaporizer when the compressor is operating at lower loads.
TEMP and the EVAP REFRIG LIQUID TEMP. The 4 to Refrigerant boiled out of the reclaimed mixture is vented to the
20 mA signal from CCM terminals J8-3 and J8-4 is converted compressor suction. The concentrated oil mixture drains out of
into a 0 to 10V DC input to the oil reclaim modulating valve by the vaporizer, through a sight glass, past the vaporizer tempera-
a 500-ohm resistor connected between CCM terminals J8-3 ture sensor, and into the oil sump. (An orifice located between
and J8-4. The oil reclaim modulating valve closes when the the vaporizer and oil sump maintains the liquid level in the va-
chiller is shut down to prevent the vaporizer and oil sump from porizer.) Additionally the oil sump heater maintains the tem-
being flooded with refrigerant. Do not manually open the oil perature of the reclaimed oil and the oil returned from the com-
reclaim modulating valve when the chiller is shut down. Doing pressor at approximately 90 F (32.2 C) when the chiller is run-
so will severely degrade the viscosity of the oil in the sump. ning and 140 F (60 C) when the chiller is off. The oil sump is
Flow of refrigerant and oil from the cooler can be observed also vented to compressor suction to increase oil viscosity by
through a sight glass on top of the vaporizer. boiling off additional refrigerant.
17
Capacity Control — The PIC III controls provide
chilled liquid temperature control by modulating the frequency
of the power delivered by the VFD to the compressor motor.
The compressor speed is adjusted in response to the difference
between the CONTROL POINT and the LEAVING CHILLED
LIQUID or ENTERING CHILLED LIQUID temperatures.
The PIC III controls respond to the difference between the
CONTROL POINT and LEAVING CHILLED LIQUID tem-
peratures when the ECL CONTROL OPTION is DISABLED. a19-957
The PIC III controls respond to the difference between the
CONTROL POINT and ENTERING CHILLED LIQUID tem- Fig. 16 — Control Sensors
peratures when the ECL CONTROL OPTION is ENABLED. (Pressure Transducers)
The chiller capacity is controlled by varying the TARGET
VFD SPEED from 0% to 100%. The PIC III controls monitor PIC III System Components (Fig. 17-23) — The
the compressor oil properties and set a COMPRESSOR MINI- chiller control system is called PIC III (Product Integrated
MUM SPEED to ensure sufficient compressor bearing lubrica- Control III). See Table 2. The PIC III control system controls
tion under all operating conditions. the chiller by monitoring all operating conditions. The PIC III
control can diagnose a problem and let the operator know what
CONTROLS the problem is and what to check. It promptly adjusts compres-
sor speed to maintain leaving chilled liquid temperature. It can
Definitions interface with auxiliary equipment such as pumps and cooling
ANALOG SIGNAL — An analog signal varies in proportion tower fans to turn them on when required. It continually checks
to the monitored source. It quantifies values between operating all safeties to prevent any unsafe operating condition. It also
limits. (Example: A temperature sensor is an analog device be- regulates the oil heater and regulates the hot gas bypass valve,
cause its resistance changes in proportion to the temperature, if installed. The PIC III controls provide critical protection for
generating many values.) the compressor motor and control of the variable frequency
drive.
DISCRETE SIGNAL — A discrete signal is a two-position
representation of the value of a monitored source. (Example: A The PIC III control system can interface with the Carrier
switch produces a discrete signal indicating whether a value is Comfort Network® (CCN) system if desired. It can also com-
above or below a set point or boundary by generating an on/off, municate with other PIC I, PIC II or PIC III equipped chillers
high/low, or open/closed signal.) and other CCN devices, such as LEI (Local Equipment Inter-
face).
General Controls Overview — The 23XRV hermetic The PIC III controls are housed inside the control center
screw liquid chiller contains a microprocessor-based control enclosure. See Fig. 2-4. The component names are listed
center that monitors and controls all operations of the chiller. below (also see Table 2):
The microprocessor control system matches the cooling
capacity of the chiller to the cooling load while providing INTERNATIONAL CHILLER VISUAL CONTROLLER
state-of-the-art chiller protection. The system controls cooling (ICVC) — The ICVC is the “brain” of the PIC III control sys-
capacity within the set point plus the deadband by sensing the tem. This module contains all the primary software needed to
leaving chilled liquid or brine temperature (see Fig. 15 and 16) control the chiller. The ICVC is the input center for all local
and regulating the compressor speed. Reducing the compressor chiller set points, schedules, configurable functions, and op-
speed decreases the volume flow rate of refrigerant through the tions. The ICVC has a stop button, an alarm light, four buttons
compressor. Chiller protection is provided by the PIC III for logic inputs, and a backlight display. The backlight will
processor, which monitors the digital and analog inputs and automatically turn off after 15 minutes of non-use. The func-
executes capacity overrides or safety shutdowns, if required. tions of the four buttons or “softkeys” are menu driven and are
shown on the display directly above the softkeys. The ICVC is
mounted on the control center door. See Fig. 2-4.
To change the contrast of the display, access the adjustment
on the back of the ICVC. See Fig. 17.
SHRINK WRAP
STRAIN RELIEF
1/8” NPT
THERMOWELL CONTRAST
ADJUSTMENT
SCREW
a23-1624
REMOVABLE
TEMPERATURE
SENSOR
Fig. 15 — Control Sensors (Temperature)
Fig.
a23-1625 17 — ICVC Contrast Adjustment
18
CHILLER CONTROL MODULE (CCM) — This module is ELECTRONIC EXPANSION VALVE (P compressors only,
located on the control panel in the control center. The CCM heat exchanger frame size A and B) — High pressure refriger-
provides the input and outputs necessary to control the chiller. ant enters the EXV and goes through the variable orifice. Re-
This module monitors refrigerant pressure, entering and frigerant flow control for different operating conditions is con-
leaving liquid temperatures and pressures, and outputs control trolled by an actuator that modulates the valve opening. The
for the oil reclaim valve, oil heaters, and oil pump. The CCM is stepper motor moves in increments and is controlled by the
the connection point for optional demand limit, automatic EXV control module. As the stepper motor rotates, motion is
chilled liquid reset, 4 to 20 mA kW output, remote temperature transferred into linear movement by the lead screw. The main
reset, and refrigerant leak sensor. EXV stepper motor has 3810 total steps, while the optional
VFD POWER MODULE — This module is located in the economizer EXV has 2625 steps. See Fig. 23.
control center. The A/C line I/O assembly executes commands Main EXV Control— The valve is modulated to achieve the
from the ICVC for functions such as starting and stopping the condenser level set point by a continuous loop that compares
condenser and evaporator liquid pumps, tower fan and alarm desired level to sensed level. At initial start-up the valve posi-
contacts. The Standard I/O Option Assembly monitors inputs tion is driven to the start position and is held at this position for
such as remote start contact, spare safety, and the high condens- approximately 2 minutes or as defined by the start delay set-
er pressure switch and provides the 4-20 mA Head Pressure ting, after which the level control algorithm takes over. After
Reference Output. See Fig. 18 for control center layout for the shutdown, the EXV will be driven to the condenser EXV start
LF-2 VFD. See Fig. 19 for control center layout for Std Tier position which will allow pressure equalization between cooler
VFD. and condenser. Default control parameters can be adjusted in
VFD GATEWAY MODULE — The VFD Gateway Module SETUP5.
translates the protocols between the ICVC, CCM and VFD. NOTE: Changing the default values of many of the values in
This module also contains logic capable of an independent SETUP4 and SETUP5 associated with the EXV control is not
safety shutdown. It shuts down the chiller if communications recommended without support from Service Engineering.
with the ICVC are lost. See Fig. 20 for power module compo- Economizer EXV Control (Option) — The economizer
nent locations. EXV is activated at approximately 75% speed or as configured
OIL HEATER CONTACTOR (1C) — This contactor is lo- when Actual VFD Speed is greater than Economizer Activate
cated on the control panel (Fig. 21) and operates the heater at Speed. After this, it is controlled to maintain the economizer
115 V. It is controlled by the PIC III control system to maintain superheat set point that provides gas flow to the compressor.
oil temperature during chiller shutdown or to keep the oil sump When it deactivates, or if the Economizer Option is disabled,
temperature at an acceptable level. the valve is fully closed. If the Economizer Option is enabled
OIL PUMP CONTACTOR (2C) — This contactor is locat- then the EXV control logic algorithm will be active 5 minutes
ed in the control panel (Fig. 21) and operates the oil pump. The after completion of startup. Default parameters can be adjusted
oil pump is controlled by the PIC III to provide oil pressure in SETUP4.
during pre-lube and when the chiller is starting or running. NOTE: Changing the default values of many of the values in
HOT GAS BYPASS CONTACTOR RELAY (3C) SETUP4 and SETUP5 associated with the EXV control is not
(Optional) — This relay, located in the power panel, controls recommended without support from Service Engineering.
the opening of the hot gas bypass valve. The PIC III energizes CONDENSER LEVEL SENSOR (P compressors only, heat
the relay based on hot gas bypass algorithm settings. exchanger frame size A and B) — This sensor monitors the
SECOND STAGE OIL HEATER CONTACTOR (5C) — liquid level in the condenser and transmits a continuous 0 to 5 v
This contactor is located in the control panel (Fig 22), and is signal proportional to the liquid level in the condenser sensing
activated by PIC III to maintain oil quality at low temperature. chamber. See Fig. 5.
VAPORIZER HEATER CONTACTOR (6C) — This con- Table 2 — Major PIC III Control Components and
tactor is located in the control panel (Fig. 21) and energizes the Panel Locations
surface mounted heater on the bottom of the vaporizer.
PIC III COMPONENT PANEL LOCATION
CONTROL TRANSFORMERS (T1, T2, T4) — Transform-
ers T1, T2 convert incoming control voltage to 24 vac power International Chiller Visual Control Center Door
Controller (ICVC) and Display
for the power panel contactor relays, CCM, ICVC, and 21 vac
VFD Power Module Inside Control Center
power for the optional UPC Open and LON modules. Trans-
former T4 (supplied only with P compressors) supplies power Chiller Control Module (CCM) Control Panel
to both the EXV and AUX1 boards. Circuit breakers CB-1A, Oil Heater Contactor (1C) Control Panel
CB-1B, CB-2A and CB-2B for the control transformers are lo- Oil Heater Contactor, 1000 W (5C) Control Panel
cated above the CCM. Oil Pump Contactor (2C) Control Panel
EXV CONTROL MODULE (PD4-EXV) — This module is Hot Gas Bypass Relay (3C) Control Panel
(Optional)
supplied with P compressors only. It is located near the top of
the control panel near the T4 control transformer. It provides Control Transformers (T1, T2) Control Panel
the input and outputs for the condenser EXV, economizer EXV Control Transformer Circuit Breakers Control Panel
(CB-1A, CB-1B, CB-2A, CB-2B)
and economizer gas temperature.
EXV Control Transformer (T4) See Fig. 22
AUXILIARY CONTROL MODULE (PD4-AUX1) — This Temperature Sensors See Fig. 5-7 and 15
module is supplied with P compressors only. It is located near
Condenser Level Sensor See Fig. 5
the PD4-EXV board. This board communicates with the PD4-
EXV board and the CCM board, and provides the input and Pressure Transducers See Fig. 5-7 and 16
output for the condenser level sensor (0 to 5 v proportional sig- Vaporizer Heater Contactor (6C) Control Panel
nal). Auxiliary Control Module Near PD-4 EXV Board
19
10
11 9 FUSE FUSE
21 20
1 2 8 13 5 22 REF DESCRIPTION
8
FU1 CLASS CC, 1A/600V
19 FU4 150A/600V
FU5 150A/600V
FU6 150A/600V
18
CLASS CC, 20A/
FU7
600V
CLASS CC, 20A/
FU8
600V
CLASS CC, 20A/
FU9
600V
CLASS CC, 15A/
FU11A&B
600V
17
16 8 14 3 4 7 6
16
12 15
LEGEND
1 — Input Inductor Assembly 12 — Fuse, Class CC, 600V, 1A (3)
2 — Capacitor Bank Assembly 13 — Transformer, 3kVA
3 — Pre-Charge Resistor Assembly 14 — Line Sync PC Board Assembly
4 — AC Contactor (3) 15 — Line Sync Board Cover
5 — Power Module Assembly 16 — Fan, 115V (3)
6 — Terminal Block, 10-Position (Extra Low Voltage) 17 — Control Power Circuit Breaker, 600V, 15A
7 — Power Module Assembly 18 — Circuit Breaker, 600V
8 — Fuse Block, 30A, 600V, Class CC 19 — Lug, Ground, 2-600 MCM
9 — Fuse, Class CC, 600V, 15A (2) 20 — Inductor Overtemperature Switch (Hidden)
10 — Fuse, Class CC, 600V, 5A (1) 21 — Input Power Wiring Access Panel
11 — Fuse, Class CC, 600V, 20A (3) 22 — Terminal Block (Hazardous voltage)
Fig. 18 — Control Center VFD Input Components (LF-2 VFD)
1 2 3
7
4
a23-1626
5 FRONT VIEW – DOORS REMOVED RIGHT SIDEWALL

INSIDE VIEW
LEGEND
1 — Input Circuit Breaker
2 — Power Module
3 — Control Relays (CR1 - CR6)
4 — Control Fuses
5 — 120V Control Transformer a23-1653
6 — 120V Vaporizer Heater Transformer
7 — 15 Amp Control Circuit Breaker
8 — Cooling Fan
Fig. 19 — Control Center VFD Input Components (Std Tier VFD)
20
1
5 3 4 16
6
20
7 23
8 25 17
9
10 18
11
26
6 25
7 24 20
3
8 19
12
10
4
11 8 21
1
a23-1627
13 22
14
15
Door Open Door Closed
LEGEND
1 — Wire Harness Assembly, Gate Driver 14 — Wire Harness Assembly, DC Bus Bleeder Resistors
2 — Current Feedback Device, 1000 A 15 — Wire Harness Assembly, Line Sync
3 — Wire Harness Assembly, Power Supply, Logic 16 — Inverter Control Assembly*
4 — 80 W Power Supply Assembly 17 — Standard I/O Option, 24 V Assembly
5 — Terminal Block, 2-Position 18 — Rectifier Control Assembly*
6 — Cable Assembly, 40-Pin 19 — AC Line I/O Assembly
7 — Cable Assembly, 30-Pin 20 — Connector, Terminal Block, 32-Pin
8 — Wire Harness Assembly, Power Supply, Upper Gate 21 — NTC Assembly
9 — Inverter Power Interface Assembly 22 — Internal Fan
10 — Wire Harness Assembly, Power Supply, Lower Gate 23 — DPI Communications Interface Assembly
11 — Insulation Sheet 24 — RS-485 Communications Assembly (VFD Gateway)
12 — Rectifier Power Interface Assembly 25 — Wire Harness Assembly, Control Sync
13 — Wire Harness Assembly, Current Feedback Device 26 — Cable Assembly, 20-pin
*The inverter control assembly (item 16) and rectifier control assembly (item 18) are physically similar but are loaded with different
software.
These boards are NOT interchangeable.
Fig. 20 — Power Module Components
21
HAZARDOUS
VOLTAGE
FIELD WIRING
TERMINAL BLOCK
SECOND STAGE
OIL HEATER
GROUND CN1B CONTACTOR (5C)
WIRE CONNECTOR VAPORIZER CN1A
CN1B HEATER
CONNECTOR CONTACTOR (6C)
CN1A
OIL PUMP HOT GAS BYPASS

CONTACTOR CONTACTOR (3C)
(2C) OPTIONAL
OIL HEATER
CONTACTOR 24V CONTROL
(1C) TRANSFORMER (T1)
20V CONTROL
TRANSFORMER
(T2)
CONTROL
TRANSFORMER
CIRCUIT
BREAKERS
HIGH PRESSURE
SWITCH CABLE
CONNECTOR
CN2
a23-1706
CN2
CONNECTOR CN3
CN3
LOW VOLTAGE
A23-1644 FIELD WIRING
TERMINAL BLOCK Fig. 22 — Control Panel (P Units)
Fig. 21 — Control Panel (R,Q Units
with LF-2 VFD)
1. Cable
2. Glass Seal
3. Motor Housing
4. Stepper Motor
5. Bearing
6. Lead Screw
7. Insert
8. Valve Piston
9. Valve Seat
10. Valve Port
MAIN EXV
ECONOMIZER EXV (OPTION)
Fig. 23 — Cutaway Views of Electronic Expansion Valves (EXV) (P Compressor Only)
22
ICVC Operation and Menus (Fig. 24-30) alarm (*) or alert (!) is indicated in the STATUS column on the
GENERAL right side of the MAINSTAT display screen. See Fig. 26.
• The ICVC display automatically reverts to the default Alarms are indicated when the control center alarm light (!)
screen after 15 minutes if no softkey activity takes place flashes. The primary alarm message is displayed on the default
(Fig. 24). screen. An additional, secondary message and troubleshooting
• If a screen other than the default screen is displayed on the information are sent to the ALARM HISTORY screen.
ICVC, the name of that screen is in the upper right corner
(Fig. 25). When an alarm is detected, the ICVC default screen will
• The ICVC may be set to display either English or SI units. freeze (stop updating) at the time of alarm. The freeze enables
Use the ICVC CONFIGURATION screen (accessed from the operator to view the chiller conditions at the time of alarm.
the SERVICE menu) to change the units. See the Service Additional information is stored in the VFD_HIST screen. The
Operation section, page 59. STATUS tables will show the updated information. Once all
• Local Operation — The PIC III can be placed in local
alarms have been cleared (by pressing the RESET softkey),
operating mode by pressing the LOCAL softkey. The
the default ICVC screen will return to normal operation.
PIC III then accepts commands from the ICVC only and
uses the Local Time Schedule to determine chiller start
and stop times. 23XRPIC3 MAINSTAT
Control Mode
POINT STATUS
Reset
• CCN Operation — The PIC III can be placed in the Run Status
Start Inhibit Timer
Tripout
0.0 min
CCN operating mode by pressing the CCN softkey. Occupied?

System Alert/Alarm
No
Alarm
Chiller Start/Stop Stop CONTRL
The PIC III then accepts modifications from any CCN Remote Start Contact
Temperature Reset
Open
0.0 ^F
C
interface or module (with the proper authority), as well Control Point

Chilled Liquid Temp
50.0 °F
55.7 °F
as from the ICVC. The PIC III uses the CCN Time
Schedule to determine start and stop times.
PRIMARY STATUS COMPRESSOR DATE TIME

MESSAGE ON TIME
SECONDARY
STATUS MANUALLY STOPPED - PRESS 11-22-04 00:09 a23-1602
MESSAGE CCN OR LOCAL TO START 15.2 HOURS
ALARM LIGHT CHL IN CHL OUT EVAP REF Fig. 26 — Example of MAINSTAT Screen
(ILLUMINATED 59.3 58.4 62.1 \\\
WHEN POWER ON)

CDL IN
76.1
CDL OUT
85.2
COND REF
84.4 ICVC MENU ITEMS — To perform any of the operations
• BLINKS CONTINUOUSLY
ON FOR AN ALARM
OIL PRESS OILTEMP % AMPS IN described below, the PIC III must be powered up and have
• CONFIRMONCE
BLINKS TO
–0.5 130.6 0.0 successfully completed its self test. The self test takes place
A STOP STATUS SCHEDULE SETPOINT SERVICE
automatically, after power-up.
Press the MENU softkey to view the list of menu struc-
STOP BUTTON
tures: STATUS , SCHEDULE , SETPOINT , and
• HOLD FOR ONE
SECOND TO STOP
SERVICE .
SOFT KEYS
• The STATUS menu allows viewing and limited calibra-
a23-1600 EACH KEY'S FUNCTION IS MENU tion or modification of control points and sensors, relays
LINE
DEFINED BY THE MENU DESCRIPTION
ON MENU LINE ABOVE
and contacts, and the options board.
• The SCHEDULE menu allows viewing and modification
Fig. 24 — ICVC Default Screen of the local and CCN Time Schedules.
• The SETPOINT menu allows set point adjustments, such
as the ENTERING CHILLED LIQUID and LEAVING
CHILLED LIQUID set points.
• The SERVICE menu can be used to view or modify
information on the ALARM HISTORY, ALERT HIS-
23XRPIC3
ALARM HISTORY
SERVICE
TORY, CONTROL TEST, CONTROL ALGORITHM
ALERT HISTORY
CONTROL TEST
STATUS, EQUIPMENT CONFIGURATION, VFD
CONTROL ALGORITHM STATUS
EQUIPMENT CONFIGURATION
CONFIG DATA, EQUIPMENT SERVICE, TIME
VFD CONFIG DATA AND DATE, ATTACH TO NETWORK DEVICE,
LOG OUT OF DEVICE, and ICVC CONFIGURA-
EQUIPMENT SERVICE
TIME AND DATE
ATTACH TO NETWORK DEVICE
LOG OUT OF DEVICE
ICVC CONFIGURATION
TION screens.
For more information on the menu structures, refer to
Fig. 27 and 28.
Press the softkey that corresponds to the menu structure to
be viewed: STATUS , SCHEDULE , SETPOINT , or
SERVICE . To view or access parameters within any of these
menu structures, use the NEXT and PREVIOUS softkeys
a23-1601 to scroll to the desired item or table. Use the SELECT soft-
Fig. 25 — ICVC Service Screen key to select that item. The softkey choices that then appear de-
pend on the selected table or menu. The softkey choices and
ALARMS AND ALERTS — An alarm shuts down the com- their functions are described in the section Basic ICVC Opera-
pressor. An alert does not shut down the compressor, but it tions beginning on page 24.
notifies the operator that an unusual condition has occurred. An
23
BASIC ICVC OPERATIONS (Using the Softkeys) — To TO VIEW STATUS (Fig. 27) — The MAINSTAT table
perform any of the operations described below, the PIC III shows the actual value of overall chiller status such as CON-
must be powered up and have successfully completed its self TROL MODE, RUN STATUS, AUTO CHILLED LIQ
test. RESET, and REMOTE RESET SENSOR.
• Press QUIT to leave the selected decision or field with- 1. On the menu screen, press STATUS to view the list
out saving any changes. of point status tables.
• Press ENTER to leave the selected decision or field and 2. Press NEXT or PREVIOUS to highlight the desired
save changes. 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
• Press NEXT to scroll the cursor bar down in order to • HEAT_EX — Status of sensors related to the heat
highlight a point or to view more points below the cur- exchangers
• POWER — Status of motor input power
rent screen. • ECON_EXV — Status of economizer EXV control
sensors (if applicable)
• COND_EXV — Status of condenser EXV control
sensors (if applicable)
• VFD_STAT — Status of the variable frequency
drive
• Press PREVIOUS to scroll the cursor bar up in order to • ICVC_PWD — Service menu password forcing
highlight a point or to view points above the current access screen
screen.
3. Press SELECT to view the desired point status table.

• Press SELECT to view the next screen level (high-
lighted with the cursor bar), or to override (if allowable)
the highlighted point value.
4. On the point status table, press NEXT or

PREVIOUS until the desired point is displayed on the
screen.
• Press EXIT to return to the previous screen level.
• Press INCREASE or DECREASE to change the high-

lighted point value.
24
DEFAULT SCREEN
CCN LOCAL RESET MENU (SOFTKEYS)
Start Chiller In CCN Control
Start Chiller in Local Control
Clear Alarms Access Main Menu
STATUS SCHEDULE SETPOINT SERVICE
1 1 1 1 (ENTER A 4-DIGIT PASSWORD)

List the
Status Tables List the Service Tables
Display The Setpoint Table

• MAINSTAT
• STARTUP
• COMPRESS List the Schedules
• HEAT_EX • Base Demand Limit
• POWER • LCL Setpoint
• VFD_STAT • ECL Setpoint
• ECON_EXV (P COMPRESSOR ONLY) • Ice Build Setpoint
• Tower Fan High Setpoint
• COND_EXV (P COMPRESSOR ONLY)
Select the Setpoint
• ICVC_PWD
NEXT PREVIOUS SELECT EXIT
Select a Status Table
Modify the Setpoint
INCREASE DECREASE QUIT ENTER
Select a Modification Point
Modify a Discrete Point

START STOP RELEASE ENTER
ON OFF
• OCCPC01S – LOCAL TIME SCHEDULE
Modify an Analog Point • OCCPC02S – ICE BUILD TIME SCHEDULE
• OCCPC03S – CCN TIME SCHEDULE
INCREASE DECREASE RELEASE ENTER Select a Schedule
Modify Control Options NEXT PREVIOUS SELECT EXIT
ENABLE DISABLE QUIT ENTER 1
2
3
4
Display the COND_EXV Table 5
6
7
8
• CONDENSER EXV Override
• TARGET CONDENSER EXV Select a Time Period/Override
• COND EXV STEPS
• CONDENSER LIQUID LEVEL
• FINE TUNE ACTIVE? Modify a Schedule Time
• DISCHARGE SUPERHEAT INCREASE DECREASE ENTER EXIT (ANALOG VALUES)
• EVAPORATOR APPROACH
• COND LEVEL SETPOINT Add/Eliminate a Day
• COND LEVEL OUTPUT [V] ENABLE DISABLE ENTER EXIT (DISCRETE VALUES)
• COND LEVEL ERROR
• COND LEVEL INTEGRAL
• COND LEVEL OUTPUT [%]
ALARM HISTORY
• COND LEVEL RANGE ALERT HISTORY
• COND EXV MAX MOVEMENT CONTROL TEST
Display the ECON_EXV Table EQUIPMENT CONFIGURATION
VFD CONFIG DATA
EQUIPMENT SERVICE
TIME AND DATE
• ECON EXV POSITION ATTACH TO NETWORK DEVICE
• TARGET ECONOMIZER EXV LOG OUT OF DEVICE
ICVC CONFIGURATION
• ECON EXV STEPS
• ECON SUPERHEAT SETPOINT NEXT PREVIOUS SELECT EXIT
• ECON SUPERHEAT
• ECON SUPERHEAT ERROR
• ECONOMIZER SAT TEMP SEE NEXT PAGE
• ECONOMIZER PRESSURE
• ECONOMIZER GAS TEMP
• VFD SPEED OUTPUT
NOTE: The ICVC menu structure and tables shown in this man-
ual are for Q/R Compressors CESR-131293-04 Version 4 and
for P Compressors CESR-131584-05 Version 2. This applies
throughout the manual.
Fig. 27 — 23XRV ICVC Menu Structure
25
SERVICE TABLE
ALARM HISTORY
ALERT HISTORY
Display Alert History
Display Alarm History (The table holds up to 25 alerts
(The table holds up to 25 alarms and with the most recent alert
alerts with the most recent alarm at the top of the screen.)
ALERT HISTORY at the top of the screen.)
CONTROL TEST List the Control Tests

• Thermistors
• Pressure Transducers
List the Control Algorithm Status Tables • Pumps
• Discrete Outputs
• CAPACITY (Capacity Control) • Oil Reclaim Output
• OVERRIDE (Override Status) • Head Pressure Output
• LL_MAINT (Lead Lag Status) • Pumpdown/Lockout
• VFD_HIST (VFD Alarm History) • Terminate Lockout
• CUR ALRM (Chiller Alarm History)
• WSMCHLRE (Water System Manager)
• OCCDEFCM (Time Schedule Status)
• LOADSHED (Reduced Capacity Control) Select a Test
Select a Table
OCCDEFM (Time Schedule Status)

• CAPACITY (Capacity Control Algorithm)
Data Select Table • OVERRIDE (Override Status)
NEXT PREVIOUS SELECT EXIT • LL_MAINT (LEADLAG Status)
• WSMDEFME (Water System Manager Control Status)
• LOADSHED (Reduced Capacity Control)
OCCPC01S (Local Status) • VFD_HIST (VFD Alarm History)
OCCPC02S (CCN, ICE BUILD Status) • CUR ALRM (Chiller Alarm History)
OCCPC03S (CCN Status)
Maintenance Table Data
EQUIPMENT CONFIGURATION List the Equipment Configuration Tables
• NET_OPT
• BRODEF
• OCCEFCS
• HOLIDAYS
• CONSUME
• RUNTIME
Select a Table
Select a Parameter
Modify a Parameter
INCREASE DECREASE QUIT ENTER (ANALOG VALUES)
ENABLE DISABLE QUIT ENTER (DISCRETE VALUES)
CONTINUED
ON NEXT PAGE a23-1604
Fig. 28 — 23XRV ICVC Service Menu Structure
26
SERVICE MENU CONTINUED
FROM PREVIOUS PAGE
VFD CONFIG DATA
EQUIPMENT SERVICE
4 4 4 4 (ENTER A 4-DIGIT PASSWORD)
Service Tables:
• OPTIONS
• SETUP1 Service Tables:
• SETUP2 • VFD CONFIG P ASSWORD
• SETUP3 • VFD_CONF
• SETUP4 (P Compressor Only)
• SETUP5 (P Compressor Only)
• LEADLAG
• RAMP_DEM
• TEMP_CTL
Select a Service Table
Select a Service Table Parameter
Modify a Service Table Parameter

INCREASE DECREASE QUIT ENTER (ANALOG VALUES)
ENABLE DISABLE QUIT ENTER (DISCRETE VALUES)
TIME AND DATE
Display Time and Date Table:

• To Modify — Current Time — Day of Week
ATTACH TO NETWORK DEVICE — Current Date — Holiday Today
INCREASE DECREASE ENTER EXIT (ANALOG VALUES)
List Network Devices
• Local • Device 6 YES
YES NO ENTER EXIT (DISCRETE VALUES)
• Device 1 • Device 7
• Device 2 • Device 8
• Device 3 • Attach To Any Device
• Device 4
• Device 5
Select a Device
NEXT PREVIOUS SELECT ATTACH
Modify Device Address

INCREASE DECREASE ENTER EXIT
• Use to attach ICVC to another CCN network or device
• Attach to "LOCAL" to enter this machine
• To upload new tables
LOG OUT OF DEVICE
Default Screen
CCN LOCAL RESET MENU
ICVC CONFIGURATION
ICVC Configuration Table
INCREASE DECREASE ENTER EXIT
• To Modify — ICVC CCN Address • To View — ICVC Software Version
— Baud Rate (last 2 digits of part number
— English (US IMP) or S.I. Metric Units indicate software version)
— Password
— LID Language
LEGEND
ICVC — International Chiller Visual
Controller
IMP — Imperial
VFD — Variable Frequency Drive a23-1675
PIC III — Product Integrated Control III
Fig. 28 —23XRV ICVC Service Menu Structure (cont)
27
OVERRIDE OPERATIONS 3. Press RELEASE to remove the override and return
To Override a Value or Status the point to the PIC III’s automatic control.
1. From any point status screen, press NEXT or
PREVIOUS to highlight the desired value.
Override Indication — An override value is indicated by

“SUPVSR,” “SERVC,” or “BEST” flashing next to the point
2. Press SELECT to select the highlighted value. Then: value on the STATUS table.
TIME SCHEDULE OPERATION (Fig. 29)
1. On the Menu screen, press SCHEDULE .
For Discrete Points — Press YES or NO to

select the desired state.
YES NO ENTER EXIT 2. Press NEXT or PREVIOUS to highlight the de-
sired schedule.
OCCPC01S — LOCAL Time Schedule
OCCPC02S — ICE Build Schedule
For Analog Points — Press INCREASE or OCCPC03S — CCN Time Schedule
DECREASE to select the desired value.
3. Press SELECT to view the desired time schedule.

3. Press ENTER to register the new value.
4. Press NEXT or PREVIOUS to highlight the de-

NOTE: When overriding or changing metric values, it is nec- sired period or override to change.
essary 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.
5. Press SELECT to access the highlighted period or
override.
2. Press SELECT to access the highlighted value.
6. a. Press INCREASE or DECREASE to change the

time values. Override values are in one-hour
increments, up to 4 hours.
28
23XRPIC3 SETPOINT SETPOINT SELECT
23XRPIC3
Base Demand Limit 100%
Control Point Source
LCL Setpoint 50.0 °F
0700 1800 ECL Setpoint 60.0 °F
0600 1300 Ice Build Setpoint 40.0 °F
0300 Tower Fan High Setpoint 75 °F
a23-1607
Fig. 30 — Example of Set Point Screen
Fig. 29 — Example of Time Schedule 2. There are 5 set points on this screen: BASE DEMAND
Operation Screen LIMIT, LCL SETPOINT (leaving chilled liquid set
b. Press ENABLE to select days in the day-of-week point), ECL SETPOINT (entering chilled liquid set
fields. Press DISABLE to eliminate days from the point), ICE BUILD SETPOINT and TOWER FAN
period. HIGH SETPOINT. Only one of the CONTROL
POINT SOURCES (LCL or ECL) can be active at one
time. The control point source that is active is deter-
mined from the TEMP_CTL screen. See the Service
Operation section, page 59.
3. Press NEXT or PREVIOUS to highlight the desired
7. Press ENTER to register the values and to move hori- set point entry.
zontally (left to right) within a period.
4. Press SELECT to modify the highlighted set point.
8. Press EXIT to leave the period or override.
5. Press INCREASE or DECREASE to change the

selected set point value.
9. Either return to Step 4 to select another period or over-
ride, or press EXIT again to leave the current time
schedule screen and save the changes.
6. Press ENTER to save the changes and return to the

previous screen.
10. The Holiday Designation (HOLIDAYS table) may be

found in the Service Operation section, page 59. The
month, day, and duration for the holiday must be
assigned. The TIME BROADCAST ENABLE func-
tion in the BRODEF screen also must be enabled for SERVICE OPERATION — To view the menu-driven pro-
holiday periods to function. grams available for Service Operation, see the Service Opera-
TO VIEW AND CHANGE SET POINTS (Fig. 30) tion section, page 59. For examples of ICVC display screens,
see Table 3.
1. To view the SETPOINT table, from the MENU screen
press SETPOINT .
29
Table 3 — ICVC Display Data
dagger shall support one time write operations for the ICVC only
IMPORTANT: The following notes apply to all Table 3 examples. when the value is initially zero. Variables preceded by two asterisks
can be changed only from the ICVC. Reference Point Names in lower
1. Only 12 lines of information appear on the ICVC screen at any one case type can be viewed by CCN or BSI only by viewing the whole
time. Press the NEXT or PREVIOUS softkey to highlight a point table.
or to view items below or above the current screen. Double-click the 7. Alarms and Alerts: An asterisk in the far right field of a ICVC status
screen indicates that the chiller is in an alarm state; an exclamation
NEXT softkey to page forward; double-click the PREVIOUS point in the far right field of the ICVC screen indicates an alert state.
softkey to page back. The asterisk (or exclamation point) indicates that the value on that
2. To access the information shown in Examples 10 through 26, enter line has exceeded (or is approaching) a limit. For more information on
alarms and alerts, see the Alarms and Alerts section, page 23.
your 4-digit password after pressing the SERVICE softkey. If no
8. Index of all ICVC Parameters is shown in Appendix A.
softkeys are pressed for 15 minutes, the ICVC automatically logs off
(to prevent unrestricted access to PIC III controls) and reverts to the LEGEND
default screen. If this happens, you must re-enter your password to 1CR — Control Relay
access the tables shown in Examples 10 through 26.
CHL — Chilled Liquid
3. Terms in the Description column of these tables are listed as they CR — Control Relay
appear on the ICVC screen. CT — Current Transformer
4. The ICVC may be configured in English or Metric (SI) units using the I2T — Motor Overload
ICVC CONFIGURATION screen. See the Service Operation section, ICVC — International Chiller Visual Controller
page 59, for instructions on making this change. ECL — Entering Chilled Liquid
5. The items in the Reference Point Name column do not appear on the HGBP — Hot Gas Bypass
ICVC screen. They are data or variable names used in CCN, Building LCL — Leaving Chilled Liquid
Systems Interface (BSI) or Local Equipment Interface (LEI) Module LRA — Locked Rotor Amps
software (optional). They are listed in these tables as a convenience mA — Milliamps
to the operator if it is necessary to cross reference CCN/BSI docu- P — Pressure
mentation or use CCN/BSI programs. For more information, see the T — Temperature
CCN literature. VFD — Variable Frequency Drive
6. Reference Point Names shown in these tables in all capital letters WSM — Liquid System Manager
can be read by CCN and BSI software. Of these capitalized names, °F — Temperature in Degrees Fahrenheit
those variables preceded by a * can also be changed (that is, written ˆF — Temperature Difference in Degrees Fahrenheit
to) by the CCN, BSI, LEI, and the ICVC. Variables preceded by a
EXAMPLE 1 — ICVC DEFAULT SCREEN

The following data is displayed in the ICVC Default screen.
DESCRIPTION RANGE UNITS REFERENCE POINT NAME DISPLAY

(ALARM HISTORY)
(PRIMARY MESSAGE)
(SECONDARY MESSAGE)
(DATE AND TIME)
Compressor Ontime 0 to 500000.0 HOURS C_HRS
Entering Chilled Liquid –40 to 245 °F (°C) ECL CHL IN
Leaving Chilled Liquid –40 to 245 °F (°C) LCL CHL OUT
Evaporator Refrigerant Temperature (See Note 1) –40 to 245 °F (°C) ERT_EST EVAP REF
Entering Condenser Liquid –40 to 245 °F (°C) ECDL CDL IN
Leaving Condenser Liquid –40 to 245 °F (°C) LCDL CDL OUT
Condenser Refrigerant Temperature –40 to 245 °F (°C) CRT COND REF
Oil Pressure Delta P –6.7 to 425 psi (kPa) OIL_PD OILPRESS
Oil Sump Temp –40 to 245 °F (°C) OILT OIL TEMP
Percent Line Current 0 to 999 % AMPS_P % AMPS IN
CCN 0 to 1 CCN
LOCAL 0 to 1 LOCAL
RESET 0 to 1 RESET
NOTES:
1. The Evaporator Refrigerant Temperature displayed is the smaller value of EVAP REFRIG LIQUID TEMP or CALC EVAP SAT TEMP.
2. The last three entries are used to indicate operating mode to the PIC III. These values may be forced by the ICVC only.
30
Table 3 — ICVC Display Data (cont)
EXAMPLE 2 — MAINTSTAT DISPLAY SCREEN
To access this display from the ICVC default screen:
1. Press MENU .
2. Press STATUS ( MAINSTAT will be highlighted).
3. Press SELECT .
DESCRIPTION STATUS UNITS POINT

Control Mode NOTE 2 NOTE 2 MODE
Run Status NOTE 3 NOTE 3 STATUS
Start Inhibit Timer 0 to 15 min T_START
Occupied ? 0/1 NO/YES OCC
System Alert/Alarm 0-2 NOTE 4 SYS_ALM
*Chiller Start/Stop 0/1 STOP/START CHIL_S_S
*Remote Start Contact 0/1 OPEN/CLOSE REMCON
Temperature Reset –30 to 30 ^F (^C) T_RESET
*Control Point 10 to 65 °F (°C) LCW_STPT
Chilled Liquid Temp –40 to 245 °F (°C) CHL_TMP
*Active Demand Limit 40 to 100 % DEM_LIM
Percent Line Current 0.0 to 9999 % LN AMPS_P
Percent Line Kilowatts 0.0 to 9999 % LINE KW_P
Auto Demand Limit Input 4 to 20 mA AUTODEM
Auto Chilled Liq Reset 4 to 20 mA AUTORES
Remote Reset Sensor –40 to 245 °F (°C) R_RESET
†Total Compressor Starts 0 to 99999 C_STARTS
Starts in 12 Hours 0 to 8 STARTS
†Compressor Ontime 0 to 500000.0 HOURS C_HRS
**Service Ontime 0 to 32767.0 HOURS S_HRS
Ice Build Contact 0/1 OPEN/CLOSE ICE_CON
Refrigerant Leak Sensor PPM 0.0 to 9999.0 mA REF_LEAK
Emergency Stop 0/1 ENABLE/EMSTOP EMSTOP
ALARM RELAY NORMAL/ALARM ALM
NOTES:
1. Numbers in parentheses indicate the equivalent CCN BEST++™ programming LEI or BACnet Translator use.
2. Off (0), Local (1), CCN (2), Reset (3)
3. Timeout (0), Ready (1), Recycle (2), Startup (3), Running (4), Demand (5), Ramping (6), Auto Restart (7), Override (8), Tripout (9), Control Test
(10), Lockout (11), Pumpdown (12), Prestart (13)
4. Normal (0), Alert (1), Alarm (2).
5. All variables with capital letter point names are available for CCN read operation.
Those shown with (*) support write operations for all CCN and LEI devices.
Those shown with (†) shall support one time write operations for the ICVC only when the value is initially zero.
Those shown with (**) shall support write operations for the ICVC only.
EXAMPLE 3 — STARTUP DISPLAY SCREEN

1. Press MENU .
2. Press STATUS .
3. Scroll down to highlight STARTUP .
4. Press SELECT .

**Chilled Liquid Pump 0/1 OFF/ON CHLP
Chilled Liquid Flow 0/1 NO/YES CHL_FLOW
**Condenser Liquid Pump 0/1 OFF/ON CDP
Condenser Liquid Flow 0/1 NO/YES CDL_FLOW
Oil Pump Relay 0/1 OFF/ON OILR
Oil Reclaim Output 0 to 100.0 % (4 to 20mA) OIL_MA
**Oil Pressure Delta P –6.7 to 200 psi (kPa) OILPD
Oil Sump Temp –40.0 to 245.0 °F (°C) OILT
Vaporizer Temp –40.0 to 245.0 °F (°C) VAP_TEMP
VFD Start 0/1 NO/YES VFDSTART
Start Complete 0/1 FALSE/TRUE START_OK
Stop Complete 0/1 FALSE/TRUE STOP_OK
VFD Speed Output 0.0 to 100.0 % VFD_OUT
Comp Motor RPM 0 to 300000 rpm CPR_RPM
Comp Motor Frequency 0 to 10000 Hz VFD_FREQ
Comp Maximum Speed 0 to 110 Hz MAXSPEED
Comp Minimum Speed 0 to 100 % MINSPEED
**Tower Fan Relay Low 0/1 OFF/ON TFR_LOW
**Tower Fan Relay High 0/1 OFF/ON TFR_HIGH
Spare Safety Input 0/1 ALARM/NORMAL SAFETY
Shunt Trip Relay 0/1 OFF/ON TRIPR
NOTE: All variables with CAPITAL LETTER point names are available for CCN read operation.
Those shown with (**) shall support write operations for the ICVC only.
31
EXAMPLE 4 — COMPRESS DISPLAY SCREEN
1. Press MENU .
2. Press STATUS .
3. Scroll down to highlight COMPRESS .
4. Press SELECT .

Actual VFD Speed 0 to 115 % VFD_ACT
Compressor Motor RPM 0 to 300000 rpm CPR_RPM
Compressor Motor Frequency 0 to 10000 Hz VFD_FREQ
Compressor Maximum Speed 0 to 101 Hz MAXSPEED
Compressor Minimum Speed 0 to 100 % MINSPEED
VFD Delta –2 to 2 % VFDDELTA
**Target VFD Speed 0 to 100 % VFD_TRG
VFD Speed Output 0 to 100 % VFD_OUT
Oil Pump Relay 0/1 OFF/ON OILR
**Oil Pressure Delta P –6.7 to 420 psi (kPa) OILPD
Oil Sump Temp –40 to 245 °F (°C) OILT
Vaporizer Temperature –40 to 245 °F (°C) VAP_TEMP
Oil Heater Relay 0/1 OFF/ON OILHEAT
Vaporizer Heater 0/1 OFF/ON VAP_HEAT
Comp Motor Winding Temp –40 to 245 °F (°C) MTRW
Comp Discharge Temp –40 to 245 °F (°C) CMPD
Discharge Superheat –20 to 999 ^F (^C) SUPRHEAT
Stall Protection Counts 0 to 5 SPC
Spare Temperature 1 –40 to 245 °F (°C) SPARE_T1
NOTE: All variables with CAPITAL LETTER point names are available for CCN read operation;
those with (**) shall support write operations for ICVC only.
EXAMPLE 5 — HEAT_EX DISPLAY SCREEN

1. Press MENU .
2. Press STATUS .
3. Scroll down to highlight HEAT_EX .
4. Press SELECT .

**Chilled Liquid Delta P –6.7 to 420 psi (kPa) CHLPD
Entering Chilled Liquid –40 to 245 °F (°C) ECL
Leaving Chilled Liquid –40 to 245 °F (°C) LCL
Chilled Liquid Delta T –40 to 245 ^F (^C) CHL_DT
Chill Liq Pulldown/Min –20 to 20 ^F (^C) CHL_PULL
Calc Evap Sat Temp –40 to 245 °F (°C) ERT
**Evaporator Pressure –6.7 to 420 psi (kPa) ERP
Evap Refrig Liquid Temp –40 to 245 °F (°C) EST
Evaporator Approach 0 to 99 ^F (^C) EVAP_APP
**Condenser Liquid Delta P (N/A for P Compressor) –6.7 to 420 psi (kPa) CDLPD
Entering Cond Liquid –40 to 245 °F (°C) ECDL
Leaving Cond Liquid –40 to 245 °F (°C) LCDL
Condenser Refrig Temp –40 to 245 °F (°C) CRT
**Condenser Pressure –6.7 to 420 psi (kPa) CRP
Condenser Approach 0 to 99 ^F (^C) COND_APP
Vaporizer Temp –40 to 245 °F (°C) VAP_TEMP
Reclaim Delta T –500 to 500 ^F (^C) R_DELTA
Oil Reclaim Output 0 to 100 % OIL_MA
VFD Coolant Flow 0 to 100 % VFD_FOUT
Hot Gas Bypass Relay 0/1 OFF/ON HGBYPASS
Active Delta P 0 to 200 psi (kPa) DP_A
Active Delta T 0 to 200 ^F (^C) DT_A
HGBP Delta T 0 to 200 ^F (^C) DT_C
Head Pressure Reference 0 to 100 % HPR
32
EXAMPLE 6 — ECON_EXV DISPLAY SCREEN (FOR P COMPRESSOR ONLY)

Applies to units enabled with EXV throttle control enabled.
1. Press MENU .
2. Press STATUS .
3. Scroll down to highlight ECON_EXV .
4. Press SELECT .

Econ EXV Position 0 to 100 % ECON_EXV
** Target Economizer EXV 0.0 to 100 % EEXV_TRG
Econ EXV Steps –160 to 100.0 % ECONSTEP
Econ Superheat Setpoint 0.0 to 30.0 (0.0 to 16.7) ^F (^C) ECONSHSP
Econ Superheat 0.0 to 30.0 (0.0 to 16.7) ^F (^C) ECON_SH
Econ Superheat Error 0.0 to 30.0 (0.0 to 16.7) ^F (^C) SH_ERR
Economizer Sat Temp –40 to 245 (–22.2 to 136.1) °F (°C) ECON_SAT
Economizer Pressure –6.7 to 420 (–46.2 to 2895.8) psi (kPa) ECON_PRS
Economizer Gas Temp –40 to 245 (–22.2 to 136.1) °F (°C) ECON_GAS
VFD Speed Output 0.0 to 100.0 % VFD_OUT
EXAMPLE 7 — COND_EXV DISPLAY SCREEN (FOR P COMPRESSOR ONLY)

Applies to units enabled with EXV throttle control enabled.
1. Press MENU .
2. Press STATUS .
3. Scroll down to highlight COND_EXV .
4. Press SELECT .

Condenser EXV 0 to 100 % COND_EXV
** Target Condenser EXV 0.0 to 100 % CEXV_TRG
Cond EXV Steps –160 to 100.0 % CONDSTEP
Condenser Liquid Level 0 to 5 V COND_LEV
Fine Tune Active? Y/N FT_ACTIVE
Discharge Superheat DSH
Evaporator Approach EVAP_APP
Cond LevelSetpoint 0 to 5 V LEV_SP
Cond Level Output 0 to 5 V LEV_OUTV
Cond Level Error 0 to 5 V LEV_ERR
Cond Level Integral 0 to 100 LEV_INT
Cond Level Output 0 to 100 % LEV_OUTP
Cond Level Range 0 to 5 V LEV_RANG
Cond EXV Max Movement 0 to 100 % CEXV_MAX
those with (**) shall support write operations for all CCN devices.
33
EXAMPLE 8 — POWER DISPLAY SCREEN
1. Press MENU .
2. Press STATUS .
3. Scroll down to highlight POWER .
4. Press SELECT .

Percent Line Current 0 to 999 % LNAMPS_P
Average Line Current 0 to 99999 AMPS LNAMPS_A
Percent Line Voltage 0 to 999 % LNVOLT_P
Average Line Voltage 0 to 99999 VOLTS LNVOLT_A
Line Power Factor 0.0 to 2.0 LINE_PF
Line Kilowatts 0 to 99999 KW LINE_KW
Percent Line Kilowatts 0 to 99999 % LINEKW_P
Percent Load Current 0 to 99999 % LDAMPS_P
Average Load Current 0 to 99999 AMPS LDAMPS_A
Motor Power Factor 0.0 to 2.0 MOTOR_PF
Motor Kilowatts 0 to 99999 KW MOTOR_KW
Percent Motor Kilowatts 0 to 99999 % MOTORKWP
Motor Kilowatt-Hours 0 to 99999 KWH MOTORKWH
Demand Kilowatts 0 to 99999 KW DEM_KW
Line Current Phase 1 (R) 0 to 99999 AMPS LN_AMPS1
Line Current Phase 2 (S) 0 to 99999 AMPS LN_AMPS2
Line Current Phase 3 (T) 0 to 99999 AMPS LN_AMPS3
Load Current Phase 1 (U) 0 to 99999 AMPS LD_AMPS1
Load Current Phase 2 (V) 0 to 99999 AMPS LD_AMPS2
Load Current Phase 3 (W) 0 to 99999 AMPS LD_AMPS3
Line Voltage Phase 1 (RS) 0 to 99999 VOLTS LN_VOLT1
Line Voltage Phase 2 (ST) 0 to 99999 VOLTS LN_VOLT2
Line Voltage Phase 3 (TR) 0 to 99999 VOLTS LN_VOLT3
Ground Fault Current 0 to 999 AMPS GF_AMPS
Line Frequency 0 to 99 Hz LINEFREQ
Rectifier Overload 0 to 100 % RECT_OV
Inverter Overload 0 to 100 % INV_OV
Motor Overload 0 to 100 % MOTOR_OV
Line Current Imbalance 0 to 100 % LN_IMB_I
Motor Current Imbalance 0 to 100 % MT_IMB_I
Line Voltage Imbalance 0 to 100 % LN_IMB_V
Line Active Current 0 to 99999 AMPS AMPS_ACT
Line Reactive Current 0 to 99999 AMPS AMPS_RE
Line Active Voltage 0 to 99999 VOLTS VOLT_ACT
Line Reactive Voltage 0 to 99999 VOLTS VOLT_RE
DC Bus Voltage Reference 0 to 99999 VOLTS BUS_REF
DC Bus Voltage 0 to 99999 VOLTS BUS_VOLT
Flux Current 0 to 99999 AMPS FLUXAMPS
Torque Current 0 to 99999 AMPS TORQAMPS
Inverter Temperature 0 to 300 °F (°C) INV_TEMP
Rectifier Temperature 0 to 300 °F (°C) REC_TEMP
VFD Dewpoint 0.0 to 300.0 °F (°C) VFDDEWPT
VFD Enclosure Temperature 0 to 300 °F (°C) VFD_ENCL
VFD Cold Plate Temperature 0 to 300 °F (°C) CP_TEMP
Humidity Sensor Input 0.0 to 5.0 VOLTS HUMID_SR
Relative Humidity 0 to 100 % HUMIDITY
VFD Coolant Flow 0 to 100 % VFD_FOUT
34
EXAMPLE 9 — VFD_STAT DISPLAY SCREEN
1. Press MENU .
2. Press STATUS .
3. Scroll down to highlight VFD_STAT .
4. Press SELECT .

VFD Fault Code 0 to 272 VFD_FLT
Single Cycle Dropout 0/1 NORMAL/ALARM CYCLE_1
Line Current Imbalance 0/1 NORMAL/ALARM LINEIM_I
Line Voltage Imbalance 0/1 NORMAL/ALARM LINEIM_V
Line Phase Reversal 0/1 NORMAL/ALARM PH_REV
High Line Voltage 0/1 NORMAL/ALARM HI_VOLT
Low Line Voltage 0/1 NORMAL/ALARM LOW_VOLT
High DC Bus Voltage 0/1 NORMAL/ALARM HI_DCBUS
Low DC Bus Voltage 0/1 NORMAL/ALARM LO_DCBUS
Motor Current Imbalance 0/1 NORMAL/ALARM MOTIM_I
Motor Overload 0/1 NORMAL/ALARM MOTOR_OV
Rectifier Overcurrent 0/1 NORMAL/ALARM RECT_OI
Rectifier Overtemp 0/1 NORMAL/ALARM RECT_OT
Rectifier Power Fault 0/1 NORMAL/ALARM RECT_PU
Inverter Overcurrent 0/1 NORMAL/ALARM INV_OI
Inverter Overtemp 0/1 NORMAL/ALARM INV_OT
Inverter Power Fault 0/1 NORMAL/ALARM INV_PU
Ground Fault 0/1 NORMAL/ALARM GRND_FLT
Frequency Fault 0/1 NORMAL/ALARM FREQFLT
VFD Power on Reset 0/1 NORMAL/ALARM VFD_POR
Start Complete 0/1 FALSE/TRUE START_OK
Stop Complete 0/1 FALSE/TRUE STOP_OK
Condenser High Pressure 0/1 NORMAL/ALARM PRS_TRIP
Motor Amps Not Sensed 0/1 NORMAL/ALARM NO_AMPS
Start Acceleration Fault 0/1 NORMAL/ALARM ACCELFLT
Stop Fault 0/1 NORMAL/ALARM AMPSTOP
VFD Start Inhibit 0/1 NORMAL/ALARM STRT_INH
VFD Checksum Error 0/1 NORMAL/ALARM CHECKSUM
VFD Comm Fault 0/1 NORMAL/ALARM VFD_COMM
VFD Fault 0/1 NORMAL/ALARM VFDFAULT
VFD Gateway Version # 0 to 255 VFG_VER
VFD Inverter Version # 0 to 1000 INV_VER
VFD Rectifier Version # 0 to 1000 REC_VER
EXAMPLE 10 — ICVC_PWD DISPLAY SCREEN

1. Press MENU .
2. Press STATUS .
3. Scroll down to highlight ICVC_PWD .
4. Press SELECT .

Disable Service Password 0/1 DS/ENABLE PSWD_DIS
**Remote Reset Option 0/1 DS/ENABLE RESETOPT
Reset Alarm ? 0/1 NO/YES REMRESET
CCN Mode ? 0/1 NO/YES REM_CCN
NOTE: The Disable Service Password parameter supports the service tool password disable access. It will only allow forcing with the service tool
for a one time bypass of both the service menu and the VFD config data table. Exit from the service menu reverts to normal password operation.
Those with (**) shall support write operations for ICVC only.
The Reset Alarm? and CCN mode? parameters support write operations from CCN and LEI devices when the Remote Reset Option is enabled.
35
EXAMPLE 11 — SETPOINT DISPLAY SCREEN
1. Press MENU .
2. Press SETPOINT (Base Demand Limit will be highlighted).
3. Press SELECT .
DESCRIPTION STATUS UNITS POINT DEFAULT

Base Demand Limit 40 to 100 % dlm 100
LCL Setpoint 10 to 60 F (–12.2 to 15.6 C) °F (°C) lcl_sp 50.0 F (10.0 C)
ECL Setpoint 15 to 65 F (–9.4 to18.3 C) °F (°C) ecl_sp 60.0 F (15.6 C)
Ice Build Setpoint 15 to 60 F (–9.4 to 15.6 C) °F (°C) ice_sp 40 F (4.4 C)
Tower Fan High Setpoint 55to 105 F (13 to 41 C) °F (°C) tfh_sp 75 F (23.9 C)
NOTE: No variables are available for CCN read operation; forcing shall not be supported on setpoint screens.
EXAMPLE 12 — CAPACITY DISPLAY SCREEN

1. Press MENU .
2. Press SERVICE .
3. Scroll down to highlight CONTROL ALGORITHM STATUS.
4. Press SELECT .
5. Scroll down to highlight CAPACITY .
Entering Chilled Liquid –40 to 245 °F (°C) ECL
Leaving Chilled Liquid –40 to 245 °F (°C) LCL
Capacity Control
Control Point 10 to 65 °F (°C) ctrlpt
Control Point Error –99 to 99 ^F (^C) cperr
ECL Delta T –99 to 99 ^F (^C) ecldt
ECL Reset –99 to 99 ^F (^C) eclres
LCL Reset –99 to 99 ^F (^C) lclres
Total Error + Resets –99 to 99 ^F (^C) error
Cap Delta –2 to 2 % capdelta
VFD Delta –2 to 2 % vfddelta
Target VFD Speed 0 to 100 % VFD_TRG
VFD Speed Output 0 to 110 % VFD_OUT
VFD Gain 0.1 to 1.5 vfd_gain
Demand Limit Inhibit 0.2 to 1 % DEM_INH
Amps/kW Ramp 0 to 100 % RAMP_LMT
forcing shall not be supported on maintenance screens.
EXAMPLE 13 — OVERRIDE DISPLAY SCREEN

1. Press MENU .
2. Press SERVICE .
3. Scroll down to highlight CONTROL ALGORITHM STATUS .
4. Press SELECT .
5. Scroll down to highlight OVERRIDE .

Comp Motor Winding Temp –40 to 245 °F (°C) MTRW
Comp Motor Temp Override 150 to 200 °F (°C) MT_OVER
Condenser Pressure –6.7 to 420 psi (kPa) CRP
Cond Press Override 150 to 260 psi (kPa) CP_OVER
Calc Evap Sat Temp –40 to 245 °F (°C) ERT
Evap Sat Override Temp 2 to 45 °F (°C) ERT_OVER
Comp Discharge Temp –40 to 245 °F (°C) CMPD
Comp Discharge Alert 125 to 200 °F (°C) CD_ALERT
Rectifier Temperature 0 to 300 °F (°C) RECT_TEMP
Rectifier Temp Override 125 to 200 °F (°C) REC_OVER
Inverter Temperature 0 to 300 °F (°C) INV_TEMP
Inverter Temp Override 125 to 200 °F (°C) INV_OVER
Discharge Superheat –20 to 999 ^F (^C) SUPRHEAT
Condenser Refrig Temp –40 to 245 °F (°C) CRT
NOTE: All variables with CAPITAL LETTER point names are available for CCN read operation; forcing shall not be supported on
maintenance screens.
36
EXAMPLE 14 — LL_MAINT DISPLAY SCREEN

1. Press MENU .
2. Press SERVICE .
4. Press SELECT .
5. Scroll down to highlight LL_MAINT .

Lead Lag Control NOTE 1
LEADLAG: Configuration NOTE 1 leadlag
Current Mode NOTE 2 llmode
Load Balance Option 0/1 DSABLE/ENABLE loadbal
LAG Start Time 0 to 60 MIN lagstart
LAG Stop Time 0 to 60 MIN lagstop
Prestart Fault Time 0 to 60 MIN preflt
Pulldown Time 0.0 to 30.0 MIN pulltime
Pulldown: Delta T/Min XX.X ^F (^C) 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
NOTES:
1. DISABLE, LEAD, LAG, STANDBY, INVALID
2. DISABLE, LEAD, LAG, STANDBY, RECOVERY, CONFIG
3. Reset, Off, Local, CCN, Blank
4. Timeout, Ready, Recycle, Prestart, Startup, Ramping, Running, Demand, Override, Shutdown, Trippout, Pumpdown, Lockout, ‘Blank’
5. Stop, Start, Retain, ‘Blank’
6. All variables with CAPITAL LETTER point names are available for CCN read operation; forcing shall not be supported on maintenance screens.
37
EXAMPLE 15 — VFD_HIST DISPLAY SCREEN
1. Press MENU .
2. Press SERVICE .
4. Press SELECT .
5. Scroll down to highlight VFD_HIST .

VFD FAULT HISTORY
Values At Last Fault:
Line Current Phase 1 (R) 0 to 99999 AMPS LNAMPS1H
Line Current Phase 2 (S) 0 to 99999 AMPS LNAMPS2H
Line Current Phase 3 (T) 0 to 99999 AMPS LNAMPS3H
Load Current Phase 1 (U) 0 to 99999 AMPS LDAMPS1H
Load Current Phase 2 (V) 0 to 99999 AMPS LDAMPS2H
Load Current Phase 3 (W) 0 to 99999 AMPS LDAMPS3H
Line Voltage Phase 1 (RS) 0 to 99999 VOLTS LNVOLT1H
Line Voltage Phase 2 (ST) 0 to 99999 VOLTS LNVOLT2H
Line Voltage Phase 3 (TR) 0 to 99999 VOLTS LNVOLT3H
Ground Fault Current 0 to 999 AMPS GF_AMPSH
Line Frequency 0 to 99 Hz LINEFRQH
Line Power Factor 0 to 2.0 LINE_PFH
Line Current Imbalance 0 to 100 % LN_IMBIH
Line Voltage Imbalance 0 to 100 % LN_IMBVH
Motor Power Factor 0 to 2.0 MOTORPFH
Motor Current Imbalance 0 to 100 % MT_IMBIH
Motor Overload 0 to 100 % MOTOROVH
Line Active Current 0 to 99999 AMPS AMPSACTH
Line Reactive Current 0 to 99999 AMPS AMPS_REH
Line Active Voltage 0 to 99999 VOLTS VOLTACTH
Line Reactive Voltage 0 to 99999 VOLTS VOLT_REH
DC Bus Voltage 0 to 99999 VOLTS BUSVOLTH
DC Bus Voltage Reference 0 to 99999 VOLTS BUS_REFH
Flux Current 0 to 99999 AMPS FLUXAMPH

Torque Current 0 to 99999 AMPS TORQAMPH
Inverter Temperature 0 to 300 °F (°C) INVTEMPH
Rectifier Temperature 0 to 300 °F (°C) RECTEMPH
VFD Dewpoint 0.0 to 300.0 °F (°C) VFDDEWPT
VFD Enclosure Temp 0 to 300 °F (°C) VFDENCLH
VFD Cold Plate Temp 0 to 300 °F (°C) CP_TEMPH
Actual VFD Speed 0 to 100 % VFD_ACTH
Comp Motor RPM 0 to 300000 rpm CPR_RPMH
Comp Motor Frequency 0 to 10000 Hz VFDFREQH
Chiller Fault State 200 to 272 VFDSTATH
VFD Fault Code 200 to 272 VFD_FLTH
forcing shall not be supported on maintenance screens.
EXAMPLE 16 — LOADSHED DISPLAY SCREEN

1. Press MENU .
2. Press SERVICE .
3. Scroll down to highlight CONTROL ALGORITHM STATUS.
4. Press SELECT .
5. Scroll down to highlight LOADSHED .

LOADSHED FUNCTION
Redline 0/1 NO/YES REDLINE
Loadshed 0/1 NO/YES LOADSHED
Loadshed Timer 0 to 480 LOADTIME
NOTE: All variables with CAPITAL LETTER point names are avail-
able for CCN read operation; forcing shall not be supported on main-
tenance screens.
38
EXAMPLE 17 — WSMCHLRE DISPLAY SCREEN

1. Press MENU .
2. Press SERVICE .
4. Press SELECT .
5. Scroll down to highlight WSMDEFME .

WSM Active? 0/1 NO/YES WSMSTAT
Chilled Water Temp 0.0 to 99.9 °F (°C) CHWTEMP
Equipment Status 0/1 OFF/ON CHWRST
Commanded State TEXT CHWRENA
CHW Setpoint Reset Value 0.0 to 25.0 ^F (^C) CHWRVAL
Current CHW Set Point 0.0 to 99.9 °F (°C) CHWSTPT
NOTE: All variables with CAPITAL LETTER point names are avail-
able for CCN read operation; forcing shall not be supported on main-
tenance screens.
EXAMPLE 18 — NET_OPT DISPLAY SCREEN

1. Press MENU .
2. Press SERVICE .
3. Scroll down to highlight EQUIPMENT CONFIGURATION .
4. Press SELECT .
5. Scroll down to highlight NET_OPT .

Loadshed Function
Group Number 1 to 16 ldsgrpn 0
Demand Limit Decrease 0 to 60 % ldsdlta 20
Maximum Loadshed Time 30 to 480 MIN maxshed 120
CCN Occupancy Config:
Schedule Number 3 to 99 occ_num 3
Broadcast Option 0 to 1 DSABLE/ENABLE occbrcst DSABLE
Alarm Configuration
Re-Alarm Time 0 to 1440 MIN retime 30
Alarm Routing 0 to 1 routing 10000000
NOTE: No variables are available for CCN read or write operation.
39
EXAMPLE 19 — VFD_CONF DISPLAY SCREEN

1. Press MENU .
2. Press SERVICE .
3. Scroll down to highlight VFD CONFIG DATA .
4. Press SELECT .
5. Scroll down to highlight VFD_CONF .
Motor Nameplate Voltage 380 to 480 VOLTS motor_nv 480
Compressor 100% Speed 54 to 110 comp_100
(Q,R Compressors)
54 to 140 Hz 70
(P Compressor)
* Rated Line Voltage 208 to 600 VOLTS vfd_volt 460
* Rated Line Amps 10 to 5000 AMPS vfd_amps 200
* Rated Line Kilowatts 0 to 999999 KW vfd_rlkw 100
*Motor Rated Load KW 0 to 999999 KW mot_rlkw 100
*Motor Rated Load Amps 10 to 5000 AMPS mot_rla 200
Motor Nameplate Amps 10 to 5000 AMPS motorni 100
 Motor Nameplate RPM 1500 to 3960 motorpm
(Q,R Compressors) 2672
1500 to 3960 3750
(P Compressor)
Motor Nameplate kW 0 to 999999 KW motorkw 100
Inverter PWM Frequency 0/1 pwm_freq
0
(0=4 kHz, 1=2 kHz)
Skip Frequency 1 0 to 102 Hz skipfrq1 102
Skip Frequency Band 0 to 102 Hz skipband 0
Line Voltage % Imbalance 1 to 10 % v_umbal 10
Line Voltage Imbal Time 1 to 10 SEC v_time 10
Line Current % Imbalance 5 to 40 % lineim_i 40
Line Current Imbal Time 1 to 10 SEC lineim_t 10
Motor Current % Imbalance 5 to 40 % motim_i 40
Motor Current Imbal Time 1 to 10 SEC motim_t 10
 Increase Ramp Time 5 to 60 SEC ramp_inc 30
(Q,R Compressors)
0 to 255
(P Compressor)
 Decrease Ramp Time 0 to 60 SEC ramp_dec 255
(Q,R Compressors) 30
5 to 255
(P Compressor)
Single Cycle Dropout 0/1 DSABLE/ENABLE cycdrop DSABLE
NOTE: Those parameters marked with a * shall not be downloaded to the VFD, but shall be used in other calculations and algorithms in the ICVC.
516 40
EXAMPLE 20 — OPTIONS DISPLAY SCREEN

1. Press MENU .
2. Press SERVICE .
3. Scroll down to highlight EQUIPMENT SERVICE .
4. Press SELECT .
5. Scroll down to highlight OPTIONS .
Auto Restart Option 0/1 DSABLE/ENABLE astart DSABLE
Remote Contacts Option 0/1 DSABLE/ENABLE r_contac DSABLE
Soft Stop Amps Threshold 40 to 100 % softstop 100
Hot Gas Bypass
HGBP Option 0, 1, 2 0=DSABLE Srg_hgbp DSABLE
1=HGBP
2=LOW LOAD HGBP
Min. Load Point (T1,P1)
HGBP Delta T1 0.5 to 20 (0.3 to 11.1) ^F (^C) hgbp_dt1 1.5 (0.8)
HGBP Delta P1 10 to 170 (68.9 to 1172.2) psi (kPa) hgbp_dp1 150 (1034.2)
Full Load Point (T2,P2)
HGBP Delta T2 0.5 to 20 (0.3 to 11.1) ^F (^C) hbgp_dt2 4 (2.2)
HGBP Delta P2 30 to 250 (206.9 to 1724) psi (kPa) hgbp_dp2 200 (1379)
HGBP Deadband 0.5 to 3 (0.3 to 1.7) ^F (^C) hbgp_db 1 (0.6)
HGBP On Delta Speed 0.0 to 20.0 % hgbp_on 5.0
HGBP Off Delta Speed 0.0 to 20.0 % hgbp_off 3.0
Stall Protection
Stall Delta % Amps 5 to 20 % stall_a 10
Stall Time Period 7 to 10 MIN stall_t 8
Ice Build Control
Ice Build Option 0/1 DSABLE/ENABLE ibopt DSABLE
Ice Build Termination 0 to 2 ibterm 0
(0=TEMP, 1=Contact, 2=Both)
Ice Build Recycle 0/1 DSABLE/ENABLE ibrecyc DSABLE
Refrigerant Leak Option 0/1 DSABLE/ENABLE leak_en DSABLE
PPM at 20mA 0 to 99999 ppm_20 1000
Refrig Leak Alarm PPM 0 to 99999 ppm_lim 500
Head Pressure Reference
Delta P at 0% (4mA) 20 to 85 (138 to 586) psi (kPa) hpdp0 25 (172)
Delta P at 100% (20mA) 20 to 85 (138 to 586) psi (kPa) hpdp100 50 (345)
Minimum Output 0 to 100 % hpdpmin% 0
41
EXAMPLE 21 — SETUP1 DISPLAY SCREEN
1. Press MENU .
2. Press SERVICE .
4. Press SELECT .
5. Scroll down to highlight SETUP1 .

Comp Motor Temp Override 150 to 200 (66 to 93) °F (°C) mt_over 200 (93)
Cond Press Override 145 to 166 (1000 to 1145) psi (kPa) cp_over 145 (1000)
Comp Discharge Alert 125 to 160 (52 to 71) ° F (°C) cd_alert 140 (60)
Rectifier Temp Override 155 to 170 (68 to 77) °F (°C) rec_over 160 (71)
(Q,R Compressors) (Q,R Compressors)
155 to 190 (68 to 88) 180
(P Compressor) (P Compressor)
Inverter Temp Override 155 to 170 (68 to 77) °F (°C) inv_over 160 (71)
(Q,R Compressors) (Q,R Compressors)
155 to 190 (68 to 88) 180
(P Compressor) (P Compressor)
Chilled Medium 0/1 WATER/BRINE medium WATER

Chilled Liquid Deadband 0.5 to 2.0 (0.3 to 1.1) ^F (^C) cldb 1.0 (0.6)
Evap Refrig Trippoint 2.0 to 10.0 (0.3-5.6) °F (°C) ert_trip 33 (0.6)
 Refrig Override Delta T 2.0 to 10.0 (0.3-5.6) ^F (^C) ref_over 5 (2.8)
 Evap Approach Alert 0.5 to 10 (0.3 to 5.6) ^F (^C) evap_al 4(2.2)
Cond Approach Alert 0.5 to 30 (0.3 to 16.6) ^F (^C) cdap_al 6 (3.3)
Condenser Freeze Point –20 to 35 (–28.9 to 1.7) °F (°C) cdfreeze 34 (1.1)
Flow Delta P Display 0/1 DSABLE/ENABLE flowdisp DSABLE

Evap Flow Delta P Cutout 0.5 to 50.0 (3.45 to 344.7) psi (kPa) evap_cut 5.0 (34.5)
Cond Flow Delta P Cutout 0.5 to 50.0 (3.45 to 344.7) psi (kPa) cond_cut 5.0 (34.5)
Oil Press Verify Time 15 to 300 SEC oilpr_t 45
Liquid Flow Verify Time 0.5 to 5 MIN lflow_t 5
Recycle Control
Restart Delta T 2.0 to 10.0 (1.1 to 5.6) ^F (^C) rcycr_dt 5 (2.8)
Shutdown Delta Speed 0.0 to 20.0 % rcycs_dv 2.0
(Q,R Compressors)
–10.0 to 20.0 0.5
(P Compressor)
Shutdown Delta T 2.0 to 10 (1.1 to 5.6) ^F (^C) rcycs_dt 5 (2.8)
(P Compressor Only)
Spare Alert/Alarm Enable

Disable=0, Lo=1/3, Hi=2/4
Spare Temp #1 Enable 0 to 4 sp1_en 0

Spare Temp #1 Limit –40 to 245 (–40 to 118) °F (°C) sp1_lim 245 (118)
Spare Temp #2 Enable 0 to 4 sp2_ en 0
Spare Temp #2 Limit –40 to 245 (–40 to 118) °F (°C) sp2_ lim 245 (118)
NOTE: No variables are available for CCN read or write operation; forcing shall not be supported on service screens.
EXAMPLE 22 — SETUP2 DISPLAY SCREEN

1. Press MENU .
2. Press SERVICE .
4. Press SELECT .

Capacity Control
Proportional Inc Band, vfd_inc
Q, R Compressors 2 to 10 6.5
Proportional Inc Band, vfd_inc
 P Compressor
2 to 15 12.0
Proportional Dec Band 2 to 10 vfd_dec 6.0
Proportional ECL Gain 1 to 3 vfd_ecl 2
VFD Speed Control
VFD Gain 0.1 to 1.5 vfd_gain 0.75
VFD Minimum Speed 15 to 50 % vfd_min 20
VFD Maximum Speed 50 to 100 % vfd_max 100
Vaporizer Heater Mode* 0/1 vhtr_mode 0
0=Normal, 1=Service
Oil Reclaim Min Output 0 to 25 % oilr_lim 25
*P compressor only.
NOTE: No variables are available for CCN read or write operation; forcing shall not be supported on service screens.
516 42
EXAMPLE 23 — SETUP3 DISPLAY SCREEN (P COMPRESSOR ONLY)
1. Press MENU .
2. Press SERVICE .
4. Press SELECT .

Oil Sump and Vap. Heater Control
Vap. Heater Turn On Speed 550 to 950 rpm vspdon 595
Vap. Heater Turn Off Speed 600 to 2500 rpm vspdoddff 625
Vap. Heater Turn On Lift 18 to 30 (10 to 17) ^F (^C) vlifton 22.5 (12.5)
Vap. Heater Turn Off Lift 25 to 35 (14 to 19) ^F (^C) vliftoff 26 (14.4)
Cond Refrig Temp Low Limit 55 to 80 (13 to 27) °F (°C) oilcrtlo 70 (21)
Sump Heater Turn On Speed 550 to 850 rpm smponsp 700
Sump Heater Turn Off Speed 600 to 2500 rpm smpoffsp 750
Sump Heater Turn On Lift 18 to 30 (10 to 17) ^F (^C) smoponlf 22.0 (12)
Sump Heater Turn Off Delta T 20 to 60 (11 to 33) ^F (^C) smpoffdt 40 (22)
NOTE: No variables are available for CCN read operation; forcing shall not be supported on service screens.
EXAMPLE 24 — SETUP3 DISPLAY SCREEN (Q AND R COMPRESSORS)

1. Press MENU .
2. Press SERVICE .
4. Press SELECT .

Compressor Type 1-3 cmp_type 0
1=TR, 2=TQ, 3=Other
VAPORIZER HEATER CONTROL
Vaporizer Heater Mode 0-1 vhtr_mode 0
Turn On Speed 550-650 RPM 595
Turn Off Speed 600-2500 RPM oilr_lim 625
Turn On Lift 18-30 % 22.5
Turn Off Lift 25-35 % 26
EXAMPLE 25 — SETUP4 DISPLAY SCREEN (P COMPRESSOR ONLY)

1. Press MENU .
2. Press SERVICE .
4. Press SELECT .

Economizer Control
Economizer Option 0/1 DSABLE/ENABLE econ_opt DSABLE
Econ Activate Speed 20 to 100 % econ_act 50
Econ Activate Deadband 0 to 20 % econ_db 10
Econ EXV Max Movement 0.5 to 5.0 % eexv_mov 3.0
Superheat Setpoint 0.0 to 20.0 (0.0 to 11.1) ^F (^C) super_sp 6.0 (3.3)
Econ Proportional Gain 0.1 to 2.0 econ_kp 0.1
Econ PID Calc Time 10 to 120 SEC pid_time 25
43
 EXAMPLE 26 — SETUP5 DISPLAY SCREEN (P COMPRESSOR ONLY)
1. Press MENU .
2. Press SERVICE .
4. Press SELECT .

Condenser Level Control
Cond EXV Max Movement 0.5 to 10.0 % cexv_mov 10
Cond EXV Min Position 15 to 60 % cexv_min 30
Cond EXV Start Position 70 to 100 % cexv_str 100
Disch Superheat Limit 2 to 10 (–16.7 to –12.2) °F (°C) dshft 6 (–14.4)
Cooler Approach Limit 1.5 to 20 (–16.9 to –6.7) °F (°C) caft 2.5 (–16.4)
Start Delay 0 to 255 SEC strt_del 120
Freeze Margin at Start 0 to 10 (0 to 5.5) ^F (^C) fmstrt 3 (1.7)
Cond Loop Timer 5 to 10 SEC cond_tim 5
Cond Level Setpoint 0.5 to 4.8 V levsetpt 3.0
Disch Sup Ht Corr Factor 0 to 1 % dshft_f 0.01
Evap App Corr Factor 0 to 2 % caft_f 0.5
Fine Tune Enabled? Y/N ft_yn Y
Fine Tune Threshold 0.1 to 1 % ft_thres 0.2
Cond Level Deadband 0.00 to 1 V cond_db 0.4
 Anti Winding Min 15 to 60 % aw_min 30
Cond Level Prop Gain 0.2 to 5.0 cond_kp 3
Cond Level Int Gain 0.0 to 5.0 cond_ki 0.04
Cond Level Int Clamp 0.5 to 3 % levclamp 1.5
Cond Level Low Limit 0.5 to 4.8 V cond_lov 1.6
Cond Level High Limit 0.5 to 4.8 V cond_hiv 3.2
Feed Forward Threshold 0.0 to 5.0 ff_thrs 1.0
Feed Forward Gain 0.0 to 30 ff_gain 0
 Evap Approach Reset Gain 0.0 to 15 app_res 10
EXAMPLE 27 — LEADLAG DISPLAY SCREEN

1. Press MENU .
2. Press SERVICE .
4. Press SELECT .
5. Scroll down to highlight LEADLAG .

Lead Lag Control
LEAD/LAG Configuration 0 to 3 leadlag 0
DSABLE=0, Lead=1
LAG=2, STANDBY=3
Load Balance Option 0/1 DSABLE/ENABLE loadbal DSABLE
Common Sensor Option 0/1 DSABLE/ENABLE commsens DSABLE
LAG % Capacity 25 to 75 % lag_per 50
LAG Address 1 to 236 lag_add 92
LAG START Timer 2 to 60 MIN lagstart 10
LAG STOP Timer 2 to 60 MIN lagstop 10
PRESTART FAULT Timer 2 to 30 MIN preflt 5
PULLDOWN Timer 1 to 30 MIN pulldown 2
STANDBY Chiller Option 0/1 DSABLE/ENABLE stnd_opt DSABLE
STANDBY % Capacity 25 to 75 % stnd_per 50
STANDBY Address 1 to 236 stnd_add 93
516 44
EXAMPLE 28 — RAMP_DEM DISPLAY SCREEN
1. Press MENU .
2. Press SERVICE .
4. Press SELECT .
5. Scroll down to highlight RAMP_DEM .

Pulldown Ramp Type: 0/1 ramp_opt 1
Select: Temp=0, KW=1
Demand Limit and kW Ramp
Demand Limit Source 0/1 dem_src 0
Select: Amps=0, kW=1
Amps or kW Ramp %/Min 5 to 20 kw_ramp 10
Demand Limit Prop Band 3 to 15 % dem_app 10
Demand Limit At 20 mA 40 to 100 % dem_20ma 40
20 mA Demand Limit Opt 0/1 DSABLE/ENABLE dem_sel DSABLE
VFD Overload Decrease 25 to 50 % vfd_dec 30
VFD Overload Delta 3 to 15 % vfd_delt 5
Demand Watts Interval 5 to 60 MIN dw_int 15
EXAMPLE 29 — TEMP_CTL DISPLAY SCREEN

1. Press MENU .
2. Press SERVICE .
4. Press SELECT .
5. Scroll down to highlight TEMP_CTL .

ECL Control Option 0/1 DSABLE/ENABLE ecl_opt DSABLE
Temp Pulldown Ramp/Min 2 to 10 (1.1 to 5.6) ^F (^C) tmp_ramp 3 (1.7)
Temperature Reset
RESET TYPE 1
Degrees Reset At 20 mA –30 to 30 (–17 to 17) ^F (^C) deg_20ma 10 (6)
RESET TYPE 2
Remote Temp –> No Reset –40 to 245 (–40 to 118) °F (°C) res_rt1 85 (29)
Remote Temp –> Full Reset –40 to 245 (–40 to 118) °F (°C) res_rt2 65 (18)
Degrees Reset –30 to 30 (–17 to 17) ^F (^C) deg_rt 10 (6)
RESET TYPE 3
CHL Delta T –> No Reset 0 to 15 (0 to 8) ^F (^C) restd_1 10 (6)
CHL Delta T –> Full Reset 0-15 (0 to 8) ^F (^C) restd_2 0 (0)
Degrees Reset –30 to 30 (–17 to 17) ^F (^C) deg_res 5 (3)
Enable Reset Type 0 to 3 res_sel 0
PIC III System Functions control adding any active chilled liquid reset to the ECL or LCL
NOTE: Words not part of paragraph headings and printed in all SET POINT. The CONTROL POINT may be viewed or over-
ridden from the MAINSTAT screen. See Fig. 27.
capital letters can be viewed on the ICVC (e.g., LOCAL,
Changes to the chiller capacity and system overrides are
CCN, RUNNING, ALARM, etc.) Words printed in both all
achieved through the VFD SPEED OUTPUT.
capital letters and italics can also be viewed on the ICVC and
The VFD SPEED OUTPUT is controlled by varying the
are parameters (CONTROL MODE ADDED EXAMPLES, output from 0 to 100%. The TARGET VFD SPEED is forcible
etc.) with associated values (e.g., modes, temperatures, pres- and allows the operator manual control of the VFD SPEED
sures, percentages, on, off, enable, disable, etc.). Words printed OUTPUT. The TARGET VFD SPEED will be allowed to
in all capital letters and in a box represent softkeys on the change every five seconds unless TARGET VFD SPEED is
ICVC (e.g., ENTER and EXIT ). See Table 3 for examples of forced.
the type of information that can appear on the ICVC screens. The TARGET VFD SPEED is controlled between the VFD
MINIMUM SPEED and VFD MAXIMUM SPEED (refer to
Figures 24-30 give an overview of ICVC operations and
SETUP2 screen) based on the Capacity Control algorithm. The
menus. The sequence of screens that should be selected to PIC III controls monitor the compressor oil properties and set a
view any parameter in the ICVC can be found in Appendix A. COMP MINIMUM SPEED to ensure sufficient compressor
CAPACITY CONTROL — The PIC III control system con- bearing lubrication under all operating conditions. The TAR-
trols the chiller capacity by changing the compressor speed in GET VFD SPEED shall not be allowed to be forced below the
response to chilled liquid temperature deviation away from the COMP MINIMUM SPEED. A summary of all capacity control
CONTROL POINT. The CONTROL POINT may be changed conditions and responses is shown in Table 4.
by a CCN network device or is calculated by the PIC III
45
Table 4 — Capacity Control Conditions Example: A 1º F (0.6º C) CHILLED LIQUID DEAD-
BAND setting controls the liquid temperature within ±0.5º F
CAPACITY
VFD SPEED CONTROL VFD SPEED CHANGE (0.3º C) of the CONTROL POINT. This may cause frequent
DELTA
changes in compressor speed if the cooling load fluctuates
TARGET VFD
FORCED
TARGET VFD = Forced Value frequently. A value of 1º F (0.6º C) is the default setting.
INCREASE —
TARGET VFD = TARGET VFD + PROPORTIONAL BANDS AND PROPORTIONAL
(VFD Delta x FD Gain) GAIN — The PIC III uses the PROPORTIONAL INC
VFD SPEED
= MAX
No Change (Increase) BAND, PROPORTIONAL DEC (Decrease) BAND,
and the PROPORTIONAL ECL (Entering Chilled Liquid)
TARGET VFD
FORCED
TARGET VFD = Forced Value GAIN to determine how fast or slow to respond. Proportional
TARGET VFD = TARGET VFD + band is the rate at which the compressor speed is changed in
DECREASE —
(VFD Delta x VFD Gain) proportion to how far the chilled liquid/brine temperature is
VFD SPEED
No Change from the CONTROL POINT. Proportional gain determines
= MIN.
how quickly the VFD reacts to how quickly the temperature is
deviating from the CONTROL POINT. The proportional bands
Changes to the TARGET VFD SPEED are implemented by and proportional gain may be viewed or modified from the
the following methods: SETUP2 screen, which is accessed from the EQUIPMENT
FORCED — The TARGET VFD SPEED can be forced from SERVICE table.
the ICVC. The TARGET VFD SPEED is set to the forced value The Proportional Band — The PIC III controls can be config-
and remains there until the force is removed or the chiller is ured to respond differently to temperature deviations above the
shut down. The forced value is limited between the VFD MIN- control point and to temperature deviations below the control
IMUM SPEED and VFD MAXIMUM SPEED. point.
NORMAL CONDITIONS — The VFD speed changes are The PIC III control’s response to temperatures above the
based on the calculated change in VFD DELTA multiplied by control point is affected by the PROPORTIONAL INC BAND.
the VFD GAIN. VFD DELTA is displayed in the COMPRESS This parameter will slow or quicken the rate at which the com-
screen. The VFD GAIN increases or decreases the commanded pressor speed is changed in response to chilled liquid/brine
VFD speed change with respect to the VFD DELTA calculated temperatures above the control point plus 1/2 times the
by the ICVC. CHILLED LIQUID DEADBAND. The PROPORTIONAL INC
CAPACITY INCREASE — If the TARGET VFD SPEED is BAND can be adjusted from a setting of 2 to 10; the default
less than the VFD MAXIMUM SPEED, the TARGET VFD setting is 6.5. A smaller value of PROPORTIONAL INC
SPEED is increased by the VFD DELTA times the VFD GAIN. BAND will increase the rate at which the compressor speed is
CAPACITY DECREASE — If the TARGET VFD SPEED is increased.
greater than the VFD MINIMUM SPEED, the TARGET VFD The response below the control point is called the PRO-
SPEED is decreased by the VFD DELTA times the VFD GAIN. PORTIONAL DEC BAND. This parameter will slow or quick-
• VFD DELTA less than 0.2% will not cause the VFD en the rate at which the compressor speed is changed in re-
SPEED OUTPUT to increase or decrease. sponse to chilled liquid temperatures below the CONTROL
POINT minus 1/2 times the CHILLED LIQUID DEAD BAND.
• If the Capacity Decrease is in effect due to an override
then the VFD SPEED OUTPUT decreases at a rate of The PROPORTIONAL DEC BAND can be adjusted on the
2.0% per 5 seconds until the decrease condition is satis- ICVC from a setting of 2 to 10. The default setting is 6.0. A
smaller value of PROPORTIONAL DEC BAND will increase
fied. This will occur regardless of VFD DELTA value.
• A VFD SPEED OUT OF RANGE fault will be declared the rate at which the compressor speed is decreased.
if the ACTUAL VFD SPEED exceeds the VFD SPEED The PROPORTIONAL ECL GAIN changes the amount the
OUTPUT ±10% for 75 seconds when the chiller is run- compressor speed is changed each time the PIC III controls
ning. command an adjustment. The PROPORTIONAL ECL GAIN
• A COMP MIN SPEED LIMITED RUN CAPACITY can be adjusted from 1 to 3. A larger value of PROPORTION-
OVERRIDE alert will be declared when the TARGET AL ECL GAIN will increase the amount the compressor speed
VFD SPEED is being limited by the COMPRESSOR changes each time the controls call for a change.
MINIMUM SPEED. DEMAND LIMITING — The PIC III control module re-
ECL CONTROL OPTION — If this option is enabled, the sponds to the ACTIVE DEMAND LIMIT set point by limiting
PIC III modulates the compressor speed in response to the the amps or kilowatts consumed by the chiller. It compares the
entering chilled liquid temperature instead of the LEAVING ACTIVE DEMAND LIMIT set point to the DEMAND LIMIT
CHILLED LIQUID temperature. The ECL CONTROL SOURCE (either the actual AVERAGE LINE CURRENT or the
OPTION may be viewed on the TEMP_CTL screen, which is actual MOTOR KW), depending on how the control is config-
accessed from the EQUIPMENT SERVICE screen. ured. DEMAND LIMIT SOURCE is on the RAMP_DEM
screen. The default DEMAND LIMIT SOURCE is the com-
CHILLED LIQUID DEADBAND — This is the tolerance pressor motor amps.
range on the chilled liquid/brine temperature control point. If
the liquid temperature goes outside the CHILLED LIQUID CHILLER TIMERS — The PIC III control module maintains
DEADBAND, the PIC III increases or decreases compressor 2 runtime clocks, known as COMPRESSOR ONTIME and
speed until the temperature is within tolerance. The PIC III SERVICE ONTIME. COMPRESSOR ONTIME indicates the
controls may be configured with a 0.5 to 2 F (0.3 to 1.1 C) total life-time compressor run hours. This timer can register up
deadband. CHILLED LIQUID DEADBAND may be viewed or to 500,000 hours before the clock turns back to zero. The
modified on the SETUP1 screen, which is accessed from the SERVICE ONTIME is a resettable timer that can be used to
EQUIPMENT SERVICE table. indicate the hours since the last service visit or any other event.
The time can be changed from the ICVC to whatever value is
desired. The SERVICE ONTIME timer can register up to
32,767 hours before it rolls over to zero.
46
The chiller also maintains a start-to-start timer and a stop- • motor stall
to-start timer. These timers limit how soon the chiller can be • temperature sensor and transducer faults
started. START INHIBIT TIMER is displayed on the MAIN- • VFD power faults
STAT screen. See the Start-Up/Shutdown/Recycle Sequence • VFD over temperature
section, page 60, for more information on this topic. • humidity surrounding the VFD coldplate
OCCUPANCY SCHEDULE — The chiller schedule, de- • reverse compressor rotation
scribed in the Time Schedule Operation section (page 28), • incorrect condenser level (for EXV controlled units)
determines when the chiller can run. Each schedule consists of • economizer pressure out of range (for EXV controlled
from 1 to 8 occupied or unoccupied time periods, set by the units)
operator. The chiller can be started and run during an occupied • economizer temperature out of range (for EXV con-
time period (when YES is displayed next to OCCUPIED? on trolled units)
the MAINSTAT display screen). It cannot be started or run VFD faults or protective devices within the VFD can shut
during an unoccupied time period (when NO is displayed next down the chiller.
to OCCUPIED? on the MAINSTAT display screen). These
time periods can be set for each day of the week and for holi- CAUTION
days. The day begins with 0000 hours and ends with
2400 hours. When any occupancy schedule is in a time period If compressor motor overload or a motor ground fault
when the chiller is allowed to run, the parameter OCCUPIED? occurs, check the motor for grounded or open phases
is YES. before attempting a restart to avoid damage to the equip-
These schedules can be set up to follow a building’s occu- ment.
pancy schedule, or can be set to be occupied 100% of the time,
if the operator wishes. In this case, the chiller is normally If the PIC III control initiates a safety shutdown, it displays
started and stopped manually using the CCN, LOCAL, and the reason for the shutdown (the fault code) on the ICVC dis-
STOP buttons. The schedules also can be bypassed by forcing play screen along with a primary and secondary message, and
the CHILLER START/STOP parameter on the MAINSTAT blinks the alarm light on the control center. The alarm is stored
screen to START. For more information on forced starts, see in memory and can be viewed on the ALARM HISTORY and
Local Start-Up, page 60. VFD_HIST screens on the ICVC, along with a message for
troubleshooting. If the safety shutdown was also initiated by a
The schedules also can be overridden to keep the chiller in
fault detected in the VFD, the conditions at the time of the fault
an occupied state for up to 4 hours, on a one time basis. See the will be stored in VFD_HIST.
Time Schedule Operation section, page 28.
To give more precise information or warnings on the
Figure 29 shows a schedule for a typical office building
chiller’s operating condition, the operator can define alert lim-
with a 3-hour, off-peak, cool-down period from midnight to its on various monitored inputs in the SETUP1 screen. Safety
3 a.m., following a weekend shutdown. Holiday periods are in contact and alert limits are defined in Table 5. Alarm and alert
an unoccupied state 24 hours per day. The building operates
messages are listed in the Troubleshooting Guide section,
Monday through Friday, 7:00 a.m. to 6:00 p.m., and Saturdays page 96.
from 6:00 a.m. to 1:00 p.m. This schedule also includes the
Monday midnight to 3:00 a.m. weekend cool-down schedule. Shunt Trip — The function of the shunt trip on the PIC III
NOTE: This schedule is for illustration only and is not control module is to act as a safety trip. The shunt trip is wired
intended to be a recommended schedule for chiller operation. from the standard I/O board to a shunt trip-equipped VFD cir-
Whenever the chiller is in the LOCAL mode, it uses Occu- cuit breaker. If the PIC III module tries to shut down the com-
pancy Schedule 01 (OCCPC01S). The chiller uses Occupancy pressor using a normal shutdown procedure but is unsuccessful
Schedule 02 (OCCPCO2S) when it is in ICE BUILD mode. for 20 seconds, the shunt trip output is energized and causes the
When the chiller is in CCN mode, it uses Occupancy Schedule circuit breaker to trip off. The ground fault trip also will ener-
03 (OCCPC03S). gize the shunt trip to trip the circuit breaker. Protective devices
in the VFD can also energize the shunt trip. The shunt trip fea-
The CCN SCHEDULE NUMBER is configured on the ture can be tested using the Control Test feature in the DIS-
NET_OPT display screen, accessed from the EQUIPMENT CRETE OUTPUTS CONTROL TEST screen. Reset the cir-
CONFIGURATION table. See Table 3, Example 18. cuit breaker immediately after performing this test.
SCHEDULE NUMBER can be changed to any value from 03
to 99. If this number is changed on the NET_OPT screen, the Default Screen Freeze — When the chiller is in an
operator must go to the ATTACH TO NETWORK DEVICE alarm state, the default ICVC display “freezes,” that is, it stops
screen to upload the new number into the SCHEDULE screen. updating. The first line of the ICVC default screen displays a
See Fig. 29. primary alarm message; the second line displays a secondary
alarm message.
Safety Controls — The PIC III control system monitors The ICVC default screen freezes to enable the operator to
all safety control inputs and, if required, shuts down the chiller see the conditions of the chiller at the time of the alarm. If the
or limits the compressor speed to protect the chiller from possi- value in alarm is one normally displayed on the default screen,
ble damage from any of the following conditions: the value flashes between normal and reverse contrast. The
• high motor winding temperature ICVC default screen remains frozen until the condition that
• high discharge temperature caused the alarm is remedied by the operator.
• low oil pressure Knowledge of the operating state of the chiller at the time an
• low evaporator refrigerant temperature alarm occurs is useful when troubleshooting. Additional chiller
• condenser high pressure or low pressure information can be viewed on the status screens and the VF-
• inadequate liquid/brine cooler and condenser flow D_HIST screen. Troubleshooting information is recorded in
• high, low, or loss of voltage the ALARM HISTORY table, which can be accessed from the
• ground fault SERVICE menu.
• voltage imbalance To determine what caused the alarm, the operator should
• current imbalance read both the primary and secondary default screen messages,
• excessive motor acceleration time as well as the alarm history. The primary message indicates the
• lack of motor current signal most recent alarm condition. The secondary message gives
• excessive motor amps
47
more detail on the alarm condition. Since there may be more and condenser high pressure limit, high VFD inverter rectifier
than one alarm condition, another alarm message may appear temperature limit, and high VFD inverter temperature limit.
after the first condition is cleared. Check the ALARM HISTO-
RY screen for additional help in determining the reasons for the Compressor Minimum Speed Override —
alarms. Once all existing alarms are cleared (by pressing the This capacity override increases compressor speed if oil vis-
RESET softkey), the default ICVC display returns to normal cosity falls below acceptable levels or if conditions exist that
operation. will prevent sufficient refrigerant cooling to the VFD or mo-
Ramp Loading — The ramp loading feature controls the tor. This override is not configurable, it is the only override that
rate at which the compressor loads up. This control can prevent will increase chiller capacity to avoid a safety shutdown.
the compressor from loading up too fast during the short period Compressor minimum speed override is most likely to happen
of time when the chiller is started and the chilled liquid loop at evaporator temperatures of 50 degrees or more, combined
has to be brought down to the CONTROL POINT. This helps with low speed, low lift, and less than 25% tons.
reduce electrical demand charges by slowly bringing the The PIC III controls regulate the minimum allowable com-
chilled liquid to the CONTROL POINT. pressor speed based on oil sump temperature and pressure and
The PIC III control system provides two methods of ramp on compressor head. The compressor bearings require higher
loading. Ramp loading can be based on chilled liquid tempera- oil viscosity when operating at low speed than they do when
ture or on motor load. The method of ramp loading is selected operating at high speeds. The controls increase compressor
from the RAMP__DEM screen. speed when the oil viscosity is too low to operate the compres-
sor at the lower speed. The low compressor speed override is
1. Temperature ramp loading (TEMP PULLDOWN DEG/ also enabled at low loads with high condensing pressure.
MIN) limits the degrees per minute rate at which either
the leaving chilled liquid or the entering chilled liquid Vaporizer Temperature Control COMPRES-
temperature decreases. This rate is configured by the SOR ON — The vaporizer temperature control is regulated
operator on the TEMP_CTL screen. The lowest tem- by the PIC III using the vaporizer heater relay and a flexible
perature ramp rate will be used if chiller power has surface heater that is attached to the bottom of the vaporizer.
been off for 3 hours or more (even if the motor kilo- The vaporizer heater relay is energized whenever the compres-
watts ramp loading is selected as the ramp loading sor is at low speed and requires additional heat to maintain a
method). sufficient vaporizer temperature. The vaporizer heater is turned
2. Motor load ramp loading (AMPS OR KW RAMP %/ off when the additional heat is no longer required. The vaporiz-
MIN) limits the percent per minute rate at which the er heater is not energized when the chiller is not running. The
compressor motor current or compressor motor load vaporizer heater also uses the values configured in the SET-
increases. The AMPS OR KW RAMP %/MIN rate is UP3 table for TURN ON SPEED and TURN ON LIFT, TURN
configured by the operator on the RAMP_DEM screen OFF SPEED and TURN OFF LIFT to allow the service techni-
in amps or kilowatts. cian to adjust the heater control based on either compressor
If kilowatts is selected for the DEMAND LIMIT SOURCE, speed or the lift across the cooler and condenser.
the MOTOR RATED LOAD KILOWATTS must be entered Oil Sump Temperature Control COMPRES-
(information found on the machine Electrical Data Nameplate)
in the VFD_CONF screen. SOR OFF — The OIL SUMP TEMP is regulated by the
PIC III control module using the (1C) oil heater relay and an
The TEMP PULLDOWN DEG/MIN may be viewed or immersion heater in the oil sump. The oil heater relay is ener-
modified on the TEMP_CTL screen which is accessed from the gized whenever the chiller compressor is off, and the OIL
EQUIPMENT SERVICE screen. PULLDOWN RAMP TYPE, SUMP TEMP is less than 140 F (60 C) or whenever the OIL
DEMAND LIMIT SOURCE, and MOTOR KW RAMP %/MIN SUMP TEMP is less than the CALC EVAP SAT TEMP plus
may be viewed or modified on the RAMP_DEM screen. 53 F (29.4 C). The oil heater is then turned off when the OIL
Capacity Override (Table 6) — Adjustable capacity SUMP TEMP is:
overrides are available to prevent the chiller from exceeding 1. More than 152 F (66.7 C) or
some limits and going into an alarm state. Alert messages 120 2. The OIL SUMP TEMP is more than 142 F (61.1 C) and
through 127 are displayed on the ICVC when capacity also warmer than the CALC EVAP SAT TEMP plus
overrides are in effect. Capacity overrides can prevent some 55 F (30.6 C).
safety shutdowns caused by exceeding the refrigerant low
temperature safety limit, motor high temperature safety limit,
48
Table 5 — Protective Safety Limits and Control Settings
ALARM
MONITORED OR
PARAMETER ALERT LIMIT COMMENTS
STATE
Temperature 260-273 -40 deg F>Temperature>245 deg F for 3 seconds Preset Alarm. See Temperature vs. Resistance/Voltage
Sensors Out of 140,141 Drop in Tables 10 and 11
Range
Pressure 262-273 0.06>Voltage Ratio>0.98 for 3 seconds Preset Alarm Voltage Ratio=Input Voltage/Voltage
Transducers Out Reference(5 Volts)
of Range
231 COMP DISCHARGE TEMP > 180 deg F(82 deg C) Preset Alarm, Configure DISCH TEMP ALERT in SETUP1
screen
High Compressor
162 COMP DISCHARGE TEMP > COMP DISCHARGE Configure COMP DISCH ALERT in SETUP1 screen
Discharge ALERT
Temperature
103 COMP DISCHARGE TEMP > COMP DISCHARGE Prestart Alert, Configure COMP DISCHARGE ALERT in
ALERT – 10 deg F(5.6 deg C) SETUP1 screen
233 COMP MOTOR WINDING TEMP > 244 deg F(118 deg C) Preset Alarm
High Motor or < –5 deg F(–21 deg C) — Open Circuit
Temperature 102 COMP MOTOR WINDING TEMP > COMP MOTOR TEMP Prestart Alert, Configure COMP MOTOR TEMP
OVERRIDE – 10 deg F(5.6 deg C) OVERRIDE in SETUP1 screen
243 Chiller in RECYCLE SHUTDOWN and CALC EVAP SAT Preset Alarm, Configure EVAP REFRIG TRIPPOINT in
TEMP or EVAP REFRIG LIQUID TEMP < EVAP REFRIG SETUP1 screen
TRIPPOINT + 1 deg F
232 For water: EVAP REFRIG LIQUID TEMP or CALC EVAP Preset Alarm, Configure EVAP APPROACH ALERT in
SAT TEMP TEMP < 33 deg F and EVAPORATOR SETUP1 screen
Low Evaporator APPROACH < EVAP APPROACH ALERT
Temperature For brine: EVAP REFRIG LIQUID TEMP or CALC EVAP Configure EVAP APPROACH ALERT and CHILLED
(Freeze SAT TEMP is between 0 deg F(-17.8C) and 40 deg F MEDIUM in SETUP1 screen
Protection) (4.4 C) (brine) and EVAPORATOR APPROACH < EVAP
APPROACH ALERT
104 CALC EVAP SAT TEMP < 33 deg F + REFRIG OVER- Prestart Alert, Configure REFRIG OVERRIDE DELTA T in
RIDE DELTA T (non-brine) SETUP1 screen
CALC EVAP SAT TEMP < EVAP REFRIG TRIPPOINT Prestart Alert, Configure EVAP REFRIG TRIP POINT and
(brine) + REFRIG OVERRIDE DELTA T CHILLED MEDIUM in SETUP1 screen
Transducer 239 TRANSDUCER VOLTAGE REF<4.5 VDC Preset Alarm
Voltage Fault
High Condenser
Pressure
- Control 235 CONDENSER PRESSURE > 166 PSI Preset Alarm
- Switch 207 High Pressure Switch Open(165 ± 5 PSIG) & VFD START Preset Alarm, Switch closes at 110 ± 7 PSIG
= YES
- Prestart 106 CONDENSER PRESSURE > COND PRESS OVERRIDE Prestart Alert, Configure COND PRESS OVERRIDE in
– 25 PSI SETUP1 screen
244 Chiller in PUMPDOWN mode and CONDENSER REFRIG Preset Alarm, Configure CONDENSER FREEZE POINT in
TEMP < CONDENSER FREEZE POINT SETUP1 screen.
Low Condenser 154 Energizes condenser pump relay if CONDENSER Configure CONDENSER FREEZE POINT in SETUP1
REFRIG TEMP < CONDENSER FREEZE POINT. De- screen
Pressure (Freeze energizes condenser pump relay when CONDENSER
Protection) REFRIG TEMP > CONDENSER FREEZE POINT + 5
deg F (2.8 deg C) and ENTERING COND LIQUID > CON-
DENSER FREEZE POINT
Oil
- Low Pressure 234 OIL PRESSURE DELTA P < 18 PSID after OIL PUMP = Preset Alarm, Configure OIL PRESS VERIFY TIME in
ON, OIL PRESS VERIFY TIME exceeded, and STARTUP SETUP1 screen
in progress
- Low Pressure 228 OIL PRESSURE DELTA P < 15 PSID and VFD START = Preset Alarm, condition must persist for 55 consecutive
TRUE seconds
- Low Pressure 142 OIL PRESSURE DELTA P < 15 PSID and VFDSTART = Preset Alert, condition must persist for 10 consecutive
TRUE seconds
- High Oil 164 Oil Pump ON and OIL PRESSURE DELTA P > 45 PSI Preset Alert, condition must persist for 55 consecutive
Pressure seconds
- Pressure 227 OIL PRESSURE DELTA P > 4 PSI immediately before oil Preset Alarm
Sensor Fault pump turned on
- Low 105 OIL SUMP TEMP < 140 deg F and OIL SUMP TEMP < Preset Prestart Alert
Temperature CALC EVAP SAT TEMP + 15 deg F (8.3 deg C)
Line Voltage
- High 211/145 Line voltage > limits are calculated by VFD (alert is Preset Alarm/Autorestart Alert
declared if AUTORESTART is ENABLED)
- High 108 PERCENT LINE VOLTAGE > 115% Preset Prestart Alert
- Low 212/146 Line voltage < limits calculated by VFD (alert is declared if Preset Alarm/Autorestart Alert
AUTORESTART is ENABLED)
- Low 107 PERCENT LINE VOLTAGE < 85% Preset Prestart Alert
- Imbalance 216 LINE VOLTAGE IMBALANCE > LINE VOLTAGE % Configure LINE VOLTAGE % IMBALANCE and LINE
IMBALANCE VOLT IMBALANCE TIME in VFD_CONF screen
Line Current
- Dropout 210/144 Line Voltage on 2 Phases < 50% for 1 Cycle Preset Alarm/Autorestart Alert
- Imbalance 209/143 LINE CURRENT IMBALANCE>LINE CURRENT % Configure LINE CURRENT % IMBALANCE and LINE
IMBALANCE CURRENT IMBALANCE TIME in VFD_CONF screen
49
Table 5 — Protective Safety Limits and Control Settings (cont)
ALARM
MONITORED OR
STATE
P Compressor
(Condenser Level)
- Condenser 169 COND_LEV < max (COND_LOV, 0.1) for Preset Alert, configure in Setup5
Liquid Level 30*CONDTIME and COND_EXV < min Cond. EXV Min
Low Position + 5%
- Condenser 170 COND_LEV > min (COND_HIV, 4.9) for 30*CONDTIME Preset Alert, configure in Setup5
Liquid Level and COND_EXV>98%
High
Power
- Line Frequency 222 47 Hz < LINE FREQUENCY < 63 Hz Preset Alarm
Trip
- Power Loss 214/148 DC BUS VOLTAGE<85% for Excessive Time Period Preset Alarm/Autorestart Alert
- Phase Reversal 226 Line power phases out of sequence Preset Alarm
Motor
- Stall 238 > 5 stall events within STALL TIME PERIOD Preset Alarm, Configure STALL DELTA% AMPS and
STALL TIME PERIOD in OPTIONS screen
- Current 225 MOTOR CURRENT IMBALANCE>MOTOR CURRENT Configure MOTOR CURRENT % IMBALANCE and
Imbalance % IMBALANCE MOTOR CURRENT IMBAL TIME in VFD_CONF screen
- Rotation 221 DISCHARGE PRESSURE decreases more than 2 PSI Preset Alarm, Must be outside -2 PSI limit for 5 consecu-
Reversed after VFDSTART = TRUE tive samples
- Overload Trip 217 Any LOAD CURRENT PHASE > 108% for Excessive Preset Alarm, Configure MOTOR LOAD ACTIVE
Time Period DEMAND LIMIT in MAINSTAT screen
- Excessive 208 PERCENT LOAD CURRENT > 110% for 30 sec. Preset Alarm
Amps
- Acceleration 203 PERCENT LOAD CURRENT > 95% at start-up and Preset Alarm, PERCENT LOAD CURRENT = AVERAGE
Fault VFDSTART = TRUE for 5 to 40 sec LOAD CURRENT/MOTOR RATED LOAD AMPS
- Amps not 202 PERCENT LOAD CURRENT < 5% and VFD Preset Alarm, PERCENT LOAD CURRENT = AVERAGE
Sensed START=TRUE for 20 sec LOAD CURRENT/MOTOR RATED LOAD AMPS
- Starts Limit 100 More than 8 starts in 12 hours Preset Prestart Alert
Exceeded
229 CHILLED LIQUID FLOW = FALSE after CHILLED Configurable Alarm, Configure LIQUID FLOW VERIFY
LIQUID PUMP = ON & LIQUID FLOW VERIFY TIME TIME in SETUP1 screen.
Low Chilled Liquid elapsed. CHILLED LIQUID DELTA P < EVAP FLOW EVAPORATOR APPROACH = LEAVING CHILLED
DELTA P CUTOUT or CALC EVAP SAT TEMP < EVAP LIQUID TEMP – EVAP REFRIG LIQUID TEMP
Flow REFRIG TRIPPOINT or EVAPORATOR APPROACH >
EVAP APPROACH ALERT and EVAP REFRIG LIQUID
TEMP < EVAP REFRIG TRIPPOINT +1
230 COND LIQUID FLOW = FALSE after COND LIQUID Configurable Alarm, Configure LIQUID FLOW VERIFY
PUMP = ON & LIQUID FLOW VERIFY TIME elapsed. TIME in SETUP1 screen.
Low Cond Liquid CONDENSER LIQUID DELTA P < COND FLOW DELTA CONDENSER APPROACH = CONDENSER REFRIG
Flow P CUTOUT or CONDENSER APPROACH > TEMP - LEAVING COND LIQUID TEMP
CONDENSER APPROACH ALERT, or CONDENSER
PRESSURE > COND PRESS OVERRIDE + 5
High Approach
- Evaporator 160 EVAPORATOR APPROACH > EVAP APPROACH Configure EVAP APPROACH ALERT in SETUP1 screen
ALERT and VFD START = TRUE EVAPORATOR APPROACH = LEAVING CHILLED
LIQUID TEMP – EVAP REFRIG LIQUID TEMP
- Condenser 161 CONDENSER APPROACH > COND APPROACH Configure COND APPROACH ALERT in SETUP1
ALERT and VFD START = TRUE screen.
VFD
- Speed Out of 245 ACTUAL VFD SPEED < VFD SPEED OUTPUT – 10% or Preset Alarm, Must be outside ± 10% range for 75 sec.
Range ACTUAL VFD SPEED > VFD SPEED OUTPUT + 10%
204 PERCENT LOAD CURRENT >15% and VFDSTART = Preset Alarm, PERCENT LOAD CURRENT = AVERAGE
- Failure to Stop NO for 20 sec LOAD CURRENT/MOTOR RATED LOAD AMPS
- Communication 224 Communication with VFD lost for more than 10 sec Preset Alarm
Failure
Rectifier
- Overcurrent 241 RECTIFIER OVERCURRENT exceeded limit determined Preset Alarm
by VFD
- High 218 RECTIFIER TEMPERATURE >exceeds limit calculated Preset Alarm
Temperature by VFD
101 RECTIFIER TEMPERATURE > RECTIFIER TEMP Prestart Alert, Configure RECTIFIER TEMP OVERRIDE
OVERRIDE – 20 deg F (11.1 deg C) in SETUP1 screen
50
Table 5 — Protective Safety Limits and Control Settings (cont)
ALARM
MONITORED OR
STATE
Inverter
- Overcurrent 246 INVERTER OVERCURRENT exceeded limit determined Preset Alarm
by VFD
- High 219 INVERTER TEMPERATURE exceeds limit calculated by Preset Alarm
Temperature VFD
109 INVERTER TEMPERATURE > INVERTER TEMP Prestart Alert, Configure INVERTER TEMP OVERRIDE in
OVERRIDE – 20 deg F (11.1 deg C) SETUP1 screen
High VFD Inductor 255 Inductor Temperature Switch Open Preset Alarm
Temperature
DC Bus Voltage
- High 205/150 DC BUS VOLTAGE Limit Exceeded, limit is calculated by Preset Alarm/Autorestart Alert
VFD
- Low 215/149 DC BUS VOLTAGE < approximately 407VDC at Preset Alarm/Autorestart Alert
400/480V Line Side Voltage
220 GROUND FAULT CURRENT > 7% of Drive Rated Amps Preset Alarm
Ground Fault Sensed
Optional Limits
- Spare 248,249 SPARE TEMPERATURE > SPARE TEMP LIMIT for 3 Optional Alarm, Configure SPARE TEMP ENABLE and
Temperature consecutive samples SPARE TEMP LIMIT in SETUP1 screen
- Spare 158,159 SPARE TEMPERATURE > SPARE TEMP LIMIT for 3 Optional Alert, Configure SPARE TEMP ENABLE and
Temperature consecutive samples SPARE TEMP LIMIT in SETUP1 screen
- Refrigerant 250 REFRIGERANT LEAK SENSOR PPM > REFRIG LEAK Optional Alarm, configure PPM AT 20 MA and REFRIG-
Leak Sensor ALARM PPM ERANT LEAK ALARM PPM in OPTIONS screen.
Table 6 — Capacity Overrides

SECOND STAGE
SECOND STAGE
FIRST STAGE SET POINT OVERRIDE
SET POINT
TERMINATION
OVERRIDE
CAPACITY CONTROL VIEW/
MODIFY DEFAULT CONFIGURABLE VALUE VALUE
ON ICVC VALUE RANGE
SCREEN
CONDENSER
CONDENSER PRESSURE > PRESSURE
COND PRESS OVERRIDE < CONDENSER
HIGH CONDENSER PRESSURE 145 PSIG 145 to 166 PSIG
SETUP1 + 2.4 PSIG(16.5 kPa) OR PRESS
(COND PRESS OVERRIDE) (1000 kPa) (1000 to 1145 kPa) CONDENSER PRESSURE OVERRIDE
> 163 PSIG (1124 kPa)
– 1 PSI (6.9 kPa)
CALC EVAP SAT TEMP, or
EVAP REFRIG LIQUID CALC EVAP SAT
TEMP < EVAP SAT TEMP and
LOW EVAPORATOR OVERRIDE TEMP EVAP REFRIG
2 to 5 ^F
TEMPERATURE SETUP1 3 ^F (1.7 ^C) LIQUID TEMP >
(1.1 to 2.8 ^C) – 1° F (.6° C) NOTE: EVAP EVAP SAT
(REFRIG OVERRIDE DELTA T) SAT OVERRIDE TEMP = OVERRIDE
EVAP REFRIG TRIPPOINT + TEMP + 2° F (1.1° C)
REFRIG OVERRIDE DELTA T
COMP MOTOR
COMP MOTOR WINDING WINDING TEMP <
HIGH MOTOR TEMPERATURE SETUP1 200° F (93° C) 150 to 200° F TEMP > COMP MOTOR TEMP COMP MOTOR
(COMP MOTOR TEMP OVERRIDE) (66 to 93° C) TEMP OVERRIDE
OVERRIDE + 10° F (5.6° C)
– 2° F (1.1° C)
160° F (71° C) 155 to 170° F (68 to 77° C) RECTIFIER
RECTIFIER TEMP > TEMP < RECTIFIER
HIGH RECTIFIER TEMPERATURE (Q,R Compressors (Q,R Compressors)
SETUP1 RECTIFIER TEMP TEMP OVERRIDE
(RECTIFIER TEMP OVERRIDE) 180° F (82° C) 155 to 190° F (68 to 88° C)
(P Compressor) (P Compressor) – 5° F (2.8° C)
INVERTER TEMP <
INVERTER TEMP > INVERTER TEMP
HIGH INVERTER TEMPERATURE 155 to 170° F
SETUP1 160° F (71° C) INVERTER TEMP OVERRIDE
(INVERTER TEMP OVERRIDE) (68 to 77° C)
– 5° F (2.8° C)
51
Oil Sump Temperature Control COMPRES- diagram). See the certified drawings for further details on con-
SOR ON — The oil heater relay (1C) is energized whenever tact ratings. The contacts must have 24 vac rating.
the chiller compressor is on, and the OIL SUMP TEMP is less
than 90 F (32.2 C) and OIL SUMP TEMP is less than the
Spare Safety and Spare Temperature Inputs —
CALC EVAP SAT TEMP plus 35 °F (19.4 °C). The oil heater is Normally closed (NC) discrete inputs for additional field-
then turned off when the OIL SUMP TEMP is: supplied safeties may be wired to the spare protective limits
input channel in place of the factory-installed jumper. (Wire
1. More than 92 F (33.3 C). multiple inputs in series.) The opening of any contact will
2. The OIL SUMP TEMP is warmer than the CALC EVAP result in a safety shutdown and a display on the ICVC. Refer to
SAT TEMP plus 37 °F (20.6 °C). the certified drawings for safety contact ratings.
For units with dual stage heater control the (1C) and (5C) Analog temperature sensors may also be added to the mod-
relays are turned OFF when: ule (SPARE TEMPERATURE #1 and #2). The analog tem-
1. OIL SUMP TEMP is greater than 150 F (65.6 C) or perature sensors may be configured to cause an alert or alarm
on the CCN network. The alert will not shut the chiller down.
2. Compressor RPM is greater than SUMP HEATER Configuring for alarm state will cause the chiller to shut down.
TURN OFF SPEED and OIL SUMP TEMP is greater The SPARE TEMP channels can be configured for low or high
than the CALC EVAP SAT TEMP plus SUMP TURN temperature limits in the SETUP1 screen.
OFF DELTA TEMP.
Both (1C) and (5C) relays are turned ON when: Spare Alarm Contacts — One normally open trip
alarm contact is provided in the control center cabinet. The
1. Oil Pressure Delta P is less than 20 psig (138 kPa) or contact ratings are provided in the certified drawings. The
2. Compressor RPM is less than SUMP HEATER TURN contacts are located on terminals 9 and 10 of the hazardous
ON SPEED and either the Difference between COND voltage terminal strip in the control center cabinet.
REF TEMP and CALC EVAP SAT TEMP is less than
SUMP HEATER TURN ON LIFT, or COND REF Refrigerant Leak Detector — A 4 to 20 mA / 0 to
TEMP is less than COND REFRIG TEMP LOW LIMIT. 5 vdc input is available on the CCM module [terminal J5-5 (–)
and J5-6 (+)] for a refrigerant leak detector. Enabling REFRIG-
When neither of above statements are true for OFF or ON ERANT LEAK OPTION (OPTIONS screen) will allow the PIC
control relay (1C) is ON. III controls to go into an alarm state at a user configured level
Configurable values for dual stage heater control that allow (REFRIG LEAK ALARM mA). The input is configured for 4 to
the service technician to adjust the heater control are located in 20 mA by setting CCM DIP switch 1 on SW2 at the ON posi-
the SETUP3 table. tion, or configured for 1 to 5 vdc by setting switch 1 at the OFF
position. The output of the refrigerant leak detector is displayed
as REFRIG LEAK SENSOR PPM on the MAINSTAT screen.
CAUTION For a 1 to 5 vdc input, 1 vdc input represents 4 mA displayed
and 5 vdc input represents 20 mA displayed.
All oil filter isolation valves should always be left open,
except when changing the oil or the oil filter as defined in 4 to 20 mA Kilowatt Output — An output is avail-
Changing Oil and Oil Filter section, page 90. Failure to do able on the CCM module [Terminal J8-1 (+) and J8-2 (–)] to
so may result in equipment shutdown, malfunction, or represent the power consumption of the chiller. The 4 to 20 mA
damage. signal generated by the CCM module can be wired to the build-
ing automation or energy management system to monitor the
chiller’s energy consumption. A 4 mA signal represents the
Remote Start/Stop Contacts — A remote device, chiller in an off state and a 20 mA signal represents the chiller
such as a timeclock that uses a set of contacts, may be used to operating at its rated peak kilowatt consumption. The rated
start and stop the chiller. However, the device should not be peak kilowatt consumption is configured by the user in the VF-
programmed to start and stop the chiller in excess of 2 or D_CONF display screen by the setting the RATED LINE
KILOWATTS from the Machine Electrical Data Nameplate.
3 times every 12 hours. If more than 8 starts in 12 hours (the The kilowatt output is designed for use with non-grounded
STARTS IN 12 HOURS parameter on the MAINSTAT screen) controllers with a maximum input impedance of 500 ohms.
occur, an excessive starts prestart alert displays, preventing the
chiller from starting. The operator must press the RESET Remote Reset of Alarms — A standard feature of the
PIC III controls is the ability to reset certain faults on a chiller
softkey on the ICVC to override the starts counter and start the in a shutdown alarm state from a remote location. If the condi-
chiller. If the chiller records 12 starts (excluding recycle starts tion which caused the alarm has cleared the fault can be reset
or auto restarts after power failure) in a sliding 12-hour period, and the chiller can be placed back into a normal CCN operating
it can be restarted only by pressing the RESET softkey mode when the REMOTE RESET OPTION (ICVC_PWD
followed by the LOCAL or CCN softkey. This ensures that, menu) is set to ENABLE. A variety of Carrier Comfort Net-
work® software systems including ComfortVIEW™ or Net-
if the automatic system is malfunctioning, the chiller will not work Service Tool™ can access the PIC III controls and reset
repeatedly cycle on and off. If the AUTORESTART OPTION certain displayed alarms. Third-party software from building
and the REMOTE CONTACT OPTION in the OPTIONS automation systems (BAS) or energy management systems
screen are enabled, the REMOTE CONTACTS must be closed (EMS) can also access the PIC III controls through a Carrier
in order for the chiller to restart following a power failure. If LEI (Local Equipment Interface) module and reset certain
faults that are displayed. All methods would access the
the automatic restart after a power failure option (AUTO ICVC_PWD screen and force the RESET ALARM? point to
RESTART OPTION on the OPTIONS screen) is not enabled YES to reset the fault condition. If the PIC III controls have de-
when a power failure occurs, and if the remote contact is termined that it is safe to start the chiller the CCN MODE?
closed, the chiller will indicate an alarm because of the loss of point (ICVC_PWD screen) can be forced to YES to place the
voltage. chiller back into normal CCN operating mode. The only excep-
tions are the following alarms, which cannot be reset from a re-
The contacts for remote start are wired into the low voltage mote location: ALARM STATES #200, 201, 204, 206, 217,
terminal strip in the control center cabinet (see wiring 218, 219, 220 and 236. To view alarm codes, refer to
52
Troubleshooting Guide, Checking Display Messages, page 97. difference between cooler and condenser pressure is more than
After the alarm has been reset the PIC III controls will incre- 35 psid (241.3 kPa) for ENTERING COND LIQUID
ment the Starts in 12 Hours counter by one upon restart. If the temperature greater than the TOWER FAN HIGH SETPOINT
limit of 8 starts in a 12-hour period occurs Prestart Alert 100 (SETPOINT menu, default 75 F [24 C]).
must be manually reset at the local chiller control panel The tower fan relay high is turned off when the condenser
(ICVC). pump is off, flow is stopped, or the CALC EVAP SAT TEMP is
Condenser Pump Control — The chiller will moni- less than the EVAP SAT OVERRIDE TEMP and ENTERING
tor the condenser pressure (CONDENSER PRESSURE) and CONDENSER LIQUID is less than 70 F (21.1 C), The tower
may turn on the condenser pump if the condenser pressure fan relay high is also turned off when the difference between
becomes too high while the compressor is shut down. The CONDENSER PRESSURE and EVAPORATOR PRESSURE is
condenser pressure override (COND PRESS OVERRIDE) less than 28 psid (193 kPa), and ENTERING CONDENSER
parameter is used to determine this pressure point. COND LIQUID temperature is less than TOWER FAN HIGH SET-
PRESS OVERRIDE is found in the SETUP1 display screen, POINT minus 3° F (1.6° C).
which is accessed from the EQUIPMENT SERVICE table. The TOWER FAN RELAY LOW and HIGH parameters are
The default value is 145 psig (543 kPa). accessed from the STARTUP screen.
If the CONDENSER PRESSURE is greater than or equal to
the COND PRESS OVERRIDE, the condenser pump will ener- IMPORTANT: A field-supplied liquid temperature control
gize to try to decrease the pressure and Alert 151 will be gener- system for condenser liquid should be installed. The system
ated. The pump will turn off when the condenser pressure is should maintain the leaving condenser liquid temperature at
less than the COND PRESS OVERRIDE threshold. a temperature that is 20º F (11º C) above the leaving chilled
liquid temperature.
Condenser Freeze Prevention — This control algo-
rithm helps prevent condenser tube freeze-up by energizing the
condenser pump relay through terminals 3 and 4 of the hazard- CAUTION
ous voltage terminal strip (TB2) in the control center. The
PIC III module controls the pump and, by starting it, helps to The tower fan relay control is not a substitute for a con-
prevent the liquid in the condenser from freezing. The PIC III denser liquid temperature control. When used with a liquid
module can perform this function whenever the chiller is not temperature control system, the tower fan relay control can
running except when it is either actively in pumpdown or in be used to help prevent low condenser liquid temperatures
pumpdown/lockout with the freeze prevention disabled. that may damage equipment.
When the CONDENSER REFRIG TEMP is less than or
equal to the CONDENSER FREEZE POINT, the CONDENS- Auto. Restart After Power Failure — This option
ER LIQUID PUMP is energized until the CONDENSER may be enabled or disabled and may be viewed or modified on
REFRIG TEMP is greater than the CONDENSER FREEZE the OPTIONS screen, which is accessed from the SERVICE
POINT plus 5º F (2.7º C) and the ENTERING CONDENSER table. If the AUTO. RESTART option is enabled, the chiller will
LIQUID TEMPERATURE is greater than or equal to the start up automatically after a power failure has occurred (after a
CONDENSER FREEZE POINT. An alarm (244) is generated single cycle dropout; low, high, or loss of voltage; and the
if the chiller is in PUMPDOWN mode and the pump is ener- power is within ±10% of normal). The 15 and 3-minute inhibit
gized. An alert (154) is generated if the chiller is not in PUMP- timers are ignored during this type of start-up.
DOWN mode and the pump is energized. If the chiller is in When power is restored after the power failure, a power
RECYCLE SHUTDOWN mode, the mode will transition to a failure restart will be enabled and the control allowed to
non-recycle shutdown. AUTORESTART the chiller, starting with the chilled liquid
pump(s), if start-up conditions are met.
Tower Fan Relay Low and High — Low condens-
er liquid temperature can cause the chiller to shut down if it If power to the ICVC module has been off for more than
causes the condenser refrigerant temperature to be too low. The 3 hours or the timeclock has been set for the first time, the
tower fan relays, located on terminals 5-8 on the hazardous compressor will start with the slowest temperature-based ramp
voltage terminal strip (TB2) in the control center, are controlled load rate possible in order to minimize oil foaming.
by the PIC III module to energize and de-energize as the pres- Fast Power Source Transfers — When the electri-
sure differential between cooler and condenser vessels chang- cal system is being prepared to transfer power from utility
es. This prevents excessively low condenser liquid tempera- power to generator power or from generator power back to util-
tures. The tower fan relay can only accomplish this if the relay ity power, and the power transfer is an open transition type, and
has been added to the cooling tower temperature controller. time to transfer is less than 5 seconds, the chiller should be
The tower fan relay low is turned on whenever the condens- stopped before the transfer occurs and restarted after the trans-
er liquid pump is running, flow is verified, the difference fer has been completed. If the chiller is not stopped before the
between cooler and condenser pressure is more than 30 psid transfer occurs, alarms on the chiller can occur that must be
(207 kPad), and the ENTERING CONDENSER LIQUID manually reset, such as a circuit breaker trip. To accomplish
temperature is greater than 65 F (18.3 C). shutdown and restart automatically, a set of dry contacts should
The tower fan relay low is turned off when the CONDENS- be opened 30 to 60 seconds before the transfer occurs, then
ER LIQUID PUMP is deenergized, when CONDENSER closed after the transfer is complete to restart the chiller. The
LIQUID FLOW indication is lost, or under the following contacts must be wired to the to the Remote START/STOP
conditions: contact in the starter or VFD (see the field wiring diagrams,
pages 130-144) and the Remote Start contact configuration
1. CALC EVAP SAT TEMP is less than EVAP SAT must be enabled. If power transfers take 5 seconds or longer,
OVERRIDE TEMP. the chiller Auto Restart after Power Failure feature (if enabled)
2. The difference between the CONDENSER PRESSURE will automatically restart the chiller.
and EVAPORATOR PRESSURE is less than 25 psi
(172 kPa). Liquid/Brine Temperature Reset — Three types of
chilled liquid or brine setpoint temperature reset are available
The tower fan relay high is turned on whenever the and can be viewed or modified on the TEMP_CTL screen,
condenser liquid pump is running, flow is verified and the which is accessed from the EQUIPMENT SERVICE table.
53
The ICVC default screen indicates when the chilled liquid set at the ON position the input is configured for an externally
reset is active. TEMPERATURE RESET on the MAINSTAT powered 4 to 20 mA signal. With the switch in the OFF
screen indicates the amount of reset. The CONTROL POINT position the input is configured for an external 1 to 5 vdc sig-
will be determined by adding the TEMPERATURE RESET to nal. One of the following modifications are also required when
the ECL SETPOINT or LCL SETPOINT. using a 1 to 5 vdc DEMAND LIMIT signal:
To activate a reset type, access the TEMP_CTL screen and 1. Install a 25 ohm resistor in series with the (+) voltage
input all configuration information for that reset type. Then, lead connected to CCM terminal J5-2.
input the reset type number (1, 2, or 3) in the SELECT/ 2. Modify the input voltage signal with an external con-
ENABLE RESET TYPE input line. troller software to calibrate the temperature interpreted
RESET TYPE 1: 4 to 20 mA (0 to 5 vdc) TEMPERATURE by the CCM. The controller should provide 4.54 v at
RESET — Reset Type 1 is an automatic chilled liquid tempera- 100% of the controller’s output range and 0.91 v at 0%
ture reset based on a remote temperature sensor input con- of the controller’s output range.
figured for either an externally powered 4 to 20 mA or a 0 to
5 vdc signal. Reset Type 1 permits up to ±30 F (±17 C) of Hot Gas Bypass (Optional) Algorithm (See
automatic reset to the ECL SETPOINT or LCL SETPOINT. Fig. 31-33) — If a hot gas bypass solenoid valve is present
and the HGBP OPTION in the OPTIONS table is set to 1 or 2,
The auto, chilled liquid reset is hardwired to CCM terminals this operator configurable feature can determine if load condi-
J5-3 (–) and J5-4 (+). Switch setting number 2 on SW2 will tions are too low for the compressor and corrective action can
determine the type of input signal. With the switch set at the be taken.
ON position the input is configured for an externally powered
4 to 20 mA signal. With the switch in the OFF position the When the HGBP OPTION = 0: the HGBP algorithm is
input is configured for an external 0 to 5 vdc signal. One of the disabled.
following modifications are also required when using a 1 to When the HGBP OPTION = 1, the algorithm determines if
5 vdc temperature reset signal: corrective action is necessary by checking the chiller operating
1. Install a 25 ohm resistor in series with the (+) voltage point against an operator configured threshold. The threshold is
lead connected to CCM terminal J5-4. calculated from a combination of the difference between Enter-
2. Modify the input voltage signal with an external con- ing and Leaving Chilled Liquid temperatures and the differ-
troller software to calibrate the temperature interpreted ence between CONDENSER PRESSURE and EVAPORATOR
by the CCM. The controller should provide 4.54 v at PRESSURE. The operator configured data points are the MIN
100% of the controller’s output range and 0.91 v at 0% LOAD POINT(T1/P1) and the FULL LOAD POINT (T2/P2).
of the controller’s output range. These points have default settings defined in the OPTIONS
screen and on Table 3. A line is drawn between these points as
RESET TYPE 2: REMOTE TEMPERATURE RESET — shown in Fig. 31 and 32. The default Load Points (to prevent
Reset Type 2 is an automatic chilled liquid temperature reset compressor stall) are shown.
based on a remote temperature sensor input signal. Reset Type
2 permits ±30 F (±17 C) of automatic reset to the ECL Whenever the ACTIVE DELTA T (actual temperature differ-
SETPOINT or LCL SETPOINT based on a temperature sensor ence between the LEAVING CHILLED LIQUID and ENTER-
wired to the CCM module (see wiring diagrams or certified ING CHILLED LIQUID) is on the left side of the line plotted
drawings). The temperature sensor must be wired to CCM in Fig. 31 and 32, the algorithm will energize the hot gas by-
terminal J4-13 and J4-14. pass valve to falsely load the chiller. If ACTIVE DELTA T falls
to the right side of the line plotted in Fig 31 and 32 by more
To configure Reset Type 2, enter the temperature of the than the HGBP DEADBAND, the hot gas bypass valve is de-
remote sensor at the point where no temperature reset will energized. The HGBP valve is also deenergized if ACTIVE
occur (REMOTE TEMPNO RESET). Next, enter the DELTA P (actual difference between CONDENSER PRES-
temperature at which the full amount of reset will occur SURE and EVAPORATOR PRESSURE) falls to below HGBP
(REMOTE TEMPFULL RESET). Then, enter the maximum DELTA P1. Instructions to configure the MIN LOAD
amount of reset required to operate the chiller (DEGREES RE- POINT(T1/P1) and FULL LOAD POINT(T2/P2) are on
SET). Reset Type 2 can now be enabled. page 76.
RESET TYPE 3 — Reset Type 3 is an automatic chilled liquid When the HGBP OPTION = 2, the option energizes the Hot
temperature reset based on the difference between ENTERING Gas Bypass relay solely based on the VFD TARGET SPEED.
CHILLED LIQUID and LEAVING CHILLED LIQUID tem- Evaluation of the VFD TARGET SPEED begins at the comple-
perature. Reset Type 3 adds ±30 F (±17 C) based on the chilled tion of ramp loading. If the VFD TARGET SPEED is less than
liquid temperature difference. the Minimum Speed plus the HGBP ON DELTA SPEED for 3
To configure Reset Type 3, enter the chilled liquid tempera- seconds then the Hot Gas Bypass is energized. When the VFD
ture difference (the difference between entering and leaving Target Speed is greater than the Minimum Speed plus the
chilled liquid) at which no temperature reset occurs (CHL HGBP ON DELTA SPEED and the HGBP OFF DELTA
DELTA TNO RESET). This chilled liquid temperature differ- SPEED for 3 seconds then the Hot Gas Bypass relay is de-en-
ence is usually the full design load temperature difference. ergized. See Fig. 33.
Next, enter the difference in chilled liquid temperature at which
the full amount of reset occurs (CHL DELTA TFULL RE- Head Pressure Output Reference (See
SET). Finally, enter the amount of temperature reset (DE- Fig. 34) — The PIC III controls output a 4 to 20 mA signal
GREES RESET). Reset Type 3 can now be enabled. for the configurable Delta P (CONDENSER PRESSURE –
EVAPORATOR PRESSURE) reference curve shown in Fig. 34.
Demand Limit Control Option — The demand limit The DELTA P AT 100% (default at 50 psi), DELTA P AT 0%
control option (20 mA DEMAND LIMIT OPT) is externally (default at 25 psi) and MINIMUM OUTPUT are configurable
controlled by a 4 to 20 mA or 1 to 5 vdc signal from an energy in the EQUIPMENT SERVICE-OPTIONS table. When con-
management system (EMS). The option is set up on the figuring this output, ensure that minimum requirements for
RAMP_DEM screen. When enabled, 4 mA is the 100% proper condenser FLASC orifice performance are maintained.
demand set point with an operator-configured minimum The 4 to 20 mA output from VFD TB1 terminals 17 and 18 can
demand at a 20 mA set point (DEMAND LIMIT AT 20 mA). be used as a reference to control a tower bypass valve, tower
The auto. demand limit is hardwired to terminals J5-1 (–) speed control, or condenser pump speed control. The head
and J5-2 (+) on the CCM. Switch setting number 1 on CCM
SW2 will determine the type of input signal. With the switch
54
pressure output is designed for use with non-grounded control-
lers with a maximum input impedence of 500 ohms. Minimum Speed + HGBP ON
DELTA SPEED + HGBP OFF
NOTE: It is up to the site design engineering agent to integrate DELTA SPEED
this analog output with any external system device(s) to pro-
duce the desired effect. Carrier does not make any claim that
this output is directly usable to control any specific piece of HGBP Off As VFD TARGET
equipment (that is, without further control elements or signal SPEED Decreases
conditioning), although it may be.
ΔP HGBP HGBP
The head pressure reference output will be on whenever the On Off
condenser pump is operating. It may also be manually operated
in CONTROLS TEST. When the head pressure differential is HGBP On As VFD TARGET
SPEED Increases
less than the value entered for DELTA P AT 0%, the output will
be maintained at 4 mA. The output is 2 mA when the chiller is
not running.
Minimum Speed
+ HGBP ON
DELTA SPEED DELTA SPEED
LEGEND
P — Condenser Pressure –
Evaporator Pressure
DEFAULT VALUES: HGBP — Hot Gas Bypass
POINT HFC-134A
T1 1.5 Fig. 33 — Hot Gas Bypass Option 2
P1 150
T2 4
P2 200
DELTA P
AT 100%
LEGEND
NON-ZERO
a23-1608 P — Condenser Pressure- EXAMPLE
Cooler Pressure
T — ECL-LCL OF
ECL — Entering Chilled MINIMUM HEAD
Liquid Temperature PRESSURE REFERENCE
LCL — Leaving Chilled DELTA P OUTPUT
Liquid Temperature
HGBP — Hot Gas Bypass
Fig. 31 — 23XRV Hot Gas Bypass

Option 1 (English)
DELTA P
AT 0%
0 mA 2 mA 4 mA 20 mA
(0%) (100%)
a23-1610 4 T0 20 mA OUTPUT
Fig. 34 — Head Pressure Output
Reference Control
a23-1609
LEGEND DEFAULT VALUES:

P Condenser Pressure-
— Cooler Pressure POINT HFC-134A
T — ECL-LCL T1 0.8
ECL — Entering Chilled P1 1034
Liquid Temperature T2 2.2
LCL — Leaving Chilled P2 1379
Liquid Temperature
HGBP — Hot Gas Bypass
Fig. 32 — 23XRV Hot Gas Bypass Option 1 (SI)
55
Lead/Lag Control — The lead/lag control system auto- To properly control the common supply point temperature
matically starts and stops a lag or second chiller in a 2-chiller sensor when chillers are piped in parallel, the liquid flow path
liquid system. A third chiller can be added to the lead/lag through the shutdown chillers must be isolated so no liquid
system as a standby chiller to start up in case the lead or lag bypass around the operating chiller occurs. The common point
chiller in the system has shut down during an alarm condition sensor option must not be used if liquid bypass around the
and additional cooling is required. Refer to Fig. 27 and 28 for operating chiller is occurring.
menu, table, and screen selection information. The output is CHILLER COMMUNICATION WIRING — Refer to the
2 mA when the chiller is not running. chiller’s Installation Instructions, Carrier Comfort Network®
NOTE: The lead/lag function can be configured on the Interface section for information on chiller communication
LEADLAG screen, which is accessed from the SERVICE wiring.
menu and EQUIPMENT SERVICE table. See Table 3, LEAD/LAG OPERATION — The PIC III control system not
Example 27. Lead/lag status during chiller operation can be only has the ability to operate 2 chillers in lead/lag, but it can
viewed on the LL_MAINT display screen, which is accessed also start a designated standby chiller when either the lead or
from the SERVICE menu and CONTROL ALGORITHM lag chiller is faulted and capacity requirements are not met. The
STATUS table. See Table 3, Example 14. lead/lag option only operates when the chillers are in CCN
Lead/Lag System Requirements: mode. If any other chiller configured for lead/lag is set to the
• All chillers in the system must have software capable of LOCAL or OFF modes, it will be unavailable for lead/lag
performing the lead/lag function. operation.
• Liquid pumps MUST be energized from the PIC III Lead/Lag Chiller Configuration and Operation
controls. • A chiller is designated the lead chiller when its LEAD/
• Liquid flows should be constant. LAG CONFIGURATION value on the LEADLAG
• The CCN time schedules for all chillers must be identi- screen is set to “1.”
cal. The lag chiller set point and demand limit are con- • A chiller is designated the lag chiller when its LEAD/
trolled by lead chiller only and cannot be written to by LAG CONFIGURATION value is set to “2.”
an external automation system. • A chiller is designated as a standby chiller when its
Operation Features: LEAD/LAG CONFIGURATION value is set to “3.”
• 2-chiller lead/lag • A value of “0” disables the lead/lag designation of a
• addition of a third chiller for backup chiller.
• manual rotation of lead chiller To configure the LAG ADDRESS value on the LEADLAG
• load balancing if configured screen, always enter the address of the other chiller on the
• staggered restart of the chillers after a power failure system. For example, to configure chiller A, enter the address
• chillers may be piped in parallel or in series chilled for chiller B as the lag address. To configure chiller B, enter the
liquid flow address for chiller A as the lag address. This makes it easier to
COMMON POINT SENSOR INSTALLATION — In rotate the lead and lag chillers.
all cases lead/lag operation does not require a common point If the address assignments in the LAG ADDRESS and
chilled liquid sensor. Common point sensors (Spare Temp #1 STANDBY ADDRESS parameters conflict, the lead/lag func-
and #2) can be added to the CCM module, if desired. Spare tion is disabled and an alert (!) message displays. For example,
Temp #1 and #2 are wired to plug J4 terminals 25-26 and 27-28 if the LAG ADDRESS matches the lead chiller’s address, the
(J4 lower, respectively). See the Lead/Lag Control Wiring fig- lead/lag will be disabled and an alert (!) message displayed.
ures on pages 143 and 144. The lead/lag maintenance screen (LL_MAINT) displays the
NOTE: If the common point sensor option is chosen on a message INVALID CONFIG in the LEAD/LAG: CONFIGU-
chilled liquid system, each chiller should have its own com- RATION and CURRENT MODE fields. Refer to Table 7.
mon point sensor installed. Each chiller uses its own common
point sensor for control when that chiller is designated as the Table 7 — Invalid Lead/Lag Addresses
lead chiller. The PIC III controls cannot read the value of com-
LEAD/LAG
mon point sensors installed on the other chillers in the chilled CONFIGURATION
liquid system. (IN LEAD/LAG
INVALID CONDITIONS
If leaving chilled liquid control (ECL CONTROL OPTION SCREEN)
is set to 0 [DSABLE], TEMP_CTL screen) and a common Local Address (Lead) =
point sensor is desired (COMMON SENSOR OPTION in Lag Address
LEADLAG screen selected as 1) then the common point Standby Chiller Option = Enable and
temperature sensor is wired in Spare Temp #1 position on the Local Address (Lead) = Standby Address
1 (Lead)
CCM. Standby Chiller Option = Enable and
If the entering chilled liquid control option (ECL CON- Lag Address = Standby Address
TROL OPTION) is enabled (configured in TEMP_CTL Local Address (Lead) =
screen) and a common point sensor is desired (COMMON Lag Address
SENSOR OPTION in LEADLAG screen selected as 1) then Standby Chiller Option = Enable and
the sensor is wired in Spare Temp #2 position on the CCM. 2 (Lag) Local Address (Lag) = Standby Address
When installing chillers in series, a common point sensor
should be used. If a common point sensor is not used, the The lead chiller responds to normal start/stop controls such
leaving chilled liquid sensor of the upstream chiller must be as the occupancy schedule, a forced start or stop, and remote
moved into the leaving chilled liquid pipe of the downstream start contact inputs. After completing start-up and ramp load-
chiller. ing, the PIC III module evaluates the need for additional capac-
If return chilled liquid control is required on chillers piped ity. If additional capacity is needed, the PIC III module initiates
in series, the common point return chilled liquid sensor should the start-up of the chiller configured at the LAG ADDRESS. If
be installed. If this sensor is not installed, the return chilled the lag chiller is faulted (in alarm) or is in the OFF or LOCAL
liquid sensor of the downstream chiller must be relocated to the modes, the chiller at the STANDBY ADDRESS (if configured)
return chilled liquid pipe of the upstream chiller. is requested to start. After the second chiller is started and is
running, the lead chiller monitors conditions and evaluates
56
whether the capacity has been reduced enough for the lead NOTE: When the lag chiller is in operation, CONTROL
chiller to sustain the system alone. If the capacity is reduced flashes on the right side of the status screen for CHILLER
enough for the lead chiller to sustain the CONTROL POINT START/STOP, DEMAND LIMIT, and CONTROL POINT
temperature alone, then the operating lag chiller is stopped. (CAPACITY).
If the lead chiller is stopped in CCN mode for any reason Lead/Lag Pulldown Timer Operation — Some lead/lag
other than an alarm (*) condition, the lag and standby chillers chiller applications with large chilled liquid loop volumes must
are also stopped. If the configured lead chiller stops for an accommodate intermittent slugs of warm ENTERING
alarm condition, the configured lag chiller takes the lead CHILLED LIQUID for short time periods. This type of tran-
chiller’s place as the lead chiller, and the standby chiller serves sient condition can result when a control valve rapidly opens to
as the lag chiller. allow flow through a previously isolated branch or zone within
If the configured lead chiller does not complete the start-up the chilled liquid system. A PULLDOWN TIMER can be con-
before the PRESTART FAULT TIMER (configured in figured to delay starting the lag chiller so it does not excessive-
LEADLAG screen) elapses, then the lag chiller starts and the ly cycle on and off for short time periods when intermittent
lead chiller shuts down. The lead chiller then monitors the start slugs of warm ENTERING CHILLED LIQUID pass through
request from the acting lead chiller. The PRESTART FAULT the chillers. A larger PULLDOWN TIMER entry gives the
TIMER is initiated at the time of a start request. The warm slug of water more time to pass through the chillers
PRESTART FAULT TIMER provides a timeout if there is a before the lag chiller will start.
prestart alert condition that prevents the acting lead chiller from The chiller CONTROL POINT can be configured to either
starting in a timely manner. The PRESTART FAULT TIMER LEAVING CHILLED LIQUID or ENTERING CHILLED
parameter is on the LEADLAG screen, which is accessed from LIQUID temperature. The PIC controls monitor the tempera-
the EQUIPMENT SERVICE table of the SERVICE menu. ture pulldown rate of the CHILLED LIQUID and display the
If the lag chiller does not achieve start-up before the result as CHILL LIQ PULLDOWN/MIN in the HEAT_EX
PRESTART FAULT TIMER elapses, the lag chiller stops, and screen. Samples of the CHILLED LIQUID temperature are
the standby chiller is requested to start, if configured and ready. taken once every 10 seconds and compared against the previ-
Standby Chiller Configuration and Operation — A chiller is ous CHILLED LIQUID sample. A positive value of CHILL
designated as a standby chiller when its LEAD/LAG CONFIG- LIQ PULLDOWN/MIN indicates that the CHILLED LIQUID
URATION value on the LEADLAG screen is set to “3.” The temperature is decreasing between successive samples. If
standby chiller can operate as a replacement for the lag chiller CHILL LIQ PULLDOWN/MIN rate is a minimum of
only if one of the other two chillers is in an alarm (*) condition 0.5 degrees F per minute then the PULLDOWN: SATISFIED
(as shown on the ICVC panel). If both lead and lag chillers are parameter in the LL_MAINT screen displays “YES”, other-
in an alarm (*) condition, the standby chiller defaults to operate wise, the PULLDOWN: SATISFIED parameter displays
in CCN mode, based on its configured occupancy schedule and “NO.”
remote contacts input. If the lead chiller is unable to achieve the CONTROL
Lag Chiller Start-Up Requirements — Before the lag chiller POINT, the lag chiller will not start unless the lead chiller is un-
can be started, the following conditions must be met: able to maintain a CHILL LIQ PULLDOWN/MIN rate of
1. The lag chiller status indicates it is in CCN mode and 0.5 degrees F per minute for a time period equal to the number
is not in an alarm condition. If the current lag chiller is of minutes entered in the PULLDOWN TIMER parameter.
in an alarm condition, the standby chiller becomes the PULLDOWN TIME in the LL_MAINT screen displays the
active lag chiller, if it is configured and available. remaining delay left before the lag chiller is allowed to start
based on the pulldown timer. PULLDOWN TIME will count
2. Lead chiller ramp loading must be complete. down starting at the value entered in PULLDOWN TIMER
3. The configured LAG START TIMER entry has elapsed. when Ramp Loading is complete and when PULLDOWN:
The LAG START TIMER starts when the lead chiller SATISIFIED = NO.
ramp loading is completed or when a lag chiller stops. The lag chiller pulldown start condition is met when PULL-
The LAG START TIMER entry is on the LEADLAG DOWN TIME lapses to 0.0 min.
screen, which is accessed from the EQUIPMENT
SERVICE table of the SERVICE menu. If PULLDOWN: SATISFIED changes to “YES” as the
PULLDOWN TIME is counting down to zero, the PULL-
4. Lead chiller ACTIVE DEMAND LIMIT (see the
DOWN TIME will start to count back up provided that the
MAINSTAT screen) value must be greater than 95% of CHILLED LIQUID temperature has not fallen to less than the
full load amps. CONTROL POINT plus one half of the CHILLED LIQUID
5. Lead CHILLED LIQUID TEMP must be greater than DEADBAND. The PULLDOWN TIME will start to count back
the CONTROL POINT temperature (see the MAIN- down again should PULLDOWN: SATISFIED change back to
STAT screen) plus 1/2 the CHILLED LIQUID DEAD- “NO.” The PULLDOWN TIME will be immediately reset to
BAND temperature (see the SETUP1 screen). the value entered in the PULLDOWN TIMER parameter if the
NOTE: The chilled liquid temperature sensor may be CHILLED LIQUID temperature decreases to less than the
the leaving chilled liquid sensor, the return liquid sen- CONTROL POINT plus one half of the CHILLED LIQUID
sor, the common supply liquid sensor, or the common DEADBAND.
return liquid sensor, depending on which options are Lag Chiller Shutdown Requirements — The following con-
configured and enabled. ditions must be met in order for the lag chiller to be stopped.
6. Lead chiller temperature pulldown rate (TEMP PULL- 1. Lead chiller AVERAGE LINE CURRENT or PERCENT
DOWN DEG/MIN on the TEMP_CTL screen) of the MOTOR KILOWATTS load value (on the MAINSTAT
chilled liquid temperature is less than 0.5º F (0.27º C) screen) is less than the Lead Chiller Percent Capacity.
per minute for a cumulative duration greater than the
PULLDOWN TIMER setting in the LEADLAG screen. NOTE: Lead Chiller Percent Capacity = 105 – LAG %
CAPACITY. The LAG % CAPACITY parameter is on
When all the above requirements have been met, the lag the LEADLAG screen, which is accessed from the
chiller is commanded to a STARTUP mode (CONTROL flash- EQUIPMENT SERVICE table on the SERVICE
ing next to the point value on the STATUS table). The PIC III menu.
controls then monitor the lag chiller for a successful start. If the
lag chiller fails to start, the standby chiller, if configured, is 2. The lead chiller CHILLED LIQUID TEMP is less than
started. the CONTROL POINT temperature (see the MAINSTAT
57
screen) plus on half of the CHILLED LIQUID DEAD- LOAD BALANCE OPTION is disabled, the ACTIVE
BAND temperature (see the SETUP1 screen). DEMAND LIMIT and the CONTROL POINT are forced to the
3. The configured LAG STOP TIMER entry has elapsed. same value as the lead chiller.
The LAG STOP TIMER starts when the lead chiller AUTO. RESTART AFTER POWER FAILURE — When
CHILLED LIQUID TEMP is less than the chilled liquid an Auto restart condition occurs, each chiller may have a delay
CONTROL POINT plus 1/2 of the CHILLED LIQUID added to the start-up sequence, depending on its lead/lag
DEADBAND and the lead chiller compressor motor load configuration. The lead chiller does not have a delay. The lag
(PERCENT MOTOR KILOWATTS or AVERAGE LINE chiller has a 45-second delay. The standby chiller has a
CURRENT on the MAINSTAT screen) is less than the 90-second delay. The delay time is added after the chiller liquid
lead chiller percent capacity. flow is verified. The delay must elapse before the oil pump is
NOTE: The use of AVERAGE LINE CURRENT or PERCENT turned on. The Auto restart delay sequence occurs whether the
MOTOR KILOWATTS in the Lag chiller shutdown decision chiller is in CCN or LOCAL mode and is intended to stagger
is based on the DEMAND LIMIT SOURCE configuration in the compressor motor starts. Preventing the motors from start-
the RAMP_DEM screen. If DEMAND LIMIT SOURCE = 0 ing simultaneously helps reduce the inrush demands on the
then AVERAGE LINE CURRENT will be used. If DEMAND building power system.
LIMIT SOURCE = 1 then PERCENT MOTOR KILOWATTS Attach to Network Device Control — The Service
will be used. menu includes the ATTACH TO NETWORK DEVICE
FAULTED CHILLER OPERATION — If the lead chiller screen. From this screen the operator can:
shuts down because of an alarm (*) condition, it stops commu- • attach the ICVC to any CCN device, if the chiller has
nicating to the lag and standby chillers. After 30 seconds, the been connected to a CCN network. This may include
lag chiller becomes the acting lead chiller and starts and stops other PIC III-controlled chillers.
the standby chiller, if necessary. • upgrade software
If the lag chiller goes into alarm when the lead chiller is also Figure 35 shows the ATTACH TO NETWORK DEVICE
in alarm, the standby chiller reverts, after 60 seconds, to a screen. The LOCAL parameter is always the ICVC module
stand-alone CCN mode of operation. address of the chiller on which it is mounted. Whenever the
If the lead chiller is in an alarm (*) condition (as shown on controller identification of the ICVC changes, the change is re-
the ICVC panel), press the RESET softkey to clear the alarm. flected automatically in the BUS and ADDRESS columns for
The lead chiller is placed in CCN mode. The lead chiller the local device. See Fig. 28. Default address for local device is
BUS 0 ADDRESS 1.
communicates and monitors the RUN STATUS of the lag and
standby chillers. If both the lag and standby chillers are When the ATTACH TO NETWORK DEVICE screen is
accessed, information can not be read from the ICVC on any
running, the lead chiller does not attempt to start and does not device until one of the devices listed on that screen is attached.
assume the role of lead chiller until either the lag or standby The ICVC erases information about the module to which it was
chiller shuts down. If only one chiller is running, the lead attached to make room for information on the new device.
chiller waits for a start request from the operating chiller. When Therefore, a CCN module must be attached when this screen is
the configured lead chiller starts, it resumes its role as lead entered.
chiller. To attach any CCN device, highlight it using the SELECT
softkey and press the ATTACH softkey. The message “UP-
If the lag chiller is the only chiller running and the lead
chiller is ready to resume its role as a lead chiller then the lag LOADING TABLES, PLEASE WAIT” displays. The ICVC
chiller will perform a RECOVERY START REQUEST (LL_- then uploads the highlighted device or module. If the module
MAINT screen). The lead chiller will start up when the follow- address cannot be found, the message “COMMUNICATION
ing conditions are met. FAILURE” appears. The ICVC then reverts back to the
1. Lag chiller ramp loading must be complete. ATTACH TO DEVICE screen. Try another device or check the
2. Lag CHILLED LIQUID TEMP (MAINSTAT screen) address of the device that would not attach. The upload process
is greater than CONTROL POINT plus 1/2 the time for each CCN module is different. In general, the upload-
CHILLED LIQUID DEADBAND temperature. ing process takes 1 to 2 minutes. Before leaving the ATTACH
3. Lag chiller ACTIVE DEMAND LIMIT value must be TO NETWORK DEVICE screen, select the local device. Oth-
greater than 95% of full load amps. erwise, the ICVC will be unable to display information on the
4. Lag chiller temperature pulldown rate (TEMP PULL- local chiller.
DOWN DEG/MIN) of the chilled liquid temperature is
less than 0.5 F (0.27 C) per minute for a cumulative
time duration greater than the PULLDOWN TIMER
setting in the lag chiller’s LEADLAG screen.
5. The standby chiller is not running as a lag chiller.
6. The configured LAG START TIMER has elapsed. The
LAG START TIMER is started when ramp loading is
completed.
LOAD BALANCING — When the LOAD BALANCE OP-
TION (see LEADLAG screen) is enabled, the lead chiller sets a23-1611
the ACTIVE DEMAND LIMIT in the lag chiller to the lead
chiller’s AVERAGE LINE CURRENT or PERCENT MOTOR Fig. 35 — Example of Attach to Network
KILOWATTS value in the POWER screen. This value has Device Screen
limits of 40% to 100%. When the lag chiller ACTIVE
DEMAND LIMIT is set, the CONTROL POINT is assigned a
value of 3º F (1.67º C) less than the lead chiller’s CONTROL
POINT value to better match the lead chiller’s load level. If the
58
ATTACHING TO OTHER CCN MODULES — If the The ICVC screen displays the following list of available
chiller ICVC has been connected to a CCN Network or other SERVICE screens:
PIC- controlled chillers through CCN wiring, the ICVC can be • Alarm History
used to view or change parameters on the other controllers. • Alert History
Other PIC III chillers can be viewed and set points changed (if • Control Test
the other unit is in CCN control), if desired, from this particular • Control Algorithm Status
ICVC module. • Equipment Configuration
If the module number is not valid, the “COMMUNICA- • VFD Config Data
TION FAILURE” message will show and a new address num- • Equipment Service
ber must be entered or the wiring checked. If the module is • Time and Date
communicating properly, the “UPLOAD IN PROGRESS” • Attach to Network Device
message will flash and the new module can now be viewed. • Log Out of Device
Whenever there is a question regarding which module on • ICVC Configuration
the ICVC is currently being shown, check the device name See Fig. 28 for additional screens and tables available from
descriptor on the upper left hand corner of the ICVC screen. the SERVICE screens listed above. Use the EXIT softkey to
See Fig. 35. return to the main MENU screen.
When the CCN device has been viewed, the ATTACH TO
NOTE: To prevent unauthorized persons from accessing the
NETWORK DEVICE table should be used to attach to the PIC ICVC service screens, the ICVC automatically signs off and
that is on the chiller. Move to the ATTACH TO NETWORK password-protects itself if a key has not been pressed for
DEVICE table (LOCAL should be highlighted) and press the 15 minutes. The sequence is as follows. Fifteen minutes after
ATTACH softkey to upload the LOCAL device. The ICVC the last key is pressed, the default screen displays, the ICVC
for the 23XRV chiller will be uploaded and default screen will screen light goes out (analogous to a screen saver), and the
ICVC logs out of the password-protected SERVICE menu.
display. The STATUS, SCHEDULE, and SETPOINT screens can be
NOTE: The ICVC will not automatically reattach to the local accessed without the password by pressing the appropriate
module on the chiller. Press the ATTACH softkey to attach to softkey.
the LOCAL device and view the local chiller operation. TO LOG OUT OF DEVICE — To access this screen and log
out of a network device, from the default ICVC screen, press
Service Operation — An overview of the tables and the MENU and SERVICE softkeys. Enter the password
screens available for the SERVICE function is shown in
Fig. 28. and, from the SERVICE menu, highlight LOG OUT OF
NETWORK DEVICE and press the SELECT softkey. The
TO ACCESS THE SERVICE SCREENS — When the
SERVICE screens are accessed, a password must be entered. ICVC default screen will now be displayed.
1. From the main MENU screen, press the SERVICE HOLIDAY SCHEDULING (Fig. 36) — The time schedules
softkey. The softkeys now correspond to the numerals may be configured for special operation during a holiday
period. When modifying a time period, the “H” in the far right
1, 2, 3, 4. column of the OCCPC01S, OCCPC02S or OCCPC03S time
2. Press the four digits of the password, one at a time. An schedule screen signifies that the period is applicable to a
asterisk (*) appears as each digit is entered. holiday. (See Fig. 29.)
The TIME BROADCAST ENABLE function must be
activated for the holidays configured on the HOLIDAYS
screen to work properly. Access the BRODEF screen from the
EQUIPMENT CONFIGURATION table, highlight TIME
BROADCAST ENABLE and select ENABLE to activate func-
NOTE: The initial factory-set password is 1-1-1-1. tion. Note that when the chiller is connected to a CCN network,
If the password is incorrect, an error message is only one chiller or CCN device can be configured as the broad-
displayed. cast device. The controller that is configured as the broadcaster
is the device responsible for transmitting holiday, time, and
daylight-savings dates throughout the network.
To access the BRODEF screen, see the SERVICE menu
structure, Fig. 28.
To view or change the holiday periods for up to 18 different
holidays, perform the following operation:
If this occurs, return to Step 1 and try to access the
SERVICE screens again. If the password is correct, the 1. At the Main Menu screen, press SERVICE to access
softkey labels change to: the Service menu.
2. If not logged on, follow the instructions for ATTACH
TO NETWORK DEVICE CONTROL or To Log Out
of Device. Once logged on, press NEXT until
EQUIPMENT CONFIGURATION is highlighted.
NOTE: The SERVICE screen password can be changed by 3. Once EQUIPMENT CONFIGURATION is high-
entering the ICVC CONFIGURATION screen under lighted, press SELECT to access.
SERVICE menu. The password is located at the bottom of the
menu. Contact Carrier Service to override the ICVC password 4. Press NEXT until HOLIDAYS is highlighted. This is
if it is lost. the Holiday Definition table.
5. Press SELECT to enter the Data Table Select
screen.This screen lists 18 holiday tables.
59
6. Press NEXT to highlight the holiday table that is to NOTE: The chiller will continue to run until this forced start is
be viewed or changed. Each table is one holiday released, regardless of the programmed schedule. To release
period, starting on a specific date, and lasting up to the forced start, highlight and select CHILLER START/STOP
99 days. from the MAINSTAT screen and press the RELEASE
7. Press SELECT to access the holiday table. The Con- softkey. This action returns the chiller to the start and stop
figuration Select table now shows the START times established by the schedule.
MONTH, START DAY, and DURATION of the holi- The chiller may also be started by overriding the time
day period. schedule. From the default screen, press the MENU and
8. Press NEXT or PREVIOUS to highlight the START SCHEDULE softkeys. Scroll down and select the current
schedule. Scroll down and select OVERRIDE, and set the
MONTH, START DAY, and DURATION.
desired override time period.
9. Press SELECT to modify the month, day, or duration. Another condition for start-up must be met for chillers that
10. Press INCREASE or DECREASE to change the have the REMOTE CONTACTS OPTION on the EQUIP-
selected value. MENT SERVICE, OPTIONS screen set to ENABLE. For
11. Press ENTER to save the changes. these chillers, the REMOTE START CONTACT parameter on
12. Press EXIT to return to the previous menu. the MAINSTAT screen must be CLOSED. From the ICVC
default screen, press the MENU and STATUS softkeys.
Scroll to high-light MAINSTAT and press the SELECT soft-
23XRPIC3
key. Scroll down the MAINSTAT screen to highlight
REMOTE START CONTACT and press the SELECT softkey.
Press the CLOSE softkey to initiate the override. To end the
override, select REMOTE START CONTACT and press the
RELEASE softkey.
a23-1612 Once local start-up begins, the PIC III performs a series of
pre-start tests to verify that all pre-start alerts and safeties are
within the limits shown in Table 5. The RUN STATUS parame-
ter on the MAINSTAT screen line now reads PRESTART. If a
test is not successful, the start-up is delayed or aborted. Failure
to verify any of the requirements up to this point will result in
the PIC III controls aborting the start and displaying the appli-
cable pre-start alert on the ICVC default screen. A pre-start
alert does not advance the starts in 12 hours counter. If the tests
Fig. 36 — Example of Holiday Period Screen are successful, the chilled liquid pump relay energizes, and the
MAINSTAT screen line now reads STARTUP.
Five seconds later, the condenser pump relay energizes.
START-UP/SHUTDOWN/ Thirty seconds later the PIC III module monitors the chilled
RECYCLE SEQUENCE (FIG. 37) liquid and condenser liquid flow devices and waits until the
Local Start-Up — Local start-up (or a manual start-up) is LIQUID FLOW VERIFY TIME (operator-configured, default 5
initiated by pressing the LOCAL menu softkey on the default minutes) expires to confirm flow. After flow is verified, the
ICVC screen. Local start-up can proceed when the chiller chilled liquid temperature is compared to CONTROL POINT
plus 1/2 CHILLED LIQUID DEADBAND. If the temperature is
schedule indicates that the current time and date have been less than or equal to this value, the PIC III controls turn off the
established as a run time and date, and after the internal condenser pump relay and goes into a RECYCLE mode.
15-minute start-to-start and the 1-minute stop-to-start inhibit
NOTE: The 23XRV chillers are not available with factory-
timers have expired. These timers are represented in the START installed external chilled liquid flow or condenser liquid
INHIBIT TIMER and can be viewed on the MAINSTAT screen flow devices. These are available as an accessory for use
and DEFAULT screen. The timer must expire before the chiller with the CCM control board.
will start. If the timers have not expired the RUN STATUS If the liquid temperature is high enough to require cooling,
parameter on the MAINSTAT screen now reads TIMEOUT. the start-up sequence continues. Tower fan control is enabled
NOTE: The time schedule is said to be “occupied” if the and the oil pump starts. Oil pressure is verified between 45 sec-
OCCUPIED? parameter on the MAINSTAT screen is set to onds and 5 minutes. The VFD is set to START following oil
YES. For more information on occupancy schedules, see the pressure verification and the controls verify that no faults exist.
sections on Time Schedule Operation (page 28), Occupancy Proper compressor rotation is verified by monitoring the
Schedule (page 47), and To Prevent Accidental Start-Up discharge pressure.
page 82), and Fig. 29. The control center monitors load current to verify that the
If the OCCUPIED? parameter on the MAINSTAT screen is compressor is running then steps the compressor up to target
set to NO, the chiller can be forced to start as follows. From the speed. The start-to-start and service ontime timers are activated
default ICVC screen, press the MENU and STATUS soft- when compressor operation is confirmed.
keys. Scroll to highlight MAINSTAT. Press the SELECT The controls will abort the start and display the applicable
pre-start alert on the ICVC if any of the conditions above are
softkey. Highlight and select CHILLER START/STOP. Press the
not verified. Any fault after the start-up process is complete
START softkey to override the schedule and start the chiller. results in a safety shutdown, advancing the STARTS IN
12 HOURS counter by one, and display of the applicable shut-
down status on the ICVC display.
60
Compressor ontime and service ontime timers start, and the • a recycle condition is present (see Chilled Liquid
compressor STARTS IN 12 HOURS counter in the MAIN- Recycle Mode section)
STAT screen and the TOTAL COMPRESSOR STARTS • the time schedule has gone into unoccupied mode
counter advance by one. • the chiller protective limit has been exceeded and chiller
is in alarm
• the start/stop status is overridden to stop from the CCN
network or the ICVC
When a stop signal occurs, the controls set TARGET VFD
SPEED to 0. This will cause the compressor to reduce speed to
the point where line amps equal the configured SOFTSTOP
AMPS THRESHOLD. (In a recycle shutdown, the compressor
will probably be at or below the soft stop threshold amps when
the stop signal is received.) At that point, or one minute after
the stop signal occurs (whichever is earlier), the VFD is set to
STOP. If the STOP key is depressed a second time during the
soft stop or within one minute of the stop signal occurring, the
compressor is immediately stopped.
When the VFD is set to STOP, the compressor is turned off.
The compressor shut down is confirmed by monitoring load
amps. When the compressor shutdown is verified, the oil pump
is turned off and VFD STOP is complete. After one minute, the
chilled liquid pump is turned off, unless it is a recycle shut-
down. At this point, the compressor on-time and service on-
time timers are turned off, and the stop-to-start timer is turned
on.
At this time the condenser liquid pump is also shut off, pro-
vided that the entering condenser liquid temperature is 115 F
(6.1 C) or greater, and the condenser refrigerant temperature is
greater than the condenser freeze point plus 5° F (3° C). Other-
wise, it remains under the control of the Condenser Pump
Control algorithm.
If the shut down is due to low evaporator refrigerant tem-
perature, the chilled liquid pump continues to run until the
leaving chilled liquid temperature is greater than the control
point, plus 5° F (3° C).
Automatic Soft Stop Amps Threshold —
A23-1645 When a non-recycle, non-alarm shutdown is called for, the soft
stop feature unloads the compressor by reducing speed to the
point where load amps equal the SOFTSTOP AMPS
A — START
started
INITIATED: Pre-start checks are made; chilled liquid pump
THRESHOLD. The compressor is then turned off (see the
B — Condenser liquid pump started (5 seconds after A) above sequence).
C — Liquid flows verified (30 sec to 5 minutes maximum after B) If the chiller enters an alarm state or if the compressor enters
a RECYCLE mode, the compressor deenergizes immediately.
D — Chilled liquid temperature checked against control point; tower fan
control enabled; oil pump on. To modify the soft stop amps threshold feature, scroll to the
E — Oil pressure verified (oil pressure verified 45 to 300 sec after D.) OPTIONS screen on the ICVC. Use the INCREASE or
F
VFD starts; phase reversal conditions monitored; compressor
— ontime and service ontime start; 15-minute inhibit timer starts (VFD DECREASE softkey to set the SOFTSTOP AMPS THRESH-
fault tests for 15 sec after “F”) OLD parameter to the percent of amps at which the motor will
G — Verify average current >5% within 15 sec after VFD start, ramp to shut down. Setting SOFT STOP AMPS THRESHOLD to 100%
VFD target speed.
H — Compressor reaches target speed, chiller set to running status
de-activates this feature. The default setting is 100% amps (no
soft stop). The range is 40 to 100%.
I — Ramp down until percent line current < soft stop amps threshold (0
to 60 sec after I)
When the soft stop amps threshold feature is being applied,
J — Shutdown
<5%.
initiated: Target VFD speed to 0%. All load currents a status message, “SHUTDOWN IN PROGRESS, COM-
PRESSOR UNLOADING” displays on the ICVC.
K — Oil pump relay off (1 to 20 sec after J)
Evaporator pump deenergized (60 sec after K); condenser pump
The soft stop amps threshold function can be terminated and
L — and tower fan control may continue to operate if condenser pres- the compressor motor de-energized immediately by depressing
sure is high; evaporator pump may continue if in RECYCLE mode the STOP button twice.
or freeze protection alarm declared.
O/A — Restart permitted (both inhibit timers expired) (minimum of 15 min- Chilled Liquid Recycle Mode — The chiller may
utes after F; minimum of 1 minute after L)
cycle off and wait until the load increases to restart when the
compressor is running in a lightly loaded condition. This
Fig. 37 — Control Sequence cycling is normal and is known as “recycle.” A recycle
shutdown is initiated when any of the following conditions are
Shutdown Sequence — Chiller shutdown begins if true:
any of the following occurs: 1. ECL CONTROL OPTION is DISABLED (LCL
• the STOP button is pressed for at least one second (the control):
alarm light blinks once to confirm the stop command) The CONTROL POINT has not been increased by at
least 1° F (0.5° C) in the last 5 min. and LEAVING
61
CHILLED LIQUID temperature is less than the BEFORE INITIAL START-UP
CONTROL POINT (MAINSTAT screen) minus 5° F
(3° C) (for units with P compressors, 5° F [3° C] is Job Data Required
configurable with RECYCLE SHUTDOWN DELTA T); • list of applicable design temperatures and pressures
or LEAVING CHILLED LIQUID temperature is less (product data submittal)
than the CONTROL POINT and the VFD TARGET • chiller certified prints
SPEED is less than the minimum speed plus RECY- • starting equipment details and wiring diagrams
CLE SHUTDOWN DELTA SPEED and ice build is not • diagrams and instructions for special controls or options
active. • 23XRV Installation Instructions
2. ECL CONTROL OPTION is ENABLED and ice build • pumpout unit instructions
is not active (ECL control): Equipment Required
The CONTROL POINT has not been increased by at
least 1° F in the last 5 min. and ENTERING CHILLED • T30 hexalobular socket screw driver to remove control
center door shipping brackets
LIQUID temperature is less than the CONTROL POINT
minus 5° F (3° C) (for units with P compressors, 5° F • mechanic’s tools (refrigeration)
[3° C] is configurable with RECYCLE SHUTDOWN • digital volt-ohmmeter (DVM)
• clamp-on ammeter
DELTA T) or ENTERING CHILLED LIQUID tempera-
ture is less than the CONTROL POINT and the VFD • electronic leak detector
TARGET SPEED is less than the Minimum Speed plus • absolute pressure manometer or wet-bulb vacuum indi-
cator (Fig. 38)
RECYCLE SHUTDOWN DELTA SPEED.
• 500-v insulation tester (megohmmeter) for compressor
3. The LEAVING CHILLED LIQUID temperature is less motors with nameplate voltage of 600 v or less
than the EVAP REFRIG TRIPPOINT plus 3° F • Reliance LCD OIM (operator interface module)
(1.7° C). (NOTE: Refer to Refrigerant Low Tempera- (optional)
ture Override.)
Whenever recycle shutdown is active the RUN Using the Optional Storage Tank and Pump-
STATUS shall be “Recycle.” out System — Refer to Chillers with Storage Tanks sec-
tion, page 87 for pumpout system preparation, refrigerant
When the chiller is in RECYCLE mode, the chilled liquid transfer, and chiller evacuation.
pump relay remains energized so the chilled liquid temperature
can be monitored for increasing load. The recycle control uses Remove Shipping Packaging — Remove any pack-
RECYCLE CONTROL RESTART DELTA T to check when the aging material from the control center, oil pump, VFD cooling
compressor should be restarted. This is an operator-configured solenoid, HGBP solenoid, oil reclaim actuator, oil heater termi-
function which defaults to 5º F (3º C). This value can be nal boxes, and relief valves.
viewed or modified on the SETUP1 table. The compressor will
restart when the chiller is: Open Oil Circuit Valves — Check to ensure the oil fil-
ter isolation valves (Fig. 14) are open by removing the valve
• in LCL CONTROL (ECL CONTROL OPTION cap and checking the valve stem.
DISABLED) and the LEAVING CHILLED LIQUID
temperature is greater than the CONTROL POINT plus Oil Charge — The oil charge for the 23XRV chiller is split
the RECYCLE CONTROL RESTART DELTA T. between the cooler and the oil vaporizer:
• in ECL CONTROL and the ENTERING CHILLED
LIQUID temperature is greater than the CONTROL FRAME COOLER OIL SUMP
TOTAL
POINT plus the RECYCLE CONTROL RESTART SIZE CHARGE CHARGE
DELTA T. A
B
Once these conditions are met, the compressor initiates a 10.0 gal.
3 1 gal.(3.8 L) 9.0 gal.(34.1 L)
start-up with a normal start-up sequence. (37.9 L)
4
An alert condition may be generated if 5 or more recycle
5
start-ups occur in less than 4 hours. Excessive recycling can
reduce chiller life; therefore, compressor recycling due to
extremely low loads should be reduced. The chiller is shipped with its oil charge. The oil level in the
vaporizer will initially be in the center of the oil sump sight
To reduce compressor recycling, use the time schedule to glass. This level will vary depending on the amount of refriger-
shut the chiller down during known low load operation periods, ant that has been absorbed by the oil and the operating
or increase the chiller load by running the fan systems. If the conditions of the chiller. Normal oil levels will vary from the
hot gas bypass is installed, adjust the values to ensure that hot top of the strainer housing sight glass to above the top of the oil
gas is energized during light load conditions. Increase the sump sight glass.
RECYCLE CONTROL RESTART DELTA T on the SETUP1
table to lengthen the time between restarts. If oil is added, it must conform to Carrier’s specification for
screw compressor use as described in the Oil Specification
The chiller should not be operated below design minimum section. Charge the oil through the oil charging valve located
load without a hot gas bypass installed. near the bottom of the oil strainer housing. The oil must be
Safety Shutdown — A safety shutdown is identical to a pumped from the oil container through the charging valve due
manual shutdown with the exception that, during a safety to the higher refrigerant pressure. The pumping device must be
shutdown, the ICVC displays the reason for the shutdown, the able to lift from 0 to 200 psig (1379 kPa) or above unit
alarm light blinks continuously, and the spare alarm contacts pressure. Oil should only be charged or removed when the
are energized. chiller is shut down.
After a safety shutdown, the RESET softkey must be Tighten All Gasketed Joints — Gaskets normally
pressed to clear the alarm. If the alarm condition is still present, relax by the time the chiller arrives at the jobsite. Tighten all
the alarm light continues to blink. Once the alarm is cleared, gasketed joints to ensure a leak-tight chiller. See Tables 8 and 9
the operator must press the CCN or LOCAL softkeys to for waterbox torque specifications.
restart the chiller.
62
Table 8 — Bolt Torque Requirements, Foot Pounds
SAE 8
SAE 2, A307 GR A SAE 5
HEX HEAD SOCKET HEAD OR HEX HEX HEAD
BOLT SIZE WITH 6 RADIAL LINES OR
NO MARKS WITH 3 RADIAL LINES, OR SA499 SA354 GR BD
(IN.) LOW CARBON STEEL MEDIUM CARBON STEEL
MEDIUM CARBON STEEL
MINIMUM MAXIMUM MINIMUM MAXIMUM MINIMUM MAXIMUM
1/ 4 6 6 9 9 13
4
5/ 8 11 13 18 20 28
16
3/ 13 19 22 31 32 46
8
7/ 21 30 35 50 53 75
16
1/ 32 45 53 75 80 115
2
9/ 46 65 75 110 115 165
16
5/ 65 95 105 150 160 225
8
3/ 105 150 175 250 260 370
4
7/ 140 200 265 380 415 590
8
1 210 300 410 580 625 893
1 1 /8 330 475 545 780 985 1,410
1 1 /4 460 660 770 1,100 1,380 1,960
1 3 /8 620 885 1,020 1,460 1,840 2,630
1 1 /2 740 1060 1,220 1,750 2,200 3,150
1 5 /8 1010 1450 1,670 2,390 3,020 4,310
1 3 /4 1320 1890 2,180 3,110 3,930 5,610
1 7 /8 1630 2340 2,930 4,190 5,280 7,550
2 1900 2720 3,150 4,500 5,670 8,100
2 1 /4 2180 3120 4,550 6,500 8,200 11,710
2 1 /2 3070 4380 5,000 7,140 11,350 16,210
2 3 /4 5120 7320 8,460 12,090 15,710 22,440
3 6620 9460 11,040 15,770 19,900 28,440
Table 9 — Bolt Torque Requirements, Foot Pounds (Metric Bolts)

BOLT SIZE CLASS 8.8 CLASS 10.9
(METRIC) MINIMUM MAXIMUM MINIMUM MAXIMUM
M4 1.75 2.5 2.5 3.5
M6 6 9 8 12
M8 14 20 20 30
M10 28 40 40 57
M12 48 70 70 100
M16 118 170 170 240
M20 230 330 330 470
M24 400 570 570 810
M27 580 830 820 1175
63
WARNING
Never charge liquid refrigerant into the chiller if the pres-
sure in the chiller is less than 35 psig (241 kPa). Charge as
a gas only, with the cooler and condenser pumps running,
until this pressure is reached, using PUMPDOWN and
TERMINATE PUMPDOWN MODE on the ICVC. Flash-
ing of liquid refrigerant at low pressures can cause tube
freeze-up and considerable damage.
c. Leak test chiller as outlined in Steps 3-7.
2. If the pressure readings are abnormal for chiller
condition:
a. Prepare to leak test chillers shipped with refriger-
ant. If chiller is shipped with refrigerant, proceed
to Step 3.
b. Check for large leaks by connecting a nitrogen
bottle and raising the pressure to 30 psig (207
a19-658 kPa). Soap test all joints. If the test pressure holds
Fig. 38 — Typical Wet-Bulb Type for 30 minutes, prepare the test for small leaks
Vacuum Indicator (Steps 2g to 2h).
c. Plainly mark any leaks which are found.
Check Chiller Tightness — Figure 39 outlines the
proper sequence and procedures for leak testing. d. Release the pressure in the system.
The 23XRV chillers are shipped with a full refrigerant and e. Repair all leaks.
oil charge. Units may be ordered with the refrigerant shipped f. Retest only those joints that were repaired.
separately, and a 15 psig (103 kPa) nitrogen-holding charge in g. After successfully completing the test for large
each vessel. To determine if there are any leaks, the chiller leaks, remove as much nitrogen, air, and moisture
should be charged with a refrigerant tracer. Use an electronic as possible, given the fact that small leaks may be
leak detector to check all flanges and solder joints after the present in the system. This can be accomplished
chiller is pressurized. If any leaks are detected, follow the leak by following the dehydration procedure, outlined
test procedure. in the Chiller Dehydration section, page 71.
If the chiller is spring isolated, keep all springs blocked in h. Slowly raise the system pressure to normal operat-
both directions to prevent possible piping stress and damage ing pressures for the refrigerant used in the chiller.
during the transfer of refrigerant from vessel to vessel during Proceed with the test for small leaks (Steps 3 to 7).
the leak test process, or any time refrigerant is being trans-
ferred. Adjust the springs when the refrigerant is in operating 3. Check the chiller carefully with an electronic leak
condition and the liquid circuits are full. detector or halide torch.
4. Leak Determination — If an electronic leak detector
Refrigerant Tracer — Carrier recommends the use of an indicates a leak, use a soap bubble solution, if possible,
environmentally acceptable refrigerant tracer for leak testing to confirm. Total all leak rates for the entire chiller.
with an electronic detector or halide torch. Leakage at rates greater than 1 lb/year (0.45 kg/year)
Ultrasonic leak detectors can also be used if the chiller is for the entire chiller must be repaired. Note total
under pressure. chiller leak rate on the start-up report.
5. If no leak is found during initial start-up procedures,
WARNING complete the transfer of refrigerant gas from the
storage tank to the chiller. Retest for leaks.
Do not use air or oxygen as a means of pressurizing 6. If no leak is found after a retest
the chiller. Mixtures of HFC-134a and air can undergo
combustion. a. Transfer the refrigerant to the storage tank and
perform a standing vacuum test as outlined in the
Leak Test Chiller — Due to regulations regarding refrig- Chiller Dehydration section, page 71.
erant emissions and the difficulties associated with separating b. If the chiller fails this test, check for large leaks
contaminants from refrigerant, Carrier recommends the follow- (Step 2b).
ing leak test procedures. See Fig. 39 for an outline of the leak c. Dehydrate the chiller if it passes the standing
test procedures. Refer to Fig. 40-43 during pumpout proce- vacuum test. Follow the procedure in the
dures. See the Pumpout and Refrigerant Transfer Procedures Chiller Dehydration section, page 71. Charge
section on page 86. Refer to Tables 10 and 11 for temperature/ chiller with refrigerant.
pressure relationships for HFC-134a refrigerant.
7. If a leak is found, pump the refrigerant back into the
1. If the pressure readings are normal for chiller storage tank, or if isolation valves are present, pump
condition: into the vessel that is not leaking.
a. Evacuate the holding charge from the vessels, if Transfer the refrigerant until chiller pressure is at least
present. equal to the pressure specified by the EPA under
b. Raise the chiller pressure, if necessary, by adding 40 CFR Part 82.
refrigerant until pressure is at equivalent saturated Repair the leak and repeat the procedure, beginning
pressure for the surrounding temperature. from Step 2h to ensure a leaktight repair. If chiller is
opened to the atmosphere for an extended period,
evacuate it before repeating leak test.
64
a23-1614
*
TABLES*)
ADD REFRIGERANT GAS UNTIL

PRESSURE IS ABOVE 35 PSIG
(241 kPa) FOR HFC-134a
65
*See Tables 10 and 11.
Fig. 39 — 23XRV Leak Test Procedure
3/8" MALE FLARE
W RELIEF VALVE CONN.
LEVEL GAGE
1/2" DIA. K.O. 0' - 9 "
ELECTRICAL CONN. [229mm]
(PUMPOUT POWER) TYPICAL
0' - 5 1/2"
[140mm]
(2) 1" NPT RELIEF

PRESSURE GAGE VALVE OUTLET (SEE FIELD
INSTALLATION NOTES)
R 1' - 7 "
[483mm]
T 0' - 5 7/8 "

[149mm]
a23-1541 B
TOP VIEW
1/2" MALE FLARE
3/4" NPT
VAPOR CONN.
PUMPOUT CONDENSER
3/4" NPT WATER OUTLET CONN.
PUMPOUT CONDENSER ELECTRICAL SERVICE
WATER INLET CONN. ACCESS SPACE
20 3/4" X 8 3/4" X 4 1/2"
NOTES: (BOTH SIDES)
1. Denotes center of gravity.

VAPOR
2. Dimensions in [ ] are in
millimeters.
3. The weights and center of
gravity values given are for an J L
empty storage tank.
4. For additional information on
the pumpout unit, see certified K F
drawings.
5. Conduit knockout is located on
the side of the control box.
6. 28 cubic ft storage tank
weight: 2334 lb (1059 kg).
7. 52 cu ft storage tank weight: 1" NPT
3414 lb (1549 kg). V LIQUID CONN. 0'- 9"
[229mm]
U 0'- 9 7/8" TYPICAL
[249mm]
N
M G
A
a23-1542
FRONT VIEW
1'-0 3/4"
[324mm]
0'- 7 15/16" DIMENSIONS

[202mm]
(FARSIDE) 3/8" MALE FLARE ENGLISH (ft-in.)
RELIEF VALVE CONN.
0'- 2 3/4" TANK
1/2" DIA. K.O. A B C D E F G H J K
[70mm]
ELECTRICAL CONN.
SIZE
(PUMPOUT POWER) 0428 10- 5 9-10 4-41/4 2-43/4 1-23/8 3-11/4 6-43/16 3-113/8 3-47/8 2-99/16
(FAR SIDE)
0452 14-111/4 14- 41/2 4-81/4 2-81/2 1-41/4 3-41/2 7-21/4 4- 31/4 3-83/4 3-17/16
TANK
L M N P R S T U V W
SIZE
H 0428 3-45/ 8 0-31/ 2 4- 91/ 2 1-77/ 8 2-03/ 8 3-9 5-01/ 4 2-5 2-97/8 2-53/4
C 0452 3-81/2 0-33/8 6-115/8 1-83/4 2-05/8 4-1 5-01/2 2-51/4 2-101/8 2-6
S SI (mm)
TANK
A B C D E F G H J K
SIZE
P
0428 3175 2997 1327 730 365 946 1935 1203 1038 852
0452 4553 4381 1429 826 413 1029 2191 1302 1137 951
TANK
0'- 3 1/4" L M N P R S T U V W
0'- 10" SIZE
[83mm]
[254mm] 0428 1032 89 1451 505 619 1143 1530 737 860 756
a23-1543
0452 1130 86 2124 527 625 1225 1537 742 867 762
LEFT SIDE VIEW
Fig. 40 — Optional Pumpout Unit and Storage Tank (Unit with R Compressor Shown)
66
RATED DRY WEIGHT AND REFRIGERANT CAPACITY
ENGLISH (lb)
TANK TANK OD DRY R-134A MAXIMUM REFRIGERANT CAPACITY (lb)

WEIGHT*
SIZE (in.) (lb) ANSI/ASHRAE 15 UL 1963
0428 24.00 2334 1860 1716
0452 27.25 3414 3563 3286
SI (kg)
TANK TANK OD DRY R-134A MAXIMUM REFRIGERANT CAPACITY (kg)

WEIGHT*
SIZE (mm) (kg) ANSI/ASHRAE 15 UL 1963
0428 610 1059 844 778
0452 692 1549 1616 1491
LEGEND
ANSI — American National Standard Institute
ASHRAE — American Society of Heating, Refrigeration,
and Air-Conditioning Engineers
OD — Outside Diameter
UL — Underwriters Laboratories
*The above dry weight includes the pumpout condensing unit weight of 164 lb (75 kg).
COOLER INLET COOLER REFRIGERANT

ISOLATION VALVE 11 COOLER CHARGING
PUMPOUT VALVE 7 VALVE 1b
COOLER
CONDENSER
CHARGING
VALVE 1a
CONTROL CENTER
DISCHARGE ISOLATION
SHIPPING BRACE VALVE (OPTIONAL)
(REMOVE PRIOR TO
START-UP)
PRESSURE
RELIEF SAFETY
VALVE
STORAGE
10 TANK LIQUID
VALVE
OIL
SEPARATOR
PUMPOUT PUMPOUT
COMPRESSOR CONDENSER
= SERVICE VALVE ON = SERVICE VALVE ON
PUMPOUT UNIT CHILLER (FIELD 2 3 PUMPOUT
SUPPLIED) CONDENSER
4 5 WATER SUPPLY
= MAINTAIN AT LEAST 2 FT (610mm) CLEARANCE AROUND AND RETURN
STORAGE TANK FOR SERVICE AND OPERATION WORK. 6 STORAGE TANK
VAPOR VALVE
a23-1634
Fig. 41 — Optional Pumpout System Piping Schematic with Storage Tank — Configured to Push
Liquid into Storage Tank (Unit with R Compressor Shown)
67
COOLER INLET
ISOLATION VALVE 11 COOLER REFRIGERANT COOLER CHARGING
COOLER
USE CONDENSER
CHARGING
VALVE TO ADD
CHARGE 1a
CONTROL CENTER
DISCHARGE ISOLATION
(REMOVE PRIOR TO
START-UP)
PRESSURE
RELIEF SAFETY
VALVE
STORAGE
10 TANK LIQUID
VALVE
OIL
SEPARATOR
PUMPOUT PUMPOUT
COMPRESSOR CONDENSER
= SERVICE VALVE ON = SERVICE VALVE ON
PUMPOUT UNIT CHILLER (FIELD 2 3 PUMPOUT
SUPPLIED) CONDENSER
4 5 WATER SUPPLY
= MAINTAIN AT LEAST 2 FT (610mm) CLEARANCE AROUND AND RETURN
STORAGE TANK FOR SERVICE AND OPERATION WORK. 6 STORAGE TANK
VAPOR VALVE
a23-1637
Fig. 42 — Optional Pumpout System Piping Schematic with Storage Tank — Configured to Pull
Vapor out of Chiller or to Charge Chiller from Storage Tank (Unit with R Compressor Shown)
68
COOLER INLET COOLER REFRIGERANT
ISOLATION VALVE 11 COOLER CHARGING
COOLER
CONDENSER
CHARGING
VALVE 1a
CONTROL CENTER
DISCHARGE ISOLATION
(REMOVE PRIOR TO
START-UP)
1a SERVICE VALVE
PRESSURE
RELIEF SAFETY
VALVE
OIL
SEPARATOR
PUMPOUT
PUMPOUT CONDENSER
= SERVICE VALVE ON = SERVICE VALVE ON COMPRESSOR
CHILLER 2 3
PUMPOUT UNIT PUMPOUT
CONDENSER
4 5 WATER SUPPLY
AND RETURN
a23-1638
Fig. 43 — Optional Pumpout System Piping Schematic without Storage Tank — Configured to Store
Refrigerant in Cooler or Condenser (Unit with R Compressor Shown)
69
Table 10 — HFC-134a Pressure — Temperature (F) Table 11 — HFC-134a Pressure — Temperature (C)
TEMPERATURE (F) PRESSURE (psig) TEMPERATURE (C) PRESSURE (kPa)
0 6.50 -18.0 44.8
2 7.52 -16.7 51.9
4 8.60 -15.6 59.3
6 9.66 -14.4 66.6
8 10.79 -13.3 74.4
10 11.96 -12.2 82.5
12 13.17 -11.1 90.8
14 14.42 -10.0 99.4
16 15.72 -8.9 108.0
18 17.06 -7.8 118.0
20 18.45 -6.7 127.0
22 19.88 -5.6 137.0
24 21.37 -4.4 147.0
26 22.90 -3.3 158.0
28 24.48 -2.2 169.0
30 26.11 -1.1 180.0
32 27.80 0.0 192.0
34 29.53 1.1 204.0
36 31.32 2.2 216.0
38 33.17 3.3 229.0
40 35.08 4.4 242.0
42 37.04 5.0 248.0
44 39.06 5.6 255.0
46 41.14 6.1 261.0
48 43.28 6.7 269.0
50 45.48 7.2 276.0
52 47.74 7.8 284.0
54 50.07 8.3 290.0
56 52.47 8.9 298.0
58 54.93 9.4 305.0
60 57.46 10.0 314.0
62 60.06 11.1 329.0
64 62.73 12.2 345.0
66 65.47 13.3 362.0
68 68.29 14.4 379.0
70 71.18 15.6 396.0
72 74.14 16.7 414.0
74 77.18 17.8 433.0
76 80.30 18.9 451.0
78 83.49 20.0 471.0
80 86.17 21.1 491.0
82 90.13 22.2 511.0
84 93.57 23.3 532.0
86 97.09 24.4 554.0
88 100.70 25.6 576.0
90 104.40 26.7 598.0
92 108.18 27.8 621.0
94 112.06 28.9 645.0
96 116.02 30.0 669.0
98 120.08 31.1 694.0
100 124.23 32.2 720.0
102 128.47 33.3 746.0
104 132.81 34.4 773.0
106 137.25 35.6 800.0
108 141.79 36.7 828.0
110 146.43 37.8 857.0
112 151.17 38.9 886.0
114 156.01 40.0 916.0
116 160.96 41.1 946.0
118 166.01 42.2 978.0
120 171.17 43.3 1010.0
122 176.45 44.4 1042.0
124 181.83 45.6 1076.0
126 187.32 46.7 1110.0
128 192.93 47.8 1145.0
130 198.66 48.9 1180.0
132 204.50 50.0 1217.0
134 210.47 51.1 1254.0
136 216.55 52.2 1292.0
138 222.76 53.3 1330.0
140 229.09 54.4 1370.0
55.6 1410.0
56.7 1451.0
57.8 1493.0
58.9 1536.0
60.0 1580.0
70
Chiller Dehydration — Dehydration is recommended if 8. If the reading continues to change after several attempts,
the chiller has been open for a considerable period of time, if perform a leak test up to the maximum 160 psig
the chiller is known to contain moisture, or if there has been a (1103 kPa) pressure. Locate and repair the leak, and
complete loss of chiller holding charge or refrigerant pressure. repeat dehydration.
Inspect Liquid Piping — Refer to piping diagrams
CAUTION provided in the certified drawings and the piping instructions in
the 23XRV Installation Instructions manual. Inspect the piping
Do not start or megohm-test the compressor motor, even
to the cooler and condenser. Be sure that the flow directions are
for a rotation check, if the chiller is under dehydration vac- correct and that all piping specifications have been met.
uum. Insulation breakdown and severe damage may result.
Piping systems must be properly vented with no stress on
Dehydration can be done at room temperatures. Using a waterbox nozzles and covers. Liquid flows through the cooler
cold trap (Fig. 44) may substantially reduce the time required and condenser must meet job requirements. Measure the pres-
to complete the dehydration. The higher the room temperature, sure drop across the cooler and the condenser.
the faster dehydration takes place. At low room temperatures, a
very deep vacuum is required to boil off any moisture. If low CAUTION
ambient temperatures are involved, contact a qualified service
representative for the dehydration techniques required. Liquid must be clean and treated to ensure proper chiller
Perform dehydration as follows: performance and to reduce the potential of tube damage
due to corrosion, scaling, or erosion. Carrier assumes no
1. Disconnect power from the VFD before placing the responsibility for chiller damage resulting from untreated
chiller under a vacuum. or improperly treated cooler or condenser liquid.
2. Connect a high capacity vacuum pump (5 cfm [.002 m3/s]
or larger is recommended) to the cooler or condenser Inspect Refrigerant Cooling Lines (Q,R Com-
charging valve (Fig. 2-4). Tubing from the pump to the pressors Only) — Inspect the refrigerant cooling lines for
chiller should be as short in length and as large in diame- condensation using an infrared temperature sensor or tempera-
ter as possible to provide least resistance to gas flow. ture meter. The leaving refrigerant cooling line from the drive
3. Use an absolute pressure manometer or a wet bulb should have a temperature of 95 to 100 F (35 to 38 C) or a tem-
vacuum indicator to measure the vacuum. Open the perature that is 3 to 5° F (2 to 3° C) greater than the condenser
shutoff valve to the vacuum indicator only when taking a refrigerant temperature. If the leaving refrigerant temperature is
reading. Leave the valve open for 3 minutes to allow the colder than these levels, or if condensation is noted on the pow-
indicator vacuum to equalize with the chiller vacuum. er module or refrigerant cooling lines, the isolation valve on the
4. If the entire chiller is to be dehydrated, open all isolation leaving refrigerant cooling line should be partially closed (typi-
valves (if present). cally about half closed) to help with temperature regulation.
See Fig. 45. Note that the adjustment is more accurate at a
5. With the chiller ambient temperature at 60 F (15.6 C) or greater load that is fixed for at least 10 minutes, and there
higher, operate the vacuum pump until the manometer should be no condensation on the tube leaving the power mod-
reads 29.9 in. Hg vacuum (750 microns), 0.1 kPa, or a ule before the orifice.
vacuum indicator reads 35 F (1.7 C). Operate the pump
an additional 2 hours.
Do not apply a greater vacuum than 29.82 in. Hg vac
(757.4 mm Hg) or go below 33 F (0.56 C) on the wet bulb
vacuum indicator. At this temperature and pressure,
isolated pockets of moisture can turn into ice. The slow
rate of evaporation (sublimation) of ice at these low
temperatures and pressures greatly increases dehydration
time.
6. Valve off the vacuum pump, stop the pump, and record
the instrument reading. ADJUST VALVE TO
7. After a 2-hour wait, take another instrument reading. If REGULATE
the reading has not changed, dehydration is complete. If TEMPERATURE
the reading indicates vacuum loss, repeat Steps 4 and 5.
Final dehydration vacuum should be 29.9 in. Hg vac or
less [500 microns, 0.07 kPa (abs)]. CONDENSER
a23-1730
Fig. 45 — Isolation Valve, Leaving Refrigerant

a19-661 Cooling Line
Fig. 44 — Dehydration Cold Trap
71
Check Optional Pumpout Compressor Liquid
Piping — If the optional pumpout storage tank and/or WARNING
pumpout system are installed, check to ensure the pumpout
condenser liquid has been piped in. Check for field-supplied DC bus capacitors retain hazardous voltage after input
shutoff valves and controls as specified in the job data. Check power has been disconnected. After disconnecting input
for refrigerant leaks on field-installed piping. See Fig. 40-43. power, wait 5 minutes for the DC bus capacitors to dis-
charge and then check the voltage with a voltmeter to
Check Relief Valves — Be sure the relief valves have ensure the DC capacitors are completely discharged before
been piped to the outdoors in compliance with the latest edition touching any internal components. Failure to observe this
of ANSI/ASHRAE Standard 15 and applicable local safety precaution could result in severe bodily injury or loss of
codes. Piping connections must allow for access to the valve life.
mechanism for periodic inspection and leak testing.
The 23XRV relief valves are set to relieve at the 185 psig
(1276 kPa) chiller design pressure. WARNING
Identify the VFD — The LiquiFlo™ 2.0 AC drive is a The drive can operate at and maintain zero speed. The user
PWM (Pulse Width Modulated), liquid-cooled drive that is responsible for assuring safe conditions for operating
provides vector and general purpose regulation for a wide personnel by providing suitable guards, audible or visual
range of applications. Identify the drive from the Drive Part alarms, or other devices to indicate that the drive is operat-
Number on the drive’s nameplate and the model number ing or may operate at zero speed. Failure to observe this
matrix in Fig. 46 and 47. precaution could result in severe bodily injury or loss of
life.
CAUTION
The drive contains ESD (Electrostatic Discharge) sensitive
parts and assemblies. Static control precautions are
required when installing, testing, servicing, or repairing the
drive. Erratic machine operation and damage to, or destruc-
tion of equipment can result if this procedure is not
followed.
The control center is designed to operate in the following

environmental conditions:
CONDITION SPECIFICATION
AMBIENT TEMPERATURE
(OUTSIDE NEMA 1 32 to 122 F (0° to 50 C)
ENCLOSURE)
STORAGE TEMPERATURE -40 to 149 F (-40 to 65 C)
(AMBIENT)
5% to 95%
HUMIDITY (non-condensing)
Fig. 46 — VFD Nameplate
LF20 0608CC R
LF20 = LiquiFlo 2.0
Continuous Ampere Rating

and Frame Size
Coolant Method
R = Refrigerant R134a
Fig. 47 — Identifying the Drive Model Number
72
IDENTIFYING THE DRIVE BY PART NUMBER — 3. Wire the AC input power leads and ground leads by
Each AC drive can be identified by its assembly number. See routing them through the opening in the top of the control
Fig. 47. This number appears on the shipping label and on the center to the main input circuit breaker.
drive’s nameplate. LiquiFlo 2.0 AC drives comprise an input
components section and a power module section. CAUTION
Each LiquiFlo™ 2.0 AC power module can be identified by
its model number. See Fig. 47. This number appears on the Do not route control wiring carrying 30 v or less within a
shipping label and on the power module’s nameplate. Power conduit carrying 50 v or higher. Failure to observe this pre-
ratings for LF-2 VFDs are provided in Table 12. Power ratings caution could result in electromagnetic interference in the
for Std Tier VFDs are provided in Table 13. control wiring.
Check Control Center 4. Connect the three-phase AC input power leads (per job
specification) to the appropriate input terminals of the cir-
CAUTION cuit breaker.
5. Tighten the AC input power terminals and lugs to the
BE AWARE that certain automatic start arrangements can proper torque as specified on the input circuit breaker.
engage the VFD. Open the disconnect ahead of the control
6. Connect and tighten the ground leads to the ground lug.
center in addition to shutting off the chiller or pump to
avoid equipment damage and possible personal injury. Checking the Installation — Use the following in-
structions to verify the condition of the installation:
CAUTION 1. Turn off, lockout, and tag the input power to the drive.
Wait a minimum of 5 minutes for the DC bus to
The main disconnect on the control center may not deener- discharge.
gize all internal circuits. Open all internal and remote dis- 2. Verify that there is no voltage at the input terminals (L1,
connects before servicing the starter to avoid equipment L2 and L3) of the power module or main circuit breaker.
damage and possible personal injury.
3. Verify that the status LEDs on the DPI communications
Input Power Wiring — All wiring should be installed in interface board are not lit. The location of the DPI
conformance with applicable local, national, and international communications interface board is shown in Fig. 20.
codes. Use grommets, when hubs are not provided, to guard 4. Remove any debris, such as metal shavings, from the
against wire chafing. enclosure.
Use the following steps to connect AC input power to the 5. Check that there is adequate clearance around the
main input circuit breaker and ground leads to the ground lug. machine.
1. Turn off, lockout, and tag the input power to the drive. 6. Verify that the wiring to the terminal strip and the AC
2. Remove the input power wiring panel from the top of the input power terminals is correct. Verify that all of the
control center and drill the required number of openings VFD power module circuit board connectors are fully
in the input power wiring panel. Take care that metal engaged and secured in place.
chips do not enter the VFD enclosure.
Table 12 — Drive Assembly and Power Module Ratings (LF-2 VFD)

INPUT MAX INPUT MAX OUTPUT
CARRIER PART NUMBER FRAME SIZE ENCLOSURE VOLTAGE (V) CURRENT CURRENT* AT 4kHz
TYPE
RANGE (AMPS) (AMPS)
23XRA2AA_ _ _ _ _ _ _ _ _ _ _ Frame 2AA NEMA 1 380 to 460 440 442
23XRA2BA_ _ _ _ _ _ _ _ _ _ _ Frame 2BA NEMA 1 380 to 460 520 442
23XRA2BB_ _ _ _ _ _ _ _ _ _ _ Frame 2BB NEMA 1 380 to 460 520 520
23XRA2CC_ _ _ _ _ _ _ _ _ _ _ Frame 2CC NEMA 1 380 to 460 608 608
*110% output current capability for one minute, 150% output current for 5 seconds.
Table 13 — Drive Assembly and Power Module Ratings (Std Tier VFD)*
INPUT VOLTAGE
(DIGIT Y OF PART MAX INPUT MAX OUTPUT
CARRIER PART NUMBER ENCLOSURE CURRENT CURRENT† AT 2kHz
TYPE NUMBER)
(AMPS) (AMPS)
Y VOLTAGE/Hz
23XVR0_ _ _00Y _ _ F0** 230 230
3 380v / 50 Hz 335 335
(R = ROCKWELL) 4 416v / 60 Hz 445 445
NEMA 1 5 416v / 60 Hz
23XVE0_ _ _00Y _ _ F0** 7 575v / 60 Hz 485 485
9 400v / 50 Hz 550 550
(E = EATON)
605 605
*All voltage and current combinations listed may not be available for sale. Please review Carrier Marketing literature for latest offering.
†110% output current capability for one minute, 150% output current for 5 seconds.
** Last character 0 indicates refrigerant-cooled; last digit A indicates air-cooled.
73
7. Check that the wire size is within terminal specifications fall into the power module. Clean and inspect the interior
and that the wires are tightened properly. of the control center if this has occurred. Contact Carrier
8. Check that specified branch circuit protection is installed Service before applying power if debris may have fallen
and correctly rated. inside of the power module.
9. Check that the incoming power is within ± 10% of chiller
nameplate voltage.
10. All wiring should be installed in conformance with the
applicable local, national, and international codes (for
example, NEC/CEC). Verify that a properly sized ground
wire is installed and a suitable earth ground is used.
Check for and eliminate any grounds between the power
leads. Verify that all ground leads are unbroken.
Inspect Wiring
WARNING
Do not check the voltage supply without proper equipment
and precautions. Serious injury may result. Follow power
company recommendations.
CAUTION
Do not apply any kind of test voltage, even for a rotation
check, if the chiller is under a dehydration vacuum. Insula-
tion breakdown and serious damage may result.
1. Examine the wiring for conformance to the job wiring
diagrams and all applicable electrical codes. Confirm that
there is at least a 6-in. clearance surrounding the control
center louvers. Use an inspection mirror to visually
inspect the top of the power module to confirm that no
debris has fallen inside of it.
2. Connect a voltmeter across the power wires to the VFD
and measure the phase to phase and phase to ground a23-1555
voltage. Compare this reading to the voltage rating on the
compressor and starter nameplates.
3. Compare the ampere ratings on the Machine Electrical
Data Nameplate. LOCKED ROTOR AMPS should be
equal to RATED LINE AMPS. OVERLOAD TRIP
AMPS should be equal to 1.08 x RATED LINE AMPS.
4. The control center must be wired to components and Fig. 48 — Machine Electrical Data Nameplate
terminals required for PIC III refrigeration control. Check (Q,R Compressor Machine Label Shown)
line side power and for control components shown on the
Certified Prints. The control center must share control of
cooler and condenser liquid pumps and cooling tower WARNING
fans.
5. Check the phase to phase and phase to ground line Do not apply power unless a qualified Carrier technician is
voltage to the optional pumpout compressor. Compare present. Electrical shock could cause serious personal
voltages against nameplate values. Refer to Fig. 48. injury or death.
6. Ensure that fused disconnects or circuit breakers have 11. Apply power to the control center. Go to the ICVC
been supplied to the control center and optional pumpout and access the MENUSERVICEVFD CONFIG
unit. DATAVFD_CONF screen. Confirm that the parame-
7. Ensure all electrical equipment and controls are properly ters entered in VFD_CONF match the information on the
grounded in accordance with the job drawings, certified Machine Nameplate and Sales Requisition. Confirm that
drawings, and all applicable electrical codes. the serial numbers on the chiller, Machine Nameplate,
8. Ensure the customer's contractor has verified proper oper- and Sales Requisition are consistent.
ation of the pumps, cooling tower fans, and associated Ground Fault Troubleshooting — Use this proce-
auxiliary equipment. This includes ensuring motors are dure only if ground faults are declared:
properly lubricated and have proper electrical supply and
proper rotation.
CAUTION
9. Tighten all wiring connections on the high and low volt-
age terminal blocks in the control center enclosure above Disconnect the motor leads from the control center before a
and below the control panel. motor insulation test is performed. The voltage generated
10. Inspect the control panel in the control center enclosure to from the testing equipment will damage the VFD.
ensure that the contractor has used the knockouts to feed
the wires into the back of the control panel. Wiring Test the compressor motor and its power lead insulation re-
through the top of the control center can cause debris to sistance with a 500-v insulation tester such as a megohmmeter.
74
With the tester connected to the motor leads, take 10 second version also appears on the ICVC CONFIGURATION screen
and 60 second megaohm readings as follows: as the last two digits of the software part number.
1. Tie terminals 1, 2, and 3 together and test between the Software Configuration
grouped motor terminals and ground.
2. Divide the 60-second resistance reading by the 10-second WARNING
reading. The ratio, or polarization index, must be one or
higher. Both the 10 and 60-second readings must be at Do not operate the chiller before the control configurations
least 50 megohms. have been checked in the ICVC and a Control Test has
3. If the readings are unsatisfactory, repeat the test with the been satisfactorily completed. Protection by safety controls
motor leads disconnected from the motor. Satisfactory cannot be assumed until all control configurations have
readings in this second test indicate the fault is in the been confirmed.
power leads.
As the 23XRV unit is configured, all configuration settings
Carrier Comfort Network® Interface — The Carrier should be written down. A log, such as the one shown on pages
Comfort Network (CCN) communication bus wiring is CL-1 to CL-10, provides a convenient list for configuration
supplied and installed by the electrical contractor. It consists of values.
shielded, 3-conductor cable with drain wire. It is recommended that all control configuration tables be
The system elements are connected to the communication uploaded via Service Tool and stored for reference when the
bus in a daisy chain arrangement. The positive pin of each sys- software configuration is complete.
tem element communication connector must be wired to the
positive pins of the system element on either side of it. The Input the Design Set Points — Access the ICVC
negative pins must be wired to the negative pins. The signal SET POINT screen and view/modify the BASE DEMAND
ground pins must be wired to the signal ground pins. See the LIMIT set point, and either the LCL SET POINT or the ECL
23XRV Installation Instructions. SET POINT. The PIC III module can control a set point to ei-
ther the leaving or entering chilled liquid. This control method
NOTE: Conductors and drain wire must be 20 AWG (Ameri- is set in the EQUIPMENT SERVICE (TEMP_CTL) table. The
can Wire Gage) minimum stranded, tinned copper. Individual default setting of ECL CONTROL OPTION is DSABLE so
conductors must be insulated with PVC, PVC/nylon, vinyl, the PIC III module will control the leaving chilled liquid tem-
Teflon, or polyethylene. An aluminum/polyester 100% foil perature.
shield and an outer jacket of PVC, PVC/nylon, chrome vinyl,
or Teflon with a minimum operating temperature range of –4 F Input the Local Occupancy Schedule
to 140 F (–20 C to 60 C) is required. See table below for cables (OCCPC01S) — Access the schedule OCCPC01S screen
that meet the requirements. on the ICVC and set up the occupied time schedule according
to the customer’s requirements. If no schedule is available, the
MANUFACTURER CABLE NO. default is factory set for 24 hours occupied, 7 days per week
ALPHA 2413 or 5463 including holidays.
AMERICAN A22503 For more information about how to set up a time schedule,
BELDEN 8772 see the Time Schedule Operation section, page 28.
COLUMBIA 02525 The CCN Occupied Schedule (OCCPC03S) should be con-
figured if a CCN system is being installed or if a secondary
When connecting the CCN communication bus to a system time schedule is needed.
element, a color code system for the entire network is recom-
mended to simplify installation and checkout. The following NOTE: The default CCN Occupied Schedule OCCPC03S is
color code is recommended: configured to be unoccupied.
Input Service Configurations — The following con-
CCN BUS CONDUCTOR
ICVC PLUG figurations require the ICVC screen to be in the SERVICE
SIGNAL TYPE J1
INSULATION COLOR
PIN NO. portion of the menu.
+ Red 1 • CONTROL TEST
• EQUIPMENT CONFIGURATION
GROUND White or Clear 2
• VFD CONFIG DATA
– Black 3 • EQUIPMENT SERVICE
• TIME AND DATE
Power Up the Controls and Check the Oil • ICVC CONFIGURATION (PASSWORD)
Heater — Ensure that an oil level is visible in the oil sump PASSWORD — When accessing the SERVICE tables, a
before energizing the controls. A separate 15A control power password must be entered. All ICVC are initially set for a pass-
circuit breaker in the control center energizes the oil heater and word of 1-1-1-1.
the control circuit. When first powered, the ICVC should dis- INPUT TIME AND DATE — Access the TIME AND
play the default screen within a short period of time. DATE table on the SERVICE menu. Input the present time of
The oil heater is energized when power is applied to the day, date, and day of the week. The HOLIDAY parameter
control circuit. This should be done several hours before start- should only be configured to YES if the present day is a holi-
up to minimize oil-refrigerant migration. The oil heater is day.
controlled by the PIC III controls and is powered through a NOTE: Because a schedule is integral to the chiller control
contactor on the power panel. This arrangement allows the sequence, the chiller will not start until the time and date have
heater to energize when the main motor circuit breaker is off been set.
for service work or extended shutdowns. The oil heater relay
status (OIL HEATER RELAY) can be viewed on the COM- CHANGE ICVC CONFIGURATION IF NECESSARY —
PRESS table on the ICVC. Oil sump temperature can be From the SERVICE table, access the ICVC CONFIGURA-
viewed on the ICVC default screen. TION screen. From there, view or modify the ICVC CCN
address, change to US Imperial (English) or Metric (SI) units,
SOFTWARE VERSION — The software part number is LID Language, and change the password. If there is more than
labeled on the backside of the ICVC module. The software
75
one chiller at the jobsite, change the ICVC CCN address on Check VFD_CONFIG TABLE — Enter the VFD_CONF
each chiller so that each chiller has its own address. Note and screen on the ICVC by entering the following screen
record the new address. Change the screen to Metric (SI) units sequence:
as required, and change the ICVC password if desired. • MENU
TO CHANGE THE PASSWORD — The password may be • SERVICE
changed from the ICVC CONFIGURATION screen. • Password (default 1111)
1. Press the MENU and SERVICE softkeys. Enter the • VFD CONFIG DATA
• Password (default 4444)
current password and highlight ICVC CONFIGURA- • VFD_CONF
TION. Press the SELECT softkey. Only the last 6 Confirm that the following parameters in the VFD_CONF
entries on the ICVC CONFIG screen can be changed: screen match the values on the Machine Electrical Data Name-
BUS #, ADDRESS #, BAUD RATE, US IMP/METRIC, plate (see Fig. 48):
PASSWORD, and LID LANGUAGE. • Motor Nameplate Voltage — Voltage required to run at
2. Use the ENTER softkey to scroll to PASSWORD. The motor rating.
• Compressor 100% Speed — Compressor speed required to
first digit of the password is highlighted on the screen. run at chiller design point.
3. To change the digit, press the INCREASE or • Rated Line Voltage — Nominal line voltage selected for the
DECREASE softkey. When the desired digit is seen, job site.
press the ENTER softkey. • Rated Line Amps — Line current required for the chiller to
run at the design point.
4. The next digit is highlighted. Change it, and the third • Rated Line Kilowatts — Line power required for the chiller
and fourth digits in the same way the first was to run at the design point.
changed. • Motor Rated Load kW — Power consumed by the motor
when running at the chiller design point.
5. After the last password digit is changed, the ICVC • Motor Rated Load Amps — Motor current required for the
goes to the LID LANGUAGE parameter. Press the chiller to run at the design point.
EXIT softkey to leave that screen and return to the • Motor Nameplate Amps — Motor nameplate full load
SERVICE menu. amps.
• Motor Nameplate RPM — Rated speed of the motor
when running at motor nameplate rated frequency, rated
IMPORTANT: Be sure to remember the password. Retain current, and rated voltage.
a copy for future reference. Without the password, access • Motor Nameplate kW — Motor nameplate rated power.
to the SERVICE menu will not be possible unless the • Inverter PWM Frequency — Sets the carrier frequency
ICVC_PWD menu on the STATUS screen is accessed by for the pulse width modulation output.
a Carrier representative NOTE: Other parameters on these screens are normally left at
the default settings; however, they may be changed by the
TO CHANGE THE ICVC DISPLAY FROM ENGLISH TO operator as required. The voltage and current imbalance level
METRIC UNITS — By default, the ICVC displays informa- and imbalance persistence time on the VFD_CONF table can
tion in English units. To change to metric units, access the be adjusted to increase or decrease the sensitivity of these fault
ICVC CONFIGURATION screen: conditions. Increasing time or persistence decreases sensitivity.
1. Press the MENU and SERVICE softkeys. Enter the Decreasing time or persistence increases sensitivity to the fault
condition.
password and highlight ICVC CONFIGURATION.
Press the SELECT softkey. Modify Minimum and Maximum Load Points (HGBP
DELTA T1/ HGBP DELTA P1, HGBP DELTA T2/ HGBP
2. Use the ENTER softkey to scroll to US imp or DELTA P2) If Necessary — The default settings of the stall
METRIC. prevention parameters in the OPTIONS screen are set so the
optional HGBP will not be energized during normal operating
3. Press the softkey that corresponds to the units desired for conditions. In addition to stall prevention, hot gas bypass may
display on the ICVC (e.g., US imp or METRIC). be useful for preventing excessive recycle restarts and main-
MODIFY CONTROLLER IDENTIFICATION IF NECES- taining temperature control in response to rapid load changes at
SARY — The ICVC module address can be changed from the low compressor speed. The chiller needs only to close the
ICVC CONFIGURATION screen. Change this address for optional hot gas bypass valve to increase capacity when the
each chiller if there is more than one chiller at the jobsite. Write chiller is running at low load with hot gas bypass active. It
the new address on the ICVC module for future reference. takes a few minutes for the chiller to start if it has shut down in
INPUT EQUIPMENT SERVICE PARAMETERS IF NEC- recycle restart mode.
ESSARY — The EQUIPMENT SERVICE table has seven When HGBP option is set to 1, hot gas bypass operation can
service tables: be adjusted for minimum chiller load and lift control. The
1. OPTIONS HGBP DELTA T1/HGBP DELTA P1, HGBP DELTA T2/
2. SETUP1 HGBP DELTA P2 parameters in the OPTIONS screen deter-
3. SETUP2 mine when the optional hot gas bypass valve will open and
4. SETUP3 close. These points should be set based on individual chiller
5. SETUP4 (P Compressor) operating conditions.
6. SETUP5 (P Compressor) An example of such a configuration is shown below.
7. LEADLAG Refrigerant: HFC-134a
8. RAMP_DEM Estimated Minimum Load Conditions:
9. TEMP_CTL 44 F (6.7 C) LCL
45.5 F (7.5 C) ECL
43 F (6.1 C) Suction Temperature
70 F (21.1 C) Condensing Temperature
76
Estimated Maximum Load Conditions: SERVICE Screen Modifications — Change the values on
44 F (6.7 C) LCL these screens according to specific job data. See the certified
54 F (12.2 C) ECL drawings for the correct values. Modifications can include:
42 F (5.6 C) Suction Temperature • Chilled liquid reset
98 F (36.7 C) Condensing Temperature • Entering chilled liquid control (Enable/Disable)
• 4 to 20 mA demand limit
Calculate Maximum Load — To calculate the minimum load • Auto restart option (Enable/Disable)
points, use data from the sales requisition or estimate the • Remote contact option (Enable/Disable)
chilled liquid delta T based on a percentage of full load where
the HGBP should be energized. The minimum condensing Owner-Modified CCN Tables — The following EQUIP-
pressure can be based on the entering condenser liquid tem- MENT CONFIGURATION screens are described for reference
perature available at minimum load. Use the proper saturated only.
pressure and temperature for R-134a. OCCDEFCS — The OCCDEFCS screen contains the Local
Suction Temperature: and CCN time schedules, which can be modified here or on the
43 F (6.1 C) = 38 psig (262 kPa) saturated SCHEDULE screen as described previously.
refrigerant pressure (R-134a) HOLIDAYS — From the HOLIDAYS screen, the days of the
Condensing Temperature: year that holidays are in effect can be configured. See the
70 F (21.1 C) = 71 psig (490 kPa) saturated holiday paragraphs in the Controls section for more details.
refrigerant pressure (R-134a) BRODEF — The BRODEF screen defines the start and end of
daylight savings time. By default this feature is enabled. Enter
Minimum Load HGBP DELTA T1 (at 15% load): the dates for the start and end of daylight savings if required
0.15 x (54-44) = 1.5º F (0.15 x (12.2 – 6.7) = 0.8º C for your location. Note that for DAY OF WEEK, 1 represents
Minimum Load HGBP DELTA P1: Monday. START WEEK and STOP WEEK refer to the instance
71 – 38 = 33 psid (490 – 262 = 228 kPad) of the selected DAY OF WEEK during the selected START
MONTH and year. To disable the feature, change START
Determine HGBP DELTA T2/HGBP DELTA P1: ADVANCE and STOP BACK times to 0 (minutes). In the
Set HGBP DELTA T2 equal to 0.1º F larger than HGBP BRODEF table the user may also identify a chiller as the time
DELTA T1: broadcaster for a CCN network with TIME BROADCAST
HGBP DELTA T2 = HGBP DELTA T1 + 0.1 = 1.6º F ENABLE. There should be only one device on a CCN network
(0.8 + 0.06 = 0.9º C) which is designated as the time broadcaster.
ALARM ROUTING (Fig. 49) — ALARM ROUTING is in
Set HGBP DELTA P2 to a large value to create a steep slope
(see Fig. 22 and 23) HGBP DELTA P2 = 200 psid (1379 kPa). the table SERVICE/EQUIPMENT CONFIGURATION/
NET_OPT under the heading Alarm Configuration. ALARM
If the hot gas bypass is energized too soon or too late: ROUTING consists of an 8-bit binary number. Only bits 1, 2,
and 4 (counting from the left) are used. The bits can be set by
HGBP ENERGIZED HGBP ENERGIZED any device which can access and change configuration tables.
TOO SOON TOO LATE
If any of these 3 bits is set to 1, the ICVC will broadcast any
Decrease HGBP DELTA T1 Increase HGBP DETLA T1
and HGBP DELTA T2 by and HGBP DELTA T2 by alarms which occur.
0.5° F (0.3° C) 0.5° F (0.3° C) Bit 1: Indicates that the alarm should be read and processed by
a front end device, such as a ComfortWORKS® device.
If variable evaporator flow is applied, changes to
DELTA T1 proportional to the reduction in evaporator liquid Bit 2: Indicates that the alarm should be read and processed by
flow rate are required. a TeLINK or Autodial Gateway module.
The differential pressure (P) and temperature (T) can be ALARM CONTROL
monitored during chiller operation by viewing ACTIVE ALARM ROUTING
DELTA P and ACTIVE DELTA T (HEAT_EX screen). Com- Alarm routing settings should be left at default settings and only be
changed by technicians trained in CCN. These settings determine
paring HGBP DELTA T to ACTIVE DELTA T will determine which CCN system elements will receive and process alarms sent
when the HGBP valve will open. The smaller the difference by the ICVC. Input for the decision consists of eight digits, each of
between the HGBP DELTA T and the ACTIVE DELTA T which can be set to either 0 or 1. Setting a digit to 1 specifies that
values, the closer to stall prevention or the point at which the alarms will be sent to the system element that corresponds to that
digit. Setting all digits to 0 disables alarm processing. Digits in
HGBP will open. this decision correspond to CCN system elements in the following
If the ACTIVE DELTA T is less than the HGBP DELTA T, manner:
the HGBP valve will be activated. The HGBP will be deacti- Alarm Printer Interface Module
vated once the ACTIVE DELTA T is greater than the HGBP Autodial Gateway
DELTA T plus the HGBP DEADBAND if the ACTIVE DELTA Local Building Supervisors(s)
or ComfortWORKS
P is less than HGBP DELTA P1. 1 1 0 1 0 0 0 0
When the HGBP option is set to 2, HGBP ON DELTA a19-1627

SPEED should be based on the estimated minimum load con- unused
ditions as was HGBP DELTA T1 in the example above. HGBP NOTE: If your CCN does not contain ComfortWORKS® con-
trols or a Building Supervisor or Autodial Gateway to serve as an
OFF DELTA SPEED functions similar to a deadband above alarm acknowledger, set all digits in this decision to 0 in order to
the temperature entered in HGBP ON DELTA T as shown in prevent unnecessary activity on the CCN Communication Bus.
Fig. 33.
Allowable Entries 00000000 to 11111111
MODIFY EQUIPMENT CONFIGURATION IF NECES- 0 = Disabled, 1 = Enabled
SARY — The EQUIPMENT SERVICE table has screens to Default Value 10000000
select, view, or modify parameters. Carrier’s certified drawings
have the configuration values required for the jobsite. Modify Fig. 49 — Alarm Control and Alarm Routing
these values only if requested.
77
Bit 4: Indicates that the alarm should be read and processed by Table 15 — Control Test Menu Functions
an alarm printer interface (an optional module), ServiceLink,
or a DataLINK™ device. TESTS TO BE
PERFORMED
DEVICES TESTED
The RE-ALARM TIME is a time period after which, if a Entering Chilled Liquid
preexisting and previously broadcast alarm has not been Leaving Chilled Liquid
Entering Cond Liquid
cleared, it will be rebroadcast on the CCN network. Leaving Cond Liquid
Evap Refrig Liquid Temp
Other Tables — The CONSUME, NET_OPT, and RUN- Comp Discharge Temp
TIME screens contain parameters used with a CCN system. 1. Thermistors
Oil Sump Temp
Vaporizer Temp
See the applicable CCN manual for more information on these Comp Motor Winding Temp
screens. These tables can only be defined from a CCN Spare Temperature 1
Building Supervisor. Spare Temperature 2
Remote Reset Sensor
Economizer Superheat Sensor (P compressor
Perform a Control Test — Check the safety controls only)
status by performing an automated control test. Access the Evaporator Pressure
CONTROL TEST table and select a test to be performed func- Condenser Pressure
Discharge Pressure
tion (see Tables 14 and 15). Oil Pressure Delta P
2. Pressure Chilled Liquid Delta P
The Automated Control Test checks all outputs and inputs Transducers Condenser Liquid Delta P
for function. The compressor must be in the OFF mode to Transducer Voltage Ref
operate the controls test. The compressor can be put in OFF Humidity Sensor Input
Relative Humidity
mode by pressing the STOP push-button on the ICVC. Each Economizer Pressure (P compressor only)
test asks the operator to confirm the operation is occurring and Operates Pump, Displays Delta P and confirms
whether or not to continue. If an error occurs, the operator can 3. Pumps flow for oil pump, chilled liquid pump and
condenser liquid pump.
try to address the problem as the test is being done or note the Oil Heater Relay
problem and proceed to the next test. Seconday Oil Heater Relay (P Compressor Only)
Vaporizer Heater
When the control test is finished or the EXIT softkey is 4. Discrete
Hot Gas Bypass Relay
pressed, the test stops, and the CONTROL TEST menu dis- Outputs
Tower Fan Relay Low
Tower Fan Relay High
plays. If a specific automated test procedure is not completed, Alarm Relay
access the particular control test to test the function when VFD Coolant Solenoid
Shunt Trip Relay
ready. The CONTROL TEST menu is described in Table 15. 5. Oil Reclaim Percentage and mA (% and mA)
The EVAPORATOR PRESSURE, CONDENSER PRES- Output
SURE, DISCHARGE PRESSURE, and OIL PRESSURE 6. Head Pressure
Head Pressure Reference (4 to 20mA)
(The output is 2 mA when the chiller is not
DELTA P pressure transducers should be calibrated prior to Output
running.)
start-up. If pressure transducers are installed on the waterbox When using pumpdown/lockout, observe freeze
nozzles, CHILLED LIQUID DELTA P and CONDENSER up precautions when removing charge:
LIQUID DELTA P transducers should also be calibrated. Instructs operator which valves to close and when.
Starts chilled liquid and condenser liquid pumps
and requests flow confirmation.
Table 14 — Control Tests 7. Pumpdown Monitors:
Lockout Evaporator pressure
CONTROL TEST Condenser pressure
CCM Check of all thermistors. Evaporator temperature during
Thermistors, pumpout procedures
PD4 EXV Turns pumps off after pumpdown.
Thermistor*
Locks out compressor.
CCM Pressure Check of all transducers.
Transducers Starts pumps and monitors flows.
Checks operation of pump outputs; pumps are activated. Instructs operator which valves to open and when.
Pumps
Also tests associated inputs such as flow or pressure. Monitors:
Discrete Outputs Activation of all on/off outputs individually. 8. Terminate Evaporator pressure
Lockout Condenser pressure
Oil Reclaim Checks CCM 4-20mA oil reclaim output with Evaporator temperature during
Output power removed from oil reclaim actuator. charging process
Head Pressure Manually varies the head pressure output Terminates compressor lockout.
Output from low voltage field wiring terminal strip.
Pumpdown prevents the low refrigerant alarm during Pressure Transducer and Optional Flow
Pumpdown/ evacuation so refrigerant can be removed form the unit.
Lockout Also locks the compressor off and starts the liquid Device Calibration — Transducers measuring single
pumps. pressure values (such as CONDENSER PRESSURE and
Terminate To charge refrigerant and enable the chiller
Lockout to run after pumpdown lockout. EVAPORATOR PRESSURE) are calibrated individually, while
Condenser Manually varies the EXV output. After test the EXV will a pair of transducers measuring a pressure differential (OIL
Level EXV be driven to the fully closed position. PRESSURE DELTA P, CHILLED LIQUID DELTA P, or
Output (P
Compressor CONDENSER LIQUID DELTA P) are calibrated together as a
Only) differential. Transducers for sensing liquid side flow are not
Economizer EXV Manually varies the economizer EXV output. After test provided as standard. Oil pressure, refrigerant pressure and
Output (P the economizer EXV will be driven to the fully closed
Compressor position. liquid delta P readings can be viewed and calibrated from the
Only) COMPRESS and HEAT_EX screens on the ICVC controller.
*P compressors with economizer option only Each transducer or transducer pair can be calibrated at two
points: “zero” (0 psig or 0 kPa) and “high end” (between 25
NOTE: During any of the tests, an out-of-range reading will have an asterisk
(*) next to the reading and a message will be displayed.
and 250 psig, or between 173 and 1724 kPa). It is good prac-
tice to calibrate at initial start-up. Calibration is particularly
important at high altitudes to ensure the proper refrigerant
temperature-pressure relationship.
ZERO POINT CALIBRATION — Shut down the compres-
sor, and cooler and condenser pumps. There must be no water
flow through the heat exchangers, but these systems must be
filled. For differential pairs, leave the transducers installed. For
78
single value transducers, disconnect the transducer’s electrical terminal connection at the CCM. This is also displayed in
cable, remove the sensor from its Schrader fitting, then recon- CONTROL TEST under PRESSURE TRANSDUCERS.
nect the cable.
Check Optional Pumpout System Controls
NOTE: If the cooler or condenser vessels are at 0 psig (0 kPa) and Compressor — Controls include an on/off switch, a
or are open to atmospheric pressure, the transducers can be 0.5-amp fuse for the secondary side of the transformer,
calibrated for the zero point without removal. 0.25-amp fuses for the primary side of the transformer, the
Access the HEAT_EX or COMPRESS screen under the compressor overloads, an internal thermostat, a compressor
STATUS menu, and view the particular transducer reading contactor, refrigerant low pressure cutout and a refrigerant high
(OIL PRESSURE DELTA P is in the COMPRESS screen; all pressure cutout. The high pressure cutout is factory set to open
others are in the HEAT_EX screen). If the displayed reading is at 185 psig (1276 kPa) and reset at 140 psig (965 kPa).
not 0 psi (0 kPa), press the SELECT key to highlight the
associated line in the display, then the ENTER key. (For zero The low pressure cutout is factory set to open at 7 psia (–15.7
point calibration, the INCREASE and DECREASE keys have in. Hg) and close at 9 psia (–11.6 in. Hg). Ensure the water-
no effect.) The value should change to 0.0. cooled condenser has been connected. Ensure oil is visible in
the compressor sight glass. Add oil if necessary.
If the ICVC fails to accept the zero point calibration, the
value will not change to 0.0 and the display will show “Higher See the Pumpout and Refrigerant Transfer Procedures sec-
Force In Effect”. This indicates that the sensor voltage is out of tion on page 86 and the Optional Pumpout System Mainte-
the acceptable range. For each single value transducer there are nance section on page 95 for details on the transfer of refriger-
3 terminals at the CCM: 0 vdc (low) connected to the black ant, oil specifications, etc.
wire, “sensor” voltage connected to the white or clear wire, and High Altitude Locations — Because the chiller is ini-
5.00 vdc (high) connected to the red wire. With a base supply tially calibrated at sea level, it is necessary to recalibrate the
voltage of 5.00 volts, the acceptable range of voltage taken pressure transducers if the chiller has been moved to a high
between the low (black wire) and sensor terminals (white or altitude location. See the calibration procedure in the Trouble-
clear wire) for zero point calibration is 0.40 to 0.55 v. For each shooting Guide section.
transducer differential pair there are two 3-terminal sets at the
CCM. With a base supply voltage of 5.00 volts, the acceptable
range of voltage taken between the sensor terminal (white or Charge Refrigerant into Chiller
clear wire) for the higher pressure transducer (liquid inlet or oil
pump discharge) and the sensor terminal (white or clear wire) CAUTION
for the lower pressure transducer (liquid outlet or oil sump) for
zero point calibration is -0.065 to +0.085 v. If this occurs with a The transfer, addition, or removal of refrigerant in spring
differential pair, one possible remedy is to swap the high end isolated chillers may place severe stress on external piping
(e.g., inlet) and low end (e.g., outlet) transducers. In most cases if springs have not been blocked in both up and down
this puts the voltage difference of the sensor pair within the directions. Failure to block springs in both up and down
acceptable range. directions could result in severe personal injury and equip-
ment damage.
HIGH END CALIBRATION — High end calibration can be
performed between 25 and 250 psig (173 and 1724 kPa),
comparing the pressure readings in the ICVC display to an CAUTION
accurate refrigeration gage. High end calibration may improve
transducer accuracy over the full pressure range. High end Always operate the condenser and chilled liquid pumps
calibration is not recommended for transducer differential during charging operations to prevent freeze-ups. Damage
pairs. Pressure can be provided by attaching a regulated may result to equipment if the condenser and chilled water
250 psig (1724 kPa) pressure source, such as from a nitrogen pumps are not operated during pumpdown or charging.
cylinder, to the transducer. It is good practice to perform the
high end calibration near a pressure that the sensor will The standard 23XRV chiller is shipped with the refrigerant
typically be exposed to. already charged in the vessels. However, the 23XRV chiller
may be ordered with a nitrogen holding charge of 15 psig
Access the HEAT_EX screen under the STATUS menu, and (103 kPa). In this case, evacuate the nitrogen from the entire
the CONDENSER PRESSURE or EVAPORATOR PRESSURE chiller, and charge the chiller from refrigerant cylinders.
to the reference pressure gage. To change the displayed read-
ing, press the SELECT key to highlight the associated line in Chillers shipped with a factory charge should arrive with all
the display, then the INCREASE or DECREASE key to set the isolation valves in the open position. Figures 2-4 and 10-13
new value, then the ENTER key. Generally, the value can be show the location of the isolation valves listed in the Initial
changed to any value within ±15% of a nominal value. Start-Up Checklist.
NOTE: Prior calibrations may have shifted the present pre- CHILLER EQUALIZATION WITHOUT A PUMPOUT
calibration value from the center of this range. In this case, the UNIT
limit of acceptable new values will be less than 15% in one
direction. WARNING
If the ICVC fails to accept the high end calibration, the
value will not change and the display will show “Higher Force When equalizing refrigerant pressure on the 23XRV chiller
In Effect.” This indicates that the sensor voltage is out of the after service work or during the initial chiller start-up, do
acceptable range for the entered value. In this case, the not use the discharge isolation valve to equalize because
pressure transducer may need to be replaced. the force that could be exerted by the valve handle could
Each pressure transducer is supplied with 5 vdc power from cause personal injury. Either the motor cooling isolation
the CCM through the red wire. Pressure transducer readings valve or the charging hose (connected between the pum-
are derived from voltage ratio, not absolute voltage, which pout valves on top of the cooler and condenser) should be
compensates for any reference voltage variation. If this power used as the equalization valve.
supply fails, a transducer voltage reference alarm (239) is To equalize the pressure differential on a refrigerant isolated
generated. If transducer readings are suspected of being faulty, 23XRV chiller, use the TERMINATE LOCKOUT function of
check the supply voltage, measured between the high and low
(red wire and black wire) terminals of any transducer 3
79
the CONTROL TEST on the SERVICE menu. This helps to connected to the cooler. This is different from unit-mounted
turn on pumps and advises the operator on proper procedures. installations on other Carrier chillers.
The following steps describe how to equalize refrigerant 1. Access the TERMINATE LOCKOUT function on the
pressure in an isolated 23XRV chiller without a pumpout unit. CONTROL TEST screen.
1. Access TERMINATE LOCKOUT function on the CON- 2. IMPORTANT: Turn on the chilled liquid and
TROL TEST screen. condenser liquid pumps to prevent possible freezing.
2. IMPORTANT: Turn on the chilled liquid and con- 3. Refer to Fig. 40-43. Open valve 4 on the pumpout unit
denser liquid pumps to prevent freezing. and open valves 1a and 1b on the chiller cooler and
condenser. Slowly open valve 2 on the pumpout unit to
3. Equalizing: equalize the pressure. This process takes approxi-
a. Preferred method: Connect a charging hose mately 15 minutes.
between the two valves on top of the cooler and 4. Once the pressures have equalized, the following iso-
condenser. Open one valve fully and open the other lation valves should be opened:
valve slowly. This process should take approxi- • discharge isolation valve
mately 15 minutes. • cooler inlet valve
b. Alternate method: Use this method if no charging • hot gas bypass valve
hose available. Slowly open the motor cooling isola- • vaporizer condenser gas valve
tion valve. The chiller cooler and condenser pressures • oil pump valve
will gradually equalize. This process takes approxi- • oil filter valve
mately 15 minutes. • oil pressure regulator valve
Note that for option (b), since the condenser con- • filter/drier valve (2 places)
tains liquid refrigerant, the valve opening must be • VFD cooling inlet valve
limited to prevent liquid refrigerant from entering • VFD cooling drain valve
the cooler which could cause potential freeze-up. Refer to Fig. 2-7 and Oil Heater section on page 91 for iso-
4. Once the pressures have equalized, the following isola- lation valve locations.
tion valves should be opened:
• discharge isolation valve WARNING
• cooler inlet valve
• HGBP isolation valve (optional) Whenever turning the discharge isolation valve, be sure
• vaporizer condenser gas valve that the spring-loaded lever lock fully engages within one
• filter/drier isolation valve (2 places) of the latch plate detents. This will prevent the valve from
• VFD cooling isolation valves (2 places) opening or closing during service work or during chiller
• oil filter isolation valve operation. Opening of the valve during service would result
• oil pump isolation valve in the release of the refrigerant charge which could result in
• oil pressure regulator valve severe personal injury or death.
Refer to Fig. 2-4 and 10-13 for isolation valve locations.
The full refrigerant charge on the 23XRV chiller will vary
with chiller components and design conditions, as indicated on
CAUTION the job data specifications. An approximate charge may be de-
termined by adding the condenser charge to the cooler charge
Whenever turning the discharge isolation valve, be sure that as listed in Tables 16 and 17.
the spring-loaded lever lock fully engages within one of the
latch plate detents. This will prevent the valve from opening
or closing during service work or during chiller operation. CAUTION
Always operate the condenser and chilled liquid pumps
CHILLER EQUALIZATION WITH PUMPOUT UNIT — whenever charging, transferring, or removing refrigerant
The following steps describe how to equalize refrigerant pres- from the chiller to prevent damage to the heat exchanger
sure on an isolated 23XRV chiller using the pumpout unit. tubes.
NOTE: The top valve tee on a unit-mounted pumpout is
connected to the condenser and the bottom valve tee is
80
Table 16 — Refrigerant Charges, Frame Sizes 3-5
COOLER CHARGE AMOUNT (R-134a)

COOLER
FRAME SIZE LENGTH CODE WITH ECONOMIZER WITHOUT ECONOMIZER
FT (M) lb (± 25 lb) kg (± 11 kg) lb (± 25 lb) kg (± 11 kg)
30 800 363 650 295
12
(3.6) 31 800 363 650 295
32 800 363 650 295
3
35 910 413 760 345
14
(4.3) 36 910 413 760 345
37 910 413 760 345
40 900 408 750 340
12
(3.6) 41 900 408 750 340
42 900 408 750 340
4
45 1015 460 865 392
14
(4.3) 46 1015 460 865 392
47 1015 460 865 392
50 1250 567 1100 499
12
(3.6) 51 1250 567 1100 499
52 1250 567 1100 499
5
55 1430 649 1280 581
14
(4.3) 56 1430 649 1280 581
57 1430 649 1280 581
Table 17 — Refrigerant Charges, Frame Sizes A,B

CHARGE AMOUNT (R-134a)
FRAME SIZE COOLER LENGTH WITH ECONOMIZER WITHOUT ECONOMIZER
FT (M)
lb (± 25 lb) kg (± 11 kg) lb (± 25 lb) kg (± 11 kg)
A1 840 381 820 372
A2 860 390 840 381
A3 12 880 399 860 390
A4 (3.6) 900 408 880 399
A5 930 422 910 413
A6 960 435 940 426
B1 950 431 930 422
B2 970 440 950 431
B3 14 1000 454 980 445
B4 (4.3) 1020 463 1000 454
B5 1060 481 1040 472
B6 1090 494 1070 485
CHILLER SHIPPED WITH HOLDING CHARGE — Use the Trimming the charge can best be accomplished when the
CONTROL TEST TERMINATE LOCKOUT function to design load is available. The calibration of the EVAP REFRIG
monitor conditions and start the pumps. LIQUID TEMP and LEAVING CHILLED LIQUID tempera-
If the chiller has been shipped with a holding charge, the ture sensors should be confirmed prior to checking for proper
refrigerant is added through the refrigerant charging valve cooler LTD. Compare the difference between EVAP REFRIG
(Fig. 40-43, valves 1a and 1b) or to the pumpout charging con- LIQUID TEMP and LEAVING CHILLED LIQUID tempera-
nection. First evacuate the nitrogen holding charge from the tures to the chiller design conditions. Add or remove refriger-
chiller vessels. Charge the refrigerant as a gas until the system ant, if necessary, to bring the cooler leaving temperature
pressure exceeds 35 psig (141 kPa) for HFC-134a. After the difference to design conditions or within minimum differential.
chiller is beyond this pressure the refrigerant should be charged Check for low load oil recovery after making adjustments to
as a liquid until all the recommended refrigerant charge has the refrigerant charge. The bubbling mixture of refrigerant and
been added. oil mixture should be visible through the vaporizer sight glass
TRIMMING REFRIGERANT CHARGE — T h e 2 3 X R V at low load when the oil reclaim valve is open. If a bubbling
chiller is shipped with the correct charge for the design duty of mixture is not observed when the oil reclaim valve is open, add
the chiller. The LTD (leaving temperature difference) between refrigerant.
the EVAP REFRIG LIQUID TEMP and LEAVING CHILLED The preferred location at which refrigerant should be added
LIQUID can be checked against the design conditions to con- directly into the chiller is through the service valves on top of
firm that the charge is correct. In the case where leaks have the cooler condenser. if these valves are not accessible due to
been found and corrected and the LTD is greater than about presence of an attached pumpdown unit which does not have a
4° F (2.2° C) above design, add refrigerant until the full load storage tank, slowly add charge through the valve connected to
design LTD is approached. (A high cooler LTD can also be the side of the condenser drain float sump. Adding charge
caused by dirty tubes, water box division plate bypass, a par- through the cooler refrigerant pumpout valve at the base of the
tially closed liquid isolation valve, or the float valve.) cooler (off the liquid line) may force debris into the condenser
float valve and is not recommended.
81
INITIAL START-UP
In order for the Reliance VFD to be eligible for the full WARNING
warranty period, the following conditions must be met:
1. The chiller must be started by a technician that has com- Do not permit liquid or brine that is warmer than 110 F
pleted Reliance LiquiFlo2 training. (43 C) to flow through the cooler or condenser. Refrigerant
overpressure may discharge through the relief valves and
2. The start-up technician must be registered with Reliance. result in the loss of refrigerant charge and possible personal
3. The start-up technician must register the chiller start-up injury.
on the Reliance web site.
Preparation — Before starting the chiller, verify: 10. Access the CONTROL TEST screen. Scroll down on the
1. Power is on to the CB2 control power circuit breaker, oil TERMINATE LOCKOUT option. Press the SELECT (to
pump relay, tower fan starter, oil heater relay, and the enable the chiller to start) and answer YES to restore unit
chiller control center. to operating mode. The chiller is locked out at the factory
in order to prevent accidental start-up.
2. The CB1 main control center circuit breaker is in the On
position. Check Oil Pressure and Compressor Stop —
3. Cooling tower liquid is at proper level and at-or-below Start the chiller and allow it to automatically ramp load.
design entering temperature. Check cooling tower bypass 1. Two minutes after start-up, note the OIL PRESSURE
valve. DELTA P reading on the ICVC default screen. The OIL
4. Chiller is charged with refrigerant and all refrigerant and PRESSURE DELTA P is the difference between the oil
oil valves are in their proper operating positions. pressure leaving the oil filter and the oil sump pressure.
5. Oil is at the proper level in the oil sump sight glass. The minimum OIL PRESSURE DELTA P is 18 psid
(124 kPad) after OIL PRESSURE VERIFY TIME is ex-
6. The Oil Sump Temperature must be above 140 F (60 C) ceeded. The OIL PRESSURE DELTA P is displayed on
or CALC EVAP SAT TEMP plus 15º F (8.3º C) before the the COMPRESS, STARTUP, PRESSURE TRANSDUC-
controls will allow the chiller to start to ensure that a suf- ERS, PUMPS, and DEFAULT screens. A normal full load
ficient amount of refrigerant has been driven out of the reading is approximately 20 to 28 psid (138 to 193 kPad).
oil.
2. Press the STOP softkey and listen for any unusual sounds
7. All valves listed on page CL-3 of the Initial Start-Up from the compressor as it coasts to a stop.
Checklist are fully open.
8. The VFD cold plate refrigerant isolation valves are open. To Prevent Accidental Start-Up — The chiller is
shipped with the CHILLER START/STOP parameter in the
9. Remove the control center shipping bracket (see Fig. 50).
MAINSTAT screen set to STOP. Once installed, a chiller STOP
NOTE: For seismic units, do not remove the shipping override setting may be entered to prevent accidental start-up
bracket.
during service or whenever necessary. Access the MAINSTAT
CAUTION screen and using the NEXT or PREVIOUS softkeys, high-
light the CHILLER START/STOP parameter. Override the cur-
Operating the chiller with the shipping bracket attached rent START value by pressing the SELECT softkey. Press the
may result in excessive vibration and noise. The shipping STOP softkey followed by the ENTER softkey. The word
brace should be removed to avoid possible equipment SUPVSR! displays on the ICVC indicating the STOP override
damage (except for seismic units). is in place.
To start the chiller the STOP override setting must first be
SHIPPING BRACKET
(FOR SEISMIC UNITS,
removed. Access the MAINSTAT screen and using NEXT
DO NOT REMOVE) or PREVIOUS softkeys highlight CHILLER START/STOP.
The 3 softkeys that appear represent 3 choices:
• START — forces the chiller ON
• STOP — forces the chiller OFF
• RELEASE — puts the chiller under remote or schedule
control.
To return the chiller to normal control, press the
RELEASE softkey followed by the ENTER softkey. For
more information, see Local Start-Up, page 60.
The default ICVC screen message line indicates which
command is in effect.
Check Chiller Operating Condition — Check to
be sure that chiller temperatures, pressures, liquid flows, and
oil and refrigerant levels indicate the system is functioning
properly.
a23-1664
Instruct the Customer Operator — Ensure the op-
Fig. 50 — Control Center Shipping Bracket erator(s) understands all operating and maintenance
(Unit with R Compressor Shown) procedures. Point out the various chiller parts and explain their
function as part of the complete system.
82
COOLER-CONDENSER — Float chamber, relief valves, 2. On the ICVC default screen, press the LOCAL or
refrigerant charging valve, temperature sensor locations, CCN softkey to start the system. If the chiller is in the
pressure transducer locations, Schrader fittings, waterboxes OCCUPIED mode and the start timers have expired, the
and tubes, and vents and drains.
start sequence will start. Follow the procedure described
OPTIONAL PUMPOUT STORAGE TANK AND PUMP-
OUT SYSTEM — Transfer valves and pumpout system, in the Start-Up/Shutdown/Recycle Sequence section,
refrigerant charging and pumpdown procedure, and relief page 60.
devices.
Check the Running System — After the compressor
COMPRESSOR ASSEMBLY — Motor cooling system, oil starts, the operator should monitor the ICVC display and ob-
system, temperature and pressure sensors, sight glasses, serve the parameters for normal operating conditions:
motor temperature sensors, synthetic oil, and compressor
serviceability. 1. The oil sump temperature will vary from 50 F to 140 F
(10 C to 60 C) depending on the operating conditions. If
COMPRESSOR LUBRICATION SYSTEM — Concen- the chiller has not been running for a few hours the OIL
trator, oil pump, oil filter, oil heaters, oil charge and specifica- SUMP TEMP will be warmer than the CALC EVAP SAT
tion, strainers, sight glasses, operating and shutdown oil level, TEMP. When the chiller is not running, the oil heater is
temperature and pressure sensors, and oil charging connec- energized whenever the OIL SUMP TEMP is less than
tions. the smaller of 140 F (60 C) or 53 F (29.4 C) greater than
CONTROL SYSTEM — CCN and LOCAL start, reset, the CALC EVAP SAT TEMP. The OIL SUMP TEMP gen-
menu, softkey functions, ICVC operation, occupancy schedule, erally decreases slowly following start-up and eventually
set points, safety controls, and auxiliary and optional controls. stabilizes at a point lower than the temperature main-
AUXILIARY EQUIPMENT — Disconnects, separate elec- tained during shutdown. The OIL PRESS DELTA P in-
trical sources, pumps, cooling tower, chilled liquid strainers, creases above 18 psid (124 kPad) during start-up and gen-
and condenser liquid strainers. erally does not vary by more than ± 2 psid (14 kPad). The
level in the oil sump is generally very stable. Changes in
DESCRIBE CHILLER CYCLES — Refrigerant, motor the oil level occur very slowly.
cooling, lubrication, and oil reclaim.
2. When the compressor is running, the liquid level should
REVIEW MAINTENANCE — Scheduled, routine, and be visible in the oil sump or the strainer housing sight
extended shutdowns, importance of a log sheet, importance of glass. Low oil pressure alarms are imminent if the oil lev-
liquid treatment and tube cleaning, and importance of main- el drops below the bottom of the oil strainer housing sight
taining a leak-free chiller. glass.
SAFETY DEVICES AND PROCEDURES — Electrical dis- 3. The OIL PRESSURE DELTA P displayed on the ICVC
connects, relief device inspection, and handling refrigerant. default screen is equal to the difference between the oil
CHECK OPERATOR KNOWLEDGE — Start, stop, and pressure leaving the oil filter and the oil sump pressure
shutdown procedures, safety and operating controls, refrigerant transducer readings. Typically the reading will be
and oil charging, and job safety. between 20 and 28 psid (138 and 193 kPad) after the oil
REVIEW THE START-UP, OPERATION AND MAINTE- pressure ramp up is complete.
NANCE MANUAL 4. The moisture indicator (dry-eye) sight glass on the refrig-
erant motor cooling line should indicate refrigerant flow
CAUTION and a dry condition.
5. The condenser pressure and temperature varies with the
Manuals and notebooks should not be stored under the chiller design conditions. Typically the pressure will
VFD power module, they will block air flow into the range between 60 and 135 psig (329 and 780 kPa) with a
power module cooling fan and cause the VFD to overheat. corresponding temperature range of 60 to 105 F (15 to
41 C). The condenser entering liquid temperature may be
OPERATING INSTRUCTIONS controlled below the specified design entering liquid
temperature to save on compressor kilowatt requirements
Operator Duties but, not be below 55 F (12.8 C).
1. Become familiar with the chiller and related equipment 6. Cooler pressure and temperature also will vary with the
before operating the chiller. design conditions. Typical pressure range will be between
2. Prepare the system for start-up, start and stop the chiller, 30 and 40 psig (204 and 260 kPa) with temperature rang-
and place the system in a shutdown condition. ing between 34 and 45 F (1 and 8 C).
3. Maintain a log of operating conditions and document any 7. The compressor may operate at full capacity for a short
abnormal readings. time after the pulldown ramping has ended, even though
the building load is small. The active electrical demand
4. Inspect the equipment, make routine adjustments, and setting can be overridden to limit the compressor kW, or
perform a Control Test. Maintain the proper oil and the pulldown rate can be decreased to avoid a high
refrigerant levels. demand charge for the short period of high demand opera-
5. Protect the system from damage during shutdown tion. Pulldown rate can be based on load rate or tempera-
periods. ture rate by PULLDOWN RAMP TYPE in the
6. Maintain the set point, time schedules, and other PIC III RAMP_DEM screen. AMPS OR KW RAMP%/MIN is ac-
functions. cessed on the Equipment SERVICE screen, RAMP_DEM
table (Table 3, Example 28). TEMP PULLDOWN RAMP/
Prepare the Chiller for Start-Up — Follow the steps MIN is accessed on the TEMP_CTL screen.
described in the Initial Start-Up section, page 82.
To Stop the Chiller
To Start the Chiller
1. The occupancy schedule starts and stops the chiller auto-
1. Start the liquid pumps, if they are not automatic. matically once the time schedule is configured.
83
2. The STOP button must be pressed for one second before Check the cooler pressure on the ICVC default screen and
the alarm light blinks once to confirm the button has been compare it to the original holding charge that was left in the
pressed. The compressor will then follow the normal chiller. If (after adjusting for ambient temperature changes) any
loss in pressure is indicated, check for refrigerant leaks. See
shutdown sequence as described in the Controls section. Check Chiller Tightness section, page 64.
The chiller will not restart until the CCN or LOCAL Recharge the chiller by transferring refrigerant from the
softkey is pressed. The chiller is now in the OFF control pumpout storage tank (if supplied). Follow the Pumpout and
mode. Refrigerant Transfer Procedures section, page 86. Observe
freeze-up precautions.
FAILURE TO STOP — If the alarm light does not blink after
pressing and holding the stop button for at least one second and Carefully make all regular preliminary and running system
the chiller fails to stop, the operator should open the main checks. Perform a Control Test before start-up. If the oil level
circuit breaker on the front of the control panel. appears abnormally high, the oil may have absorbed refriger-
ant. A LOW OIL TEMPERATURE prestart alert will be
IMPORTANT: Do not attempt to stop the chiller by declared if the oil temperature is not greater than the CALC
opening an isolating knife switch. High intensity arcing EVAP SAT TEMP plus 15 F (8.3 C) or 140 F (60 C), whichever
may occur. is lower.
Cold Weather Operation — When the entering con-
Do not restart the chiller until the problem is diagnosed and denser liquid drops very low (55 F [13 C] minimum), the oper-
corrected. ator or tower control should automatically cycle the cooling
tower fans off to keep the temperature up. Piping may also be
After Limited Shutdown — No special preparations arranged to bypass the cooling tower. The PIC III controls have
should be necessary. Follow the regular preliminary checks and a Tower Fan Low control contact that can be used to assist in
starting procedures. this control (see the Physical Data section on page 125 for wir-
Preparation for Extended Shutdown — The refrig- ing schematics).
erant should be transferred into the pumpout storage tank (if
supplied; see Pumpout and Refrigerant Transfer Procedures) to Refrigeration Log — A refrigeration log, such as the
reduce chiller pressure and the possibility of leaks. Maintain a one shown in Fig. 51, provides a convenient checklist for
holding charge of 5 to 10 psi (34 to 69 kPa) of refrigerant or routine inspection and maintenance, and provides a continuous
nitrogen to prevent air from leaking into the chiller. record of chiller performance. It is an aid in scheduling routine
maintenance and in diagnosing chiller problems.
If freezing temperatures are likely to occur in the chiller
area, drain the chilled liquid, condenser liquid, and the Keep a record of the chiller pressures, temperatures, and
pumpout condenser liquid circuits to avoid freeze-up. Keep the liquid levels on a sheet similar to that shown. Automatic
waterbox drains open. recording of PIC III data is possible through the use of CCN
devices such as the Data Collection module and a Building
Leave the oil charge in the chiller with the oil heater and
controls energized to maintain the minimum oil reservoir Supervisor. Contact your Carrier representative for more
temperature. information.
After Extended Shutdown — Ensure the liquid sys-
tem drains are closed. It may be advisable to flush the liquid
circuits to remove any soft rust which may have formed. This
is a good time to brush the tubes and inspect the Schrader
fittings on the optional liquid side flow devices for fouling, if
necessary.
84
PLANT MODEL NO. SERIAL NO. REFRIGERANT TYPE
DATE:
_____ COOLER CONDENSER CONCENTRATOR COMPRESSOR VFD
OPER-
REFRIGERANT LIQUID REFRIGERANT LIQUID VFD ATOR REMARKS
OIL OIL OIL COMP. AVG. AVG. AVG.
TIME PRESSURE TEMP PRESSURE TEMP RECLAIM RECLAIM OIL PRESS SUMP DISCH. LINE LINE LINE LOAD INVERTER RECTIFIER COOLANT INITIALS
PRESS. TEMP PRESS. TEMP DELTA T LEVEL KW TEMP TEMP FLOW
OUTPUT DELTA P TEMP TEMP CURRENT VOLTAGE CURRENT
IN OUT GPM IN OUT IN OUT GPM IN OUT
85
REMARKS: Indicate shutdowns on safety controls, repairs made, oil or refrigerant added or removed, operating hours, and start counts. Include amounts.
Fig. 51 — Refrigeration Log: Carrier 23XRV Hermetic Screw Refrigeration

PUMPOUT AND REFRIGERANT (backseated) during operation. Rotate the valve stem fully
TRANSFER PROCEDURES counterclockwise to open. Frontseating the valve closes
the refrigerant line and opens the gage port to compressor
Preparation — The 23XRV chiller may come equipped pressure.
with an optional pumpout storage tank, pumpout system, or 2. Ensure that the compressor holddown bolts have been
pumpout compressor. The refrigerant can be pumped for loosened to allow free spring travel.
service work to either the chiller compressor evaporator vessel
or chiller condenser vessel by using the optional pumpout 3. Open the refrigerant inlet valve on the pumpout
system. If a pumpout storage tank is supplied, the refrigerant compressor.
can be isolated in the storage tank. The following procedures 4. Oil should be visible in the pumpout unit compressor
describe how to transfer refrigerant from vessel to vessel and sight glass under all operating conditions and during
perform chiller evacuations. shutdown. If oil is low, add oil as described under
Optional Pumpout System Maintenance section, page 95.
WARNING The pumpout unit control wiring schematic is detailed in
Fig. 52.
Always run the chiller cooler and condenser liquid pumps TO READ REFRIGERANT PRESSURES during pumpout or
and always charge or transfer refrigerant as a gas when the leak testing:
chiller pressure is less than 35 psig (241 kPa). Below these
pressures, liquid refrigerant flashes into gas, resulting in 1. The ICVC display on the chiller control center is suitable
extremely low temperatures in the cooler/condenser tubes for determining refrigerant-side pressures and low (soft)
and possibly causing tube freeze-up. vacuum. To assure the desired range and accuracy when
measuring evacuation and dehydration, use a quality vac-
uum indicator or manometer. This can be placed on the
Schrader connections on each vessel by removing the
WARNING evaporator or condenser pressure transducer (Fig. 5-7).
During transfer of refrigerant into and out of the optional 2. To determine pumpout storage tank pressure, a 30 in. Hg
storage tank, carefully monitor the storage tank level gage. vacuum –0-400 psi (–101 kPa -0-2769 kPa) compound
Do not fill the tank more than 90% of capacity to allow for gage is attached to the storage tank.
refrigerant expansion. Overfilling may result in damage to 3. Refer to Fig. 40-43 and 53, for valve locations and num-
the tank or personal injury. bers.
CAUTION
CAUTION
Transfer, addition, or removal of refrigerant in spring-
Do not mix refrigerants from chillers that use different isolated chillers may place severe stress on external piping
compressor oils. Compressor damage can result. if springs have not been blocked in both up and down
directions.
Operating the Optional Pumpout Unit
1. Be sure that the suction and the discharge service valves
on the optional pumpout compressor are open
C 2 OL
L1
FIELD C 2 OL
L2 MTR-1 PUMP OUT
POWER COMPRESSOR
SUPPLY C 2 OL
L3
GND HTR-1
L1
8 CRANKCASE HEATER
L2 240-600v
7 27-40 WATT
0.25A
0.25A
FU1
FU2
H1 H4
LEGEND
CONTROL POWER C — Contactor
TRANSFORMER X1 X2 FU — Fuse
XFMR-1
69 VA GND — Ground
HTR — Heater
MTR — Motor
NC — Normally Closed
0.5A
FU3
OL — Overload
HIGH PRESSURE SS — Selector Switch
SAFETY
NC OPEN > 185psig X2
2 1 6
SS-1
OFF
AUTO ON
2 X2
4 5 C
LOW PRESSURE CONTROL
NC OPEN < 7 psia (-15.7 in. HG)
CLOSE > 9 psia (-11.6 in. HG)
2
3 a23-1615
Fig. 52 — 23XRV Pumpout Unit Wiring Schematic
86
Chillers with Storage Tanks — In the Valve/Condi- charging valve 10 to let liquid refrigerant drain into
tion tables that accompany these instructions, the letter “C” the chiller.
indicates a closed valve. Figures 40-43 and 53 show the
locations of the valves. VALVE 1A 1B 2 3 4 5 6 7 10 11
CONDITION C C
CAUTION
2. Transfer remaining refrigerant.
Always run chiller cooler and condenser water pumps and a. Close valve 5 and open valve 4.
always charge or transfer refrigerant as a gas when chiller
vessel pressure is less than 35 psig (241 kPa). Below these VALVE 1A 1B 2 3 4 5 6 7 10 11
pressures, liquid refrigerant flashes into gas, resulting in CONDITION C C
extremely low temperatures in the cooler/condenser tubes b. Turn off the pumpout condenser water, and turn on
and possibly causing tube freeze-up. the pumpout compressor in manual mode to push
liquid refrigerant out of the storage tank. Monitor
the storage tank level until the tank is empty.
FRAME
CONTROL
ASSEMBLY c. Close refrigerant charging valves 7 and 10.
PANEL
d. Turn off the pumpout compressor.
e. Turn off the chiller water pumps.
f. Close valves 3 and 4.
g. Open valves 2 and 5.
VALVE
VALVE 1A 1B 2 3 4 5 6 7 10 11
2 VALVE
3
CONDITION C C C C
VALVE COMPRESSOR
4
h. Turn on pumpout condenser water.
OIL
HEATER
i. Run the pumpout compressor in manual mode until
the storage tank pressure reaches 5 psig (34 kPa),
VALVE
5 18 in. Hg vacuum (41 kPa absolute).
ENTERING OIL FILL
j. Turn off the pumpout compressor.
WATER FITTING
OIL
SEPARATOR
k. Close valves 1a, 1b, 2, 5, and 6.
LEAVING CONDENSER a23-1546
WATER
VALVE 1A 1B 2 3 4 5 6 7 10 11
Fig. 53 —Optional Pumpout Unit CONDITION C C C C C C C C C
TRANSFER REFRIGERANT FROM PUMPOUT STOR- l. Turn off pumpout condenser water.
AGE TANK TO CHILLER TRANSFER THE REFRIGERANT FROM CHILLER TO
PUMPOUT STORAGE TANK
WARNING 1. Equalize refrigerant pressure.
a. Valve positions:
During transfer of refrigerant into and out of the 23XRV
storage tank, carefully monitor the storage tank level gage. VALVE 1A 1B 2 3 4 5 6 7 10 11
Do not fill the tank more than 90% of capacity to allow for CONDITION C C C C C
refrigerant expansion. Overfilling may result in damage to
the tank and personal injury. b. Slowly open valve 5 and refrigerant charging
valves 7 and 10 to allow liquid refrigerant to drain
1. Equalize refrigerant pressure. by gravity into the storage tank.
a. Turn on chiller water pumps and monitor chiller VALVE 1A 1B 2 3 4 5 6 7 10 11
pressures. CONDITION C C
b. Close pumpout and storage tank valves 2, 4, 5, and 2. Transfer the remaining liquid.
10, and close refrigerant charging valve 7; open
chiller isolation valve 11 and any other chiller iso- a. Turn off pumpout condenser water. Place valves in
lation valves, if present. the following positions:
c. Open pumpout and storage tank valves 3 and 6; VALVE 1A 1B 2 3 4 5 6 7 10 11
open chiller valves 1a and 1b.
CONDITION C C
VALVE 1A 1B 2 3 4 5 6 7 10 11 b. Run the pumpout compressor in automatic mode
CONDITION C C C C C until vacuum switch is satisfied and compressor
d. Gradually crack open valve 5 to increase chiller stops. Close valves 7 and 10.
pressure to 35 psig (241 kPa). Slowly feed refriger-
ant to prevent freeze-up. VALVE 1A 1B 2 3 4 5 6 7 10 11
CONDITION C C C C
e. Open valve 5 fully after the chiller pressure rises
above the freezing point of the refrigerant. Let the c. Turn off the pumpout compressor.
storage tank and chiller pressure equalize. Open 3. Remove any remaining refrigerant.
refrigerant charging valve 7 and storage tank
a. Turn on chiller water pumps.
b. Turn on pumpout condenser water.
87
c. Place valves in the following positions: This operation can be done in Automatic or On
mode. In Automatic mode, the compressor will
VALVE 1A 1B 2 3 4 5 6 7 10 11 stop automatically at approximately 15 in. Hg
CONDITION C C C C vacuum (51 kPa absolute).
d. Run the pumpout compressor until the chiller pres- d. Close valve 1a.
sure reaches 35 psig (241 kPa); then, shut off the e. Turn off pumpout compressor.
pumpout compressor. Warm chiller condenser
water will boil off any entrapped liquid refrigerant f. Close valves 1b, 3, and 4.
and chiller pressure will rise. VALVE 1A 1B 2 3 4 5 11
e. When chiller pressure rises to 40 psig (276 kPa), CONDITION C C C C C C C
turn on the pumpout compressor until the pressure
again reaches 35 psig (241 kPa), then, turn off the g. Turn off pumpout condenser water.
pumpout compressor. Repeat this process until the h. Turn off chiller water pumps and lock out chiller
chiller pressure no longer rises; then, turn on the compressor.
pumpout compressor and pump out until the chiller Transfer All Refrigerant to Chiller Cooler Vessel
pressure reaches 18 in. Hg vacuum (41 kPa abso-
lute). This can be done in On or Automatic mode. 1. Push refrigerant into the chiller cooler vessel.
f. Close valves 1a, 1b, 3, 4, and 6. a. Turn on the chiller water pumps and monitor the
chiller pressure.
VALVE 1A 1B 2 3 4 5 6 7 10 11 b. Valve positions:
CONDITION C C C C C C C C C
VALVE 1A 1B 2 3 4 5 11
g. Turn off the pumpout condenser water. CONDITION C C
4. Establish vacuum for service. To conserve refrigerant,
operate the pumpout compressor as described in Step 3e c. Equalize the refrigerant in the chiller cooler and
until the chiller pressure is reduced to 18 in. Hg condenser.
vacuum (41 kPa absolute). d. Turn off chiller water pumps and pumpout con-
This operation can be done in Automatic or On mode. denser water.
In Automatic mode, the compressor will stop automati- e. Turn on pumpout compressor to push refrigerant
cally at approximately 15 in. Hg vacuum (51 kPa out of the chiller condenser.
absolute). f. When all liquid is out of the chiller condenser,
CHILLERS WITH ISOLATION VALVES — The valves re- close valve 11 and any other liquid isolation valves
ferred to in the following instructions are shown in Fig. 41-43 on the chiller.
and 53. Valve 7 remains closed. g. Turn off the pumpout compressor.
Transfer All Refrigerant to Chiller Condenser Vessel 2. Evacuate gas from chiller condenser vessel.
1. Push refrigerant into chiller condenser vessel. a. Turn on chiller water pumps.
a. Turn on the chiller water pumps and monitor the b. Make sure that pumpout valves 3 and 4 are closed
chiller pressure. and valves 2 and 5 are open.
b. Valve positions: VALVE 1A 1B 2 3 4 5 11
CONDITION C C C
VALVE 1A 1B 2 3 4 5 11
CONDITION C C c. Turn on pumpout condenser water.
c. Equalize the refrigerant in the chiller cooler and d. Run the pumpout compressor until the chiller con-
condenser. denser reaches 18 in. Hg vacuum (41 kPa absolute)
in Manual or Automatic mode. Monitor pressure at
d. Turn off chiller water pumps and pumpout con-
the chiller control panel and refrigerant gages.
denser water supply.
e. Close valve 1b.
e. Turn on pumpout compressor to push liquid out of
the chiller cooler vessel. f. Turn off pumpout compressor.
f. When all liquid has been pushed into the chiller g. Close valves 1a, 2, and 5.
condenser vessel, close the cooler refrigerant isola-
tion valve (11). VALVE 1A 1B 2 3 4 5 11
CONDITION C C C C C C C
g. Turn on the chiller water pumps.
h. Turn off the pumpout compressor. h. Turn off pumpout condenser water.
2. Evacuate gas from chiller cooler vessel. i. Turn off chiller water pumps and lock out chiller
compressor.
a. Close pumpout valves 2 and 5; open valves 3
and 4. Return Refrigerant to Normal Operating Conditions
1. Be sure that the chiller vessel that was opened has been
VALVE 1A 1B 2 3 4 5 11 evacuated.
CONDITION C C C 2. Turn on chiller water pumps.
b. Turn on pumpout condenser water. 3. Open valves 1a, 1b, and 3.
c. Run pumpout compressor until the chiller cooler
VALVE 1A 1B 2 3 4 5 11
vessel pressure reaches 18 in. Hg vacuum (41 kPa
absolute). Monitor pressures on the chiller control CONDITION C C C C
panel and on refrigerant gages.
88
4. Crack open valve 5, gradually increasing pressure in the Safety Data Sheet and the latest ASHRAE Safety Guide for
evacuated chiller vessel to 35 psig (241 kPa). Feed refrig- Mechanical Refrigeration to learn more about safe handling of
erant slowly to prevent tube freeze-up. this refrigerant.
5. Leak test to ensure chiller vessel integrity.
6. Open valve 5 fully. WARNING
VALVE 1A 1B 2 3 4 5 11 HFC-134a will dissolve oil and some non-metallic materi-

CONDITION C C C als, dry the skin, and, in heavy concentrations, may dis-
place enough oxygen to cause asphyxiation. In handling
7. Close valves 1a, 1b, 3, and 5. this refrigerant, protect the hands and eyes and avoid
8. Open chiller isolation valve 11 and any other isolation breathing fumes.
valves, if present.
VALVE 1A 1B 2 3 4 5 11
Adding Refrigerant — Follow the procedures described
CONDITION C C C C C C
in the Charge Refrigerant into Chiller section, page 79.
9. Turn off chiller water pumps. CAUTION

DISTILLING THE REFRIGERANT
Always use the compressor pumpdown function in the
1. Transfer the refrigerant from the chiller to the pumpout Control Test mode to turn on the evaporator pump and lock
storage tank as described in the Transfer the Refrigerant out the compressor when transferring refrigerant. Liquid
from Chiller to Pumpout Storage Tank section. refrigerant may flash into a gas and cause possible freeze-
2. Equalize the refrigerant pressure. up when the chiller pressure is below 35 psig (241 kPa).
a. Turn on chiller water pumps and monitor chiller
pressures. Removing Refrigerant — If the optional pumpout sys-
b. Close pumpout and storage tank valves 2, 4, 5, and tem is used, the 23XRV refrigerant charge may be transferred
10, and close chiller charging valve 7; open chiller to a storage vessel or within the condenser or cooler if isolation
isolation valve 11 and any other chiller isolation valves are present. Follow procedures in the Pumpout and
valves, if present. Refrigerant Transfer Procedures section when removing refrig-
c. Open pumpout and storage tank valves 3 and 6; erant from the storage tank to the chiller.
open chiller valves 1a and 1b. Adjusting the Refrigerant Charge — If the addi-
VALVE 1A 1B 2 3 4 5 6 7 10 11
tion or removal of refrigerant is required for improved chiller
performance, follow the procedures given under the Trim
CONDITION C C C C C
Refrigerant Charge section, on page 90.
d. Gradually crack open valve 5 to increase chiller
pressure to 35 psig (241 kPa). Slowly feed refriger- Refrigerant Leak Testing — Because HFC-134a is
ant to prevent freeze-up. above atmospheric pressure at room temperature, leak testing
can be performed with refrigerant in the chiller. Use an elec-
e. Open valve 5 fully after the chiller pressure rises tronic leak detector, halide leak detector, soap bubble solution,
above the freezing point of the refrigerant. Let the or ultra-sonic leak detector. Be sure that the room is well venti-
storage tank and chiller pressure equalize. lated and free from concentration of refrigerant to keep false
3. Transfer remaining refrigerant. readings to a minimum. Before making any necessary repairs
a. Close valve 3. to a leak, transfer all refrigerant from the leaking vessel. The
chiller should be leak tested at least once per year.
b. Open valve 2.
Refrigerant Leak Rate — ASHRAE recommends that
VALVE 1A 1B 2 3 4 5 6 7 10 11 chillers should be immediately taken off line and repaired if the
CONDITION C C C C refrigerant leakage rate for the entire chiller is more than 10%
of the operating refrigerant charge per year.
c. Turn on pumpout condenser water.
Additionally, Carrier recommends that leaks totaling less
d. Run the pumpout compressor until the storage tank than the above rate but more than a rate of 1 lb (0.5 kg) per year
pressure reaches 5 psig (34 kPa), 18 in. Hg vacuum should be repaired during annual maintenance or whenever the
(41 kPa absolute) in Manual or Automatic mode. refrigerant is pumped over for other service work.
e. Turn off the pumpout compressor.
f. Close valves 1a, 1b, 2, 5, and 6.
Test After Service, Repair, or Major Leak — If
all refrigerant has been lost or if the chiller has been opened for
g. Turn off pumpout condenser water. service, the chiller or the affected vessels must be pressured
and leak tested. Refer to the Leak Test Chiller section to per-
VALVE 1A 1B 2 3 4 5 6 7 10 11 form a leak test.
CONDITION C C C C C C C C C
REFRIGERANT TRACER — Use an environmentally ac-
4. Drain the contaminants from the bottom of the storage ceptable refrigerant as a tracer for leak test procedures.
tank into a container. Dispose of contaminants safely. TO PRESSURIZE WITH DRY NITROGEN — Another
method of leak testing is to pressure with nitrogen only and use
GENERAL MAINTENANCE soap bubble solution or an ultrasonic leak detector to determine
if leaks are present. This should only be done if all refrigerant
Refrigerant Properties — HFC-134a is the standard has been evacuated from the vessel.
refrigerant in the 23XRV chiller. At normal atmospheric pres-
sure, HFC-134a will boil at –14 F (–25 C), and must, therefore, 1. Connect a copper tube from the pressure regulator on the
be kept in pressurized containers or storage tanks. The refriger- cylinder to the refrigerant charging valve. Never apply
ant is practically odorless when mixed with air. HFC-134a is full cylinder pressure to the pressurizing line. Follow the
non-combustible at atmospheric pressure. Read the Material listed sequence.
89
2. Open the charging valve fully. TEMP plus 15 F (8.3 C), whichever is lower. The control will
3. Slowly open the cylinder regulating valve. continue with start-up only after the temperature is within limits.
4. Observe the pressure gage on the chiller and close the
regulating valve when the pressure reaches test level. Do SCHEDULED MAINTENANCE
not exceed 140 psig (965 kPa).
Establish a regular maintenance schedule based on the actu-
5. Close the charging valve on the chiller. Remove the cop- al chiller requirements such as chiller load, run hours, and cool-
per tube if no longer required. er and condenser liquid quality. The time intervals listed in this
Repair the Refrigerant Leak, Retest, and section are offered as guides to service only. Jobsite conditions
Apply Standing Vacuum Test — After pressurizing may dictate that maintenance schedule is performed more often
the chiller, test for leaks with a soap bubble solution, an elec- than recommended.
tronic leak detector, a halide torch, or an ultrasonic leak detec- NOTE: The Optional Extended Warranty includes specific
tor. Bring the chiller back to atmospheric pressure, repair any maintenance requirements and service intervals that must be
leaks found, and retest. documented. See specific details in the Optional Extended
After retesting and finding no leaks, apply a standing vacu- Warranty agreement.
um test. Then dehydrate the chiller. Refer to the Chiller Dehy- Service Ontime — The ICVC will display a SERVICE
dration in the Before Initial Start-Up section, page 71. ONTIME value on the MAINSTAT table. This value should be
Trim Refrigerant Charge — If it becomes necessary reset to zero by the service person or the operator each time
to adjust the refrigerant charge to obtain optimum chiller per- major service work is completed so that time between service
formance, operate the chiller at design load and then add or re- can be seen.
move refrigerant slowly until the difference between LEAVING Inspect the Control Center — Maintenance is gener-
CHILLED LIQUID chilled liquid temperature and the EVAP ally limited to general cleaning and tightening of connections.
REFRIG LIQUID TEMP reaches design conditions. Do not Vacuum the control center enclosure to eliminate dust build-up.
overcharge. For superheat information, see the Troubleshoot- In the event of chiller control malfunctions, refer to the Trou-
ing Guide section on page 96. bleshooting Guide section for control checks and adjustments.
Refrigerant may be added either through the optional stor- Power connections on newly installed equipment may relax
age tank or directly into the chiller as described in the section and loosen after a month of operation. Turn off power and
entitled, Refrigerant Charging. re-tighten, check annually thereafter.
To remove any excess refrigerant, follow the procedure in
Transfer Refrigerant from Chiller to Pumpout Storage Tank DANGER
section, Steps 1a, b on page 87.
Be sure power to the control center is off when cleaning
WEEKLY MAINTENANCE and tightening connections inside the control center. Fail-
ure to be sure power is off will result in severe personal
Check the Lubrication System — Mark the oil lev- injury or death.
el on the oil sump sight glasses and observe the level each
week while the chiller is running. Check the moisture indicator
on the motor cooling line. Check Safety and Operating Controls
Monthly — To ensure chiller protection, the Automated
If the level goes below the bottom of the oil sump sight Control Test in the service menu should be done at least once
glass, the oil reclaim system will need to be checked for proper per month. See Table 5 for safety control settings.
operation. The oil reclaim system is operating properly if the
level in the oil sump increases after running the chiller near full
load with a 95 F (35 C) or higher CONDENSER TEMPERA- CAUTION
TURE for 1 hour. If additional oil is required, add it through the
oil charging valve (Fig. 2-7). A hand pump is required for add- Do not manually open the oil reclaim isolation valve when
ing oil against refrigerant pressure. The oil charge for the the chiller is shut down. Doing so will flood the vaporizer
with refrigerant and severely degrade the viscosity of the
23XRV chiller is 7.5 gallons (28 L).
oil in the sump.
The oil must meet Carrier’s specifications for the 23XRV
chillers. Refer to Changing Oil and Oil Filter section. Any oil
that is added should be logged by noting the amount and date Changing Oil and Oil Filter — If the OIL PRES-
in Fig. 51 on page 85. Any oil that is added due to oil loss not SURE DELTA P approaches the 18 psid (124 kPad) LOW OIL
related to service will eventually return to the sump. Excess oil PRESSURE ALARM threshold, change oil filter as needed.
must be removed when the level is above the top of the oil Otherwise, change the oil filter on a two year schedule.
sump sight glass. Oil analysis is an important part of a good preventive main-
A 530-watt oil sump heater is controlled by the PIC III con- tenance program. Carrier recommends a yearly oil analysis.
trols to maintain oil temperature above 140 F (60 C) or CALC Changing oil is not recommended unless the oil analysis indi-
EVAP SAT TEMP plus 53 F (29.4 C) when the compressor is cates problems. (The Optional Extended Warranty program
off (see the Controls section on page 18). The ICVC Status has specific requirements.) If no analysis is being performed,
COMPRESS table displays whether the heater is energized or change the oil after 5 years. See Oil Specification section on
not. If the PIC III controls show that the sump heater is ener- page 91 for additional information.
gized, but the sump is not heating up, the power to the oil sump
heater may be off or the oil level may be too low. Check the oil CAUTION
level, the sump oil heater contactor voltage, and oil heater re-
sistance. Compressor oil is hygroscopic. Containers should remain
The PIC III controls will not permit compressor start-up if tightly sealed in a clean and dry environment to prevent
the oil temperature is less than 140 F (60 C) or CALC EVAP SAT moisture absorption from the air.
90
CHANGING OIL — The 23XRV oil pump and filter can be  Oil type. . . . . . . . . . . . . . . . . . . . .Inhibited polyolester-based
isolated to change the oil filter and oil while the refrigerant re- synthetic compressor lubricant suitable for use
mains inside the chiller. Use the following procedures to in screw compressors where high viscosity
change the oil and oil filter (if required): and compatibility with HFC-134a
1. Make sure the compressor is off and the CB1 main circuit refrigerants is required.
breaker for the control center is open.  ISO Viscosity Grade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
 Specific Gravity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.981
2. Open the CB2 control power and oil heater circuit break-  Viscosity, cSt at 40 C (104 F) . . . . . . . . . . . . . . . . 198 to 242
er in order to turn off the power to the oil heater. cSt at 100 C (212 F) . . . . . . . . . . . . . . . . . .18 to 21
3. Record the oil level observed in the oil sump sight glass. SSU at 100 F (38 C) . . . . . . . . . . . . . . . 1005 ± 100
SSU at 210 F (99 C) . . . . . . . . . . . . . . . . . . . 91 ± 7
CAUTION  Pour Point (maximum) . . . . . . . . . . . . . . . . . . . .–6 F (–21 C)
 Flash Point (minimum) . . . . . . . . . . . . . . . . . . .428 F (220 C)
Be sure the power to the oil heater is off when the oil sump  Moisture Content (maximum) . . . . . . . . . . . . . . . . . . 50 ppm
is drained. If the oil heater remains energized when the  Acid Number (maximum). . . . . . . . . . . .0.15 mg KOH/gram
sump is empty, it will overheat any residual oil on the heat-  Critical Solution Temperature with HFC-134a (maximum)
ing element and become fouled. Overheating the elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . –8 F(–22 C)
will also significantly reduce their useful life.
CAUTION
4. Connect an oil charging hose to the oil drain valve on the
strainer housing. See Fig. 5-7. Place the other end of the Compressor oil is hygroscopic. Containers should remain
oil charging hose in a clean container suitable for used oil. tightly sealed in a clean and dry environment to prevent
A portion of the oil drained from the sump should be used moisture absorption from the air.
as an oil sample and should be sent to a laboratory for
proper analysis. Do not contaminate this sample.  This oil (part number PP23BZ110001 [1x1 gal. can] and
5. Slowly open the drain valve in order to drain the oil from PP23BZ110005 [1x5 gal. can]) may be ordered from your
the sump. local Carrier representative.
Oil Heater — Inspect the oil heater for carbon build-up on
WARNING the heating element if an adequate oil sump temperature cannot
be maintained when the chiller is shut down. It may be neces-
The oil sump is at high pressure. Relieve pressure slowly to sary to temporarily install the heater element terminal cover to
prevent injury. provide additional leverage while threading the oil heater into
the sump. The sump oil heater elements must be positioned
6. Charge new oil through the drain valve on the strainer vertically to allow proper heat convection. See Fig. 54 and 55.
housing. A hand pump or portable electric oil pump will The heater element must be installed with the word “TOP” on
be required to charge oil back into the oil sump against re- the threaded fitting facing upward.
frigerant pressure.
 7. Add oil (approximately 10 gal [38 L]) until it returns to Refrigerant Filter/Drier — A refrigerant filter/drier, lo-
cated on the motor cooling line, should be changed once every
the level noted in Step 3. The oil sight glass will not fill two years, or as necessary, if the condition of the filter indicates
completely since a small amount of gas will be trapped a need for less or more frequent replacement (see Fig. 56). A
inside (even under vacuum conditions). moisture indicator (dry eye) sight glass is located beyond the
8. Apply power through the CB2 controls and oil heater filter/drier to indicate the concentration of moisture in the
circuit breaker. refrigerant. If the moisture indicator indicates moisture, locate
Changing Oil Filter the source of the liquid immediately by performing a thorough
leak check. Close the isolation valves on either side of the filter
1. Make sure the compressor is off and the disconnect for drier. Use the Schrader valve to relieve pressure in the isolated
the compressor starter is open. filter/drier. Replace the filter/drier and evacuate the isolated
2. Close both oil filter isolation valves. See Fig. 54. section of tubing with a vacuum pump attached to the Schrader
3. Place a container underneath the oil filter assembly. valve.
4. When a Schrader valve is provided, use it to relieve the
pressure. Slowly open the drain plug, located on the
Oil Strainers — The oil reclaim system has two strainers.
bottom of the oil filter housing, to relieve pressure. Do One is installed in the VFD refrigerant cooling line between the
not remove the plug. cooler and condenser. The second strainer is located in the oil
sump strainer housing (see Fig. 54). The oil sump strainer must
5. Remove the filter canisters by unscrewing the retainer be replaced or inspected with the refrigerant charge isolated in
nut. The filter may now be removed and disposed of the condenser. Inspect the oil sump strainer for obstructions or
properly. damage every time the oil is changed. The strainer threads into
6. Install new oil filter. Install the new O-ring. Tighten the the oil sump strainer housing. Install a new strainer o-ring if the
retainer nut. entire strainer does not require replacement.
7. If a Schrader valve is supplied, evacuate the oil filter by
connecting the vacuum pump to the Schrader valve. VFD Refrigerant Strainer — A refrigerant strainer is
located in the line that supplies refrigerant to the VFD. Three
8. Slowly open the isolation valve located near the oil pump isolation valves in the refrigerant cooling lines must be closed
to equalize the pressure. Fully open both oil filter isola- before this strainer is changed. See Fig. 56.
tion valves.
Vaporizer Refrigerant Return Line Orifice —
Oil Specification — If oil is to be added, it must meet the There is a metering orifice where the refrigerant return line at-
following Carrier specifications: taches to the vaporizer (see Fig. 54). This orifice can only be
  Carrier Part Number . . . . . . . PP23BZ110001 (1x1 gal. can) inspected by cutting the vaporizer refrigerant return line near
. . . . . . . . . . . . . . . . . . . . . . . . . . PP23BZ110005 (1x5 gal. can) the vaporizer. This orifice should be inspected if hot condenser
gas flow through the vaporizer appears to be obstructed.
91 516
Compressor Inlet Bearing Oil Orifice — The oil 2. Remove the float access cover.
line leading to the compressor lubrication block is connected to 3. Clean the chamber and valve assembly thoroughly. Be
the inlet bearing oil orifice. The orifice is pressed into a sure the valve moves freely. Ensure that all openings are
standard reducer/expander fitting and protected by a 50 x 50 free of obstructions.
mesh screen (see Fig. 57). Compressor oil lines and fittings be-
tween the oil filter and compressor must be capped during dis- 4. Apply thread locking adhesive (P/N 24221 [10 ml] or
assembly to prevent contamination. Inspect the inlet bearing oil 24231 [50 ml]) the 3/8-in. - 16 bolts that hold the float
orifice whenever the oil line between the oil filter and compres- valve in place. See Fig. 58 for a view of the float valve
sor is disconnected. design. Inspect the orientation of the float slide pin. It
must be pointed toward the bubbler tube for proper
Inspect Condenser Refrigerant Float System operation.
(Frame 3-5 Heat Exchangers) — Perform this in- 5. Apply gasket sealant (P/N 19XL680-002) to both sides of
spection when the condenser is opened for service. See Fig. 58. new gasket when reinstalling cover.
1. Transfer the refrigerant into the cooler vessel or into a
pumpout storage tank.
OIL SUPPLY
LINE (TO
COMPRESSOR)
OIL PRESSURE
OIL RECLAIM LEAVING FILTER OIL PRESSURE
ACTUATOR SENSOR REGULATOR LINE
OIL FILTER
SCHRADER OIL RECLAIM
VALVE LINE ( FROM
COOLER)
VAPORIZER REFRIGERANT
RETURN ORIFICE
OIL SUMP
PRESSURE
OIL SUMP STRAINER SENSOR
OIL FILTER
ISOLATION VALVE
OIL SUMP
TEMPERATURE
OIL FILTER SENSOR
OIL PUMP OIL PUMP

ISOLATION VALVE JUNCTION BOX
a23-1639
Fig. 54 — Oil Sump Strainer and Filter
CONDENSER
GAS INLET
VAPORIZER HEATER
OIL RETURN JUNCTION BOX
FROM COMPRESSOR
OIL
PRESSURE
REGULATOR
VALVE
OIL SUMP
SIGHT GLASS
OIL SUMP VERTICALLY ORIENTED VAPORIZER VAPORIZER
TEMPERATURE OIL HEATER TEMPERATURE DRAIN SIGHT
SENSOR ELEMENTS SENSOR THERMOWELL GLASS
(ON FAR END
OF OIL SUMP) OIL SUMP OIL PRESSURE
HEATER REGULATOR
a23-1630 JUNCTION ISOLATION VALVE
BOX
Fig. 55 — Oil Reclaim Cross Section (Q,R Compressors Shown)
92
FILTER DRIER
ISOLATION VALVE
MOISTURE INDICATOR
VFD REFRIGERANT COOLING
ISOLATION VALVES (2)
VFD REFRIGERANT REFRIGERANT
STRAINER FILTER/DRIER
FILTER/DRIER
ISOLATION VALVE
a23-1616
Fig. 56 — Refrigerant Filter/Drier
ORIFICE SCREEN
a23-1631
Fig. 57 — Compressor Inlet Bearing Oil Orifice
1
LEGEND
2 1 — Refrigerant Inlet from FLASC Chamber
2 — Linear Float Assembly
3 — Float Screen
4 — Bubbler Line
5 — Float Cover
6 — Bubble Line Connection
7 — Refrigerant Outlet to Cooler
3
8 — Gasket
a23-1632 6
Fig. 58 — 23XRV Float Valve Design (Frame 3-5 Heat Exchangers Only)
93
Inspect Variable Frequency Drive — Perform the consult the warranty’s specific requirements.) A 500-v meg-
following variable frequency drive inspections annually: ohmmeter test is recommended to assist troubleshooting if
• Inspect the cooling fan. there are indications of problems including, but not limited to,
• Clean the power module and cabinet (vacuum clean). moisture in the refrigerant, and chronic current imbalance or
• Check and tighten electrical connections as needed. over current trips. See guidelines for megohmmeter test in the
• Perform visual inspection and capacitor test of the filter sec- Before Initial Start-Up, Ground Fault Troubleshooting section
tion of the VFD. on page 74.
• Perform visual inspection of the inductors for overheating
or other signs of deterioration. If yes, isolate and check for CAUTION
voltage leak.
• Test to ground (line and link reactors if applicable). The motor leads must be disconnected from the VFD
• Inspect, clean, and test harmonic filter (if applicable). before an insulation test is performed. The voltage gener-
• Review and record the alarm history of the starter. ated from the test equipment can damage the solid-state
• Check drive configurations for accuracy. VFD components.
• Verify that the variable frequency drive installed location is
in an ambient temperature range and humidity (non-con- Inspect the Heat Exchanger Tubes
densing) within its design values and altitude level.
• Verify that the variable speed drive throughout the year is in COOLER — Inspect and clean the cooler tubes at the end of
a clean, ventilated location. the first operating season. Because these tubes have internal
• Verify the power supply for the VFD does not include ridges, a rotary-type tube cleaning system is necessary to fully
power factor correction capacitors. clean the tubes. Upon inspection, the tube condition will deter-
• Do not try to maintain chiller operation through an open mine the scheduled frequency for cleaning, and will indicate
power transfer from secondary power supplies. whether liquid treatment is adequate in the chilled liquid/
• Verify that the variable speed drive is not subject to dirty brine circuit. Inspect the entering and leaving chilled liquid
electrical power, spikes, low voltage, sags, or other electri- temperature sensors for signs of corrosion or scale. Replace the
cal power abnormalities. sensor if corroded or remove any scale if found.
CONDENSER — Since this liquid circuit is usually an open-
Inspect Relief Valves and Piping — The relief type system, the tubes may be subject to contamination and
valves on this chiller protect the system against the potentially scale. Clean the condenser tubes with a rotary tube cleaning
dangerous effects of overpressure. To ensure against damage to system at least once per year and more often if the liquid is
the equipment and possible injury to personnel, these devices contaminated. Inspect the entering and leaving condenser liq-
must be kept in peak operating condit ion. Inspect the relief uid sensors for signs of corrosion or scale. Replace the sensor if
valves in accordance with local codes. corroded or remove any scale if found.
At a minimum, the following maintenance is required. Higher than normal condenser pressures, together with the
1. At least once a year, disconnect the vent piping at the inability to reach full refrigeration load, usually indicate dirty
valve outlet and carefully inspect the valve body and tubes or air in the chiller. If the refrigeration log indicates a rise
mechanism for any evidence of internal corrosion or rust, above normal condenser pressures, check the condenser refrig-
dirt, scale, leakage, etc. erant temperature against the leaving condenser liquid tem-
2. If corrosion or foreign material is found, do not attempt to perature. If this reading is more than what the design difference
repair or recondition. Replace the valve. is supposed to be, then the condenser tubes may be dirty or liq-
uid flow may be incorrect. Because HFC-134a is a high-pres-
3. If the chiller is installed in a corrosive atmosphere or the sure refrigerant, air usually does not enter the chiller.
relief valves are vented into a corrosive atmosphere,
make valve inspections at more frequent intervals. During the tube cleaning process, use brushes especially
designed to avoid scraping and scratching the tube wall.
Compressor Bearing Maintenance — The com- Contact your Carrier representative to obtain these brushes. Do
pressor bearings are designed to last for the life of the chiller. not use wire brushes.
The key to good bearing maintenance is proper lubrication.
Use the proper grade of oil, maintained at recommended level, CAUTION
temperature, and pressure. Inspect the lubrication system
regularly and thoroughly. Hard scale may require chemical treatment for its preven-
Excessive bearing wear can be detected through increased tion or removal. Consult a liquid treatment specialist for
vibration. Carrier recommends that periodic vibration analysis proper treatment. Failure to properly treat liquid could
be performed as part of compressor preventative maintenance result in property damage or personal injury.
program. For Optional Extended Warranty, consult the warran-
ty’s specific requirements. Contact an experienced and respon- Water/Brine Leaks — Moisture in the refrigerant is in-
sible service organization to perform vibration analysis on the dicated during chiller operation by the refrigerant moisture
compressor. indicator on the refrigerant motor cooling line. See Fig. 2-4.
Compressor Rotor Check — Use Carrier specified Leaks should be repaired immediately.
oil. Excessive compressor rotor wear is shown by a lack of
performance. If a lack of performance is noted, have the CAUTION
compressor rotors inspected by a trained service person.
The rotors can be visually inspected once every 5 to The chiller must be dehydrated after repair of liquid leaks.
See Chiller Dehydration section, page 71. Failure to dehy-
10 years or as needed depending on chiller operating
conditions. drate the chiller after repair of liquid leaks could result in
equipment damage or personal injury.
Motor Insulation — Periodic checks of the motor insula-
tion are recommended. (For Optional Extended Warranty,
94
Water/Brine Treatment — Untreated or improperly sure gage reading. Check all transducers (up to 9): the oil pres-
treated water/brine may result in corrosion, scaling, erosion, or sure delta P transducers, discharge pressure transducer, the con-
algae. The services of a qualified water/brine treatment special- denser pressure transducer, the cooler pressure transducer, and
ist should be obtained to develop and monitor a treatment the optional water side pressure transducers (consisting of 4
program. optional flow devices: 2 cooler, 2 condenser).
Note the evaporator and condenser pressure readings on the
CAUTION HEAT_EX screen (EVAPORATOR PRESSURE and
CONDENSER PRESSURE). Attach an accurate set of refriger-
Water/brine must be within design flow limits, clean, and ation gages to the cooler and condenser Schrader fittings.
treated to ensure proper chiller performance and to reduce Compare the two readings. If there is a difference in readings,
the potential of tubing damage due to corrosion, scaling, the transducer can be calibrated as described in the Trouble-
erosion, and algae. Carrier assumes no responsibility for shooting Guide section. Oil differential pressure (OIL PRES-
chiller damage resulting from untreated or improperly SURE DELTA P on the COMPRESS screen) should be close to
treated water/brine. zero whenever the compressor is off. The oil pressure delta P
transducers indicate the difference between oil pressure leaving
Inspect the Control Center — Before working on filter and oil sump pressure.
any starter, shut off the chiller, open and tag all disconnects Optional Pumpout System Maintenance — For
supplying power to the control center. pumpout unit compressor maintenance details, refer to the
19XR Positive Pressure Storage System Installation, Start-Up,
WARNING and Service Instructions.
OPTIONAL PUMPOUT COMPRESSOR OIL
Before working on any VFD, shut off the chiller, open and CHARGE — Use oil conforming to Carrier specifications for
tag all disconnects supplying power to the starter. After dis- reciprocating compressor usage. Oil requirements are as
connecting input power to a VFD and before touching any follows:
internal components, wait 5 minutes for the DC bus capaci-
tors to discharge, then check the voltage with a voltmeter. • HFC-134a ISO Viscosity. . . . . . . . . . . . . . . . . .68 or 220
Failure to observe this warning could result in severe • Viscosity SSU 100 F (38 C) . . . . . . . . . . . . .300 or 1005
bodily injury or death. • Carrier Part Number . . PP23BZ-103 or PP23BZ110005
The total oil charge is 13 oz (0.5 L).
WARNING CAUTION
The disconnect on the front of the control center does not Compressor oil is hygroscopic. Containers should remain
deenergize all internal circuits. Open all internal control tightly sealed in clean and dry environments to prevent
power and remote disconnects before servicing the starter. moisture absorption from the air.
CAUTION Oil should be visible in the pumpout compressor sight glass

both during operation and at shutdown. Always check the oil
The motor leads must be disconnected from the VFD level before operating the pumpout compressor. Before adding
before an insulation test is performed. The voltage gener- or changing oil, relieve the refrigerant pressure through the
ated from the tester can damage the drive components. access valves.
Relieve refrigerant pressure and add oil to the pumpout unit
as follows:
WARNING 1. Refer to Fig. 53. Close service valves 2 and 4.
Never open isolating knife switches while equipment is 2. Run the pumpout compressor in Automatic mode for one
operating. Electrical arcing can cause serious injury. minute or until the vacuum switch is satisfied and com-
pressor shuts off.
3. Move the pumpout selector switch to OFF. Pumpout
Periodically vacuum or blow off accumulated debris on the compressor shell should now be under vacuum.
internal parts with a high-velocity, low-pressure blower.
4. Oil can be added to the shell with a hand oil pump
Power connections on newly installed control centers may through the access valve in the compressor base.
relax and loosen after a month of operation. Turn power off and
retighten. Recheck annually thereafter. NOTE: Compressor access valve has a self-sealing fitting
which will require a hose connection with a depressor to open.
CAUTION OPTIONAL PUMPOUT SAFETY CONTROL SETTINGS
(Fig. 59) — The optional pumpout system high-pressure
Loose power connections can cause voltage spikes, over- switch should open at 185 psig (1276 kPa) and closes automat-
heating, malfunctioning, or failures. ically at 140 psig (965 kPa). Check the switch setting by
operating the pumpout compressor and slowly throttling the
pumpout condenser liquid.
Recalibrate Pressure Transducers — Once a
year, the pressure transducers should be checked against a pres-
95
CONTROL BOX (INTERIOR)
a23-1569
Fig. 59 — Optional Pumpout System Controls
Ordering Replacement Chiller Parts — When or- • If an operating fault is detected, an alarm or alert message is
dering Carrier specified parts, the following information must generated and displayed on the ICVC default screen. A
accompany an order. more detailed message — along with a diagnostic message
• chiller model number and serial number — is also stored into the ALARM HISTORY and ALERT
• VFD model number and serial number (if applicable) HISTORY tables. Refer to Tables 19 and 20.
• name, quantity, and part number of the part required • Review the ALERT HISTORY table to view other less crit-
• delivery address and method of shipment ical events and abnormal conditions which may have
occurred. Compare timing of relevant alerts and alarms.
TROUBLESHOOTING GUIDE Table 18 — Control Algorithm
Maintenance Screens
Overview — The PIC III controls have many features to
help the operator and technician troubleshoot a 23XRV chiller. SCREEN TITLE DESCRIPTION
• The ICVC shows the chiller’s actual operating conditions Capacity This table shows all values
and can be viewed while the unit is running. CAPACITY Control used to calculate the chilled
liquid control point.
• The ICVC default screen freezes when an alarm occurs.
Override Details of all chilled liquid and
The freeze enables the operator to view the chiller condi- OVERRIDE Status VFD control override values.
tions at the time of alarm. The STATUS screens continue LL_MAINT LEAD/LAG Indicates LEAD/LAG
to show current information. Once all alarms have been Status operation status.
VFD Alarm Displays VFD values at last
cleared (by correcting the problems and pressing the VFD_HIST
History fault.
RESET softkey), the ICVC default screen returns to LOADSHED
Loadshed Displays Loadshed (Demand
normal operation. Status Limit) status.
• The CONTROL ALGORITHM STATUS screens (which CUR_ALRM Current Displays current chiller
Alarm Status alarms.
include the CAPACITY, OVERRIDE, LL_MAINT,
Liquid The liquid system manager is
VFD_HIST, CUR_ALRM, LOADSHED, WSMDEFME, System a CCN module that can turn
and OCCDEFCM screens) display information that helps to Manager on the chiller and change the
WSMDEFME
diagnose problems with chilled liquid temperature control, Status chilled liquid control point. This
chilled liquid temperature control overrides, hot gas bypass, screen indicates the status of
this system.
surge algorithm status, and time schedule operation. Refer
to Table 18. Time The Local and CCN occupied
Schedules schedules are displayed here
• The CONTROL TEST screen under the SERVICE menu Status to help the operator quickly
facilitates the proper operation and test of temperature OCCDEFCM determine whether the
sensors, pressure transducers, oil reclaim output, head schedule is in the “occupied”
pressure output, oil pump, liquid pumps, tower control, and mode or not.
other discrete on/off outputs while the compressor is HGBP The hot gas bypass control
Status algorithm status is viewed
stopped. It also has the ability to lock out the compressor HEAT_EX* from this screen. All values
and turn on liquid pumps for pumpout operation. The ICVC related to this control are
shows the temperatures and pressures required during these displayed.
operations. *The HEAT_EX screen is under the STATUS menu.
• From other SERVICE tables, the operator or technician can
access configured items, such as chilled liquid temperature
resets, override set points, etc.
96
Checking Display Messages — The first area to used by the PIC III to determine the refrigerant temperatures.
check when troubleshooting the 23XRV chiller is the ICVC The OIL PRESSURE DELTA P (oil pressure leaving filter – oil
display. If the alarm light is flashing, check the primary and sump pressure) is calculated by the CCM.
secondary message lines on the ICVC default screen (Fig. 24). All pressure transducers should be calibrated prior to initial
These messages will indicate where the fault is occurring. start-up. At high altitude locations, it is necessary to calibrate
These messages contain the alarm message with a specified the transducers to ensure the proper refrigerant temperature/
code. This code or state appears with each alarm and alert mes- pressure relationship. Each transducer is supplied with 5 vdc
sage. The ALARM and ALERT HISTORY tables on the ICVC power from the CCM. If the power supply fails, a transducer
voltage reference alarm (239) is declared. If the transducer
SERVICE menu also contain a message to further expand on reading is suspected of being faulty, check the TRANSDUCER
the fault condition. Note that the date format in these tables is VOLTAGE REF supply voltage. It should be 5 vdc ± .5 v
MM/DD/YY. For a complete list of possible alarm messages, displayed in CONTROL TEST under PRESSURE TRANS-
see Table 19. If the alarm light starts to flash while accessing a DUCERS. If the TRANSDUCER VOLTAGE REF is correct,
menu screen, press the EXIT softkey to return to the default the transducer should be recalibrated or replaced.
screen to read the alarm message. The STATUS screen can also Also check that inputs on CCM J5-1 through J5-6 have not
be accessed to determine where an alarm exists. A “C” to the been grounded and are not receiving anything other than a 4 to
right of a parameters value means there is a communications 20 mA signal.
fault on that channel. COOLER CONDENSER PRESSURE TRANSDUCER
AND OPTIONAL WATER SIDE PRESSURE TRANS-
Checking Temperature Sensors — Except for the DUCER CALIBRATION — Calibration can be checked by
motor temperature sensors, all temperature sensors are installed comparing the pressure readings from the transducer to an
in thermowells. This eliminates the need to drain the refriger- accurate refrigeration gage reading. These readings can be
ant, oil, or liquid from the chiller to replace the sensor. All viewed or calibrated from the HEAT_EX screen on the ICVC.
temperature sensors are thermistor-type sensors. This means The transducer can be checked and calibrated at 2 pressure
that the resistance of the sensor varies with temperature. All points. These calibration points are 0 psig (0 kPa) and between
sensors have the same resistance characteristics. 25 and 250 psig (173 and 1724 kPa). To calibrate these trans-
RESISTANCE CHECK — Turn off the control power and, ducers:
from the module, disconnect the terminal plug of the sensor in 1. Shut down the compressor, cooler, and condenser pumps.
question. With a digital ohmmeter, measure sensor resistance
between receptacles as designated by the wiring diagram. NOTE: There should be no flow through the heat
The resistance and corresponding temperature are listed in exchangers.
Table 21 or 22. Check the resistance of both wires to ground. 2. Disconnect the transducer in question from its Schrader
This resistance should be infinite. fitting for cooler or condenser transducer calibration. For
VOLTAGE DROP — The voltage drop across any energized oil pressure delta P, the optional cooler and condenser
sensor can be measured with a digital voltmeter while the liquid delta P, or flow device calibration, leave the trans-
control is energized. Table 21 or 22 lists the relationship be- ducer in place.
tween temperature and sensor voltage drop (volts dc measured NOTE: If the cooler or condenser vessels are at 0 psig
across the energized sensor). Exercise care when measuring (0 kPa) or are open to atmospheric pressure, the transduc-
voltage to prevent damage to the sensor leads, connector plugs, ers can be calibrated for zero without removing the
and modules. Sensors should also be checked at the sensor transducer from the vessel.
plugs. Check the sensor wire at the sensor for 5 vdc if the con- 3. Access the HEAT_EX (or the ECON_EXV for ECONO-
trol is powered on.
MIZER PRESSURE for P compressor with economizer
CHECK SENSOR ACCURACY — Place the sensor in a option) screen and view the particular transducer reading
medium of known temperature and compare that temperature
to the measured reading. The thermometer used to determine (the EVAPORATOR PRESSURE or CONDENSER
the temperature of the medium should be of laboratory quality PRESSURE parameter on the HEAT_EX screen). To cal-
with 0.5º F (.25º C) graduations. The sensor in question should ibrate oil pressure or water side pressure transducer, view
be accurate to within 2º F (1.2º C). the particular reading (CHILLED LIQUID DELTA P and
See Fig. 5-7 for sensor locations. Temperature sensors are CONDENSER LIQUID DELTA P on the HEAT_EX
inserted into a thermowell in the refrigerant or liquid circuits. screen, and OIL PRESSURE DELTA P on the COM-
When installing a new sensor thermowell, apply a pipe sealant
or thread sealant (RCD part number 56507) to the thermowell PRESS screen). It should read 0 psi (0 kPa). If the reading
threads. Coat the temperature sensors with thermally conduc- is not 0 psi (0 kPa), but within ± 5 psi (35 kPa), the value
tive grease (RCD Part Number PP8024) before inserting into may be set to zero by pressing the SELECT softkey
the thermowell. while the appropriate transducer parameter is highlighted
DUAL MOTOR TEMPERATURE SENSORS — For ser- on the ICVC screen. Then press the ENTER softkey.
vicing convenience, there are 2 sensors on the motor tempera- The value will now go to zero. No high end calibration is
ture sensor. If one of the sensors is damaged, the other can be necessary for OIL PRESSURE DELTA P, optional
used by simply moving a wire. The number 2 terminal in the
sensor terminal box is the common line. To use the second sen- CHILLED LIQUID DELTA P or CONDENSER LIQUID
sor, move the wire from the number 1 position to the num- DELTA P or for flow devices.
ber 3 position. If the transducer value is not within the calibration range,
Checking Pressure Transducers — There are as the transducer returns to the original reading. If the pres-
many as 9 pressure transducers on 23XRV chillers. They deter- sure is within the allowed range (noted above), check the
mine EVAPORATOR PRESSURE, CONDENSER PRESSURE, voltage ratio of the transducer. To obtain the voltage ratio,
oil pressure leaving filter, oil sump pressure, DISCHARGE divide the voltage (dc) input from the transducer (white
PRESSURE, and optional CHILLED LIQUID DELTA P and wire to black wire) by the TRANSDUCER VOLTAGE
CONDENSER LIQUID DELTA P. The EVAPORATOR PRES- REF supply voltage signal (displayed in CONTROL
SURE and CONDENSER PRESSURE transducers are also TEST menu in the PRESSURE TRANSDUCERS
97
screen). The TRANSDUCER VOLTAGE REF can be
measured across the positive (+ red) and negative CAUTION
(– black) leads of the transducer. For example, the con-
denser transducer reference voltage is measured at CCM Be sure to use a back-up wrench on the Schrader fitting
terminals J2-4 (black) and J2-6 (red). The condenser whenever removing a transducer, since the Schrader fitting
transducer input voltage is measured at CCM terminals may back out with the transducer, causing a large leak and
J2-4 (black) and J2-5 (clear or white). The input voltage possible injury to personnel.
to reference voltage ratio must be between 0.80 and 0.11
for the software to allow calibration. Pressurize the
transducer until the ratio is within range, then attempt Control Algorithms Checkout Procedure —
calibration again. One of the tables on the ICVC SERVICE menu is CONTROL
ALGORITHM STATUS. The maintenance screens may be
4. A high pressure point can also be calibrated between 25 viewed from the CONTROL ALGORITHM STATUS table to
and 250 psig (172.4 and 1723.7 kPa) by attaching a regu- see how a particular control algorithm is operating.
lated 250 psig (1724 kPa) pressure (usually from a nitro- These maintenance screens are very useful in helping to
gen cylinder). The high pressure point can be calibrated determine how the control temperature is calculated and for
by accessing the appropriate transducer parameter on the observing the reactions from load changes, control point over-
HEAT_EX screen, highlighting the parameter, pressing rides, hot gas bypass, surge prevention, etc. See Table 18.
the SELECT softkey, and then using the INCREASE Control Test — The Control Test feature can check all the
or DECREASE softkeys to adjust the value to the exact thermistor temperature sensors, pressure transducers, pumps
pressure on the refrigerant gage. Press the ENTER and their associated flow devices, the oil reclaim output, the
softkey to finish the calibration. Pressures at high head pressure output, and other control outputs such as tower
fans, VFD cooling solenoid (if applicable), shut trip relay, oil
altitude locations must be compensated for, so the chiller heaters, alarm relay, and hot gas bypass. The tests can help to
temperature/pressure relationship is correct. determine whether a switch is defective or if a pump relay is
The PIC III controls do not allow calibration if the transduc- not operating, as well as other useful troubleshooting issues.
er is too far out of calibration. In this case, a new transducer During pumpdown operations, the pumps are energized to pre-
must be installed and re-calibrated. If calibration problems are vent freeze-up and the vessel pressures and temperatures are
encountered on the OIL PRESSURE DELTA P channel, some- displayed. The Pumpdown/Lockout feature prevents compres-
times swapping the oil pressure leaving filter and the oil sump sor start-up when there is no refrigerant in the chiller or if the
pressure transducer locations will offset an adverse transducer vessels are isolated. The Terminate Lockout feature ends the
tolerance stack up and allow the calibration to proceed. Pumpdown/Lockout after the pumpdown procedure is reversed
and refrigerant is added.
TRANSDUCER REPLACEMENT — Since the pressure
transducers are mounted on Schrader-type fittings, there is no
need to remove refrigerant from the vessel when replacing the LEGEND FOR TABLE 19
transducers. Disconnect the transducer wiring by pulling up on CCM — Chiller Control Module
the locking tab while pulling up on the weather-tight connect- CCN — Carrier Comfort Network®
ing plug from the end of the transducer. Do not pull on the ICVC — International Chiller Visual Controller
CHL — Chilled Liquid
transducer wires. Unscrew the transducer from the Schrader PIC III — Product Integrated Control III
fitting. When installing a new transducer, do not use pipe sealer VFD — Variable Frequency Drive
(which can plug the sensor). Put the plug connector back on the WSM — Water System Manager
sensor and snap into place. Check for refrigerant leaks.
98
Table 19 — ICVC Primary and Secondary Messages and
Custom Alarm/Alert Messages with Troubleshooting Guides
A. MANUAL STOP
PRIMARY MESSAGE SECONDARY MESSAGE PROBABLE CAUSE/REMEDY
MANUALLY STOPPED — PRESS CCN OR LOCAL TO START PIC III in OFF mode, press CCN or LOCAL softkey to start unit.
TERMINATE PUMPDOWN MODE TO SELECT CCN OR LOCAL Enter the CONTROL TEST table and select TERMINATE LOCKOUT
to unlock compressor.
SHUTDOWN IN PROGRESS COMPRESSOR UNLOADING Chiller unloading before shutdown due to soft/stop feature.
COMPRESSOR DEENERGIZED Chiller compressor is being commanded to stop. Liquid pumps are
SHUTDOWN IN PROGRESS deenergized within one minute.
ICE BUILD OPERATION COMPLETE Chiller shutdown from Ice Build operation.
SHUTDOWN IN PROGRESS RECYCLE RESTART PENDING Chiller is shutting down in recycle mode
B. READY TO START
UNOCCUPIED MODE Time schedule for PIC III is unoccupied. Chillers will start only when
READY TO START IN XX MIN occupied.
READY TO START IN XX MIN REMOTE CONTACTS OPEN Remote contacts are open. Close contacts on Terminal Block TB1 to start.
STOP COMMAND IN EFFECT Chiller START/STOP on MAINSTAT manually forced to stop.
READY TO START IN XX MIN Release force or send START force to start.
READY TO START IN XX MIN OCCUPIED MODE Chiller timer counting down. Unit ready to start.
REMOTE CONTACTS CLOSED Chiller timer counting down. Unit ready to start.
READY TO START IN XX MIN Remote contact enabled and closed.
The chiller will stop when the contacts are opened.
START COMMAND IN EFFECT Chiller START/STOP on MAINSTAT manually forced to start.
READY TO START IN XX MIN Release force to start under normal control.
READY TO START IN XX MIN RECYCLE RESTART PENDING Chiller in recycle mode.
UNOCCUPIED MODE Time schedule for PIC III is unoccupied. Chiller will start when occupied.
READY TO START Make sure the time and date are correct. Change values in TIME AND
DATE screen.
REMOTE CONTACTS OPEN Remote contacts have stopped the chiller. Close contact on Terminal Block
READY TO START TB1 to start.
STOP COMMAND IN EFFECT Chiller START/STOP on MAINSTAT manually forced to stop. Release
READY TO START point to start.
READY TO START OCCUPIED MODE Chiller timer count down complete, unit start will commence.
READY TO START REMOTE CONTACTS CLOSED Chiller timer count down complete. Unit ready for start.
START COMMAND IN EFFECT Chiller START/STOP on MAINSTAT has been manually forced to start.
READY TO START Chiller will start regardless of time schedule or remote contact status.
STARTUP INHIBITED LOADSHED IN EFFECT CCN loadshed module commanding chiller to stop.
C. IN RECYCLE SHUTDOWN
OCCUPIED MODE Unit in recycle mode, chilled liquid temperature is not sufficiently above
RECYCLE RESTART PENDING set point to start.
REMOTE CONTACTS CLOSED Unit in recycle mode, chilled liquid temperature is not sufficiently above
RECYCLE RESTART PENDING set point to start.
START COMMAND IN EFFECT Chiller START/STOP on MAINSTAT manually forced to start, chilled
RECYCLE RESTART PENDING liquid temperature is not sufficiently above set point to start.
ICE BUILD MODE Chiller in ICE BUILD mode. Chilled liquid temperature is satisfied for ICE
RECYCLE RESTART PENDING BUILD conditions.
99
Custom Alarm/Alert Messages with Troubleshooting Guides (cont)
D. PRE-START ALERTS: These alerts are only declared after a start command is issued and only delay start-up. When alert is corrected, the start-up will
continue. No reset is necessary.
STATE PRIMARY SECONDARY ALARM MESSAGE ADDITIONAL CAUSE/REMEDY

MESSAGE MESSAGE PRIMARY CAUSE
100
PRESTART STARTS LIMIT 100->Excessive compressor starts Depress the RESET softkey if additional start is
ALERT EXCEEDED (8 in 12 hours) required. Reassess start-up requirements.
HIGH RECTIFIER 101->Rectifier Temperature [VALUE] Check RECTIFIER TEMPERATURE in POWER screen.
101
PRESTART TEMP exceeded limit of [LIMIT]*. Check VFD refrigerant isolation valves.
Check VFD power module cooling fan.
ALERT Check RECTIFIER TEMP OVERRIDE in SETUP1 screen.
See Table 5.
HIGH MOTOR 102->Comp Motor Winding Temp Check COMP MOTOR WINDING TEMP in COMPRESS screen.
TEMPERATURE [VALUE] exceeded limit of [LIMIT]*. Check motor temperature sensors for wiring and accuracy.
102
PRESTART Check motor cooling line for proper operation, or restrictions.
ALERT Check for excessive starts within a short time span.
Check MOTOR TEMP OVERRIDE in SETUP1 screen.
See Table 5.
HIGH DISCHARGE 103->Comp Discharge Temp Check COMP DISCHARGE TEMP in COMPRESS screen.
TEMP [VALUE] exceeded limit of [LIMIT]*. Allow Compressor Discharge Sensor to cool.
103
PRESTART Check for Compressor Discharge sensor wiring and accuracy.
ALERT Check for excessive starts.
Check COMP DISCHARGE ALERT in SETUP1 screen.
See Table 5.
LOW REFRIGERANT 104->Evaporator Refrig Temp Check EVAPORATOR PRESSURE in HEATEX screen.
TEMP [VALUE] exceeded limit of [LIMIT]*. Check Evaporator Pressure transducer wiring and accuracy.
104
PRESTART Check for low chilled fluid supply temperatures.
ALERT Check refrigerant charge.
Check REFRIG OVERRIDE DELTA T in SETUP1 screen.
See Table 5.
LOW OIL 105->Oil Sump Temp Check OIL SUMP TEMP in ICVC default screen.
TEMPERATURE [VALUE] exceeded limit of [LIMIT]*. Check Oil Sump Temperature sensor wiring and accuracy.
PRESTART Check 1C oil heater contactor/relay and power.
105 Check oil level and oil pump operation. Confirm that oil
ALERT reclaim valve is closed when chiller is not running.
See Table 5.
Check oil heater element for carbon build-up.
HIGH CONDENSER 106->Condenser Pressure Check CONDENSER PRESSURE in HEATEX screen.
PRESTART PRESSURE [VALUE] exceeded limit of [LIMIT]*. Check Condenser Pressure transducer wiring and accuracy.
106 Check for high condenser liquid temperatures.
ALERT Check COND PRESS OVERRIDE in SETUP1 screen.
See Table 5.
LOW LINE VOLTAGE 107->Percent Line Voltage Check Line Voltage in POWER screen.
[VALUE] exceeded limit of [LIMIT]*. Check voltage supply.
107
PRESTART Check voltage transformers. Consult power utility if voltage is low.
ALERT Check FU1, FU2, and FU3 in the VFD.
Check connectors on VFD Line Synch Printed Circuit Board.
See Table 5.
HIGH LINE VOLTAGE 108->Percent Line Voltage Check Line Voltage in POWER screen.
PRESTART [VALUE] exceeded limit of [LIMIT]*. Check voltage supply.
108 Check power transformers.
ALERT Consult power utility if voltage is high.
See Table 5.
HIGH INVERTER TEMP 109->Inverter Temperature Check INVERTER TEMPERATURE in POWER screen.
PRESTART [VALUE] exceeded limit of [LIMIT]*. Check VFD refrigerant isolation valves.
109 Check VFD power module cooling fan.
ALERT Check INVERTER TEMP OVERRIDE in SETUP1 screen.
See Table 5.
*[LIMIT] is shown on the ICVC as temperature, pressure, voltage, etc., predefined or selected by the operator as an override or an alert. [VALUE] is the
actual pressure, temperature, voltage, etc., at which the control tripped.
100
E. START-UP IN PROGRESS
PRIMARY MESSAGE SECONDARY MESSAGE CAUSE/REMEDY
STARTUP IN PROGRESS OCCUPIED MODE Chiller is starting. Time schedule is occupied (OCCUPIED? = YES).
REMOTE CONTACT Chiller is starting. REMOTE CONTACTS OPTION is set to ENABLE.
STARTUP IN PROGRESS CLOSED Remote contacts input on terminal block TB1 terminals 23 and 24 are closed.
START COMMAND Chiller is starting. CHILLER START/STOP in MAINSTAT manually forced to START.
STARTUP IN PROGRESS IN EFFECT
AUTORESTART IN OCCUPIED MODE Chiller is starting after power failure. Time schedule is occupied
PROGRESS (OCCUPIED? = YES).
AUTORESTART IN REMOTE CONTACT Chiller is starting after power failure. REMOTE CONTACTS OPTION is set to
CLOSED ENABLE. Remote contacts input on terminal block TB1 terminals 23 and 24
PROGRESS are closed.
AUTORESTART IN START COMMAND Chiller is starting after power failure. CHILLER START/STOP on MAINSTAT
PROGRESS IN EFFECT manually forced to START.
F. NORMAL RUN
PRIMARY MESSAGE SECONDARY MESSAGE CAUSE/REMEDY
BY 4-20 mA SIGNAL Auto chilled liquid reset active based on external input. ENABLE RESET
TYPE =1. A non-zero temperature reset based on a 4-20 mA signal on
RUNNING — RESET ACTIVE CCM J5-3 and J5-4 is being added to the SETPOINT to determine the
CONTROL POINT. See TEMP_CTL screen.
REMOTE TEMP SENSOR Auto chilled liquid reset active based on external input. ENABLE RESET TYPE =2.
A non-zero temperature reset based on the remote sensor signal on CCM J4-13
RUNNING — RESET ACTIVE and J4-14 is being added to the SETPOINT to determine the CONTROL POINT.
See TEMP_CTL screen.
CHL TEMP DIFFERENCE Auto chilled liquid reset active based on cooler Delta T. ENABLE RESET TYPE =3.
A non-zero temperature reset based on the difference between the ENTERING
RUNNING — RESET ACTIVE CHILLED LIQUID and LEAVING CHILLED LIQUID is being added to the
SETPOINT to determine the CONTROL POINT. See TEMP_CTL screen.
LEAVING CHILLED LIQUID Default method of temperature control. ECL CONTROL OPTION = DSABLE.
RUNNING — TEMP Chiller capacity is being controlled so the LEAVING CHILLED LIQUID temperature
CONTROL is being maintained within 1/2 of the CHILLED LIQUID DEADBAND on either side
of the CONTROL POINT. See TEMP_CTL screen.
ENTERING CHILLED LIQUID Entering Chilled Liquid (ECL) control enabled. ECL CONTROL OPTION
RUNNING — TEMP = ENABLE. Chiller capacity is being controlled so the ENTERING CHILLED
CONTROL LIQUID temperature is being maintained within 1/2 of the CHILLED LIQUID
DEADBAND on either side of the CONTROL POINT. See TEMP_CTL screen.
TEMPERATURE RAMP Ramp Loading based on LEAVING CHILLED LIQUID or ENTERING CHILLED
RUNNING — TEMP LOADING LIQUID is in effect. PULLDOWN RAMP TYPE = 0. Capacity inhibit is in effect
CONTROL because LEAVING CHILLED LIQUID or ENTERING CHILLED LIQUID has fallen
below the ramping temperature pulldown setpoint. See RAMP_DEM screen.
BY DEMAND RAMP Ramp Loading based on PERCENT LINE CURRENT or PERCENT LINE
RUNNING — DEMAND LOADING KILOWATTS is in effect. PULLDOWN RAMP TYPE = 0. Capacity inhibit is in
LIMITED effect because PERCENT LINE CURRENT or PERCENT LINE KILOWATTS has
exceeded the ramping active demand limit. See RAMP_DEM screen.
BY LOCAL DEMAND Actual demand has exceeded ACTIVE DEMAND LIMIT. 20mA DEMAND LIMIT
RUNNING — DEMAND SETPOINT OPTION is DISABLED. ACTIVE DEMAND LIMIT is set equal to BASED DEMAND
LIMITED LIMIT. PERCENT LINE CURRENT or PERCENT LINE KILOWATTS is greater than
ACTIVE DEMAND LIMIT.
BY 4-20 mA SIGNAL Actual demand has exceeded ACTIVE DEMAND LIMIT. 20mA DEMAND
RUNNING — DEMAND LIMIT OPTION is ENABLED. ACTIVE DEMAND LIMIT is adjusted based on
LIMITED 4-20 mA signal received on CCM J5-1 and J5-2. PERCENT LINE CURRENT or
PERCENT LINE KILOWATTS is greater than ACTIVE DEMAND LIMIT.
BY CCN SIGNAL Actual demand has exceeded ACTIVE DEMAND LIMIT. Chiller CONTROL
RUNNING — DEMAND MODE = CCN. Value of ACTIVE DEMAND LIMIT is being forced by a CCN
LIMITED device. PERCENT LINE CURRENT or PERCENT LINE KILOWATTS is greater
than ACTIVE DEMAND LIMIT.
BY LOADSHED/REDLINE Actual demand has exceeded ACTIVE DEMAND LIMIT. Chiller CONTROL
MODE = CCN. Value of ACTIVE DEMAND LIMIT was set equal to PERCENT
RUNNING — DEMAND LINE CURRENT or PERCENT LINE KILOWATTS at the time a Redline command
LIMITED was received by the loadshed POC (Program Outboard Control). PERCENT LINE
CURRENT or PERCENT LINE KILOWATTS is greater than ACTIVE DEMAND LIMIT.
See LOADSHED screen.
RUNNING — TEMP HOT GAS BYPASS HOT GAS BYPASS OPTION is set to ENABLE and HOT GAS BYPASS RELAY is ON.
CONTROL
RUNNING — DEMAND BY LOCAL SIGNAL ACTIVE DEMAND LIMIT has been manually forced on MAINSTAT screen.
LIMITED
RUNNING — TEMP ICE BUILD MODE ICE BUILD OPTION is set to ENABLE and chiller is running under Ice Build
CONTROL temperature control.
RUNNING — DEMAND MOTOR LOAD CURRENT Actual demand has exceeded ACTIVE DEMAND LIMIT. Capacity inhibit is active
LIMITED because PERCENT LOAD CURRENT is greater than 100%.
RUNNING — DEMAND VFD LINE CURRENT Actual demand has exceeded ACTIVE DEMAND LIMIT. Capacity inhibit is active
LIMITED because PERCENT LINE CURRENT exceeds 100%.
101
G. NORMAL RUN WITH OVERRIDES
STATE PRIMARY SECONDARY ALARM MESSAGE ADDITIONAL
MESSAGE MESSAGE PRIMARY CAUSE CAUSE/REMEDY
120
RUN CAPACITY HIGH CONDENSER
PRESSURE
120->Condenser Pressure [VALUE]
exceeded limit of [LIMIT]*.
Check for high condenser liquid temperatures.
Check COND PRESS OVERRIDE setting
LIMITED in SETUP1.
HIGH MOTOR 121->Comp Motor Winding Temp Check motor cooling lines.
121
RUN CAPACITY TEMPERATURE [VALUE] exceeded limit of [LIMIT]*. Check for closed valves.
LIMITED Check COMP MOTOR TEMP OVERRIDE setting
in SETUP1.
LOW EVAP REFRIG 122->Evaporator Refrig Temp [VALUE] Check REFRIG OVERRIDE DELTA T
122
RUN CAPACITY TEMP exceeded limit of [LIMIT]*. setting in SETUP1 screen.
LIMITED Check refrigerant charge.
Check for low entering cooler temperatures.
HIGH RECTIFIER TEMP 123->Rectifier Temperature [VALUE] Check VFD refrigerant isolation valves.
123
RUN CAPACITY exceeded limit of [LIMIT]* Check VFD refrigerant cooling solenoid valve.
LIMITED Check RECTIFIER TEMP OVERRIDE in
SETUP1 screen.
124
RUN CAPACITY MANUAL SPEED TARGET VFD SPEED in COMPRESS screen is
LIMITED CONTROL forced to a fixed value.
HIGH INVERTER TEMP 125->Inverter Temperature [VALUE] Check VFD refrigerant isolation valves.
125
RUN CAPACITY exceeded limit of [LIMIT]* Check VFD refrigerant cooling solenoid valve.
LIMITED Check INVERTER TEMP OVERRIDE in
SETUP1 screen.
126
RUN CAPACITY COMP MIN SPEED IN TARGET VFD SPEED is clamped to COMP
OVERRIDE EFFECT MINIMUM SPEED due to oil viscosity.
127
RUN CAPACITY COMP MAX SPEED
LIMITED
TARGET VFD SPEED is clamped to VFD
MAXIMUM SPEED.
OVERRIDE Check VFD MAXIMUM SPEED in SETUP2 screen.
*[LIMIT] is shown on the ICVC as the temperature, pressure, voltage, etc., set point predefined or selected by the operator as an override, alert,
or alarm condition. [VALUE] is the actual pressure, temperature, voltage, etc., at which the control has recorded at the time of the fault condition.
H. OUT-OF-RANGE SENSOR ALARMS

PRIMARY SECONDARY ALARM MESSAGE ADDITIONAL
STATE
LEAVING CHILLED 260->Sensor Fault: Check Leaving Check sensor resistance or voltage drop against
LIQUID Chilled Liquid Sensor Table 21 or 22.
Check for proper wiring between Leaving Chilled
260 SENSOR FAULT Liquid Temperature sensor and CCM.
Check for grounded sensor lead.
See Table 5.
ENTERING CHILLED 261->Sensor Fault: Check Entering Check sensor resistance or voltage drop against
LIQUID Chilled Liquid Sensor Table 21 or 22.
Check for proper wiring between Entering Chilled
261 SENSOR FAULT Liquid Sensor and CCM.
See Table 5.
CONDENSER 262->Sensor Fault: Check Confirm that 5V Reference voltage is available
PRESSURE Condenser Pressure Sensor on CCM.
Check sensor voltage drop.
Check for proper wiring between Condenser
262 SENSOR FAULT Pressure Sensor and CCM.
Check for condensation inside of pressure
sensor connector.
See Table 5.
EVAPORATOR 263->Sensor Fault: Check Confirm that 5V Reference voltage is available
PRESSURE Evaporator Pressure Sensor on CCM.
Check for proper wiring between Evaporator
Check for condensation inside of pressure sensor
connector.
See Table 5.
OIL PRESS SENSOR 264->Sensor Fault: Check Oil Confirm that 5V Reference voltage is available
FAULT Pressure Delta P Sensor on CCM.
Check sensor voltage drops.
Check for proper wiring between Oil Sump
Pressure and Oil Pressure Leaving Filter Sensors
264 SENSOR FAULT and CCM.
connectors.
See Table 5.
102
H. OUT-OF-RANGE SENSOR ALARMS (cont)
STATE
OIL SUMP TEMP 266->Sensor Fault: Check Oil Sump Check sensor resistance or voltage drop against
Temp Sensor Table 21 or 22.
Check for proper wiring between Oil Sump
See Table 5.
COMP DISCHARGE 267->Sensor Fault: Check Comp Check sensor resistance or voltage drop against
TEMP Discharge Temp Sensor Table 21 or 22.
267 SENSOR FAULT Check for proper wiring between sensor and CCM.
See Table 5.
CHILLED LIQUID FLOW 268->Sensor Fault: Check Chilled Check for 4300 ohm load resistor on J3-14 and J3-15.
Liquid Delta P Sensor Check for jumper between J3-17 and J3-18.
Confirm that 5V Reference voltage is available
on CCM.
See Table 5.
Check for proper wiring between optional Entering
268 SENSOR FAULT Chilled Liquid Pressure and Leaving Chilled
Liquid Pressure Sensors and CCM.
Check for condensation inside of optional pressure
sensor connectors.
J3-17 to J3-18 jumper must be replaced with a
4300 ohm resistor if optional flow switch is installed,
see Certified Prints.
COND LIQUID FLOW 269->Sensor Fault: Check Cond Check for 4300 ohm load resistor on J3-20 and J3-21.
Liquid Delta P Sensor. Check for jumper between J3-23 and J3-24.
ECONOMIZER PRES- Confirm that 5V Reference voltage is available
SURE (P compressor) 269->Sensor Fault: Check Economizer on CCM.
Pressure Sensor. See Table 5.
Check for proper wiring between optional Entering
269 SENSOR FAULT Condenser Liquid Pressure and Leaving Condenser
Liquid Pressure Sensors and CCM.
Check for condensation inside of optional pressure
sensor connectors.
J3-17 to J3-18 jumper must be replaced with a
4300 ohm resistor if optional flow switch is installed,
see Certified Prints.
EVAP REFRIG 270->Sensor Fault: Check Evap Check sensor resistance or voltage drop against
LIQUID TEMP Refrig Liquid Temp Sensor Table 21 or 22.
Check for proper wiring between Evaporator Refrigerant
270 SENSOR FAULT Liquid Temperature Sensor and CCM.
See Table 5.
VAPORIZER TEMP 271->Sensor Fault: Check Vaporizer Check sensor resistance or voltage drop against
Temp Sensor Table 21 or 22.
Check for proper wiring between Vaporizer
271 SENSOR FAULT Temperature Sensor and CCM.
See Table 5.
DISCHARGE 272->Sensor Fault: Check Discharge Confirm that 5V Reference voltage is available
PRESSURE Pressure Sensor on CCM.
Check for proper wiring between Compressor
272 SENSOR FAULT Discharge Pressure Sensor and CCM.
connector.
See Table 5.
ECONOMIZER GAS 273->Sensor Fault: Check Economizer Check connection on and to EXV board J3-1 and J3-2.
273 SENSOR FAULT TEMPERATURE Gas Temp Sensor Confirm reading of 5000 ohm thermistor.
(P Compressor) Check for any loose connections.
103
I. CHILLER PROTECTIVE LIMIT FAULTS
RECTIFIER POWER 200->Rectifier Power Fault: Check VFD FAULT CODE in VFD_HIST screen.
200 PROTECTIVE LIMIT FAULT Check VFD Status See VFD FAULT CODES in Table 20.
INVERTER POWER 201->Inverter Power Fault: Check VFD FAULT CODE in VFD_HIST screen.
201 PROTECTIVE LIMIT FAULT Check VFD Status See VFD FAULT CODES in Table 20 .
MOTOR AMPS NOT 202->Motor Amps Not Sensed — Check main circuit breaker for trip.
SENSED Average Load Current [VALUE] Check VFD FAULT CODE in VFD_HIST screen.
See VFD FAULT CODES in Table 20.
202 PROTECTIVE LIMIT Check MOTOR RATED LOAD AMPS
setting in VFD_CONF screen.
See Table 5.
MOTOR 203->Motor Acceleration Fault — Check starter for proper operation.
ACCELERATION Average Load Current [VALUE] Reduce Condenser pressure if possible.
FAULT Check VFD FAULT CODE in VFD_HIST screen.
203 FAILURE TO START See VFD FAULT CODES in Table 20.
Check MOTOR RATED LOAD AMPS setting
in VFD_CONF screen.
See Table 5.
VFD SHUTDOWN 204->VFD Shutdown Fault: Check VFD FAULT CODE in VFD_HIST screen.
204 FAILURE TO STOP FAULT Check Inverter Power Unit See VFD FAULT CODES in Table 20.
See Table 5.
HIGH DC BUS 205->High DC Bus Voltage: Check DC BUS VOLTAGE and VFD FAULT
205 PROTECTIVE LIMIT VOLTAGE [VALUE] exceeded limit of CODE in VFD_HIST screen.
[LIMIT]* See VFD FAULT CODES in Table 20.
VFD FAULT 206->VFD Fault Code: [VALUE]; Check DC BUS VOLTAGE and VFD FAULT
206 PROTECTIVE LIMIT Check VFD Fault Code List CODE in VFD_HIST screen.
HIGH CONDENSER 207->High Cond Pressure trip. Check for electrical continuity across
PRESSURE [VALUE] exceeded Switch High Pressure Switch.
Trippoint. Check connections at VFD A33 Gate Kill Terminals.
Check for high condenser water temperatures,
low water flow, fouled tubes.
207 PROTECTIVE LIMIT Check for division plate/gasket bypass.
Check for noncondensables in refrigerant.
Check Condenser Pressure transducer wiring
and accuracy.
See Table 5.
EXCESSIVE MOTOR 208->Percent Load Current Check Load Currents in VFD_HIST screen.
AMPS [VALUE] exceeded limit of Check MOTOR RATED LOAD AMPS setting
208 PROTECTIVE LIMIT [LIMIT]*. in VFD_CONF screen.
Check condenser water flow.
See Table 5.
LINE CURRENT 209->Line Current Imbalance: Check LINE CURRENTs and VFD FAULT
IMBALANCE Check VFD Fault History for CODE in VFD_HIST screen.
Values. See VFD FAULT CODES in Table 20.
Check LINE CURRENT IMBALANCE
209 PROTECTIVE LIMIT settings in VFD_CONF screen.
Check power distribution bus.
Consult power company.
See Table 5.
LINE VOLTAGE 210->Single Cycle Line Check LINE VOLTAGE and VFD FAULT
DROPOUT Voltage Dropout CODE in VFD_HIST screen.
210 PROTECTIVE LIMIT Check SINGLE CYCLE DROPOUT
See Table 5.
HIGH LINE 211->High Percent Line Check LINE VOLTAGE and VFD FAULT
VOLTAGE Voltage [VALUE] CODE in VFD_HIST screen.
211 PROTECTIVE LIMIT See Table 5.
Check distribution bus.
LOW LINE 212->Low Percent Line Check LINE VOLTAGE and VFD FAULT
VOLTAGE Voltage [VALUE] CODE in VFD_HIST screen.
VFD MODULE 213->VFD Module Power-On Check LINE VOLTAGE and VFD FAULT
213 PROTECTIVE LIMIT RESET Reset When Running CODE in VFD_HIST screen.
POWER LOSS 214->Control Power Loss Check LINE VOLTAGE in VFD_HIST screen.
When Running Check control power voltage on ICVC terminal J1.
*[LIMIT] is shown on the ICVC as the temperature, pressure, voltage, etc., set point predefined or selected by the operator as an
override, alert, or alarm condition. [VALUE] is the actual pressure, temperature, voltage, etc., at which the control tripped.
104
I. CHILLER PROTECTIVE LIMIT FAULTS (cont)
STATE MESSAGE MESSAGE PRIMARY CAUSE CAUSE/REMEDY
LOW DC BUS 215->Low DC Bus Voltage: Check DC BUS VOLTAGE and VFD FAULT
VOLTAGE [VALUE] exceeded limit of CODE in VFD_HIST screen.
215 PROTECTIVE LIMIT [LIMIT]* See VFD FAULT CODES in Table 20.
See Table 5.
LINE VOLTAGE 216->Line Voltage Imbalance; Check LINE VOLTAGE and VFD FAULT
Check LINE VOLTAGE IMBALANCE
settings in VFD_CONF screen.
MOTOR OVERLOAD 217->Motor Overload Trip; Check LOAD CURRENT and VFD FAULT
TRIP Check VFD configurations CODE in VFD_HIST screen.
See VFD FAULT CODEs in Table 20.
217 PROTECTIVE LIMIT Check MOTOR RATED LOAD AMPS
in VFD_CONF screen.
See Table 5.
VFD RECTIFIER 218->VFD Rectifier Temp Exceeded: Check VFD FAULT CODE in VFD_HIST screen.
OVERTEMP Check Cooling and VFD Config. See VFD FAULT CODES in Table 20.
See Table 5.
Check VFD refrigerant isolation valves
218 PROTECTIVE LIMIT and solenoid valve.
Check cooling fan on bottom of VFD
power module. Configure RECTIFIER
TEMP OVERRIDE in SETUP1 screen.
VFD INVERTER 219->VFD Inverter Temp Exceeded: Check VFD FAULT CODE in VFD_HIST screen.
OVERTEMP Check Cooling and VFD Config. See VFD FAULT CODES in Table 20.
See Table 5.
Check VFD refrigerant isolation valves and
219 PROTECTIVE LIMIT solenoid valve.
Check cooling fan on bottom of VFD
power module.
Configure INVERTER TEMP OVERRIDE
in SETUP1 screen.
GROUND FAULT 220->Ground Fault Trip; Check GROUND FAULT CURRENT and
Check Motor and Current Sensors VFD FAULT CODE in VFD_HIST screen.
220 PROTECTIVE LIMIT See VFD FAULT CODES in Table 20.
See Table 5.
MOTOR ROTATION 221->Motor Rotation Reversed: Check if discharge pressure sensor is
REVERSED Check Wiring from VFD to Motor out of range in CONTROL TEST screen.
Check resistor between CCM J3-7 and J3-8.
LINE FREQUENCY 222->Line Frequency [VALUE]: Check LINE FREQUENCY and VFD FAULT
TRIP Check Power Supply. CODE in VFD_HIST screen.
See Table 5.
WITH VFD 223->Loss of SIO Comm with Check SIO communication harness between the
223
LOSS OF GATEWAY VFD Gateway: Check VFG Gateway and the J7 CCM connector.
COMMUNICATION MODULE Module and Power Check status lights on CCM and Gateway
per Fig. 61 and 63.
VFD 224->Loss of DPI Comm with Check ribbon cable and connectors between the
224 PROTECTIVE LIMIT COMMUNICATIONS VFD Gateway: Check VFG to Gateway and the VFD DPI Communications
FAULT VFD Comm. Interface Board per Fig. 62 and 63.
MOTOR CURRENT 225->Motor Current Imbalance: Check LOAD CURRENT and VFD FAULT
Check MOTOR CURRENT IMBALANCE
settings in VFD_CONF screen.
LINE PHASE 226->Line Phase Reversal: Check VFD FAULT CODE in VFD_HIST screen.
226 PROTECTIVE LIMIT REVERSAL Check Line Phases See VFD FAULT CODES in Table 20.
OIL PRESS 227->Oil Pressure Delta P See Table 5.
SENSOR FAULT [VALUE] (Pump Off): Check Select OIL PRESSURE DELTA P in
Pump/Transducers COMPRESS screen to calibrate sensors.
227 PROTECTIVE LIMIT Check OIL SUMP PRESSURE and OIL
PRESSURE LEAVING FILTER pressure
transducer wiring and voltage drop.
Check oil line isolation valves.
105
STATE MESSAGE MESSAGE PRIMARY CAUSE CAUSE/REMEDY
LOW OIL 228->Low Operating Oil Pressure Check oil level in Oil Sump sight glasses.
PRESSURE [VALUE]: Check Oil Pump Check OIL SUMP PRESSURE and OIL
and Filter PRESSURE LEAVING FILTER transducer
wiring and voltage drop.
See Table 5.
Check power supply to pump and pump operation.
Look for oil flow through vaporizer drain
228 PROTECTIVE LIMIT sight glass when chiller is running.
Check for partially closed isolation valves.
Check oil filter.
Check for foaming oil at start-up in oil sump.
Check OIL PRESSURE DELTA P transducer
calibration in COMPRESS screen.
Check vaporizer and oil sump heaters and
contactors.
LOW CHILLED 229->Low Chilled Liquid Flow; Perform Pump Control Test in CONTROLS
LIQUID FLOW Check Switch/Delta P TEST screen.
Config & Calibration Check EVAP REFRIG LIQUID TEMP and
LEAVING CHILLER LIQUID sensor
accuracy and wiring.
See Table 5.
229 PROTECTIVE LIMIT Check chilled liquid valves, pumps, and strainers.
Check EVAP REFRIG TRIPPOINT, EVAP
APPROACH ALERT, and EVAP FLOW DELTA P
CUTOUT, and LIQUID FLOW VERIFY TIME
settings.
Check optional liquid flow switches or liquid
delta P transducer calibration.
LOW CONDENSER 230->Low Condenser Liquid Perform Pump Control Test in CONTROLS
LIQUID FLOW Flow; Check Switch/Delta P TEST screen.
Config & Calibration See Table 5.
Check CONDENSER PRESSURE and LEAVING
COND LIQUID sensors accuracy and wiring.
Check condenser liquid valves, pumps,
230 PROTECTIVE LIMIT and strainers.
Check COND APPROACH ALERT, COND
PRESS OVERRIDE, LIQUID FLOW VERIFY TIME,
and COND FLOW DELTA P CUTOUT settings.
Check optional liquid flow switches or liquid
delta P transducer calibration.
HIGH DISCHARGE 231->Comp Discharge Temp Check discharge isolation valve position.
TEMP [VALUE] Exceeded Limit of See Table 5.
[LIMIT]* Check COMP DISCHARGE TEMP sensor
resistance or voltage drop.
231 PROTECTIVE LIMIT Check for proper COMP DISCHARGE TEMP
sensor wiring.
Check for proper condenser flow and temperature.
Check for fouled tubes, plugged liquid strainers
or noncondensables in the system.
LOW REFRIGERANT 232->Evaporator Refrig Temp Alarm declared when chiller is running,
TEMP [VALUE] exceeded limit of see Table 5.
[LIMIT]*. Check Cooler Refrig Liquid Line Isolation
Valve Position.
Check for proper refrigerant charge.
Check Condenser Float Valve operation,
232 PROTECTIVE LIMIT check if CHILLED LIQUID APPROACH
decreases when CONDENSER PRESSURE
increases.
Check EVAP APPROACH ALERT setting.
Check for proper fluid flow and temperature
against chiller design conditions.
HIGH MOTOR 233->Comp Motor Winding Temp Check COMP MOTOR WINDING TEMP
TEMPERATURE VALUE] exceeded limit of sensor wiring and accuracy.
[LIMIT]*. See Table 5.
Check motor cooling line for proper operation,
restrictions, and isolation valve position.
Check motor cooling filter/drier and look for
233 PROTECTIVE LIMIT refrigerant flow through motor cooling sight
glass.
Check for excessive starts within a
short time span.
The high motor temperature switch in the windings
or the motor temperature sensor circuit is open if
COMP MOTOR WINDING TEMP = 245 F(118 C).
106
LOW OIL
234->Low Prelube Oil Press [VALUE]: Check for low oil level in oil sump sight glass.
PRESSURE
Check Oil Pump & Filter See Table 5.
Refrigerant has not been adequately removed
from the oil if bubbling can be observed through
234 PROTECTIVE LIMIT oil sump sight glass.
Check vaporizer and oil sump heaters and
contactors.
Check OIL PRESS VERIFY TIME.
HIGH CONDENSER 235->Condenser Pressure Check for high condenser liquid temperatures
PRESSURE [VALUE] exceeded limit of against chiller design conditions.
Check Condenser Approach in HEAT_EX screen.
Check for low liquid flow, plugged liquid strainers,
and fouled tubes. Check for division plate/gasket
235 PROTECTIVE LIMIT bypass.
Check for noncondensables in refrigerant.
Check CONDENSER PRESSURE transducer
wiring and accuracy.
Configure COND PRESS OVERRIDE in
SETUP1 screen.
CCN OVERRIDE 236->CCN Emergency/Override CCN has signaled the chiller to stop.
STOP Stop EMERGENCY STOP in the MAINSTAT
screen has been set to EMSTOP.
236 PROTECTIVE LIMIT Reset and restart when ready. If the
signal was sent by the ICVC, release the
stop signal on the STATUS01 table.
SPARE SAFETY 237->Spare Safety Device Spare safety input has tripped or factory-installed
237 PROTECTIVE LIMIT DEVICE jumper is not present between terminals 19 and
20 on the Low Voltage Field Wiring Terminal Strip.
COMPRESSOR 238->Compressor Stall: Check condenser liquid flow and temperatures
MOTOR STALL Check Compressor and Motor against chiller design conditions.
See Table 5.
238 PROTECTIVE LIMIT Check STALL TIME PERIOD and STALL %
AMPs settings.
Check for excessive refrigerant charge and
oil loss.
TRANSDUCER 239->Transducer Voltage Ref Check If CCM PRESSURE TRANSDUCER
VOLTAGE FAULT [VALUE] exceeded limit of VOLTAGE REFERENCE is less than 4.5 V
[LIMIT]*. in CONTROLS TEST screen.
Confirm PRESSURE TRANSDUCER VOLTAGE
REFERENCE across a CCM Pressure Transducer
(e.g., CCM J3-1 to J3-3).
239 PROTECTIVE LIMIT Confirm that none of the transducers have
been shorted to ground.
Look for changes in voltage if customer wiring
to CCM J5-1 through J5-6 and J8-1 to J8-2 are
temporarily removed.
Check for 24 VAC across CCM terminals
J1-1 and J1-2.
COMPATIBILITY 240->VFD Gateway Compatibility ICVC and Gateway software compatibility numbers
CONFLICT Conflict: Check VFG/ICVC do not match. See ICVC SOFTWARE PART # in
240 VFD GATEWAY Versions ICVC CONFIGURATION SCREEN.
See VFD GATEWAY VERSION # in VFD_STAT
screen.
RECTIFIER 241->Rectifier Overcurrent Fault: Check LOAD CURRENT and VFD FAULT
241 PROTECTIVE LIMIT OVERCURRENT Check VFD Status CODE in VFD_HIST screen.
WITH CCM 242->Loss of Communication Check wiring and connectors between CCM
MODULE With CCM: Check Comm. terminal J6 and ICVC terminal J7.
LOSS OF Connectors Check CCM status lights.
242 Check for 24V control power to CCM J1-1
COMMUNICATION and J1-2.
Confirm that all CCM SW1 switches are in the
“off” position.
EVAP PRESS/TEMP 243->Evaporator Refrig Temp Alarm declared at power up and after chiller is
TOO LOW [VALUE] exceeded limit of shutdown, see Table 5.
[LIMIT]*. Check EVAPORATOR PRESSURE transducer.
Check EVAP REFRIG TRIP POINT.
243 POTENTIAL FREEZE-UP Check for proper refrigerant charge.
Check float operation.
Check for proper evaporator fluid flow
and temperature.
COND PRESS/TEMP 244->Condenser Refrig Temp Alarm declared when chiller in shutdown,
244 POTENTIAL FREEZE-UP TOO LOW [VALUE] exceeded limit of
[LIMIT]*.
see Table 5.
Check CONDENSER PRESSURE transducer.
Check CONDENSER FREEZE POINT setting.
107
VFD SPEED OUT 245->Actual VFD Speed Check if ACTUAL VFD SPEED exceeds VFD
OF RANGE exceeded limit of Target SPEED OUTPUT ±10% in COMPRESS
VFD Speed ± 10%]*. or CAPACITY screen.
Check for VFD FAULT CODES in VFD_HIST
screen.
INVERTER 246->Inverter Overcurrent Fault: Check LINE CURRENTs and VFD FAULT
246 PROTECTIVE LIMIT OVERCURRENT Check VFD Status CODE in VFD_HIST screen.
VFD START 247->VFD Start Inhibit: Check Check VFD FAULT CODE in VFD_HIST screen.
247 PROTECTIVE LIMIT INHIBIT VFD Diagnostic Parameters See VFD FAULT CODES in Table 20.
212/214
SPARE 248->Spare Temperature #1 Check component that SPARE TEMPERATURE #1
TEMPERATURE #1 [VALUE] exceeded limit of is monitoring.
Check SPARE TEMPERATURE #1 settings
248 PROTECTIVE LIMIT in SETUP1 screen.
Check SPARE TEMPERATURE #1 sensor
resistance or voltage drop on CCM terminals
J4-25 and J4-26.
Check SPARE TEMPERATURE #1 sensor wiring.
SPARE 249->Spare Temperature #2 Check component that SPARE TEMPERATURE #2
TEMPERATURE #2 [VALUE] exceeded limit of is monitoring.
Check SPARE TEMPERATURE #2 settings in
249 PROTECTIVE LIMIT SETUP1 screen.
Check SPARE TEMPERATURE #2 sensor
resistance or voltage drop on CCM terminals
J4-27 and J4-28.
Check SPARE TEMPERATURE #2 sensor wiring.
REFRIGERANT 250->Refrigerant Leak REFRIGERANT LEAK OPTION is enabled.
LEAK SENSOR Sensor ppm [VALUE] The refrigerant leak detector output wired to
exceeded Limit of [LIMIT]* CCM terminals J5-5 and J5-6 has reached
the alarm threshold (PPM AT 20 MA).
See Table 5.
250 PROTECTIVE LIMIT Check for leaks.
Check leak detector.
Check REFRIGERANT LEAK OPTION, REFRIG
LEAK ALARM PPM and PPM AT 20 MA settings in
OPTIONS screen.
VFD CONFIG 251->VFD Config Conflict; VFD Parameters stored in Gateway and ICVC
CONFLICT Verify & Save VFD Config are not consistent.
Data to Reset Enter VFD_CONF screen and check settings stored
in ICVC against Machine Electrical Data Nameplate.
If parameter values are unacceptable,
251 PROTECTIVE LIMIT exit VFD_CONF by pressing cancel. Re-enter
VFD_CONF screen and check settings uploaded
from Gateway against Machine Electrical Data
Nameplate. Press SAVE before exiting
VFD_CONF.
VFD CHECKSUM 253->Checksum Error: VFD inverter or rectifier checksum must
ERROR Press Reset to Restore be regenerated.
Configuration Check VFD FAULT CODE in VFD_HIST screen.
Press RESET softkey on ICVC to restore
VFD configuration.
VFD DEW 254->VFD Dew Prevention - VFD Reducing VFD COOLANT FLOW to 0% did not
PREVENTION Coolant too Cold, Check Solenoid adequately increase VFD COLDPLATE TEMP.
and Cond T Check HUMIDITY SENSOR INPUT on CCM J3-7,
J3-9 and J4-10 and RELATIVE HUMIDITY in
POWER or CONTROLS TEST screen.
Check humidity sensor wiring on CCM.
254 PROTECTIVE LIMIT Check VFD refrigerant cooling solenoid operation.
Increase Entering Condenser Liquid Temperature.
Reduce humidity surrounding chiller.
Check that VFD A34 NTC cold plate thermocouple is
wired to VFD A12 AC LINE I/O card TB1-19 and
TB1-20.
INDUCTOR 255->Inductor Overtemp Temperature switch in VFD inductor has opened.
OVERTEMP Trip - Check Temp Switch Middle Control Center door must be fully closed
and Cooling Fans to properly route airflow around VFD inductors.
Check wiring to inductor temperature switch.
255 PROTECTIVE LIMIT Check inductor cooling fan operation.
Check for inductor cooling fan airflow obstructions.
Check VFD FAULT CODE in VFD_HIST screen.
COMPATIBILITY 256->VFD Gateway Compatibility VFD INVERTER VERSION # and/or VFD
CONFLICT Conflict: Check VFG/VFD RECTIFIER VERSION # are not compatible
256 VFD GATEWAY Versions with the GATEWAY VERSION #.
Check software version numbers in
VFD_STAT screen.
108
 Table 19 — ICVC Primary and Secondary Messages and
J. CHILLER ALERTS
STATE PRIMARY MESSAGE SECONDARY ALARM MESSAGE ADDITIONAL
MESSAGE PRIMARY CAUSE CAUSE/REMEDY
LEAVING COND 140->Sensor Fault: Check Temperature sensor reading out of range.
LIQUID TEMP Leaving Cond Liquid Check LEAVING COND LIQUID TEMP sensor
Sensor resistance or voltage drop at CCM.
140 SENSOR ALERT Check for grounded sensor leads.
Check for proper wiring.
See Table 5.
ENTERING COND 141->Sensor Fault: Check Temperature sensor reading out of range.
LIQUID TEMP Entering Cond Liquid Check ENTERING COND LIQUID TEMP sensor
Sensor resistance or voltage drop at CCM.
141 SENSOR ALERT Check for grounded sensor leads.
See Table 5.
LOW OIL 142->Oil Pressure Delta P Check for partially or closed oil line isolation
PRESSURE [VALUE] Exceeded Limit of valves.
[LIMIT] Check oil filter.
Check oil level.
142 SENSOR ALERT Check Oil Pressure Leaving Filter and Oil Sump
Pressure transducer wiring and OIL PRESSURE
DELTA P accuracy.
See Table 5.
LINE CURRENT 143->Line Current Chiller automatically restarting - AUTORESTART
IMBALANCE Imbalance: OPTION is enabled.
Check VFD Fault History Power loss has been detected in any phase.
for Values Check LINE CURRENTs and VFD FAULT CODE
AUTORESTART in VFD_HIST screen.
143 See VFD FAULT CODES in Table 20.
PENDING Check LINE CURRENT IMBALANCE settings in
VFD_CONF screen.
See Table 5.
LINE VOLTAGE 144->Single Cycle Line Chiller is automatically restarting -
DROP OUT Voltage Dropout AUTORESTART OPTION is enabled.
A drop in line voltage has been detected within
2 voltage cycles.
AUTORESTART Check LINE VOLTAGE and VFD FAULT CODE
144 in VFD_HIST screen.
PENDING
See Table 5.
Check SINGLE CYCLE DROPOUT
HIGH LINE 145>High Percent Line Chiller is automatically restarting -
VOLTAGE voltage [VALUE] AUTORESTART OPTION is enabled.
Check LINE VOLTAGE and VFD FAULT CODE
145 See VFD FAULT CODES in Table 20.
PENDING
See Table 5.
*[LIMIT] is shown on the ICVC as the temperature, pressure, voltage, etc., set point predefined or selected by the operator
as an override, alert, or alarm condition. [VALUE] is the actual pressure, temperature, voltage, etc., at which the control tripped.
109 516
J. CHILLER ALERTS (cont)
LOW LINE 146->Low Percent Line Chiller is automatically restarting -
VOLTAGE voltage [VALUE] AUTORESTART OPTION is enabled.
Check LINE VOLTAGE and VFD FAULT CODE
146 PENDING See VFD FAULT CODES in Table 20.
See Table 5.
VFD MODULE 147->VFD Module Chiller is automatically restarting -
RESET Power-On Reset When AUTORESTART OPTION is enabled.
AUTORESTART Running VFD Module has detected a hardware fault
147 and has reset.
PENDING Check LINE VOLTAGE and VFD FAULT CODE
in VFD_HIST screen.
POWER LOSS 148->Control Power-Loss Chiller is automatically restarting -
When Running AUTORESTART OPTION is enabled.
Check LINE VOLTAGE in VFD_HIST screen.
AUTORESTART Check 24 vac control power voltage on ICVC
148 PENDING terminals J1-4 and J1-5.
See Table 5.
LOW DC BUS 149->Low DC Bus Chiller is automatically restarting -
VOLTAGE Voltage: [VALUE] AUTORESTART OPTION is enabled.
AUTORESTART Exceeded Limit of Check DC BUS VOLTAGE and VFD FAULT CODE
149 PENDING [LIMIT]* in VFD_HIST screen.
See Table 5.
HIGH DC BUS 150->High DC Bus Chiller is automatically restarting -
VOLTAGE Voltage: [VALUE] AUTORESTART OPTION is enabled.
AUTORESTART Exceeded Limit of Check DC BUS VOLTAGE and VFD FAULT
150 [LIMIT]* CODE in VFD_HIST screen.
PENDING See VFD FAULT CODES in Table 20.
See Table 5.
Check input power for high voltage transients.
PUMP RELAY 151->High Condenser Check COND PRESS OVERRIDE in
ENERGIZED Pressure [VALUE]: Pump SETUP1 screen.
Energized to Check CONDENSER PRESSURE sensor
CONDENSER Reduce Pressure. wiring and accuracy.
151 PRESSURE Check condenser liquid flow, strainers,
ALERT and condenser liquid temperature.
Check for fouled tubes.
This alarm is not caused by the High
Pressure Switch.
EXCESSIVE RECYCLE 152->Excessive Chiller load is too low to keep compressor on line
STARTS recycle starts. and there has been more than 5 starts in 4 hours.
Check HGBP Isolation valve position.
RECYCLE Increase chiller load.
152 Adjust hot gas bypass parameters in
ALERT
OPTIONS screen.
Increase (RECYCLE CONTROL)
RESTART DELTA T in SETUP1 Screen.
no message; 153->Lead/Lag Disabled: Illegal chiller address configuration in
no message: ALERT only Duplicate Chiller Address; Lead/Lag screen, see Table 7.
153 Check Configuration Check chiller addresses in LEAD/LAG
ALERT only
and ICVC CONFIGURATION screens.
COND PRESS/TEMP 154->Condenser freeze The chiller is not in pumpdown mode and the
TOO LOW up prevention condenser pressure transducer is reading a
pressure that could freeze the condenser tubes.
Check CONDENSER FREEZE POINT setting.
See Table 5.
POTENTIAL Check for condenser refrigerant leaks.
154 Check condenser liquid temperature.
FREEZE-UP
Check CONDENSER PRESSURE sensor wiring
and accuracy on CCM terminals J2-4, J2-5 and
J2-6.
Place the chiller in PUMPDOWN mode if the
vessel is evacuated.
110
REMOTE RESET 155->Sensor Fault/Option Type 2 Temperature Reset is enabled and
SENSOR Disabled: Remote Remote Reset sensor on CCM J4-13 and
Reset Sensor J4-14 is out of range.
OPTION Check Temperature Reset settings in
155 SENSOR FAULT TEMP_CNTL screen.
Check REMOTE RESET sensor resistance
or voltage drop.
Check for proper REMOTE RESET sensor wiring.
AUTO CHILLED 156->Sensor Fault/Option Type 1 Temperature Reset is enabled and Auto
LIQUID RESET Disabled: Auto Chilled Chilled Water Reset input on CCM J5-3 and
OPTION Liquid Reset J5-4 is < 2 mA.
156 Check Temperature Reset settings in
SENSOR FAULT TEMP_CNTL screen.
Check that Auto Chilled Liquid Reset input is
between 4 mA and 20 mA.
AUTO DEMAND 157->Sensor Fault/Option 20 mA DEMAND LIMIT OPTION is enabled and
LIMIT INPUT Disabled: Auto Demand Auto Demand Limit input on CCM J5-1 and J5-2
OPTION Limit Input is < 2 mA.
157 Check 20 mA DEMAND LIMIT setting in
SENSOR FAULT RAMP_DEM screen.
Check that Auto Demand Limit input is between
4 mA and 20 mA.
SPARE 158->Spare Temperature Check component that SPARE TEMPERATURE
TEMPERATURE #1 #1 [VALUE] exceeded #1 is monitoring.
limit of [LIMIT].* Check SPARE TEMPERATURE #1 settings in
SETUP1 screen.
158 SENSOR ALERT Check SPARE TEMPERATURE #1 sensor
resistance or voltage drop on CCM J4-25 and
J4-26.
Check for proper SPARE TEMPERATURE
#1 wiring.
SPARE 159->Spare Temperature Check component that SPARE TEMPERATURE
TEMPERATURE #2 #2 [VALUE] exceeded #2 is monitoring.
limit of [LIMIT].* Check SPARE TEMPERATURE #2 settings in
SETUP1 screen.
159 SENSOR ALERT Check SPARE TEMPERATURE #2 sensor
resistance or voltage drop on CCM J4-27
and J4-28.
Check for proper SPARE TEMPERATURE
#2 wiring.
EVAPORATOR 160->Evaporator Check position of refrigerant liquid
APPROACH Approach [VALUE] line isolation valve.
Exceeded Limit of Check EVAP APPROACH ALERT setting in
[LIMIT]* SETUP1 screen.
Check Evaporator Liquid Flow.
See Table 5.
Check EVAP REFRIG LIQUID TEMP and
CHILLED LIQUID TEMP sensor resistances
or voltage drops.
160 SENSOR ALERT Check for proper EVAP REFRIG LIQUID TEMP
and CHILLED LIQUID TEMP sensor wiring.
Check for oil loss.
Check for low refrigerant charge.
Check float valve operation and for refrigerant
stacking in the condenser.
Check for evaporator division plate bypass.
Check for fouled tubes.
Check for air in water box.
CONDENSER 161->Condenser Check COND APPROACH ALERT setting in
APPROACH Approach [VALUE] SETUP1 screen.
Exceeded Limit of Check Condenser Liquid flow.
[LIMIT]* See Table 5.
Check CONDENSER PRESSURE and LEAVING
COND LIQUID temperature sensor resistances or
voltage drops.
Check for proper CONDENSER PRESSURE and
161 SENSOR ALERT LEAVING COND LIQUID temperature sensor
wiring.
Check condenser shell temperature against
condenser pressure measured with refrigerant
gage for evidence of noncondensables in
refrigerant charge.
Check for condenser division plate bypass.
Check for fouled condenser tubes.
Check for air in water box.
111
HIGH DISCHARGE 162->Comp Discharge Check position of condenser isolation valve.
TEMP Temp [VALUE] Exceeded Check COMP DISCHARGE ALERT setting in
Limit of [LIMIT]* SETUP1 screen.
See Table 5.
Check COMP DISCHARGE TEMP sensor
162 SENSOR ALERT resistance or voltage drop.
Check for proper condenser liquid flow and
temperature.
Check for fouled tubes, plugged strainers,
or noncondensables in the refrigerant.
WITH WSM 163->WSM Cool Communications interrupted between
Source - Loss of supervisory component and equipment
LOSS OF Communication component of WSM (Water System Manager).
163 COMMUNICATION Check settings in WSMDEFME screen.
Check CCN communications link with WSM.
Check supervisory part of WSM.
HIGH OIL 164->High Oil Pressure See Table 5.
PRESSURE [VALUE], Check Oil Check oil pressure regulator isolation valve.
Regulator and Valves Check oil pressure regulator.
Check for bent oil lines.
Check Oil Sump Pressure and Oil Pressure
Leaving filter transducer resistances or
164 SYSTEM ALERT voltage drops.
Check OIL PRESSURE DELTA P wiring to CCM.
Check for debris in Compressor Inlet Bearing
Oil Orifice Strainers.
Normal alert if chiller was charged and started
within a few hours of pulling dehydration vacuum
with oil heater on.
AUTORESTART VFD COMMUNICATIONS 165-> Loss of DPI Comm Check that the gateway board is properly con-
165 FAULT With VFD Gateway, Check nected to the DPI. Check ribbon cable. Make sure
PENDING VFG to VFD Comm both boards have power to them.
VFD COMMUNICATIONS 166-> Loss of SIO Comm Check the SIO communication cable from the CCM
AUTORESTART FAULT With VFD Gateway; Check board to the power panel, then the cable from the
166 VFG module and Power power panel to the VFD gateway. Check power to
PENDING
the VFD (main circuit breaker may be tripped)
HUMIDITY 168->Sensor Fault: See Table 5.
SENSOR INPUT Check Humidity Humidity Sensor Input voltage is outside of
Sensor Input 0.5 V to 4.5 V range.
Check Humidity Sensor wiring to CCM terminals
168 SENSOR ALERT J3-7, J3-9, and J4-10.
Check Humidity Sensor Input in Controls
Test screen.
Check resistance 4.3 kohm load resistor
between CCM J3-7 and J3-8.
CONDENSER LIQUID LEVEL 169->Sensor Fault: Check EXV operation.
 169 MACHINE ALERT LOW Condenser Liquid Level
Low
CONDENSER LIQUID LEVEL 170->Sensor Fault: Check EXV operation.
 170 MACHINE ALERT HIGH Condenser Liquid Level
High
519
112
Table 20 — VFD Fault Description and Corrective Actions
FAULT FAULT TYPE* DESCRIPTION ACTION FAULT
CODE STATE
2 Auxiliary Input 1 Input is open. Check remote wiring. 206
3 Power Loss 1, 3 DC bus voltage remained below 85% of Monitor the incoming AC line for low voltage or 149
nominal for longer than Power Loss Time line power interruption. 215
(185).
Enable/disable with Fault Config 1 (238).
4 UnderVoltage 1, 3 DC bus voltage fell below the minimum Monitor the incoming AC line for low voltage or 149
value of 407V DC at 400/480V input. power interruption. 215
5 OverVoltage 1 DC bus voltage exceeded maximum Monitor the AC line for high line voltage or tran- 150
value. sient conditions. Extend the decel time or check 205
RATED LINE VOLTAGE setting.
7 Motor Overload 1, 3 Internal electronic overload is set to trip An excessive motor load exists. Reduce load so 217
when the motor current equals 135% of drive output current does not exceed the MOTOR
Motor NP FLA(42) for 1.5 seconds or NAMEPLATE AMPS setting.
when PERCENT LOAD CURRENT is
sustained above 108%.
8 Invtr Base Temp 1 Base temperature exceeded limit. 1. Check operation of VFD cooling solenoid, VFD 219
isolation valves, and humidity sensor.
2. Check for proper temperature and flow rate of
coolant.
9 Invtr IGBT Temp 1 Output transistors have exceeded their 1. Check operation of VFD cooling solenoid, VFD 219
maximum operating temperature. isolation valves, and humidity sensor.
coolant.
12 HW OverCurrent 1 The drive output current has exceeded Check programming. Check for excess load. 246
the hardware current limit. Contact Carrier Service.
13 Ground Fault 1 A current path to earth ground in excess Check the motor and external wiring to the drive 220
of 7% of drive rated amps has been output terminals for a grounded condition.
detected at one or more of the drive out-
put terminals.
24 Decel Inhibit 3 The drive is not following a commanded 1. Verify input voltage is within drive specified 204
deceleration because it is attempting to limits.
limit bus voltage. 2. Verify system ground impedance follows
proper grounding techniques.
25 OverSpeed Limit 1 Functions such as slip compensation or Remove excessive load conditions. 206
bus regulation have attempted to add an
output frequency adjustment greater
than that programmed in Overspeed
Limit (83).
29 Analog In Loss 1, 3 An analog input is configured to fault on 1. Check parameters. 206
signal loss. A signal loss has occurred. 2. Check for broken/loose connections at inputs.
Configure with Anlg In 1, 2 Loss (324,
327).
33 Auto Rstrt Tries 3 Drive unsuccessfully attempted to reset 1. Correct the cause of the fault and manually 206
a fault. clear.
2. Check parameters in VFD_CONF screen
35 Current Fbk Lost 4 The magnitude of motor current feed- 1. Verify connection of current feedback device 206
back was less than 5% Motor NP FLA and motor terminals.
(42) for the time configured in Imbalance 2. If fault repeats, replace current feedback
Time (50). Detection of this fault is dis- devices and/or power supply.
abled when Imbalance Time (50) is set 3. Check VFD_CONF screen parameters.
to the maximum value of 10.0 seconds.
36 SW OverCurrent 1 The drive output current has exceeded 1. Check for excess load. 246
the software current.
37 Motor I Imbalance 4 Phase current displayed in Imbalance 1. Press ICVC RESET key to clear fault. 225
Display (221) > percentage set in Imbal- 2. Check motor leads and terminals.
ance Limit (49) for time set in Imbalance
Time (50).
38 Phase U to Grnd 4 A phase-to-ground fault has been 1. Check the wiring between the drive and motor. 220
39 Phase V to Grnd 4 detected between the drive and motor in 2. Check motor for grounded phase.
this phase. 3. Contact Carrier Service.
40 Phase W to Grnd 4
41 Phase UV Short 4 Excessive current has been detected 1. Check the motor and drive output terminal 220
42 Phase VW Short 4 between these two output terminals. wiring for a shorted condition.
2. Contact Carrier Service, replace drive.
43 Phase UW Short 4
*Fault Type indicates if the fault is: NOTE: VFD Troubleshooting should only be performed by a
1 — Auto-resettable Reliance Certified LiquiFlo2 technician.
2 — Non-resettable
3 — User-configurable
4 — Normal Fault resettable using Carrier ICVC
“RESET” softkey
113
Table 20 — VFD Fault Description and Corrective Actions (cont)
CODE STATE
48 Params Defaulted 4 The drive was commanded to write 1. Press ICVC RESET key or cycle power to the 206
default values to EEPROM. VFD.
2. Program the drive parameters as needed.
63 Shear Pin 3 Programmed Current Lmt Val (148) has Check MOTOR RATED LOAD AMPS setting in 206
been exceeded. VFD_CONF screen.
Enabled/disable with Fault Config 1
(238).
64 Drive OverLoad 4 Drive rating of 102% for 1 minute or Check RATED LINE AMPS and MOTOR RATED 246
150% for 5 seconds has been LOAD AMPS in VFD_CONF screen.
exceeded.
70 HW Fault 4 Inverter section of power module Contact Carrier Service 206
detected an unexpected fault during
power stage diagnostics.
71- 75 Port 1-5 Net Loss 4 The network card connected to DPI port 1. Check communication board for proper 206
stopped communicating. connection to external network.
The fault code indicates the offending 2. Check external wiring to module on port.
port number (71 = port 1, 72 = port 2, Check ribbon cables, connectors, and pins.
etc.) 3. Verify external network fault.
77 IR Volts Range 4 The drive autotuning default is calcu- Check Motor Nameplate parameters in VFD_- 206
lated, and the value calculated for IR CONF screen.
Drop Volts is not in the range of accept-
able values.
78 FluxAmpsRef Rang 4 The value for flux amps determined by Check MOTOR NAMEPLATE AMPS in VFD_- 206
the autotune procedure exceeds the CONF screen.
programmed Motor NP FLA (42).
79 Excessive Load 4 Motor did not come up to speed in the 1. Check parameters in VFD_CONF screen. 203
allotted time. 2. Contact Carrier Service.
80 AutoTune Aborted 4 The autotune procedure was canceled Press ICVC RESET key to restart procedure. 206
by the user.
81- 85 Port 1-5 DPI Loss 4 DPI port stopped communicating. 1. If module was not intentionally disconnected, 206
An attached peripheral with control check ribbon cables, connectors, and pins.
capabilities via Local Mask (288) (or Replace wiring port expander, modules, Main
OIM control) was removed. Control Board or complete drive as required.
The fault code indicates the offending 2. Check OIM connection if used.
port number (81 = port 1, etc.)
87 Ixo Voltage Range 4 Ixo voltage calculated from motor name- 1. Press ICVC RESET key. 206
plate data is too high 2. Contact Carrier Service.
100 Parameter Chksum 2 The checksum read from the board 1. Press ICVC RESET key to restore defaults. 206
does not match the checksum calcu- 2. Cycle power to the VFD.
lated.
101 UserSet1 Chksum 2 The checksum read from the user 1. Press ICVC RESET key to restore defaults. 206
102 UserSet2 Chksum 2 set does not match the checksum 2. Cycle power to the VFD.
calculated.
103 UserSet3 Chksum 2
104 Pwr Brd Chksum1 4 The checksum read from the EEPROM 1. Press ICVC RESET key to restore defaults. 206
does not match the checksum calcu- 2. Cycle power to the VFD.
lated from the EEPROM data.
105 Pwr Brd Chksum2 2 The checksum read from the board 1. Cycle power to the VFD. 206
does not match the checksum calcu- 2. If problem persists, contact Carrier Service.
lated.
106 Incompat MCB-PB 2 Drive rating information stored on the Load compatible version files into drive. 206
power board is incompatible with the
Main Control board.
107 Replaced MCB-PB 2 Main Control board was replaced and Program parameters into VFD_CONF screen. 206
parameters were not programmed.
120 I/O Board Mismatch 4 Incorrect I/O board identified. Program parameters into VFD_CONF screen. 206
121 I/O Board Comm 2 Loss of communication to I/O board. 1. Press ICVC RESET key. 206
Loss 2. Check VFD board ribbon cables and connec-
tor pins.
122 I/O Board Fail 4 Board failure. 1. Press ICVC RESET key, cycle power to the 206
VFD.
2. If fault repeats, replace I/O board.
200 Inverter Dsat 4 High current was detected in an IGBT. 1. Check for loose connection in IGBT wire 201
U, V, W harness.
201 2. Check IGBTs.
3. Check precharge resistors and fuses.
202 4. Check precharge contactor.
“RESET” softkey
114
Table 20 — VFD Fault Description and Corrective Actions (cont)
CODE STATE
203 Inverter OverCurrent 4 High current was detected in an IGBT. Check parameters in VFD_CONF screen. 246
204 U, V, W
205
207 Invtr Gate Kill 4 Inverter gate kill contact is open. 1. Check that condenser high pressure switch is 207
wired to the VFD gate kill contact. 235
2. Check that high pressure switch is closed.
208 Rectifier Dsat 4 High current was detected in an IGBT. 1. Press RESET key on ICVC. 200
209 R, S, T 2. Contact Carrier Service.
210
211 Rectifier Over Cur 4 Rectifier overcurrent Check parameters in VFD_CONF screen. 241
212 R, S, T
213
214 Reactor Temp 4 Temperature switch in reactor opened. Check for proper temperature and fan operation. 255
215 Rctfr HW Unused 4 Rectifier portion of power structure hard- 1. Verify connection between rectifier control 206
ware reported unexpected fault board and rectifier power board.
2. If fault persists, replace rectifier power board.
3. If fault still persists, replace rectifier inverter
control board.
216 Rectifier Ground Fault 4 Excessive ground current measured. Check for grounded input wiring. 220
217 Rectifier Base Temp 4 Excessive rectifier temperature 1. Check VFD cooling solenoid, VFD refrigerant 218
measured. strainer, and VFD isolation valves.
coolant.
218 Rectifier IGBT Temp 4 Excessive calculated IGBT temperature. 1. Check VFD cooling solenoid, VFD refrigerant 218
strainer, and VFD isolation valves.
coolant.
219 Rectifier IT Overload 4 Short-term current rating of rectifier Low input voltage can result in increased current 146
exceeded. load. Provide proper input voltage to the drive. 212
220 Rectifier I2T Overload 4 Long-term current rating of rectifier Low input voltage can result in increased current 146
exceeded. load. Provide proper input voltage to the drive. 212
221 Ride Thru Abort 4 Input power loss timed out. 1. Verify input power and connections. 146
2. Check Line Sync board, connectors and pins. 147
3. Check AC Line I/O board, connectors, and 212
pins. 213
222 High AC Line 4 Input line voltage is too high. Reduce input voltage to meet RATED LINE 145
VOLTAGE ±10%. 211
223 Low DC Bus 4 The bus voltage is too low. 1. Verify proper input voltage. 149
2. Check control center and input power fuses. 215
224 Rctfr Over Volt 4 The bus voltage is too high. Monitor the AC line for high line voltage or tran- 150
sient conditions. Extend the decel time. 205
225 Input Amp Imbalance 4 Input phase current imbalance 1. Check for loose connection in input power 143
exceeded limits. wiring. 209
2. Check precharge contactors.
226 Input Volt Imbalance 4 Input voltage imbalance exceeded lim- 1. Check for problem in input power distribution. 216
its. 2. Check input wiring connections.
227 AC Line Lost 4 Input power Lost 1. Verify proper input voltage. 144
2. Check line sync board and fuse. 210
3. Check AC line I/O board.
4. Verify connections between boards.
228 Line Frequency 4 Line frequency not in the range of Verify connection between AC Line Sync and AC 222
47-63 Hz. Line I/O boards. Confirm that connectors are fully
engaged.
229 Rectifier Checksum 4 The checksum read from the board 1. Check all power module connectors and cycle 253
does not match the checksum calcu- power to the VFD.
lated. 2. Press ICVC RESET key to restore defaults.
3. Check parameters in VFD_CONF screen.
230 Invtr HW Unk 4 Inverter section of power structure hard- 1. Verify connection between inverter control 206
ware reported unexpected fault. board and inverter power board.
2. If fault persists, replace inverter power board.
3. If fault still persists, replace inverter control
board.
“RESET” softkey
115
 Table 20 — VFD Fault Description and Corrective Actions (cont)
CODE STATE
231 Rctfr HW Unk 4 Rectifier portion of power structure hard- 1. Verify connection between rectifier control 206
ware reported unexpected fault. board and rectifier power board.
2. If fault persists, replace rectifier power board
3. If fault still persists, replace rectifier control
board.
232 Rctfr Not OK 4 A fault was detected in the rectifier other Look at rectifier parameter 243 to see fault code. 200
than one specifically decoded. Contact Carrier.
233 Precharge closed 4 Precharge was closed when it should be 1. Check AUX contacts on precharge. Check if 206
open. precharge contactor is energized.
2. Check input bit 0 in rectifier parameter 216 to
view status of input.
3. Check wiring.
234 Precharge open 4 Precharge was open when it should be 1. Check AUX contacts on precharge. Check if 206
closed. precharge contactor is de-energized.
2. Check input bit 0 in rectifier parameter 216 to
view status of input.
3. Check wiring.
235 Rctfr Pwr Board 4 Drive rating information stored on the Load compatible version files into drive. 206
power board is incompatible with the 1. Cycle power to the VFD.
Main Control board. 2. If problem persists, contact Carrier Service.
The checksum read from the board
does not match the checksum calcu-
lated.
236 Rctfr I/O Board 4 Loss of communication to I/O board. 1. Cycle power to the VFD. 206
Board failure. 2. Check I/O board ribbon cables, connectors,
and pins.
3. If fault repeats, replace I/O board.
237 Not at Voltage 4 The rectifier did not regulate to the 1. Check all fuses and cabinet wiring. 149
desired bus voltage within the defined 2. Replace line synch board. 215
time. 3. Replace AC Line I/O board.
4. Replace rectifier control board and/or rectifier
power board.
238 Rectfr Not Logged In 4 Rectifier took too long to connect to 1. Check the cabling, connectors, and pins 206
inverter. between the communications interface and the
two control boards.
2. Verify the DPI Data Rate (270) is set to 500K.
3. Connect one DPI device at a time to determine
if one of the DPI devices is causing the
problem.
4. Replace the communications interface.
5. Replace the rectifier control board.
6. Swap 80W power supplies to determine if the
fault follows the power supply. Replace the
power supply if needed.
239 Power Phased ACB 4 Input Power is phased ACB rather than Switch two of the input power phases. 226
ABC.
“RESET” softkey
516 116
Table 21 — Thermistor Temperature (F) vs Resistance/Voltage Drop
PIC III PIC III PIC III

TEMPERATURE RESISTANCE TEMPERATURE RESISTANCE TEMPERATURE RESISTANCE
VOLTAGE VOLTAGE VOLTAGE
(F) (OHMS) (F) (OHMS) (F) (OHMS)
DROP (V) DROP (V) DROP (V)
–25 4.700 97,706 66 2.565 6,568 157 0.630 893
–24 4.690 94,549 67 2.533 6,405 158 0.619 876
–23 4.680 91,474 68 2.503 6,246 159 0.609 859
–22 4.670 88,480 69 2.472 6,092 160 0.599 843
–21 4.659 85,568 70 2.440 5,942 161 0.589 827
–20 4.648 82,737 71 2.409 5,796 162 0.579 812
–19 4.637 79,988 72 2.378 5,655 163 0.570 797
–18 4.625 77,320 73 2.347 5,517 164 0.561 782
–17 4.613 74,734 74 2.317 5,382 165 0.551 768
–16 4.601 72,229 75 2.287 5,252 166 0.542 753
–15 4.588 69,806 76 2.256 5,124 167 0.533 740
–14 4.576 67,465 77 2.227 5,000 168 0.524 726
–13 4.562 65,205 78 2.197 4,880 169 0.516 713
–12 4.549 63,027 79 2.167 4,764 170 0.508 700
–11 4.535 60,930 80 2.137 4,650 171 0.499 687
–10 4.521 58,915 81 2.108 4,539 172 0.491 675
–9 4.507 56,981 82 2.079 4,432 173 0.484 663
–8 4.492 55,129 83 2.050 4,327 174 0.476 651
–7 4.477 53,358 84 2.021 4,225 175 0.468 639
–6 4.461 51,669 85 1.993 4,125 176 0.460 628
–5 4.446 50,062 86 1.965 4,028 177 0.453 616
–4 4.429 48,536 87 1.937 3,934 178 0.445 605
–3 4.413 47,007 88 1.909 3,843 179 0.438 595
–2 4.396 45,528 89 1.881 3,753 180 0.431 584
–1 4.379 44,098 90 1.854 3,667 181 0.424 574
0 4.361 42,715 91 1.827 3,582 182 0.418 564
1 4.344 41,380 92 1.800 3,500 183 0.411 554
2 4.325 40,089 93 1.773 3,420 184 0.404 544
3 4.307 38,843 94 1.747 3,342 185 0.398 535
4 4.288 37,639 95 1.721 3,266 186 0.392 526
5 4.269 36,476 96 1.695 3,192 187 0.385 516
6 4.249 35,354 97 1.670 3,120 188 0.379 508
7 4.229 34,270 98 1.644 3,049 189 0.373 499
8 4.209 33,224 99 1.619 2,981 190 0.367 490
9 4.188 32,214 100 1.595 2,914 191 0.361 482
10 4.167 31,239 101 1.570 2,849 192 0.356 474
11 4.145 30,298 102 1.546 2,786 193 0.350 466
12 4.123 29,389 103 1.523 2,724 194 0.344 458
13 4.101 28,511 104 1.499 2,663 195 0.339 450
14 4.079 27,663 105 1.476 2,605 196 0.333 442
15 4.056 26,844 106 1.453 2,547 197 0.328 435
16 4.033 26,052 107 1.430 2,492 198 0.323 428
17 4.009 25,285 108 1.408 2,437 199 0.318 421
18 3.985 24,544 109 1.386 2,384 200 0.313 414
19 3.960 23,826 110 1.364 2,332 201 0.308 407
20 3.936 23,130 111 1.343 2,282 202 0.304 400
21 3.911 22,455 112 1.321 2,232 203 0.299 393
22 3.886 21,800 113 1.300 2,184 204 0.294 387
23 3.861 21,163 114 1.279 2,137 205 0.290 381
24 3.835 20,556 115 1.259 2,092 206 0.285 374
25 3.808 19,967 116 1.239 2,047 207 0.281 368
26 3.782 19,396 117 1.219 2,003 208 0.277 362
27 3.755 18,843 118 1.200 1,961 209 0.272 356
28 3.727 18,307 119 1.180 1,920 210 0.268 351
29 3.700 17,787 120 1.161 1,879 211 0.264 345
30 3.672 17,284 121 1.143 1,840 212 0.260 339
31 3.644 16,797 122 1.124 1,801 213 0.256 334
32 3.617 16,325 123 1.106 1,764 214 0.252 329
33 3.588 15,868 124 1.088 1,727 215 0.248 323
34 3.559 15,426 125 1.070 1,691 216 0.245 318
35 3.530 14,997 126 1.053 1,656 217 0.241 313
36 3.501 14,582 127 1.036 1,622 218 0.237 308
37 3.471 14,181 128 1.019 1,589 219 0.234 303
38 3.442 13,791 129 1.002 1,556 220 0.230 299
39 3.412 13,415 130 0.986 1,524 221 0.227 294
40 3.382 13,050 131 0.969 1,493 222 0.224 289
41 3.353 12,696 132 0.953 1,463 223 0.220 285
42 3.322 12,353 133 0.938 1,433 224 0.217 280
43 3.291 12,021 134 0.922 1,404 225 0.214 276
44 3.260 11,699 135 0.907 1,376 226 0.211 272
45 3.229 11,386 136 0.893 1,348 227 0.208 267
46 3.198 11,082 137 0.878 1,321 228 0.205 263
47 3.167 10,787 138 0.864 1,295 229 0.203 259
48 3.135 10,500 139 0.849 1,269 230 0.198 255
49 3.104 10,221 140 0.835 1,244 231 0.195 251
50 3.074 9,949 141 0.821 1,219 232 0.192 248
51 3.042 9,689 142 0.808 1,195 233 0.190 244
52 3.010 9,436 143 0.795 1,172 234 0.187 240
53 2.978 9,190 144 0.782 1,149 235 0.184 236
54 2.946 8,951 145 0.769 1,126 236 0.182 233
55 2.914 8,719 146 0.756 1,104 237 0.179 229
56 2.882 8,494 147 0.744 1,083 238 0.176 226
57 2.850 8,275 148 0.731 1,062 239 0.174 223
58 2.819 8,062 149 0.719 1,041 240 0.172 219
59 2.788 7,855 150 0.707 1,021 241 0.169 216
60 2.756 7,655 151 0.696 1,002 242 0.167 213
61 2.724 7,460 152 0.684 983 243 0.164 210
62 2.692 7,271 153 0.673 964 244 0.162 207
63 2.660 7,088 154 0.662 945 245 0.160 204
64 2.628 6,909 155 0.651 928 246 0.158 201
65 2.596 6,736 156 0.640 910 247 0.155 198
248 0.153 195
117
Table 22 — Thermistor Temperature (C) vs Resistance/Voltage Drop
PIC III PIC III

TEMPERATURE VOLTAGE RESISTANCE TEMPERATURE VOLTAGE RESISTANCE
(C) (OHMS) (C) (OHMS)
DROP (V) DROP (V)
–33 4.722 105 616 44 1.338 2 272
–32 4.706 99 640 45 1.300 2 184
–31 4.688 93 928 46 1.263 2 101
–30 4.670 88 480 47 1.227 2 021
–29 4.650 83 297 48 1.192 1 944
–28 4.630 78 377 49 1.158 1 871
–27 4.608 73 722 50 1.124 1 801
–26 4.586 69 332 51 1.091 1 734
–25 4.562 65 205 52 1.060 1 670
–24 4.538 61 343 53 1.029 1 609
–23 4.512 57 745 54 0.999 1 550
–22 4.486 54 411 55 0.969 1 493
–21 4.458 51 341 56 0.941 1 439
–20 4.429 48 536 57 0.913 1 387
–19 4.399 45 819 58 0.887 1 337
–18 4.368 43 263 59 0.861 1 290
–17 4.336 40 858 60 0.835 1 244
–16 4.303 38 598 61 0.811 1 200
–15 4.269 36 476 62 0.787 1 158
–14 4.233 34 484 63 0.764 1 117
–13 4.196 32 613 64 0.741 1 079
–12 4.158 30 858 65 0.719 1 041
–11 4.119 29 211 66 0.698 1 006
–10 4.079 27 663 67 0.677 971
–9 4.037 26 208 68 0.657 938
–8 3.994 24 838 69 0.638 906
–7 3.951 23 545 70 0.619 876
–6 3.906 22 323 71 0.601 846
–5 3.861 21 163 72 0.583 818
–4 3.814 20 083 73 0.566 791
–3 3.765 19 062 74 0.549 765
–2 3.716 18 097 75 0.533 740
–1 3.667 17 185 76 0.518 715
0 3.617 16 325 77 0.503 692
1 3.565 15 513 78 0.488 670
2 3.512 14 747 79 0.474 648
3 3.459 14 023 80 0.460 628
4 3.406 13 341 81 0.447 608
5 3.353 12 696 82 0.434 588
6 3.298 12 087 83 0.422 570
7 3.242 11 510 84 0.410 552
8 3.185 10 963 85 0.398 535
9 3.129 10 444 86 0.387 518
10 3.074 9 949 87 0.376 502
11 3.016 9 486 88 0.365 487
12 2.959 9 046 89 0.355 472
13 2.901 8 628 90 0.344 458
14 2.844 8 232 91 0.335 444
15 2.788 7 855 92 0.325 431
16 2.730 7 499 93 0.316 418
17 2.672 7 160 94 0.308 405
18 2.615 6 839 95 0.299 393
19 2.559 6 535 96 0.291 382
20 2.503 6 246 97 0.283 371
21 2.447 5 972 98 0.275 360
22 2.391 5 711 99 0.267 349
23 2.335 5 463 100 0.260 339
24 2.280 5 226 101 0.253 330
25 2.227 5 000 102 0.246 320
26 2.173 4 787 103 0.239 311
27 2.120 4 583 104 0.233 302
28 2.067 4 389 105 0.227 294
29 2.015 4 204 106 0.221 286
30 1.965 4 028 107 0.215 278
31 1.914 3 861 108 0.210 270
32 1.865 3 701 109 0.205 262
33 1.816 3 549 110 0.198 255
34 1.768 3 404 111 0.193 248
35 1.721 3 266 112 0.188 242
36 1.675 3 134 113 0.183 235
37 1.629 3 008 114 0.178 229
38 1.585 2 888 115 0.174 223
39 1.542 2 773 116 0.170 217
40 1.499 2 663 117 0.165 211
41 1.457 2 559 118 0.161 205
42 1.417 2 459 119 0.157 200
43 1.377 2 363 120 0.153 195
118
Control Modules — Turn controller power off before 2. If a green LED is on continuously, check the communica-
servicing controls. This ensures safety and prevents damage to tion wiring. If a green LED is off, check the red LED op-
the controller. eration. If the red LED is normal, check the SIO address
The ICVC and CCM modules perform continuous diagnos- switches (Fig. 60 and 61). Confirm all SW1 SIO address
tic evaluations of the hardware to determine its condition. dip switches on the CCM are in the OFF position.
Proper operation of all modules is indicated by LEDs (light- All system operating intelligence resides in the ICVC.
emitting diodes) located on the circuit board of the ICVC and Some safety shutdown logic resides in the VFD Gate-
CCM. way in case communications are lost between the VFD
There is one green LED located on the CCM board, and one and ICVC. Outputs are controlled by the CCM and
red LED located on the ICVC and CCM boards. VFD Gateway as well.
RED LED (Labeled as STAT) — If the red LED: 3. In the control center, a 3 KVA transformer steps down
• Blinks continuously at a 2-second interval — the module line power to 115 V. This supplies power to the oil pump,
is operating properly oil vaporizer heater, oil sump heater, and control power
• Is lit continuously — there is a problem that requires transformers. Power is supplied to the ICVC and CCM
replacing the module modules within the control center via the T1 24-VAC
• Is off continuously — the power should be checked transformer.
• Blinks 3 times per second — a software error has been The control power transformers are located on the
discovered and the module must be replaced power panel.
If there is no input power, check the CB2 control power Transformer T1 supplies 24 V power to the ICVC and
circuit breaker and control power transformer circuit breakers CCM. Transformer T2 provides 20 V power to
(CB1A and CB1B). If the breakers are good, check for a short- optional DataPort™ or DataLINK™ modules.
ed 24 vac secondary of the T1 transformer or, if power is pres- Power is connected to Plug J1 on the ICVC and CCM
ent to the module, replace the module. modules.
GREEN LED (Labeled as COM) — These LEDs indicate
the communication status between different parts of the con- Chiller Control Module (CCM) (Fig. 61)
troller and the network modules and should blink continuously. INPUTS — Each input channel has 2 or 3 terminals. Refer to
individual chiller wiring diagrams for the correct terminal
Notes on Module Operation numbers for your application.
1. The chiller operator monitors and modifies configura- OUTPUTS — CCM terminals J11 and J12 are discrete (on/
tions in the microprocessor by using the 4 softkeys and off) outputs that switch 24 volts. The 4 to 20 mA output chan-
the ICVC. Communications between the ICVC and the nel on terminals J8-1 and J8-2 is designed for non-grounded
CCM is accomplished through the SIO (Sensor Input/ controllers with a maximum input impedance of 500 ohms.
Output) bus, which is a phone cable. The communication J8-3 and J8-4 are used with a 500-ohm resistor to control the
between the CCM and VFD is accomplished through a oil reclaim actuator.
3-wire SIO communication protocol cable.
GROUND
SIO COMMUNICATIONS (J7)
POWER AND CCN (J1)
RJ-14 SERVICE
CONNECTION (J8)
a23-1640
Fig. 60 — Rear of ICVC (International Chiller Visual Controller)
119
SW1 SIO ADDRESS
J11 J12 DIPSWITCH
DISCRETE DISCRETE J1
OUTPUTS OUTPUTS SET ALL TO “OFF” 24 VAC
ANALOG OUT
J8
SIO
J7
SIO
J6
SW2 V/I
INPUT
CONFIGURATION
V/I INPUTS
J5
a23-1617 STAT COMM THERMISTORS DIFF PRESSURE PRESSURE

J4 J3 J2
Fig. 61 — Chiller Control Module (CCM)

Replacing Defective ICVC Modules — The mod- also be copied manually. The data sheets on pages CL-4
ule replacement part number is printed on a small label on the through CL-10 are provided for this purpose. Default
rear of the ICVC module. The chiller model and serial num- values are shown so that only deviations from these need
bers are printed on the chiller nameplate located on the right to be recorded.
side of the control center. The proper software is factory- If a CCN Building Supervisor or Service Tool is avail-
installed by Carrier in the replacement module. When ordering able, the module configuration should have already been
a replacement international chiller visual controller (ICVC) uploaded into memory. When the new module is
module, specify the complete replacement part number, full installed, the configuration can be downloaded from the
chiller model number, and chiller serial number. The installer computer.
must configure the new module to the original chiller data.
Follow the procedures described in the Software Configuration 3. To install this module, record values for the TOTAL
section on page 75. COMPRESSOR STARTS, SERVICE ONTIME, and the
COMPRESSOR ONTIME from the MAINSTAT screen
on the ICVC.
CAUTION
4. Power off the controls.
Electrical shock can cause personal injury. Disconnect all 5. Remove the old ICVC.
electrical power before servicing. 6. Install the new ICVC module. Turn the control power
back on.
INSTALLATION 7. The ICVC now automatically attaches to the local net-
1. Verify the existing ICVC module is defective by using the work device.
procedure described in the Troubleshooting Guide sec- 8. Set the current time and date in the SERVICE / TIME
tion, page 96, and the Control Modules section, on this AND DATE screen. Set the CCN Bus and Address in the
page. Do not select the ATTACH TO NETWORK SERVICE / ICVC CONFIGURATION screen. Press the
DEVICE table if the ICVC indicates a CCN communica- alarm RESET soft key (from the default screen). Upload
tion failure. Doing so will probably lock up the ICVC via Service Tool or manually reenter all non-default con-
because it will not be able to communicate with the CCN. figuration values. (Refer to pages CL-4 through CL-10).
2. Any communication wires from other chillers or CCN If the correct VFD_CONF values are displayed when that
modules should be disconnected prior to installation of a table is viewed, simply press EXIT then SAVE to reload
new module to prevent the new ICVC from uploading all of them. Using Service Tool or manually reenter
incorrect run hours into memory. Data regarding the TOTAL COMPRESSOR STARTS, COMPRESSOR
ICVC configuration should have been recorded and ONTIME, and SERVICE ONTIME. If forced using
saved. This data must be reconfigured into the new Service Tool, release the force on SERVICE ONTIME
ICVC. If this data is not available, follow the procedures after the desired value has been set. TOTAL COMPRES-
described in the Software Configuration section. If the SOR STARTS and TOTAL COMPRESSOR ONTIME can
module to be replaced is functional, configurations may only be changed prior to the first completed start. If a start
120
is completed and the COMPRESSOR STARTS or COM- MS STATUS INDICATOR — The MS status indicator is the
PRESSOR ON TIME are both incorrect, the ICVC soft- second LED from the right of the Gateway. See Table 24.
ware must be downloaded again before these settings can
be changed. Table 24 — Gateway MS Status Indicator
9. Check and recalibrate pressure transducer readings (refer STATE CAUSE CORRECTIVE ACTION
to page 95). Check that the CURRENT TIME and DATE OFF The Gateway is not • Securely connect the
in the TIME AND DATE screen are correct. powered. Gateway to the drive using
DPI Communications Interface Board Status LEDs — VFD the ribbon cable.
• Apply power to the drive.
status can be determined from the status LEDs on the DPI
FLASHING Recoverable Fault Cycle power to the drive. If
Communications Interface Board shown in Fig. 62. The DPI RED Condition cycling power does not cor-
Board is mounted on the front of the VFD power module in a rect the problem, the firm-
vertical orientation. ware may need to be flashed
into the module.
Gateway Status LEDs — The RS485 VFD Gateway SOLID The module has failed • Cycle power to the drive
provides a communication link between the CCM and ICVC RED the hardware test. • Replace the Gateway
SIO bus to the VFD Drive Peripheral Interface (DPI) board. FLASHING The Gateway is opera- Normal behavior during SIO
The SIO bus communicates with the Gateway through VFD GREEN tional. No I/O data is configuration initialization
connector A32. See Fig. 63. being transferred. process.
SOLID The Gateway is opera- No action required.
The Gateway has four status indicators on the top side of the GREEN tional and transferring
module. I/O data.
DRIVE STATUS INDICATOR — The DRIVE status indi-
cator is on the right side of the Gateway. See Table 23. NET A STATUS INDICATOR — The NET A status indica-
tor is the third LED from the right of the Gateway. See
Table 23 — Gateway DRIVE Status Indicator Table 25.
STATE CAUSE CORRECTIVE ACTION Table 25 — Gateway NET A Status Indicator
OFF The Gateway is not • Securely connect the
powered or is not con- Gateway to the drive STATE CAUSE CORRECTIVE ACTION
nected properly to the using the DPI ribbon
drive. cable. OFF The module is not pow- • Securely connect the
• Apply power to the drive. ered or is not properly Gateway ribbon cable to
connected to the the drive DPI board.
FLASHING The Gateway is not • Verify that cables are network. • Attach the RS485 cable in
RED receiving a ping mes- securely connected. Gateway to the connector.
sage from the drive. • Cycle power to the drive. First incoming network
command not yet • Apply power to the drive.
SOLID The drive has refused IMPORTANT: Cycle power recognized.
RED an I/O connection from after making the following
the Gateway. correction: FLASHING Network has timed out. Cycle power to the drive.
• Verify that all DPI cables RED
on the drive are securely SOLID The Gateway has Check node address and
connected and not dam- RED detected an error that data rate switch positions on
aged. Replace cables if has made it incapable the front of the Gateway.
necessary. of communication on Cycle power to the drive.
ORANGE The Gateway is con- • Check wires leading to the network.
nected to a product the A32 terminal block. FLASHING Online to network, but No action required. The
that does not support • Check that A32 terminal GREEN not producing or con- LED will turn solid green
Rockwell Automation block is fully engaged. suming I/O information. when communication
DPI communications. resumes.
FLASHING The Gateway is estab- Normal behavior. SOLID The module is properly No action required.
GREEN lishing an I/O connec- GREEN connected and commu-
tion to the drive or the nicating on the network.
I/O has been disabled.
SOLID The Gateway is prop- No action required. NET B STATUS INDICATOR — The NET B status indica-
GREEN erly connected and is
communicating with tor is the left LED on the Gateway. See Table 26.
the drive.
Table 26 — Gateway NET B Status Indicator
STATE CAUSE CORRECTIVE ACTION
OFF Gateway not receiving • Check wires leading to
data over the network. A32 terminal block.
• Check that A32 terminal
block is fully engaged.
SOLID OR Gateway is transmit- No action required.
BLINKING ting data.
GREEN
121
DPI COMMUNICATIONS INTERFACE BOARD
a19-1634
RECTIFIER LED INVERTER LED
INVERTER STATUS LIGHT

COLOR STATE DESCRIPTION
Flashing Drive ready, but not running and no faults are present.
GREEN
Steady Drive running, no faults are present.
Flashing The drive is not ready. A VFD start inhibit is in effect. Normal condition when chiller not running because the ICVC has issued a stop command.
YELLOW
Steady An alarm condition exits. Check VFD FAULT CODE in ICVC VFD_STAT screen.
Flashing A fault has occurred. Check VFD FAULT CODE in ICVC VFD_STAT screen.
RED
Steady A non-resettable fault has occurred. Check VFD FAULT CODE in ICVC VFD_STAT screen.
RED INVERTER Steady VFD Gate Kill circuit has opened because the compressor high pressure switch has opened.
GREEN
RECTIFIER
RECTIFIER STATUS LIGHT

COLOR STATE DESCRIPTION
Flashing Rectifier ready, but not running and no faults are present.
GREEN
Steady Rectifier running, no faults are present.
Flashing Rectifier is not ready. A VFD start inhibit is in effect. This is a normal state if the inverter is not running and/or the precharge contacts are open.
YELLOW
Steady Rectifier alarm condition exits. Check VFD FAULT CODE in ICVC VFD_STAT screen.
Flashing Rectifier fault has occurred. Check (VFD FAULT CODE in ICVC VFD_STAT screen.
RED
Steady A non-resettable fault has occurred. Check VFD FAULT CODE in ICVC VFD_STAT screen.
RED INVERTER Steady VFD Gate Kill circuit has opened because the compressor high pressure switch has opened.
GREEN
RECTIFIER
INVERTER AND RECTIFIER CONTROL BOARD FAILURE STATUS LIGHT PATTERNS

COLOR DESCRIPTION
RED/GREEN ALTERNATING Control board application firmware may be corrupt. Call Carrier Service.
YELLOW/GREEN/RED Control board RAM failure or control board firmware may be corrupt. Call Carrier Service.
REPEATING PATTERN
Fig. 62 — DPI Communications Interface Board Status LEDs
122
DPI RIBBON
PD4 EXV BOARD (P COMPRESSOR ONLY) — See
CABLE CONNECTOR Fig. 64. The PD4 EXV board communicates with the master
CCM board through an RS-485 port. It provides input/output
for both the main condenser EXV and optional economizer
EXV, as well as the economizer gas temperature. Dip switch
NODE ADDRESS
TENS DIGIT = 0
settings are shown in Fig. 64.
(DO NOT
CHANGE) During communication a green activity LED will be dis-
DATA
played, and a red LED will blink during normal operation at a
RATE = PGM 1-second-on, one-second-off frequency (0.5 Hz).
(DO NOT
CHANGE) PD4 AUX1 BOARD (P COMPRESSOR ONLY) — See
Fig. 65. The AUX1 board communicates through RS-485 (J9)
with the PD4 EXV board and the master CCM board. It pro-
vides input/output for the condenser liquid sensor. Dip switch
settings are shown in Fig. 65.
A32 The red LED indicates the AUX1 board status as follows:
TERMINAL BLOCK
RED LED
NODE ADDRESS CONDITION AUX BOARD SOFTWARE STATUS
ONES DIGIT = 1
(DO NOT CHANGE) Off continuously Board unpowered or power supply defective
a23-1618 On continuously Board is powered but board microcontroller is
STATUS inactive or defective
NUMBER DESCRIPTION
INDICATOR Flashing (1 sec- Board is operating with correct board microcon-
1 DRIVE DPI Connection Status ond on, 1 sec- troller operation
2 MS Module Status ond off, 0.5 Hz)
3 NET A Serial Communication Status Flashing at any Board is operating defectively
4 NET B Serial Communication Traffic Status
other frequency
NOTE: If all status indicators are off, the Gateway is not receiving power.
The green LED lights every time the AUX board transmits
a message, so the frequency of the green LED is consistent
Fig. 63 — Gateway Status LEDs with the frequency of transmitted messages.
J4
COMMUNICATION
J3
ECONOMIZER GAS
TEMPERATURE
ON
DIP SWITCH
1 2 3 4 5 6 7 8
SETTINGS
J2B
CONDENSER EXV
J2A
ECONOMIZER EXV
LED
LIGHTS
a23-1721
J1 A23-1721
24 VAC
 Fig. 64 — PD4 EXV Board (P Compressor Only)
123 516
J9 J8 J7
CCM EXV LIQUID LEVEL
COMMUNICATION COMMUNICATION SENSOR
JUMPER
GREEN LED
RED LED
7 8
3 4 5 6
1 2
ON
DIP SWITCH
SETTINGS
a23-1722
J1
24 VAC
 Fig. 65 — PD4 AUX1 Board (P Compressor Only)
EXV TROUBLESHOOTING — If it appears that the main new o-ring available. Do not use the existing o-ring. Place the
EXV or economizer EXV is not properly controlled, perform piston in the fully open position to disassembly the EXV. When
the following checks. Through Controls Test move the EXV assembling the VFD, it is easier to install the motor assembly
fully open. The actuator should be felt through the EXV body. with the piston in the fully closed position. See Fig. 23 for
Then close the valve fully. The actuator should knock when it EXV cross-section diagrams. See Figs. 66 and 67 for disassem-
reaches the bottom of its stroke. bly and assembly instructions.
If the valve is not operating properly, continue checking the
PD4 EXV DIP switch settings (Fig. 64). Check the EXV out-
put signals at J2A and J2B respectively on the EXV module.
Connect positive test lead to J2A or J2B (as appropriate) termi-
nal 5 and move the valve output using the Controls Test to
100%, while being careful not to short any pins as board dam-
age will occur. During the next several seconds (while moving 1 1/16 in. (27 mm)
the actuator) carefully connect the negative test to pins 1, 2, 3
and 4 in succession. The digital voltmeter will average this sig-
nal and display approximately 6 vdc . If the output remains at a
constant voltage other than 6 vdc or shows 0 volts, remove the
connector to the valve and recheck. If confirmed, this may in-
dicate a bad EXV board. Note that 12 vdc is the output from
the EXV board when the valve is stationary.
If the reading is correct, the expansion valve and EXV wir-
ing should be checked. Check the EXV connector and inter-
connecting wiring by double checking color-coding and make
sure that all are connected to the correct terminals and that
wires are not crossed. Check for continuity and tight connec- a23-1723
tions at all pin terminals.
Disassembling and Assembling the EXV — Disassemble
the EXV to check EXV motor windings and the condenser liq-
uid level sensor. When disassembling the EXV, always have a Fig. 66 — EXV Disassembly
516 124
36 ft-lb (50 Nm) + 30˚
1 1/16 in. (27 mm)
a23-1724
Fig. 67 — EXV Assembly
Check EXV Motor Windings Resistance — To check the

resistance of the EXV motor windings, remove the EXV plug CAUTION
at J2A (economizer EXV) or J2B (condenser EXV) and check
resistance. The resistance should be 52 ohms (± 10%). See Before rigging the compressor, disconnect all wires enter-
ing the power panel to avoid damage to the panel.
Fig. 68.
COIL B
COIL A WIRE, PVC

22 AWG
12 TO 14 in. EXT
LABEL
a23-1725 ½ in. NPT CONDUIT

COIL A = 52 OHMS
COIL B = 52 OHMS
Fig. 68 — EXV Motor Windings Resistance O-RING
Check Condenser Level Sensor Resistance — The level sen-
sor provides a voltage between white (output) and black 2 5/16 in. - 12 UNF 2A
(ground) wires proportional to red (+) and black (ground) volt-
age. If the level sensor is suspected of misreading, check the re-
sistance between red (+) and black (ground) wries. It should
measure approximately 1800 ohms. Figure 69 shows condens- LO = 4 in. ± 1/16 in.
er liquid level sensor components.
FLOAT
Physical Data — Tables 27-40 and Fig. 70-81 provide
additional information on component weights, physical and
electrical data, and wiring schematics for the operator’s conve-
nience during troubleshooting.
GRIP RING
CAUTION 13 1
2 /16 in. ± /8 in. a23-1726
Do not attempt to disconnect flanges while the machine is (INDICATION= 2 1/4 in.)
under pressure. Failure to relieve pressure can result in per- (0.31 in. DIAM.)
sonal injury or damage to the unit. (1.02 in. DIAM.)
Fig. 69 — Condenser Liquid Level Sensor
125
Table 27 — 23XRV Cooler Frame Size A1-A6, B1-B6 Heat Exchanger Weights
ENGLISH METRIC (SI)
FRAME DRY DRY
SIZE STEEL COPPER REFRIG. SHIP WT WATER OPER. STEEL COPPER REFRIG. SHIP WT WATER OPER.
RIGGING RIGGING
WT (lb) WT (lb) WT (lb) (lb) VOL (Gal) WT (lb) WT (kg) WT (kg) WT (kg) (kg) VOL (L) WT (kg)
WT* (lb) WT* (kg)
A1 2506 734 3240 270 3510 47 3904 1137 333 1470 122 1592 178 1771
A2 2506 789 3295 290 3585 51 4009 1137 358 1495 132 1627 193 1819
A3 2506 889 3395 310 3705 57 4182 1137 403 1540 141 1681 216 1897
A4 2506 962 3468 330 3798 62 4315 1137 436 1573 150 1723 235 1958
A5 2506 1076 3582 360 3942 69 4520 1137 488 1625 163 1788 261 2050
A6 2506 1190 3696 390 4086 77 4725 1137 540 1677 177 1854 291 2144
B1 2642 839 3481 305 3786 54 4236 1198 381 1579 138 1717 204 1921
B2 2642 901 3543 325 3868 58 4352 1198 409 1607 147 1754 220 1974
B3 2642 1016 3658 355 4013 65 4558 1198 461 1659 161 1820 246 2067
B4 2642 1099 3741 375 4116 71 4706 1198 498 1696 170 1866 269 2134
B5 2642 1229 3871 415 4286 79 4946 1198 557 1755 188 1943 299 2242
B6 2642 1360 4002 445 4447 87 5177 1198 617 1815 202 2017 329 2348
*Dry rigging weight = Steel weight + Copper weight.
Table 28 — 23XRV Condenser Frame Size A1-A6, B1-B6 Heat Exchanger Weights
ENGLISH METRIC (SI)
FRAME DRY DRY
SIZE STEEL COPPER REFRIG. SHIP WT WATER OPER. STEEL COPPER REFRIG. SHIP WT WATER OPER.
RIGGING RIGGING
WT (lb) WT (lb) WT (lb) (lb) VOL (Gal) WT (lb) WT (kg) WT (kg) WT (kg) (kg) VOL (L) WT (kg)
WT* (lb) WT* (kg)
A1 3390 734 4124 550 4674 47 5068 1538 333 1871 249 2120 178 2299
A2 3390 844 4234 550 4784 54 5237 1538 383 1921 249 2170 204 2375
A3 3390 944 4334 550 4884 61 5391 1538 428 1966 249 2215 231 2445
A4 3390 1049 4439 550 4989 67 5552 1538 476 2014 249 2263 254 2518
A5 3390 1190 4580 550 5130 77 5769 1538 540 2078 249 2327 291 2617
A6 3390 1345 4735 550 5285 87 6007 1538 610 2148 249 2397 329 2724
B1 3571 839 4410 625 5035 54 5485 1620 381 2001 283 2284 204 2488
B2 3571 964 4535 625 5160 62 5677 1620 437 2057 283 2340 235 2575
B3 3571 1078 4649 625 5274 69 5853 1620 489 2109 283 2392 261 2655
B4 3571 1198 4769 625 5394 77 6037 1620 543 2163 283 2446 291 2738
B5 3571 1360 4931 625 5556 87 6286 1620 617 2237 283 2520 329 2851
B6 3571 1537 5108 625 5733 99 6558 1620 697 2317 283 2600 375 2974
*Dry rigging weight = Steel weight + Copper weight.
Table 29 — 23XRV Code 30-57 Heat Exchanger Weights

ENGLISH SI
DRY RIGGING WEIGHT DRY RIGGING WEIGHT
MACHINE CHARGE MACHINE CHARGE
(lb)* (kg)*
CODE REFRIGERANT LIQUID VOLUME REFRIGERANT LIQUID
COOLER CONDENSER WEIGHT (lb) (Gal) COOLER CONDENSER WEIGHT (kg) VOLUME (L)
ONLY ONLY WITH WITHOUT ONLY ONLY WITH WITHOUT
COOLER CONDENSER COOLER CONDENSER
ECONOMIZER ECONOMIZER ECONOMIZER ECONOMIZER
30 4148 3617 800 650 56 56 1877 1676 363 295 212 212
31 4330 3818 800 650 64 65 1959 1769 363 295 242 246
32 4522 4023 800 650 72 74 2046 1860 363 295 273 280
35 4419 4529 910 760 61 61 2000 2089 413 345 231 231
36 4627 4758 910 760 70 72 2094 2195 413 345 265 273
37 4845 4992 910 760 80 83 2193 2299 413 345 303 314
40 5008 4962 900 750 103 110 2675 2746 408 340 390 416
41 5178 5155 900 750 111 119 2758 2839 408 340 420 450
42 5326 5347 900 750 119 129 2832 2932 408 340 450 488
45 5463 5525 1015 865 112 120 2882 3001 460 392 424 454
46 5659 5747 1015 865 122 130 2976 3108 460 392 462 492
47 5830 5967 1015 865 130 141 3061 3214 460 392 492 534
50 5827 6013 1250 1100 132 147 3182 3304 567 499 500 556
51 6053 6206 1250 1100 143 156 3294 3397 567 499 541 590
52 6196 6387 1250 1100 150 165 3364 3485 567 499 568 625
55 6370 6708 1430 1280 144 160 3429 3620 649 581 545 606
56 6631 6930 1430 1280 156 171 3556 3726 649 581 590 647
57 6795 7138 1430 1280 164 181 3636 3826 649 581 621 685
*Rigging weights are for standard tubes of standard wall thickness (Turbo-B3 and Spikefin NOTES:
2, 0.025-in. [0.635 mm] wall). 1
1. Cooler includes the suction elbow and /2 the distribution piping weight.
2. Condenser includes float valve and sump, discharge stub-out, and 1/2 the distribution
piping weight.
3. For special tubes refer to the 23XRV Computer Selection Program.
4. All weights for standard 2-pass NIH (nozzle-in-head) design with Victaulic grooves.
126
 Table 30 — 23XRV Compressor and Motor Weights
ENGLISH SI
COMPRESSOR MOTOR TOTAL MOTOR TOTAL MOTOR
STATOR ROTOR STATOR ROTOR
TYPE SIZE COMPRESSOR TERMINAL COMPRESSOR TERMINAL
WEIGHT WEIGHT WEIGHT WEIGHT
WEIGHT COVER WEIGHT COVER
(lb) (lb) (kg) (kg)
(lb) (lb) (kg) (kg)
P H,J 3036 110 167 N/A 1377 50 76 N/A
Q V 4090 370 193 39 1855 168 88 18

P,Q,R,S,T,
R 4866 441 229 46 2207 200 104 21
U,V,X
 Table 31 — 23XRV Maximum Component Weights*

FRAME A HEAT FRAME B HEAT FRAME 3 HEAT FRAME 4 HEAT FRAME 5 HEAT
COMPONENT EXCHANGER EXCHANGER EXCHANGER EXCHANGER EXCHANGER
lb kg lb kg lb kg lb kg lb kg
Isolation Valves 70 32 70 32 115 52 70 32 70 32
P Compressor N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A
Suction Elbow Q Compressor 159 72 187 85 184 83 N/A N/A N/A N/A
R Compressor 179 81 237 108 232 105 N/A N/A N/A N/A
P Compressor N/A N/A N/A N/A N/A N/A 584 265 584 265
Discharge Elbow/
Q Compressor 597 271 597 271 597 271 N/A N/A N/A N/A
Muffler
R Compressor 747 339 747 339 747 339 N/A N/A N/A N/A
Vaporizer and Oil Sump 700 318 700 318 700 318 700 318 700 318
Economizer 542 246 542 246 542 246 174 79 174 79
*To determine compressor frame size, refer to Fig. 1.
 Table 32 — VFD (Variable Frequency Drive) Weight Table
DRIVE TYPE COMPRESSOR VOLTAGE/Hz AMPERAGE (A) WEIGHT (lb)

248 998
P/Q/R 480/60 & 380/400/415/50
Std. Tier 361 & 477 1200
Q/R 575/60 389 & 469 1650
380-415 50/60 440 1400
LF2 Q/R 440-480 50/60 440 1500
380-415 & 440-480 50/60 520 & 608 1800
Table 33 — 23XRV Waterbox Cover Weights, Frames 3,4,5 — English (lb)

COOLER CONDENSER
WATERBOX FRAME 3 FRAME 4 FRAME 5 FRAME 3 FRAME 4 FRAME 5
DESCRIPTION VICTAULIC VICTAULIC FLANGED VICTAULIC FLANGED VICTAULIC FLANGED VICTAULIC FLANGED VICTAULIC FLANGED
FLANGED
NOZZLES NOZZLES NOZZLES NOZZLES NOZZLES NOZZLES
NIH 1 Pass Cover,
150 psig 282 318 148 185 168 229 282 318 148 185 168 229
NIH 2 Pass Cover, 287 340 202 256 222 276 287 340 191 245 224 298
150 psig
NIH 3 Pass Cover, 294 310 472 488 617 634 294 310 503 519 628 655
150 psig
NIH Plain End, 243 243 138 138 154 154 225 225 138 138 154 154
150 psig
MWB End Cover, 243/315 243/315 138/314 138/314 154/390 154/390 225/234 225/234 138/314 138/314 154/390 154/390
150 psig*
NIH 1 Pass Cover, 411 486 633 709 764 840 411 486 633 709 764 840
300 psig
NIH 2 Pass Cover, 411 518 626 733 760 867 411 578 622 729 727 878
300 psig
NIH 3 Pass Cover, 433 468 660 694 795 830 433 468 655 689 785 838
300 psig
NIH Plain End, 291 291 522 522 658 658 270 270 522 522 658 658
300 psig
MWB End Cover, 445/619 445/619 522/522 522/522 658/658 658/658 359/474 359/474 522/522 522/522 658/658 658/658
300 psig*
LEGEND NOTE: Weight for NIH 2-pass cover, 150 psig (1034 kPa), is included in the heat exchanger
weights shown in Tables 27-29.
NIH — Nozzle-in-Head
MWB — Marine Waterbox
*Rows with two entries list nozzle end and return end weights.
127 1016
Table 34 — 23XRV Waterbox Cover Weights, Frames 3,4,5 — SI (kg)
COOLER CONDENSER
WATERBOX FRAME 3 FRAME 4 FRAME 5 FRAME 3 FRAME 4 FRAME 5
DESCRIPTION VICTAULIC FLANGED VICTAULIC FLANGED VICTAULIC FLANGED VICTAULIC FLANGED VICTAULIC FLANGED VICTAULIC FLANGED
NOZZLES NOZZLES NOZZLES NOZZLES NOZZLES NOZZLES
NIH 1 Pass Cover,
1034 kPa 128 144 67 84 76 104 128 144 67 84 76 104
NIH 2 Pass Cover, 130 154 92 116 101 125 130 154 87 111 102 135
1034 kPa
NIH 3 Pass Cover, 133 141 214 221 280 288 133 141 228 235 285 297
1034 kPa
NIH Plain End, 110 110 63 63 70 70 102 102 63 63 70 70
1034 kPa
MWB End Cover 110/143 110/143 63/142 63/142 70/177 70/177 102/106 102/106 63/142 63/142 70/177 70/177
1034 kPa*
NIH 1 Pass Cover, 186 220 287 322 347 381 186 220 287 322 346 381
2068 kPa
NIH 2 Pass Cover, 186 235 284 332 344 393 186 235 282 331 330 398
2068 kPa
NIH 3 Pass Cover, 196 212 299 315 361 376 196 212 297 313 356 380
2068 kPa
NIH Plain End 132 132 237 237 298 298 122 122 237 237 298 298
2068 kPa
MWB End Cover 202/281 202/281 237/237 237/237 298/298 298/298 163/215 163/215 237/237 237/237 298/298 298/298
2068 kPa*
LEGEND NOTE: Weight for NIH 2-pass cover, 150 psig (1034 kPa), is included in the heat exchanger
weights shown in Tables 27-29.
NIH — Nozzle-in-Head
*Rows with two entries list nozzle end and return end weights.
Table 35 — 23XRV Waterbox Cover Weights, Frames A/B — English (lb)

COOLER FRAMES A AND B CONDENSER FRAMES A AND B
WATERBOX
DESCRIPTION VICTAULIC VICTAULIC
FLANGED FLANGED
NOZZLES NOZZLES
NIH,1-Pass Cover 150 psig 217 244 242 274
NIH/Marine Plain End, 150 psig 157 157 173 173
MWB Cover, 150 psig 296 296 332 332
NIH/Marine Plain End, 300 psig 157 157 173 173
MWB Cover, 300 psig 296 296 332 332
LEGEND NOTE: Weight for NIH 2-pass cover, 150 psig (1034 kPa), is
NIH — Nozzle-in-Head included in the heat exchanger weights shown in Tables 27-29.
Table 36 — 23XRV Waterbox Cover Weights, Frames A/B — SI (kg)

COOLER FRAMES A AND B CONDENSER FRAMES A AND B
WATERBOX
DESCRIPTION VICTAULIC VICTAULIC
NOZZLES FLANGED NOZZLES FLANGED
NIH,1-Pass Cover 1034 kPa 98 111 110 124
NIH/Marine Plain End, 1034 kPa 71 71 78 78
MWB Cover, 1034 kPa 134 134 151 151
NIH/Marine Plain End, 2068 kPa 71 71 78 78
MWB Cover, 2068 kPa 134 134 151 151
LEGEND NOTE: Weight for NIH 2-pass cover, 150 psig (1034 kPa), is
NIH — Nozzle-in-Head included in the heat exchanger weights shown in Tables 27-29.
128
Table 37 — Optional Storage Tank and/or Pumpout System Physical Data
MAXIMUM REFRIGERANT CAPACITY
TANK OUTSIDE
UNIT DIAMETER DRY WEIGHT ASHRAE/ANSI 15 UL-1963
SIZE HFC-134A HFC-134A
in. mm lb kg lb kg lb kg
28 24.00 610 2334 1059 1860 844 1716 778
52 27.25 692 3414 1549 3563 1616 3286 1491
LEGEND NOTES:
ANSI — American National Standards Institute 1. ANSI/ASHRAE 15 — Safety Code for Mechanical Refrigeration
ASHRAE — American Society of Heating, Refrigerating, 2. Dry weights include the pumpout condensing unit weight of
and Air-Conditioning Engineers 164 lb (75 kg).
Table 38 — Optional Storage Tank and/or Pumpout System Electrical Data

VOLTS-PH-HZ MAX RLA LRA
208/230-3-50/60 15.8 105.0
460-3-60 7.8 52.0
400-3-50 7.8 52.0
LEGEND
LRA — Locked Rotor Amps
RLA — Rated Load Amps
Table 39 — 23XRV Compressor Torque Specification Chart

TORQUE
LOCATION/USAGE DESCRIPTION PART NO.
LB-FT NM
Hermetic Term, Outlet Casing Sub-Assembly
Motor Side Seal Installation M5 X 0.8 X 16LG SHCS GR 12.9 8TR0115 5-7 7-9
M5 X 0.8 X 30LG SHCS GR 12.9 8TR0116 5-7 7-9
Inlet Seal Installation
M5 X 0.8 X 60LG SHCS GR 12.9 8TR0117 5-7 7-9
Bearing Cover Installation M10 X 1.5 X 40LG SHCS GR 12.9 8TR0303 50-55 68-75
Outlet Casing Process Bolts M20 X 1.0 X 120LG SHCS GR 12.9 8TR0304 430-450 583-610
Motor Terminal Cover Install
M12 X 1.75 X 50LG SHCS GR 12.9 8TR0120 90- 95 122-129
and Lube Block
Motor Housing and
Bearing Cover Installation M20 X 2.5 X 80LG SHCS GR 12.9 8TR0122 430-450 583-610
Discharge Flange M20 X 2.5 X 310LG HHCS GR 12.9 8TR0381 430-450 583-610
Motor Stator Sub-Assembly Set Screw M10 X 1.5 X 30 8TC0089C 30-35 41-47
Bearing Cover Lube Plug 1/  NPTF 8TC0290C 20-25 27-34
4
Rotor Caps and Male Axial Seal M6 X 1.0 X 25LG SHCS GR 12.9 8TQ0189 7-9 9-12
3/ SAE (9/
8 16 Thread) 8TC0107C 17-9 23-26
Plug Installation 3/ SAE (9/
8 16 Thread) 8TR0106 17-9 23-26
Rotor Housing 3/ SAE (11/
4 16 Thread) 8TC0109C 83-92 112-125
Motor Housing Air Gap Check 7/ SAE (13/
8 16 Thread) 8TR0128 92-103 125-140
13/16, Terminal Pin Body HY85AA062 45-55 61-75
Motor Installation 5/ , Term Nut, Mtr Lead, Term Nut
8 HY85AA062 40-45 54-61
Motor Rotor (Special) M16 X 2 X 70LG HHCS GR 10.9 8TR0121 17-22 23-30
Lube Cover Plate Installation
M12 X 1.75 X 30LG SHCS GR 12.9 8TC1044 87-93 118-126
Valve Pad Installation
8
Economizer Cover 5/ — 11UNC X 1.88 LG HHCS GR 8 8TR0238 185-195 251-264
Lube Block and Bearing Cover Plate 1/ 27 NPT (Brass) Orifice 8TR0357 4-6 5-8
8
Lube Block 3/ SAE (9/
8 16 Thread) Choke Orifice 8TR0358 17-19 23-26
Suction and Discharge Covers 7/ 9 UNC X 2LG HHCS GR 8 8TR0363 430-450 583-610
8
Terminal Pins M5 X 0.8 X 24LG SHCS GR 12.9 8TR0395 5-7 7-9
M20 X 2.5 X 247LG HHCS GR 12.9 ITQ0406 430-450 583-610
Discharge Cover M20 X 2.5 X 260LG HHCS GR 12.9 ITQ0045 430-450 583-610
1 — 8UNC X 3 LG HHCS GR 5 AA06BR419 430-450 583-610
M12 X 1.75 X 35LG HHCS 8TB0396 90-110 122-149
Economizer Shipping Plate
O-Ring Plug (7/16-20 Thread) 05GA501762 10-12 14-16
LEGEND
GR — Grade
HHCS — Hex Head Cap Screw
LG — Long
SAE — Society of Automotive Engineers
SHCS — Socket Head Cap Screw
UNC — Unified Coarse Thread
129
1016
NOTES:
1. This feature is standard in the 23XRV controls, but requires a
controller with a non-grounded 4 to 20 mA or 1 to 5 vdc output
signal, not by Carrier.
2. This feature is standard in the 23XRV controls, but requires an
external controller with a non-grounded 4 to 20mA output signal,
not by Carrier.
3. This feature is standard in the 23XRV controls, but requires a
sensor package option, by Carrier. (Item #3 see option listing.)
4. This feature is standard in the 23XRV controls. Controllers moni-
toring this signal must have a non-grounded input with a maxi-
mum impedance of 500 ohms.
5. See Fig. 71 for P compressor control panel component layout.
UPC OR LON
MODULE UPC/LON
SHIELD
130
UPC MODULE
LON MODULE
UPC OR LON
MODULES
SENSOR PACKAGE (OPTION)
a23-1641
 Fig. 70 — 23XRV Controls Layout (Q,R Compressors)
SECOND STAGE OIL
OIL HEATER HEATER CONTACTOR
CONTACTOR (1C) (5C) EXV CONTROL
EXV TRANSFORMER (T4)
BOARD VAPORIZER HEATER
CONTACTOR (6C)
CONNECTOR
CN1B AUX EXV
BOARD
CONNECTOR
CN1A
OIL PUMP
CONTACTOR (2C)
24 V CONTROL 24 V CONTROL
TRANSFORMER TRANSFORMER
UPC/LON (T1)
(T2)
CONNECTOR
CONNECTOR CN3
CN2
Fig. 71 — PIC III Control Component Layout (P Compressor Units)
131
132
Fig. 72 — 23XRV Controls Schematic
P COMPRESSOR ONLY
AXX VFD TERMINAL BOARD (EXAMPLE A12) P COMPRESSOR ONLY

CB-XX CIRCUIT BREAKER (EXAMPLE CB-1B)
CCM CHILLER CONTROL MODULE
EXV ELECTRONIC EXPANSION VALVE
TB TERMINAL BLOCK
UPC UNIFIED PROTOCOL CONVERTER
VFD VARIABLE FREQUENCY DRIVE
VFG VARIABLE FREQUENCY (DRIVE) GATEWAY
 Fig. 73 — 23XRV Controls Schematic Details (Rockwell LF-2 VFD)
133 516
CN CONNECTOR
CR CONTROL RELAY
TB TERMINAL BLOCK
VFD VARIABLE FREQUENCY DRIVE
VFG VARIABLE FREQUENCY (DRIVE) GATEWAY
Fig. 74 — 23XRV Controls Schematic Details (Rockwell Standard Tier VFD)
CN CONNECTOR
OPT OPTION CARD
TB TERMINAL BLOCK
Fig. 75 — 23XRV Controls Schematic Details (Eaton Standard Tier VFD)
134
a23-1633
CLASS 'CC' CN1B
AC INPUT 15A
L1 L2 L3 FIELD WIRING 102A 101A
1 SH 1
T1 FU11B
150B
CONTROL POWER 2 SH2
CB2 CLASS 'CC'
TRANSFORMER
CONTROL BREAKER 102B 15A 101B
(2 POLE, 15A) (3.0kVA, 120V, 25A)
X1 FU11A
104 L1 T1 103 H1 102C 5A 190 CN1A
GND
FU10
106 L2 T2 105 H* 1 L L1
X2 150A
2 LL2
*T1 INPUT (50/60Hz)
H1-H4: 380-415VAC PE
H1-H5: 440-480VAC 101D
A22 TB1
STANDARD I/O AI V1- 1
150D 101C
AI V1+ 2
CB1 2 151 150C AI V2- 3
MAIN ST AI V2+ 4
CIRCUIT BREAKER Vref COM 5
1 152
AO V1- 6
R S T AO V1+ 7 CN2
171
108 107 AO I1- 8
P1-11 P1-10 AO I1+ 9
172 OIL INT/LOCK
FU1 10
110 109 OIL INT/LOCK
IND1 DO NC1 11
FU2 DO COM1 12
112 111 0.5A F1
INPUT INDUCTOR P1 DO NO1 13
FILTER CAP ASSY FU3 DO NC2 14
179
1A/600V P1-1 P2-1 /AB>BC 1 DO COM2 15
1 2 3 180 TB1
CLASS 'CC' P1-3 DO NO2 16
100k , 50W P2-2 /BC>CA 2 15 HIGH PRESS SW
AI I1- 17
P1-5 P2-3 /CA>AB 3 AI I1+ 18 A33 16 HIGH PRESS SW
150A 1 125
600V AI I2- 19 17 4-20mA PRESS REF-
113 P2-4 I/O_ DGND 4 GATE-KILL
114 M2 126 SIGNAL AI I2+ 20
+5V_I/O 18 4-20mA PRESS REF+
P2-5 5 -10V 21 TB1
46uF ea 2 150F CONDITIONING 19 SPARE SAFETY
FU6 P2-6 -12VDC_I/O 6 +10V 22 169
AND ISOLATION 1 20 SPARE SAFETY
23
115 6 1 123 MECHANICAL P2-7 I/O_AGND 7 +24V 24 170
2 21 ICE BUILD
116 ( JUMPER ) LOGIC COM 25
5 M3 124 P2-8 +12VDC_I/O 8 174 22 ICE BUILD
24V COM 26
4 P2-9 I/O_AGND 9 173 23 REMOTE START
FU5 2 DI1 27
1 75 24 REMOTE START
142 P2-10 RECT_AC_LINE 10 DI2 28
117 1 1 77
118 DI3 29
2 DI4 30
120V_N P1-13 DI5 31
FU4 3 P 1 -9 DI6 32
2 1 P1-12
2V 145
120A 119A 4 CN3
1uF 1 TERM
TS1 WHT
4x 140J TB 3 P1-7 P2-13 OVER_TEMP_1 11 2 A 154 1 NEG
7 8 9
P1-8 P2-14 OVER_TEMP_2 12 3 B 156 BLK
135
137A,B A32 2 COM
4 COM 155
13 6 183 TB1 RS485 RED
AO I1- 1 5 SHIELD 3 POS
127 PILOT P2-17 +24V_COIL 13 AO I1+ 2 6 GND
184 EXV C2- 3
130A 133
RELAY EXV C2+ 4
P2-18 COIL_RETURN 14
DO NC1 5
20A 20A 20A 120V P1-14 DO COM1 6
FU7 FU8 FU9 DO NO1 7
600V 600V 600V SWITCHED
DO NC2 8
128 131 DO COM2 9
134 A2 LINE SYNC PCB DO NO2 10 TB2
DO NC3 11
159
PRECHARGE 1 EVAP PUMP
DO COM3 12 160
R4 RESISTORS R5 R6 2 EVAP PUMP
DO NO3 13 161
10 , 600W VOLTMETER AMMETER D O NC 4 14 3 COND PUMP
L2 162
L1 L3 DO COM4 15 4 COND PUMP
129 1 32 135 163
DO NO4 16 5 TOWER FAN LOW
138 139 1 40 VM1 AM1 185 164
AO V1- 17
13 14 13 14 13 14 141 6 TOWER FAN LOW
AO V1+ 18 165
B2 B1 A2 A1 186 EXT NTC 19 A34 7 TOWER FAN HIGH
+ + 166
EXT COM 20 8 TOWER FAN HIGH
L1 T1 L1 T1 L1 T1 SW1 NTC 167
21 9 TRIP ALARM
LOGIC COM 22 168
10 TRIP ALARM
LOGIC IN 1 23
L2 T2 L2 T2 L2 T2
LOGIC IN 2 24
187 LOGIC IN 3 25
L3 L3 L3
(OPTIONAL) LOGIC IN 4 26
T3 T3 T3 NOTE: MOTOR OVERLOAD IS
K1A K1B K1C METERS W/SWITCH 188 DO NC5 27
1 121 DO COM5 28
A1 A2 PRECHARGE A1 A2 A1 A2 DO NO5 29
FACTORY PRE-SET.
CONTACTORS M4 122 DO NC6 30
T3
L3 W DO NOT ADJUST.
2 DO COM6 31
DO NO6 32 M1
15 3 154 155 15 6 15 7 158 T2
L2 A12 V
MOTOR
AC LINE I/O T1
U GND
L1
EXTERNAL- REF. ONLY
A1 VFD POWER MODULE
FOR TECHNICAL SUPPORT CALL 1-800-726-8112
Fig. 76 — 23XRV VFD Schematic (LF-2)

(SEE NEXT PAGE)
(SEE NEXT PAGE)
136
(SEE NEXT PAGE)
Fig. 77 — 23XRV VFD Schematic (Rockwell Standard Tier VFD)

FROM PREVIOUS
PAGE
Fig. 77 — 23XRV Controls Schematic (Rockwell Standard Tier VFD Shown) (cont)
137
a23-1585
Fig. 78 — Typical Field Wiring Schematic (LF-2 VFD Shown)
138
a23-1586
Fig. 78 — Typical Field Wiring Schematic (LF-2 VFD Shown) (cont)
139
See Notes on page 141.
Fig. 78 — Typical Field Wiring Schematic (LF-2 VFD Shown) (cont)
140
NOTES FOR FIG. 78
GENERAL 3.2 Remove jumper wire between TB1-19 and TB1-20 before
1.0 Variable frequency drive (VFD) shall be designed and connecting auxiliary safeties between these terminals.
manufactured in accordance with Carrier engineering 3.3 Each integrated contact output can control loads (VA) for
requirements. evaporator pump, condenser pump, tower fan low, tower fan
1.1 All field-supplied conductors, devices and the field- high, and alarm annunciator devices rated 5 amps at
installation wiring, termination of conductors and devices, 115 VAC and up to 3 amps at 277 VAC.
must be in compliance with all applicable codes and job
specifications. WARNING
1.2 The routing of field-installed conduit and conductors and the
location of field-installed devices, must not interfere with Control wiring required for Carrier to start pumps and tower fan
equipment access or the reading, adjusting or servicing of motors and establish flows must be provided to assure machine
any component. protection. If primary pump, tower fan and flow control is by
1.3 Equipment installation and all starting and control devices, other means, also provide a parallel means for control by
must comply with details in equipment submittal drawings Carrier. Failure to do so could result in machine freeze-up or
and literature. overpressure.
1.4 Contacts and switches are shown in the position they would
assume with the circuit de-energized and the chiller shut Do not use control transformers in the control center as the
down. power source for external or field-supplied contactor coils,
1.5 actuator motors or any other loads.
3.4 Do not route control wiring carrying 30 V or less within a
WARNING conduit or tray which has wires carrying 50 V or higher or
along side wires carrying 50 V or higher.
Do not use aluminum conductors. Contractor/installer assumes 3.5 Spare 4-20 mA output signal is designed for controllers with
all liability resulting from the use of aluminum conductors within a non-grounded 4-20 mA input signal and a maximum input
the VFD enclosure. impedance of 500 ohms.
3.6 Flow devices to confirm evaporator or condenser pump flow
are not required. However; if flow devices are used, wire as
POWER WIRING TO VFD
shown on drawing 23XRC1-1 (J3 lower). Remove jumper
2.0 Provide a means of disconnecting branch feeder power to installed at these terminals and wire in a 4.3 K resistor in its
VFD. Provide short circuit protection and interrupt capacity place.
for branch feeder in compliance with all applicable codes.
2.1 If metal conduit is used for the power wires, the last 4 feet or CCM
greater should be flexible to avoid transmitting unit vibration J3 (LOWER)
into the power lines and to aid in serviceability.
2.2 Line side power conductor rating must meet VFD nameplate
voltage and chiller minimum circuit ampacity.
2.3 Lug adapters may be required if installation conditions
dictate that conductors be sized beyond the minimum
ampacity required. Circuit breaker lugs will accommodate a23-1587
the quantity (#) and size cables (per phase) as shown in
Table 40.
2.4 Compressor motor and controls must be grounded by using The flow device and resistor must be installed in parallel at
equipment grounding lug provided inside unit mounted VFD these terminals such that the resistor provides a signal when
enclosure. the flow device is open.
CONTROL WIRING
3.0 Field-supplied control conductors to be at least 18 AWG or
larger.
3.1 Ice build start/terminate device contacts, remote start/stop
device contacts and spare safety device contacts, (devices
not supplied by Carrier), must have 24 VAC rating. Max cur-
rent is 60 mA, nominal current is 10 mA. Switches with gold
plated bifurcated contacts are recommended.
Table 40 — Lug Capacity

VFD STANDARD 65K AIC LUG CAPACITY OPTIONAL 100K AIC LUG CAPACITY
MAX INPUT (PER PHASE) (PER PHASE)
AMPS NO. CONDUCTORS CONDUCTOR RANGE NO. CONDUCTORS CONDUCTOR RANGE
225A 3 2/0 — 400MCM 3 2/0 — 400MCM
338A 3 2/0 — 400MCM 3 2/0 — 400MCM
440A 3 2/0 — 400MCM 3 2/0 — 400MCM
520A 3 2/0 — 400MCM 3 2/0 — 400MCM
608A 3 2/0 — 400MCM 3 2/0 — 400MCM
NOTE: If larger lugs are required, they can be purchased from the  For larger lugs and cable reducers refer to PPS HH87LZ500.
manufacturer of the circuit breaker.
516
141
DRAIN WIRE GROUND DRAIN WIRE DRAIN WIRE DRAIN WIRE
BLACK BLACK BLACK BLACK
WHITE WHITE WHITE WHITE
RED RED RED RED
142
P COMPRESSOR
R COMPRESSOR Q COMPRESSOR
a23-1703
LEGEND NOTE: Field-supplied terminal strip must be located in control panel.
Factory Wiring
Field Wiring
Fig. 79 — CCN Communication Wiring for Multiple Chillers (Typical)

a23-1597
143
Fig. 80 — Lead/Lag Control Wiring (Parallel Flow Unit with R Compressor Shown)
144
a23-1598
Fig. 81 — Lead/Lag Control Wiring (Series Flow Unit with R Compressor Shown)
APPENDIX A — ICVC PARAMETER INDEX
PARAMETER MENU SOFTKEY TABLE SCREEN NAME CONFIGURABLE
0=Temp,1=Contact,2=Both SERVICE EQUIPMENT SERVICE OPTIONS x
20mA Demand Limit Opt SERVICE EQUIPMENT SERVICE RAMP_DEM x
Active Delta P STATUS HEAT_EX
Active Delta T STATUS HEAT_EX
Active Demand Limit STATUS MAINSTAT x
Actual VFD Speed STATUS COMPRESS
Actual VFD Speed STATUS POWER
Actual VFD Speed SERVICE CONTROL ALGORITHM STATUS CAPACITY
Actual VFD Speed SERVICE CONTROL ALGORITHM STATUS VFD_HIST
Alarm Relay STATUS MAINSTAT
Alarm Routing SERVICE EQUIPMENT CONFIGURATION NET_OPT
Amps or KW Ramp %/Min. SERVICE EQUIPMENT SERVICE RAMP_DEM x
Amps/KW Ramp SERVICE CONTROL ALGORITHM STATUS CAPACITY
 Anti Winding Min SERVICE EQUIPMENT SERVICE SETUP5 x
Auto Chilled Liq Reset STATUS MAINSTAT
Auto Demand Limit Input STATUS MAINSTAT
Auto Restart Option SERVICE EQUIPMENT SERVICE OPTIONS x
Average Line Current STATUS POWER
Average Line Voltage STATUS POWER
Average Load Current STATUS POWER
Base Demand Limit SETPOINT SETPOINT x
Broadcast Option SERVICE EQUIPMENT CONFIGURATION NET_OPT
Calc Evap Sat Temp STATUS HEAT_EX
Calc Evap Sat Temp SERVICE CONTROL ALGORITHM STATUS OVERRIDE
Capacity Control SERVICE CONTROL ALGORITHM STATUS CAPACITY
CapDelta SERVICE CONTROL ALGORITHM STATUS CAPACITY
CCN Mode ? STATUS ICVC_PWD
Chill Liq Pulldown/Min STATUS HEAT_EX
Chilled Liquid Deadband SERVICE EQUIPMENT SERVICE SETUP1 x
Chilled Liquid Delta P STATUS HEAT_EX x
Chilled Liquid Delta T STATUS HEAT_EX
Chilled Liquid Flow STATUS MAINSTAT
Chilled Liquid Pump STATUS MAINSTAT x
Chilled Liquid Temp STATUS MAINSTAT
Chilled Medium SERVICE EQUIPMENT SERVICE SETUP1 x
Chilled Water Temp SERVICE CONTROL ALGORITHM STATUS WSMCHLRE
Chiller Fault State SERVICE CONTROL ALGORITHM STATUS VFD_HIST
Chiller Start/Stop STATUS MAINSTAT x
CHL Delta T->Full Reset SERVICE EQUIPMENT SERVICE TEMP_CTL x
CHL Delta T->No Reset SERVICE EQUIPMENT SERVICE TEMP_CTL x
CHW Setpt Reset Value SERVICE CONTROL ALGORITHM STATUS WSMCHLRE
Commanded State SERVICE CONTROL ALGORITHM STATUS WSMCHLRE
Common Sensor Option SERVICE EQUIPMENT SERVICE LEADLAG x
Comp Discharge Alert SERVICE CONTROL ALGORITHM STATUS OVERRIDE
Comp Discharge Alert SERVICE EQUIPMENT SERVICE SETUP1 x
Comp Discharge Temp STATUS COMPRESS
Comp Discharge Temp SERVICE CONTROL ALGORITHM STATUS OVERRIDE
Comp Maximum Speed STATUS MAINSTAT
Comp Maximum Speed STATUS COMPRESS
Comp Maximum Speed STATUS POWER
Comp Maximum Speed SERVICE CONTROL ALGORITHM STATUS CAPACITY
Comp Minimum Speed STATUS MAINSTAT
Comp Minimum Speed STATUS COMPRESS
Comp Minimum Speed STATUS POWER
Comp Minimum Speed SERVICE CONTROL ALGORITHM STATUS CAPACITY
Comp Motor Frequency STATUS MAINSTAT
Comp Motor Frequency STATUS COMPRESS
Comp Motor Frequency STATUS POWER
Comp Motor Frequency SERVICE CONTROL ALGORITHM STATUS CAPACITY
Comp Motor Frequency SERVICE CONTROL ALGORITHM STATUS VFD_HIST
Comp Motor RPM STATUS MAINSTAT
Comp Motor RPM STATUS COMPRESS
Comp Motor RPM STATUS POWER
145 516
APPENDIX A — ICVC PARAMETER INDEX (cont)
Comp Motor RPM SERVICE CONTROL ALGORITHM STATUS CAPACITY
Comp Motor RPM SERVICE CONTROL ALGORITHM STATUS VFD_HIST
Comp Motor Temp Override SERVICE CONTROL ALGORITHM STATUS OVERRIDE
Comp Motor Temp Override SERVICE EQUIPMENT SERVICE SETUP1 x
Comp Motor Winding Temp STATUS COMPRESS
Comp Motor Winding Temp SERVICE CONTROL ALGORITHM STATUS OVERRIDE
Compressor 100% Speed SERVICE VFD_CONF x
Compressor Ontime STATUS MAINSTAT
Compressor Type SERVICE EQUIPMENT SERVICE SETUP3 x
Cond Approach Alert SERVICE EQUIPMENT SERVICE SETUP1 x
Cond EXV Max Movement STATUS COND_EXV CEXV_MAX
Cond EXV Max Movement SERVICE EQUIPMENT SERVICE SETUP5
Cond EXV Min Position SERVICE EQUIPMENT SERVICE SETUP5
Cond EXV Start Position SERVICE EQUIPMENT SERVICE SETUP5
Cond EXV Steps STATUS COND_EXV CONDSTEP
Cond Flow Delta P Cutout SERVICE EQUIPMENT SERVICE SETUP1 x
Cond Level Deadband SERVICE EQUIPMENT SERVICE SETUP5 x
Cond Level Error STATUS COND_EXV LEV_ERR
Cond Level High Limit SERVICE EQUIPMENT SERVICE SETUP5 x
Cond Level Int Clamp SERVICE EQUIPMENT SERVICE SETUP5 x
Cond Level Integral STATUS COND_EXV LEV-INT
Cond Level Int Gain SERVICE EQUIPMENT SERVICE SETUP5 x
Cond Level Low Limit SERVICE EQUIPMENT SERVICE SETUP5
Cond Level Output STATUS COND_EXV LEV_OUTV
Cond Level Output STATUS COND_EXV LEV_OUTP
Cond Level Prop Gain SERVICE EQUIPMENT SERVICE SETUP5
Cond Level Range STATUS COND_EXV LEV_RANG
Cond Level Rounding SERVICE EQUIPMENT SERVICE SETUP5 x
Cond Level Setpoint STATUS COND_EXV LEV_SP
Cond Level Setpoint SERVICE EQUIPMENT SERVICE SETUP5 x
Cond Loop Timer SERVICE EQUIPMENT SERVICE SETUP5 x
Cond Press Override SERVICE CONTROL ALGORITHM STATUS OVERRIDE
Cond Press Override SERVICE EQUIPMENT SERVICE SETUP1 x
Cond Refrig Temp Low Limit SERVICE EQUIPMENT SERVICE SETUP3 x
Condenser Approach STATUS HEAT_EX
Condenser EXV STATUS COND_EXV COND_EXV
Condenser Freeze Point SERVICE EQUIPMENT SERVICE SETUP1 x
Condenser High Pressure STATUS VFD_STAT
Condenser Liquid Delta P STATUS HEAT_EX x
Condenser Liquid Flow STATUS MAINSTAT
Condenser Liquid Level STATUS COND_EXV COND_LEV
Condenser Liquid Pump STATUS MAINSTAT x
Condenser Pressure STATUS HEAT_EX x
Condenser Pressure SERVICE CONTROL ALGORITHM STATUS OVERRIDE
Condenser Refrig Temp STATUS HEAT_EX
Condenser Refrig Temp SERVICE CONTROL ALGORITHM STATUS OVERRIDE
Control Mode STATUS MAINSTAT
Control Point STATUS MAINSTAT x
Control Point SERVICE CONTROL ALGORITHM STATUS CAPACITY
Control Point Error SERVICE CONTROL ALGORITHM STATUS CAPACITY
Cooler Approach Limit SERVICE EQUIPMENT SERVICE SETUP5 x
Current CHW Setpoint SERVICE CONTROL ALGORITHM STATUS WSMCHLRE
Current Mode SERVICE CONTROL ALGORITHM STATUS LL_MAINT
DC Bus Voltage STATUS POWER
DC Bus Voltage SERVICE CONTROL ALGORITHM STATUS VFD_HIST
DC Bus Voltage Reference STATUS POWER
DC Bus Voltage Reference SERVICE CONTROL ALGORITHM STATUS VFD_HIST
Decrease Ramp Time SERVICE VFD_CONF x
Degrees Reset SERVICE EQUIPMENT SERVICE TEMP_CTL x
Degrees Reset at 20 mA SERVICE EQUIPMENT SERVICE TEMP_CTL x
Delta P at 0% (4 mA) SERVICE EQUIPMENT SERVICE OPTIONS x
Delta P at 100% (20 mA) SERVICE EQUIPMENT SERVICE OPTIONS x
146
Demand Kilowatts STATUS POWER
Demand Limit At 20 mA SERVICE EQUIPMENT SERVICE RAMP_DEM x
Demand Limit Decrease SERVICE EQUIPMENT CONFIGURATION NET_OPT
Demand Limit Inhibit SERVICE CONTROL ALGORITHM STATUS CAPACITY
Demand Limit Prop Band SERVICE EQUIPMENT SERVICE RAMP_DEM x
Demand Limit Source SERVICE EQUIPMENT SERVICE RAMP_DEM x
Demand Watts Interval SERVICE EQUIPMENT SERVICE RAMP_DEM x
Disable Service Password STATUS ICVC_PWD
Disch Superheat Limit SERVICE EQUIPMENT SERVICE SETUP5 x
Disch Sup Ht Corr Factor SERVICE EQUIPMENT SERVICE SETUP5 x
Discharge Superheat STATUS COMPRESS
Discharge Superheat SERVICE CONTROL ALGORITHM STATUS OVERRIDE
Discharge Superheat STATUS COND_EXV DSH
ECL Control Option SERVICE EQUIPMENT SERVICE TEMP_CTL x
ECL Delta T SERVICE CONTROL ALGORITHM STATUS CAPACITY
ECL Reset SERVICE CONTROL ALGORITHM STATUS CAPACITY
ECL Setpoint SETPOINT SETPOINT x
Econ Activate Deadband SERVICE EQUIPMENT SERVICE SETUP4 x
Econ Activate Speed SERVICE EQUIPMENT SERVICE SETUP4 x
Econ EXV Max Movement SERVICE EQUIPMENT SERVICE SETUP4 x
Econ EXV Position STATUS ECON_EXV ECON_EXV
Econ EXV Steps STATUS ECON_EXV EEXV_TRG
Econ Integral Gain SERVICE EQUIPMENT SERVICE SETUP4 x
Econ PID Calc Time SERVICE EQUIPMENT SERVICE SETUP4 x
Econ Superheat STATUS ECON_EXV ECON_SH
Econ Superheat Error STATUS ECON_EXV SH_ERR
Econ Superheat Setpoint STATUS ECON_EXV ECONSHSP
Economizer Gas Temp STATUS ECON_EXV ECON_GAS
Economizer Option SERVICE EQUIPMENT SERVICE SETUP4 x
Economizer Pressure STATUS ECON_EXV ECON_PRS
Economizer Sat Temp STATUS ECON_EXV ECON_SAT
Emergency Stop STATUS MAINSTAT
Enable Reset Type SERVICE EQUIPMENT SERVICE TEMP_CTL x
Entering Chilled Liquid STATUS HEAT_EX
Entering Chilled Liquid SERVICE CONTROL ALGORITHM STATUS CAPACITY
Entering Cond Liquid STATUS HEAT_EX
Equipment Status SERVICE CONTROL ALGORITHM STATUS WSMCHLRE
Evap App Corr Factor SERVICE EQUIPMENT SERVICE SETUP5 x
Evap Approach Alert SERVICE EQUIPMENT SERVICE SETUP1 x
 Evap Approach Alert Reset Gain SERVICE EQUIPMENT SERVICE SETUP5 x
Evap Flow Delta P Cutout SERVICE EQUIPMENT SERVICE SETUP1 x
Evap Refrig Liquid Temp STATUS HEAT_EX
Evap Refrig Trippoint SERVICE EQUIPMENT SERVICE SETUP1 x
Evap Sat Override Temp SERVICE CONTROL ALGORITHM STATUS OVERRIDE
Evaporator Approach STATUS HEAT_EX
Evaporator Approach STATUS COND_EXV EVAP_APP
Evaporator Pressure STATUS HEAT_EX x
Feed Forward Gain SERVICE EQUIPMENT SERVICE SETUP5 x
Feed Forward Threshold SERVICE EQUIPMENT SERVICE SETUP5 x
Fine Tune Active? STATUS COND_EXV FT_ACTIVE
Fine Tune Enabled? SERVICE EQUIPMENT SERVICE SETUP5 x
Fine Tune Threshold SERVICE EQUIPMENT SERVICE SETUP5 x
Flow Delta P Display SERVICE EQUIPMENT SERVICE SETUP1 x
Flux Current STATUS POWER
Flux Current SERVICE CONTROL ALGORITHM STATUS VFD_HIST
Freeze Margin at Start SERVICE EQUIPMENT SERVICE SETUP5 x
Frequency Fault STATUS VFD_STAT
Full Load Point (T2,P2) SERVICE EQUIPMENT SERVICE OPTIONS x
Ground Fault STATUS VFD_STAT
Ground Fault Current STATUS POWER
Ground Fault Current SERVICE CONTROL ALGORITHM STATUS VFD_HIST
Group Number SERVICE EQUIPMENT CONFIGURATION NET_OPT x
Head Pressure Reference STATUS HEAT_EX
HGBP Deadband SERVICE EQUIPMENT SERVICE OPTIONS x
147 516
HGBP Delta P1 SERVICE EQUIPMENT SERVICE OPTIONS x
HGBP Delta T STATUS HEAT_EX
HGBP Delta T1 SERVICE EQUIPMENT SERVICE OPTIONS x
HGBP Delta T2 SERVICE EQUIPMENT SERVICE OPTIONS x
HGBP Delta_P2 SERVICE EQUIPMENT SERVICE OPTIONS x
HGBP Off Delta Speed SERVICE EQUIPMENT SERVICE OPTIONS x
HGBP On Delta Speed SERVICE EQUIPMENT SERVICE OPTIONS x
HGBP Option SERVICE EQUIPMENT SERVICE OPTIONS x
High DC Bus Voltage STATUS VFD_STAT
High Line Voltage STATUS VFD_STAT
Hot Gas Bypass Relay STATUS HEAT_EX
Humidity Sensor Input STATUS POWER
Ice Build Contact STATUS MAINSTAT
Ice Build Option SERVICE EQUIPMENT SERVICE OPTIONS x
Ice Build Recycle SERVICE EQUIPMENT SERVICE OPTIONS x
Ice Build Setpoint SETPOINT SETPOINT x
Ice Build Termination SERVICE EQUIPMENT SERVICE OPTIONS x
Increase Ramp Time SERVICE VFD_CONF x
Inverter Overcurrent STATUS VFD_STAT
Inverter Overload STATUS POWER
Inverter Overtemp STATUS VFD_STAT
Inverter Power Fault STATUS VFD_STAT
Inverter PWM Frequency SERVICE VFD_CONF x
Inverter Temp Override SERVICE CONTROL ALGORITHM STATUS OVERRIDE
Inverter Temp Override SERVICE EQUIPMENT SERVICE SETUP1 x
Inverter Temperature STATUS POWER
Inverter Temperature SERVICE CONTROL ALGORITHM STATUS OVERRIDE
Inverter Temperature SERVICE CONTROL ALGORITHM STATUS VFD_HIST
LAG % Capacity SERVICE EQUIPMENT SERVICE LEADLAG x
LAG Address SERVICE EQUIPMENT SERVICE LEADLAG x
LAG CHILLER: Mode SERVICE CONTROL ALGORITHM STATUS LL_MAINT
LAG START Time SERVICE CONTROL ALGORITHM STATUS LL_MAINT
LAG START Timer SERVICE EQUIPMENT SERVICE LEADLAG x
LAG STOP Time SERVICE CONTROL ALGORITHM STATUS LL_MAINT
LAG STOP Timer SERVICE EQUIPMENT SERVICE LEADLAG x
LCL Reset SERVICE CONTROL ALGORITHM STATUS CAPACITY
LCL Setpoint SETPOINT SETPOINT x
LEAD CHILLER in Control SERVICE CONTROL ALGORITHM STATUS LL_MAINT
LEAD/LAG: Configuration SERVICE EQUIPMENT SERVICE LEADLAG x
LEAD/LAG: Configuration SERVICE CONTROL ALGORITHM STATUS LL_MAINT
Leaving Chilled Liquid STATUS HEAT_EX
Leaving Chilled Liquid SERVICE CONTROL ALGORITHM STATUS CAPACITY
Leaving Cond Liquid STATUS HEAT_EX
Line Active Current STATUS POWER
Line Active Current SERVICE CONTROL ALGORITHM STATUS VFD_HIST
Line Active Voltage STATUS POWER
Line Active Voltage SERVICE CONTROL ALGORITHM STATUS VFD_HIST
Line Current % Imbalance SERVICE VFD_CONF x
Line Current Imbal Time SERVICE VFD_CONF x
Line Current Imbalance STATUS POWER
Line Current Imbalance STATUS VFD_STAT
Line Current Imbalance SERVICE CONTROL ALGORITHM STATUS VFD_HIST
Line Current Ph1(R) STATUS POWER
Line Current Ph1(R) SERVICE CONTROL ALGORITHM STATUS VFD_HIST
Line Current Ph2(S) STATUS POWER
Line Current Ph2(S) SERVICE CONTROL ALGORITHM STATUS VFD_HIST
Line Current Ph3(T) STATUS POWER
Line Current Ph3(T) SERVICE CONTROL ALGORITHM STATUS VFD_HIST
Line Frequency STATUS POWER
Line Frequency SERVICE CONTROL ALGORITHM STATUS VFD_HIST
Line Kilowatts STATUS POWER
Line Phase Reversal STATUS VFD_STAT
Line Power Factor STATUS POWER
148
Line Power Factor SERVICE CONTROL ALGORITHM STATUS VFD_HIST
Line Reactive Current STATUS POWER
Line Reactive Current SERVICE CONTROL ALGORITHM STATUS VFD_HIST
Line Reactive Voltage STATUS POWER
Line Reactive Voltage SERVICE CONTROL ALGORITHM STATUS VFD_HIST
Line Volt Imbalance Time SERVICE VFD_CONF x
Line Voltage % Imbalance SERVICE VFD_CONF x
Line Voltage Imbalance STATUS POWER
Line Voltage Imbalance STATUS VFD_STAT
Line Voltage Imbalance SERVICE CONTROL ALGORITHM STATUS VFD_HIST
Line Voltage Ph1(RS) STATUS POWER
Line Voltage Ph1(RS) SERVICE CONTROL ALGORITHM STATUS VFD_HIST
Line Voltage Ph2(ST) STATUS POWER
Line Voltage Ph2(ST) SERVICE CONTROL ALGORITHM STATUS VFD_HIST
Line Voltage Ph3(TR) STATUS POWER
Line Voltage Ph3(TR) SERVICE CONTROL ALGORITHM STATUS VFD_HIST
Liquid Flow Verify Time SERVICE EQUIPMENT SERVICE SETUP1 x
Load Balance Option SERVICE CONTROL ALGORITHM STATUS LL_MAINT
Load Balance Option SERVICE EQUIPMENT SERVICE LEADLAG x
Load Current Ph1(U) STATUS POWER
Load Current Ph1(U) SERVICE CONTROL ALGORITHM STATUS VFD_HIST
Load Current Ph2(V) STATUS POWER
Load Current Ph2(V) SERVICE CONTROL ALGORITHM STATUS VFD_HIST
Load Current Ph3(W) STATUS POWER
Load Current Ph3(W) SERVICE CONTROL ALGORITHM STATUS VFD_HIST
Loadshed SERVICE CONTROL ALGORITHM STATUS LOADSHED
Loadshed Timer SERVICE CONTROL ALGORITHM STATUS LOADSHED
Low DC Bus Voltage STATUS VFD_STAT
Low Line Voltage STATUS VFD_STAT
Maximum Loadshed Time SERVICE EQUIPMENT CONFIGURATION NET_OPT
Min. Load Point (T1,P1) SERVICE EQUIPMENT SERVICE OPTIONS x
Minimum Output SERVICE EQUIPMENT SERVICE OPTIONS x
Motor Amps Not Sensed STATUS VFD_STAT
Motor Current % Imbalance SERVICE VFD_CONF x
Motor Current Imbal Time SERVICE VFD_CONF x
Motor Current Imbalance STATUS POWER
Motor Current Imbalance STATUS VFD_STAT
Motor Current Imbalance SERVICE CONTROL ALGORITHM STATUS VFD_HIST
Motor Kilowatt Hours STATUS POWER
Motor Kilowatts STATUS POWER
Motor Nameplate Amps SERVICE VFD_CONF x
Motor Nameplate KW SERVICE VFD_CONF x
Motor Nameplate RPM SERVICE VFD_CONF x
Motor Nameplate Voltage SERVICE VFD_CONF x
Motor Overload STATUS POWER
Motor Overload STATUS VFD_STAT
Motor Overload SERVICE CONTROL ALGORITHM STATUS VFD_HIST
Motor Power Factor STATUS POWER
Motor Power Factor SERVICE CONTROL ALGORITHM STATUS VFD_HIST
Motor Rated Load Amps SERVICE VFD_CONF x
Motor Rated Load KW SERVICE VFD_CONF x
Occupied? STATUS MAINSTAT
Oil Heater Relay STATUS COMPRESS
Oil Press Verify Time SERVICE EQUIPMENT SERVICE SETUP1 x
Oil Pressure Delta P STATUS MAINSTAT
Oil Pressure Delta P STATUS COMPRESS x
Oil Pump Relay STATUS MAINSTAT
Oil Pump Relay STATUS COMPRESS
Oil Reclaim Min Output SERVICE EQUIPMENT SERVICE SETUP2 x
Oil Reclaim Output STATUS MAINSTAT
Oil Reclaim Output STATUS HEAT_EX
Oil Sump Temp STATUS MAINSTAT
Oil Sump Temp STATUS COMPRESS
149
PPM at 20 mA SERVICE EQUIPMENT SERVICE OPTIONS x
PRESTART FAULT Time SERVICE CONTROL ALGORITHM STATUS LL_MAINT
PRESTART FAULT Timer SERVICE EQUIPMENT SERVICE LEADLAG x
Proportional Dec Band SERVICE EQUIPMENT SERVICE SETUP2 x
Proportional ECL Gain SERVICE EQUIPMENT SERVICE SETUP2 x
Proportional Inc Band SERVICE EQUIPMENT SERVICE SETUP2 x
Pulldown Ramp Type: SERVICE EQUIPMENT SERVICE RAMP_DEM x
PULLDOWN Time SERVICE CONTROL ALGORITHM STATUS LL_MAINT
PULLDOWN Timer SERVICE EQUIPMENT SERVICE LEADLAG x
Pulldown: Delta T / Min SERVICE CONTROL ALGORITHM STATUS LL_MAINT
Rated Line Amps SERVICE VFD_CONF x
Rated Line Kilowatts SERVICE VFD_CONF x
Rated Line Voltage SERVICE VFD_CONF x
Re-alarm Time SERVICE EQUIPMENT CONFIGURATION NET_OPT
Reclaim Delta T STATUS HEAT_EX
Recovery Start Request SERVICE CONTROL ALGORITHM STATUS LL_MAINT
Rectifier Overcurrent STATUS VFD_STAT
Rectifier Overload STATUS POWER
Rectifier Overtemp STATUS VFD_STAT
Rectifier Power Fault STATUS VFD_STAT
Rectifier Temp Override SERVICE CONTROL ALGORITHM STATUS OVERRIDE
Rectifier Temp Override SERVICE EQUIPMENT SERVICE SETUP1 x
Rectifier Temperature STATUS POWER
Rectifier Temperature SERVICE CONTROL ALGORITHM STATUS OVERRIDE
Rectifier Temperature SERVICE CONTROL ALGORITHM STATUS VFD_HIST
Redline SERVICE CONTROL ALGORITHM STATUS LOADSHED
Refrig Leak Alarm PPM SERVICE EQUIPMENT SERVICE OPTIONS x
Refrig Leak Sensor PPM STATUS MAINSTAT
Refrig Override Delta T SERVICE EQUIPMENT SERVICE SETUP1 x
Relative Humidity STATUS POWER
Remote Contacts Option SERVICE EQUIPMENT SERVICE OPTIONS x
Remote Reset Option STATUS ICVC_PWD x
Remote Reset Sensor STATUS MAINSTAT
Remote Start Contact STATUS MAINSTAT x
Remote Temp->Full Reset SERVICE EQUIPMENT SERVICE TEMP_CTL x
Remote Temp->No Reset SERVICE EQUIPMENT SERVICE TEMP_CTL x
Reset Alarm ? STATUS ICVC_PWD
Restart Delta T SERVICE EQUIPMENT SERVICE SETUP1 x
Run Status STATUS MAINSTAT
Run Status SERVICE CONTROL ALGORITHM STATUS LL_MAINT
Satisfied? SERVICE CONTROL ALGORITHM STATUS LL_MAINT
Schedule Number SERVICE EQUIPMENT CONFIGURATION NET_OPT
Service Ontime STATUS MAINSTAT x
Shunt Trip Relay STATUS MAINSTAT
Shutdown Delta Speed SERVICE EQUIPMENT SERVICE SETUP1 x
Single Cycle Dropout STATUS VFD_STAT
Single Cycle Dropout SERVICE VFD_CONF x
Skip Frequency 1 SERVICE VFD_CONF x
Skip Frequency Band SERVICE VFD_CONF x
Soft Stop Amps Threshold SERVICE EQUIPMENT SERVICE OPTIONS x
Spare Safety Input STATUS MAINSTAT
Spare Temp #1 Enable SERVICE EQUIPMENT SERVICE SETUP1 x
Spare Temp #1 Limit SERVICE EQUIPMENT SERVICE SETUP1 x
Spare Temp #2 Enable SERVICE EQUIPMENT SERVICE SETUP1 x
Spare Temp #2 Limit SERVICE EQUIPMENT SERVICE SETUP1 x
Spare Temperature 1 STATUS COMPRESS
Spare Temperature 1 SERVICE CONTROL ALGORITHM STATUS LL_MAINT
150
Percent Line Current STATUS MAINSTAT
Percent Line Current STATUS POWER
Percent Line Kilowatts STATUS MAINSTAT
Percent Line Kilowatts STATUS POWER
Percent Line Voltage STATUS POWER
Percent Load Current STATUS POWER
Percent Motor Kilowatts STATUS POWER
Spare Temperature 2 STATUS COMPRESS
Spare Temperature 2 SERVICE CONTROL ALGORITHM STATUS LL_MAINT
Stall Delta % Amps SERVICE EQUIPMENT SERVICE OPTIONS x
Stall Protection Counts STATUS COMPRESS
Stall Time Period SERVICE EQUIPMENT SERVICE OPTIONS x
STANDBY % Capacity SERVICE EQUIPMENT SERVICE LEADLAG x
STANDBY Address SERVICE EQUIPMENT SERVICE LEADLAG x
STANDBY Chiller Option SERVICE EQUIPMENT SERVICE LEADLAG x
STANDBY CHILLER: Mode SERVICE CONTROL ALGORITHM STATUS LL_MAINT
Start Acceleration Fault STATUS VFD_STAT
Start Complete STATUS MAINSTAT
Start Complete STATUS VFD_STAT
Start Delay SERVICE EQUIPMENT SERVICE SETUP5 x
Start Inhibit Timer STATUS MAINSTAT
Start/Stop SERVICE CONTROL ALGORITHM STATUS LL_MAINT
Starts in 12 Hours STATUS MAINSTAT
Stop Complete STATUS MAINSTAT
Stop Complete STATUS VFD_STAT
Stop Fault STATUS VFD_STAT
Sump Heater Turn Off Delta T SERVICE EQUIPMENT SERVICE SETUP3 x
Sump Heater Turn Off Speed SERVICE EQUIPMENT SERVICE SETUP3 x
Sump Heater Turn On Lift SERVICE EQUIPMENT SERVICE SETUP3 x
Sump Heater Turn Speed SERVICE EQUIPMENT SERVICE SETUP3 x
Superheat Setpoint SERVICE EQUIPMENT SERVICE SETUP4 x
System Alert/Alarm STATUS MAINSTAT
Target Condenser EXV STATUS COND_EXV CEXV_TRG x
Target Economizer EXV STATUS ECON_EXV EEXV_TRG x
Target VFD Speed STATUS COMPRESS x
Target VFD Speed SERVICE CONTROL ALGORITHM STATUS CAPACITY
Temp Pulldown Ramp/Min SERVICE EQUIPMENT SERVICE TEMP_CTL x
Temperature Reset STATUS MAINSTAT
Temperature Reset SERVICE EQUIPMENT SERVICE TEMP_CTL x
Torque Current STATUS POWER
Torque Current SERVICE CONTROL ALGORITHM STATUS VFD_HIST
Total Compressor Starts STATUS MAINSTAT
Total Error + Resets SERVICE CONTROL ALGORITHM STATUS CAPACITY
Tower Fan High Setpoint SETPOINT SETPOINT x
Tower Fan Relay High STATUS MAINSTAT x
Tower Fan Relay Low STATUS MAINSTAT x
Turn Off Lift SERVICE EQUIPMENT SERVICE SETUP3 x
Turn Off Speed SERVICE EQUIPMENT SERVICE SETUP3 x
Turn On Lift SERVICE EQUIPMENT SERVICE SETUP3 x
Turn On Speed SERVICE EQUIPMENT SERVICE SETUP3 x
Vap. Heater Turn Off Lift SERVICE EQUIPMENT SERVICE SETUP3 x
Vap. Heater Turn Off Speed SERVICE EQUIPMENT SERVICE SETUP3 x
Vap. Heater Turn On Lift SERVICE EQUIPMENT SERVICE SETUP3 x
Vap. Heater Turn On Speed SERVICE EQUIPMENT SERVICE SETUP3 x
Vaporizer Heater STATUS COMPRESS
Vaporizer Heater Mode SERVICE EQUIPMENT SERVICE SETUP2 x
Vaporizer Heater Mode SERVICE EQUIPMENT SERVICE SETUP3 x
Vaporizer Temp STATUS MAINSTAT
Vaporizer Temp STATUS COMPRESS
Vaporizer Temp STATUS HEAT_EX
VFD Checksum Error STATUS VFD_STAT
VFD Cold Plate Temp STATUS POWER
151
VFD Cold Plate Temp SERVICE CONTROL ALGORITHM STATUS VFD_HIST
VFD Comm Fault STATUS VFD_STAT
VFD Coolant Flow STATUS HEAT_EX
VFD Coolant Flow STATUS POWER
VFD Delta STATUS COMPRESS
VFD Delta SERVICE CONTROL ALGORITHM STATUS CAPACITY
VFD Dewpoint STATUS POWER
VFD Dewpoint SERVICE CONTROL ALGORITHM STATUS VFD_HIST
VFD Enclosure Temp STATUS POWER
VFD Enclosure temp SERVICE CONTROL ALGORITHM STATUS VFD_HIST
VFD Fault STATUS VFD_STAT
VFD Fault Code STATUS VFD_STAT
VFD Fault Code SERVICE CONTROL ALGORITHM STATUS VFD_HIST
VFD Gain SERVICE CONTROL ALGORITHM STATUS CAPACITY
VFD Gain SERVICE EQUIPMENT SERVICE SETUP2 x
VFD Gateway Version # STATUS VFD_STAT
VFD Inverter Version # STATUS VFD_STAT
VFD Maximum Speed SERVICE EQUIPMENT SERVICE SETUP2 x
VFD Minimum Speed SERVICE EQUIPMENT SERVICE SETUP2 x
VFD Overload Decrease SERVICE EQUIPMENT SERVICE RAMP_DEM x
VFD Overload Delta SERVICE EQUIPMENT SERVICE RAMP_DEM x
VFD Power On Reset STATUS VFD_STAT
VFD Rectifier Version # STATUS VFD_STAT
VFD Speed Output STATUS MAINSTAT
VFD Speed Output STATUS COMPRESS
VFD Speed Output SERVICE CONTROL ALGORITHM STATUS CAPACITY
VFD Speed Output STATUS ECON_EXV VFD_OUT
VFD Start STATUS MAINSTAT
VFD Start Inhibit STATUS VFD_STAT
WSM Active? SERVICE CONTROL ALGORITHM STATUS WSMCHLRE
152
APPENDIX B — MAINTENANCE SUMMARY AND LOG SHEETS
NOTE: Always check the Optional Extended Warranty for
specific maintenance requirements pertaining to that warranty.
23XRV Maintenance Interval Requirements
WEEKLY
COMPRESSOR Check Oil Level. CONTROLS Review ICVC Alarm/Alert History.
COOLER None. STARTER None.
CONDENSER None. OIL RECLAIM None.
MONTHLY
COMPRESSOR None. CONTROLS Perform an Automated Controls test.
COOLER None. STARTER None.
CONDENSER None. OIL RECLAIM None.
FIRST YEAR
Send oil sample out for analysis. Leak test. Perform general cleaning. Tighten connections. Check
Inspect inlet bearing oil orifice. (Orifice pressure transducers against a gage. Recalibrate if neces-
COMPRESSOR should be inspected whenever oil line is CONTROLS sary. Confirm accuracy of thermistors.
removed.) Change motor cooling line filter-
drier.
Inspect and clean cooler tubes. Inspect relief Perform general cleaning. Tighten connections. Change
valves. Leak test. Verify water pressure dif- VFD refrigerant strainer.
COOLER ferential. Inspect water pumps and cooling STARTER
tower. Perform eddy current test.
Replace refrigerant filter/drier. Inspect and Inspect oil sump strainer.
clean condenser tubes. Inspect relief valves.
CONDENSER Leak test. Verify water pressure differential. OIL RECLAIM
Inspect water pumps and cooling tower.
Perform eddy current test.
ANNUALLY
Send oil sample out for analysis. Leak test. Perform general cleaning. Tighten connections. Check
COMPRESSOR Perform vibration analysis. Meg-ohm test CONTROLS pressure transducers against a gage. Recalibrate if neces-
motor. sary. Confirm accuracy of thermistors.
Inspect and clean cooler tubes. Inspect relief Perform general cleaning. Tighten connections. Change
valves. Leak test. Verify water pressure dif- VFD refrigerant strainer.
COOLER STARTER
ferential. Inspect water pumps and cooling
tower.
Inspect and clean condenser tubes. Inspect None.
CONDENSER relief valves. Leak test. Verify water pressure OIL RECLAIM
differential. Inspect water pumps and cooling
tower.
EVERY 2 YEARS
COMPRESSOR Change oil filter, change motor cooling filter-

drier.
EVERY 3-5 YEARS
COMPRESSOR None. CONTROLS None.
COOLER Eddy current tube test. STARTER None.
CONDENSER Inspect float valve and strainer. Eddy current OIL RECLAIM Inspect oil sump strainer. Inspect oil sump heater.
tube test.
EVERY 10 YEARS
Change oil charge if yearly analysis not com- None.
COMPRESSOR pleted. Inspect compressor rotors (every 5- CONTROLS
10 years).
COOLER Perform eddy current test (every 5-10 years). STARTER None.
Cooler tube cleaning.
Perform eddy current test. Condenser tube None.
CONDENSER OIL RECLAIM
ccleaniong.
SEASONAL SHUTDOWN
COMPRESSOR None. CONTROLS Do not disconnect control power.
Isolate and drain waterbox. Remove water- None.
COOLER box cover from one end. Use compressed air STARTER
to clear tubes.
Isolate and drain waterbox. Remove water- None.
CONDENSER box cover from one end. Use compressed air OIL RECLAIM
to clear tubes.
NOTE: Equipment failures caused by lack of adherence to the Main-
tenance Interval Requirements are not covered under warranty.
153
APPENDIX B — MAINTENANCE SUMMARY AND LOG SHEETS (cont)
23XRV Weekly Maintenance Log
Plant ___________________________Machine Serial No. ________________________________
Machine Model No. ________________Refrigerant Type __________________________________
CHECK ALARMS OPERATOR

DATE OIL LEVEL / FAULTS INITIALS REMARKS
NOTE: Equipment failures caused by lack of adherence to the Main-

tenance Interval Requirements are not covered under warranty.
154
23XRV Maintenance Log for Monthly, Quarterly, and Annual Checks
MONTH 1 2 3 4 5 6 7 8 9 10 11 12
DATE / / / / / / / / / / / / / / / / / / / / / / / /
OPERATOR
UNIT SECTION ACTION UNIT ENTRY

Change Oil Charge yes/no
Record Oil Temperature °F
COMPRESSOR Send Oil Sample Out for Analysis yes/no
Perform Vibration Analysis yes/no
Leak Test ppm
Inspect and Clean Cooler Tubes yes/no
Inspect Relief Valves yes/no
Leak Test PPM
COOLER Record Water Pressure Differential PSI
Record Cooler Pressure PSI
Record Entering and Leaving Water Temperature °F
Inspect Water Pumps yes/no
Leak Test PPM
Inspect and Clean Condenser Tubes yes/no
Record Water Pressure Differential (PSI) PSI
Record Cooler Pressure PSI
155
CONDENSER Record Entering and Leaving Water Temperature °F
Inspect Water Pumps and Cooling Tower yes/no
Inspect Relief Valves yes/no
Replace Refrigerant Filter Drier yes/no
Inspect Float Valve and Strainer yes/no
General Cleaning and Tightening Connections yes/no
Confirm Accuracy of Pressure Transducers yes/no
CONTROLS
Confirm Accuracy of Thermistors yes/no
Perform Automated Controls Test yes/no
General Tightening and Cleaning Connections yes/no
STARTER
Change VFD Refrigerant Strainer yes/no
NOTE: Equipment failures caused by lack of adherence to the Maintenance Interval Requirements
are not covered under warranty.
Annually
23XRV Seasonal Shutdown Log
MONTH 1 2 3 4 5 6 7 8 9 10 11 12
DATE / / / / / / / / / / / / / / / / / / / / / / / /
OPERATOR
UNIT SECTION ACTION ENTRY

Isolate and Drain Waterbox
COOLER Remove Waterbox Cover from One End
Use Compressed Air to Clean Tubes
Isolate and Drain Waterbox
CONDENSER Remove Waterbox Cover from One End
Use Compressed Air to Clean Tubes
CONTROLS Do Not Disconnect Control Power
NOTE: Equipment failures caused by lack of adherence to the Maintenance Interval Requirements
are not covered under warranty.
156
APPENDIX C — BACNET COMMUNICATION OPTION
The following section is used to configure the UPC Open con-
troller which is used when the BACnet* communication 9 0
1
option is selected. The UPC Open controller is mounted in a
7 8
2 34
10's
separate enclosure below the main control box. a48-8578
6
5
TO ADDRESS THE UPC OPEN CONTROLLER — The
user must give the UPC Open controller an address that is 9 0
1
7 8
2 34
unique on the BACnet network. Perform the following proce- 1's
dure to assign an address:
6
5
1. If the UPC Open controller is powered, pull the screw ter-

minal connector from the controller's power terminals la- Fig. A — Address Rotary Switches
beled Gnd and HOT. The controller reads the address
each time power is applied to it. BACNET DEVICE INSTANCE ADDRESS — The UPC
2. Using the rotary switches (see Fig. A and B), set the con- Open controller also has a BACnet Device Instance address.
troller's address. Set the Tens (10's) switch to the tens dig- This Device Instance MUST be unique for the complete BAC-
it of the address, and set the Ones (1's) switch to the ones net system in which the UPC Open controller is installed. The
digit. Device Instance is auto generated by default and is derived by
adding the MAC address to the end of the Network Number.
As an example in Fig. A, if the controller’s address is 25, The Network Number of a new UPC Open controller is 16101,
point the arrow on the Tens (10's) switch to 2 and the arrow on but it can be changed using i-Vu® Tools or BACView device.
the Ones (1's) switch to 5. By default, a MAC address of 20 will result in a Device In-
stance of 16101 + 20 which would be a Device Instance of
1610120.
BT485
TERMINATOR
BACNET
CONNECTION POWER LED
(BAS PORT)
Tx1 LED
Rx1 LED
Tx2 LED
Rx2 LED BACNET
BAUD RATE
8
67 9 DIP SWITCHES
01
EIA-485
45
23
JUMPERS ADDRESS
8
67 9 ROTARY
01
45
23 SWITCHES
RUN LED
ERROR LED
Fig. B — UPC Open Controller
a48-8579
* Sponsored by ASHRAE (American Society of Heating, Refrigerat-
ing, and Air-Conditioning Engineers).
157
APPENDIX C — BACNET COMMUNICATION OPTION (cont)
CONFIGURING THE BAS PORT FOR BACNET MS/
TP — Use the same baud rate and communication settings for
all controllers on the network segment. The UPC Open con-
troller is fixed at 8 data bits, No Parity, and 1 Stop bit for this
protocol's communications.
If the UPC Open controller has been wired for power, pull a48-8580
the screw terminal connector from the controller's power termi-
nals labeled Gnd and HOT. The controller reads the DIP
Switches and jumpers each time power is applied to it.
Set the BAS Port DIP switch DS3 to “enable.” Set the BAS
Port DIP switch DS4 to “E1-485.” Set the BMS Protocol DIP
switches DS8 through DS5 to “MSTP.” See Table A.
Fig. C — DIP Switches
Table A — SW3 Protocol Switch Settings
for MS/TP Wire the controllers on an MS/TP network segment in a dai-
DS8 DS7 DS6 DS5 DS4 DS3 sy-chain configuration. Wire specifications for the cable are
Off Off Off Off On Off
22 AWG (American Wire Gage) or 24 AWG, low-capacitance,
twisted, stranded, shielded copper wire. The maximum length
Verify that the EIA-485 jumpers below the CCN Port are set is 2000 ft.
to EIA-485 and 2W. Install a BT485 terminator on the first and last controller on
The example in Fig. C shows the BAS Port DIP Switches a network segment to add bias and prevent signal distortions
set for 76.8k (Carrier default) and MS/TP. due to echoing. See Fig. B, D, and E.
Set the BAS Port DIP Switches DS2 and DS1 for the appro- To wire the UPC Open controller to the BAS network:
priate communications speed of the MS/TP network (9600, 1. Pull the screw terminal connector from the controller's
19.2k, 38.4k, or 76.8k bps). See Fig. C and Table B. BAS Port.
Table B — Baud Selection Table 2. Check the communications wiring for shorts and
grounds.
BAUD RATE DS2 DS1
3. Connect the communications wiring to the BAS port’s
9,600 Off Off
screw terminals labeled Net +, Net -, and Shield.
19,200 On Off
38,400 Off On
NOTE: Use the same polarity throughout the network
segment.
76,800 On On
4. Insert the power screw terminal connector into the UPC
WIRING THE UPC OPEN CONTROLLER TO THE MS/ Open controller's power terminals if they are not current-
TP NETWORK — The UPC Open controller communicates ly connected.
using BACnet on an MS/TP network segment communications 5. Verify communication with the network by viewing a
at 9600 bps, 19.2 kbps, 38.4 kbps, or 76.8 kbps. module status report. To perform a module status report
using the BACview keypad/display unit, press and hold
the “FN” key then press the “.” Key.
a48-8581
Fig. D — Network Wiring
158
a48-8582
Fig. E — BT485 Terminator Installation
To install a BT485 terminator, push the BT485 terminator temperature rating specifications list two acceptable alterna-
on to the BT485 connector located near the BACnet connector. tives. The Halar specification has a higher temperature rating
NOTE: The BT485 terminator has no polarity associated with and a tougher outer jacket than the SmokeGard specification,
it. and it is appropriate for use in applications where the user is
concerned about abrasion. The Halar jacket is also less likely to
To order a BT485 terminator, consult Commercial Products crack in extremely low temperatures.
i-Vu Open Control System Master Prices.
NOTE: Use the specified type of wire and cable for maximum
MS/TP WIRING RECOMMENDATIONS — Recommen- signal integrity.
dations are shown in Tables C and D. The wire jacket and UL
Table C — MS/TP Wiring Recommendations

SPECIFICATION RECOMMMENDATION
CABLE Single twisted pair, low capacitance, CL2P, 22 AWG (7x30), TC foam FEP, plenum rated cable
CONDUCTOR 22 or 24 AWG stranded copper (tin plated)
INSULATION Foamed FEP 0.015 in. (0.381 mm) wall 0.060 in. (1.524 mm) O.D.
COLOR CODE Black/White
TWIST LAY 2 in. (50.8 mm) lay on pair 6 twists/foot (20 twists/meter) nominal
SHIELDING Aluminum/Mylar shield with 24 AWG TC drain wire
SmokeGard Jacket (SmokeGard PVC) 0.021 in. (0.5334 mm) wall 0.175 in. (4.445 mm) O.D.
JACKET
Halar Jacket (E-CTFE) 0.010 in. (0.254 mm) wall 0.144 in. (3.6576 mm) O.D.
DC RESISTANCE 15.2 Ohms/1000 feet (50 Ohms/km) nominal
CAPACITANCE 12.5 pF/ft (41 pF/meter) nominal conductor to conductor
CHARACTERISTIC IMPEDANCE 100 Ohms nominal
WEIGHT 12 lb/1000 feet (17.9 kg/km)
SmokeGard 167 F (75 C)
UL TEMPERATURE RATING
Halar –40 to 302 F (–40 to 150 C)
VOLTAGE 300 Vac, power limited
LISTING UL: NEC CL2P, or better
LEGEND
AWG — American Wire Gage
CL2P — Class 2 Plenum Cable
DC — Direct Current
FEP — Fluorinated Ethylene Polymer
NEC — National Electrical Code
O.D. — Outside Diameter
TC — Tinned Copper
159
Table D — Open System Wiring Specifications and Recommended Vendors
WIRING SPECIFICATIONS RECOMMENDED VENDORS AND PART NUMBERS
CONNECT AIR CONTRACTORS

WIRE TYPE DESCRIPTION BELDEN RMCORP
INTERNATIONAL WIRE AND
CABLE
22 AWG, single twisted shielded pair, low capacitance, CL2P,
TC foam FEP, plenum rated. See MS/TP Installation Guide for W221P-22227 — 25160PV CLP0520LC
MS/TP specifications.
NETWORK
(RS-485) 24 AWG, single twisted shielded pair, low capacitance, CL2P,
TC foam FEP, plenum rated. See MS/TP Installation Guide W241P-2000F 82841 25120-OR —
for specifications.
RNET 4 conductor, unshielded, CMP, 18 AWG, plenum rated. W184C-2099BLB 6302UE 21450 CLP0442
LEGEND
AWG — American Wire Gage
CL2P — Class 2 Plenum Cable
CMP — Communications Plenum Rated
FEP — Fluorinated Ethylene Polymer
TC — Tinned Copper
LOCAL ACCESS TO THE UPC OPEN CONTROL- The factory default settings for CCN Element and CCN Bus
LER — The user can use a BACview6 handheld keypad dis- number are 1 and 0 respectively.
play unit or the Virtual BACview software as a local user inter- If modifications to the default Element and Bus number are
face to an Open controller. These items let the user access the required, the UPC Open configuration must be changed.
controller network information. These are accessory items and
do not come with the UPC Open controller. The following configurations are used to set the CCN Ad-
dress and Bus Number in the UPC Open controller. These con-
The BACview6 unit connects to the local access port on the figurations can be changed using the accessory BACview6 dis-
UPC Open controller. See Fig. F. The BACview software must play.
be running on a laptop computer that is connected to the local
access port on the UPC Open controller. The laptop will re- Navigation: BACview→CCN
quire an additional USB link cable for connection. Home: Element Comm Stat
See the BACview Installation and User Guide for instruc- Element: 1
tions on connecting and using the BACview6 device. Bus: 0
To order a BACview6 Handheld (BV6H), consult Commer- TROUBLESHOOTING — If there are problems wiring or
cial Products i-Vu Open Control System Master Prices. addressing the UPC Open controller, contact Carrier Technical
CONFIGURING THE UPC OPEN CONTROLLER'S Support.
PROPERTIES — The UPC Open device must be set to the
same CCN Address (Element) number and CCN Bus number.
a48-8583ef
Fig. F — BACview6 Device Connection
160
COMMUNICATION LEDS — The LEDs indicate if the
.
controller is communicating with the devices on the network. IMPORTANT: Power must be ON to the UPC Open when
See Tables E and F. The LEDs should reflect communication replacing the battery, or the date, time, and trend data will be
traffic based on the baud rate set. The higher the baud rate the lost.
more solid the LEDs become. See Fig. B for location of LEDs
on UPC Open module. Remove the battery from the controller, making note of the
battery's polarity. Insert the new battery, matching the battery's
REPLACING THE UPC OPEN BATTERY — The UPC polarity with the polarity indicated on the UPC Open
Open controller's 10-year lithium CR2032 battery provides a controller.
minimum of 10,000 hours of data retention during power
outages. NETWORK POINTS LIST — The points list for the control-
ler is shown in Table G.
Table E — LED Status Indicators

LED STATUS
Lights when power is being supplied to the controller. The UPC Open controller is protected by internal solid-state polyswitches on
POWER the incoming power and network connections. These polyswitches are not replaceable and will reset themselves if the condition
that caused the fault returns to normal.
RX Lights when the controller receives data from the network segment; there is an Rx LED for Ports 1 and 2.
TX Lights when the controller transmits data to the network segment; there is an Tx LED for Ports 1 and 2.
RUN Lights based on controller status. See Table F.
ERROR Lights based on controller status. See Table F.
Table F — Run and Error LEDs Controller and Network Status Indication
RUN LED ERROR LED STATUS
Off Normal
2 flashes, alternating with Run LED Five minute auto-restart delay after system error
2 flashes per second 3 flashes, then off Controller has just been formatted
1 flash per second Controller is alone on the network
On Exec halted after frequent system errors or control programs halted
On Exec start-up aborted, Boot is running
5 flashes per second
Off Firmware transfer in progress, Boot is running
7 flashes per second 7 flashes per second, alternating with Run LED Ten-second recovery period after brownout
14 flashes per second 14 flashes per second, alternating with Run LED Brownout
161
 Table G — Network Points List
POINT DESCRIPTION CCN READ/ UNITS DEFAULT RANGE BACNET BACNET

POINT NAME WRITE VALUE OBJECT ID OBJECT NAME
Active Delta T DT_A_ R psi N/A 0 to 200 AV:4 dt_a_1
Active Demand Limit DEM_LIM R/W % N/A 40 to 100 AV:5 dem_lim_1
Actual VFD Speed VFD_ACT R % N/A 0 to 110 AV:6 vfd_act_1
Auto Chilled Liq Reset AUTO_RES R mA N/A 4 to 20 AV:7 auto_res_1
Auto Demand Limit Input AUTO_DEM R mA N/A 4 to 20 AV:8 auto_dem_1
Base Demand Limit DLM R/W % N/A 40 to 100 AV:9 dlm_1
Calc Evap Sat Temp ERT R °F N/A -40 to 245 AV:10 ert_1
Chill Liq Pulldown/Min CHL_PULL R/W ^F N/A -20 to 20 AV:13 chl_pull_1
Chilled Liquid Temp CHL_TMP R °F N/A -40 to 245 AV:11 chl_tmp_1
Chilled Water Temp CHWTEMP R °F N/A 0.0 to 99.9 AV:12 chwtemp_1
Chiller Start/Stop CHIL_S_S R/W N/A STOP/START BV:5 chil_s_s_1
Comp Discharge Alert CD_ALERT R °F 140 125 to 160 AV:14 cd_alert_1
Comp Discharge Temp CMPD R °F N/A -40 to 245 AV:15 cmpd_1
Comp Motor Frequency VFD_FREQ R Hz N/A 0 to 10000 AV:49 vfd_freq_1
Comp Motor RPM CPR_RPM R rpm N/A 0 to 300000 AV:50 cpr_rpm_1
Condenser Liquid Pump CDP N/A OFF/ON BV:4 cdp_1
Condenser Pressure CRP R psi N/A -6.7 to 420 AV:16 crp_1
Condenser Refrig Temp CRT R °F N/A -40 to 245 AV:17 crt_1
0=Off, 1=Local ,
Control Mode MODE R N/A AV:51 mode_1
2=CCN, 3=Reset
Control Point LCW_STPT R/W °F N/A 10 to 65 AV:18 lcw_stpt_1
Current CHW Setpoint CHWSTPT R °F N/A 0.0 to 99.9 AV:19 chwstpt_1
Demand Level 1 R % N/A 0 to 100 AV:1 dmv_lvl_1_perct_1
Comm Normal
Element Communications Alarm R N/A Comm Lost BV:15 comm_lost_alm_1
Element Comm Status R N/A No Comm/Normal BV:2999 element_stat_1
Entering Chilled Liquid ECL R °F N/A -40 to 245 AV:20 ecl_1
Entering Cond Liquid ECDL R °F N/A -40 to 245 AV:21 ecdl_1
Evap Refrig Liquid Temp EST R °F N/A -40 to 245 AV:23 est_1
Evap Refrig Trippoint ERT_TRIP R °F 33 10 to 40.0 AV:24 ert_trip_1
Evaporator Pressure ERP R psi N/A -6.7 to 420 AV:22 erp_1
Ground Fault Current GF_AMPS R A N/A 0 to 999 AV:25 gf_amps_1
Head Pressure Reference HPR R % N/A 0 to 100 AV:52 hpr_1
Leaving Chilled Liquid -
LCL R °F N/A -40 to 245 AV:26 lcl_1
Prime Variable
Leaving Cond Liquid LCDL R °F N/A -40 to 245 AV:27 lcdl_1
Local Schedule R N/A ON/OFF BV:1 schedule_1
Occupied? OCC R NO/YES BV:6 occ_1
Oil Heater Relay 1 OILHEAT1 R N/A OFF/ON BV:7 oilheat1_1
Oil Heater Relay 2 OILHEAT2 R N/A OFF/ON BV:11 oilheat2_1
Oil Pump Relay OILR R N/A OFF/ON BV:8 oilr_1
Oil Pressure Delta P OILPD R psi N/A -6.7 to 420 AV:28 oilpd_1
Oil Sump Temp OILT R °F N/A -40 to 245 AV:29 oilt_1
Percent Line Current LNAMPS_P R % N/A 0.0 to 9999 AV:30 lnamps_p_1
Percent Line Kilowatts LINEKW_P R % N/A 0.0 to 9999 AV:31 linekw_p_1
LEGEND
CHW — Chilled Water
R — Read
VFD — Variable Frequency Drive
W — Write
516 162
 Table G — Network Points List (cont)
POINT DESCRIPTION CCN READ/ UNITS DEFAULT RANGE BACNET BACNET

POINT NAME WRITE VALUE OBJECT ID OBJECT NAME
Relative Humidity HUMIDITY R N/A 0 to 100 AV:32 humidity_1
Remote Reset Sensor R_RESET R °F N/A -40 to 245 AV:33 r_reset_1
Remote Start Contact REM_CON R/W N/A OPEN/CLOSE BV:9 rem_con_1
1=Timeout,
2=Ready,
3=Recyle,
4=Startup,
5=Running,
6=Demand,
7=Ramping,
Run Status STATUS R N/A AV:34 status_1
8=not used,
9=Override,
10=Tripout,
11=Control Test,
12=Lockout,
13=Pumpdown,
14=Prestart
Service Ontime S_HRS R/W hr N/A 0 to 32767 AV:35 s_hrs_1
Shunt Trip Relay TRIPR R N/A OFF/ON BV:17 tripr_1
Stall Protection Counts SPC R N/A 0 to 5 AV:36 spc_1
Start Complete START_OK R N/A FALSE/TRUE BV:18 start_ok_1
Stop Fault AMPSTOP R N/A NORMAL/ALARM BV:10 ampstop_1
0=Normal
System Alert/Alarm SYS_ALM R N/A 1=Alert AV:37 sys_alm_1
2=Alarm
System Cooling Demand Level R N/A N/A AV:9006 cool_demand_level_1
System Demand Limiting R N/A Active/Inactive BV:2 dem_lmt_act_1
Target VFD Speed VFD_TRG R % N/A 0 to 100 AV:38 vfd_trg_1
Torque Current TORQ_I R A N/A 0 to 99999 AV:39 torq_i_1
Tower Fan Relay High TFR_HIGH R N/A OFF/ON BV:19 tfr_2_1
Tower Fan Relay Low TFR_LOW R N/A OFF/ON BV:20 tfr_1_1
User Defined Analog 1 R N/A N/A AV:2901 user_analog_1_1
User Defined Binary 1 R BV:2911 user_binary_1_1
User Defined Binary 2 R N/A BV:2912 user_binary_2_1
Vaporizer Temp VAP_TEMP R °F N/A -40 to 245 AV:45 vap_temp_1
VFD Cold Plate Temp CP_TEMP R °F N/A 0 to 300 AV:46 cp_temp_1
VFD Start VFDSTART R N/A NO/YES BV:21 vfdstart_1
LEGEND
CHW — Chilled Water
R — Read
VFD — Variable Frequency Drive
W — Write
516
163
INDEX
Abbreviations and explanations 5 Motor-compressor description 12 Spare alarm contacts 52
BACnet communication option 157-163 Motor cooling cycle 16 Spare safety inputs 52
Before initial start-up 62-81 Motor insulation 94 Spare temperature inputs 52
Carrier Comfort Network® Interface 75 Muffler description 12 Start the chiller 83
Carrier Comfort Network communication Network device control, attaching to 58 Start-up, initial 82,83
wiring 142 Oil and oil filter changes 90 Start-up, initial preparation 82
Capacity control 18 Oil charge 62 Start-up/shutdown/recycle
Capacity override 48 Oil circuit valves (open) 62 sequence 60-62
Chilled liquid recycle mode 61 Oil heater 91 Stop the chiller 83
Chiller control module (CCM) 119 Oil pressure and compressor Storage vessel (optional) description 12
Chiller dehydration 71 stop (check) 82 System components 5
Chiller familiarization 5-13 Oil reclaim system 17 Temperature sensors (checking) 97
Chiller identification nameplate 5 Oil specification 91 Test after service, repair or
Chiller start-up (prepare for) 82,83 Oil strainers 91 major leak 89
Chillers with storage tanks 87 Oil sump temperature control 48, 52 Tighten all gasketed joints 62
Chiller tightness (check) 64 Operating instructions 83-85 Tower fan relay low and high 53
Cold weather operation 84 Operating the optional pumpout unit 86 Troubleshooting guide 96-144
Compressor bearing maintenance 94 Operator duties 83 Vaporizer refrigerant return
Compressor inlet bearing oil orifice 92 Optional flow device calibration 78 line orifice 91
Compressor minimum speed override 48 Optional pumpout compressor Vaporizer temperature control 48
Compressor rotor check 94 liquid piping (check) 72 VFD, identify 72
Condenser description 12 Optional pumpout system controls VFD refrigerant strainer 91
Condenser freeze prevention 53 and compressor (check) 79 VFD schematic 135-138
Condenser pump control 53 Optional pumpout Water/brine leaks 94
Control algorithms checkout system maintenance 95 Water/brine treatment 95
procedure 98 Optional storage tank and Weekly maintenance 90
Control center pumpout system (using) 62 Wiring, inspecting 74
description 12 Ordering replacement chiller parts 96 Wiring schematics
check before start-up 74 Overview (troubleshooting guide) 96 CCN communication wiring 142
inspect 90, 95 Physical data 125 Controls 130-134
Control modules 119 PIC III system components 18 Field wiring 138-141
Controls 18-60 PIC III system functions 45 Lead/lag control wiring 143, 144
Controls (definitions) 18 Preparation (pumpout and VFD schematics 135-137
Controls overview 18 refrigerant transfer procedures) 86
Controls schematics 130-134 Pressure transducers 78, 95, 97
Control test 78, 98 Prevent accidental start-up 82
Cooler, description 12 Pumpout and refrigerant
Default screen freeze 47 transfer procedures 86-89
Defective ICVC modules Ramp loading 48
(replacing) 120 Refrigerant (adding) 89
Demand limit control option 54 Refrigerant (adjusting the charge) 89
Design set points (input) 75 Refrigerant charge (trim) 90
Display messages (checking) 97 Refrigerant filter/drier 91
Equipment required 62 Refrigerant float system (inspect) 92
Extended shutdown (preparation for) 84 Refrigerant into chiller (charge) 79
Extended shutdown (after) 84 Refrigerant leak detector 52
Fast power source transfers 53 Refrigerant leak rate 89
Field wiring schematic 138 Refrigerant leak testing 89
Gateway status LEDs 121 Refrigerant properties 89
General maintenance 89, 90 Refrigerant (removing) 89
Ground fault troubleshooting 74 Refrigerant tracer 64
Head pressure output reference 54 Refrigeration cycle 13-15
Heat exchanger tubes (inspect) 94 Refrigeration log 84
High altitude locations 79 Relief valves (check) 72
Hot gas bypass (optional) algorithm 54 Relief valves and piping (inspect) 94
ICVC operation and menus 23 Remote start/stop contacts 52
ICVC parameter index 145-152 Remote reset of alarms 52
Initial start-up checklist CL-1 to CL-10 Repair the refrigerant leak retest
Input power wiring 73 and apply standing vacuum test 90
Instruct the customer operator 82 Restart after power failure 53
Job data required 62 Running system (check) 83
Lead/lag control 56 Safety and operating
Lead/lag control wiring 143,144 controls (check monthly) 90
Leak test chiller 64 Safety considerations 1,2
Limited shutdown, after 84 Safety controls 47
Liquid piping, inspecting 71 Safety shutdown 62
Liquid/brine temperature reset 53 Scheduled maintenance 90-96
Local occupied schedule (input) 75 Service configurations (input) 75
Local start-up 60 Service ontime 90
Lubrication cycle 16-18 Service operation 59
Lubrication cycle (details) 16 Shipping packaging (remove) 62
Lubrication cycle (summary) 16 Shunt trip 47
Lubrication system (check) 90 Shutdown sequence 61
Maintenance log 153-156 Soft stop amps threshold, automatic 61
Module operation (notes) 119 Software configuration 75
© Carrier Corporation 2014
Catalog No. 04-53230011-01 Printed in U.S.A. Form 23XRV-5SS Pg 164 1016 11-14 Replaces: 23XRV-4SS
INITIAL START-UP CHECKLIST
FOR 23XRV VARIABLE SPEED SCREW CHILLER WITH GREENSPEED® INTELLIGENCE
(Remove and use for job file.)
NOTE: To avoid injury to personnel and damage to equipment or

property when completing the procedures listed in this start-up
checklist, use good judgment, follow safe practices, and adhere
to the safety considerations/information as outlined in preceding
sections of this Controls, Start-Up, Operation, Maintenance
Instructions document.
MACHINE INFORMATION:
NAME JOB NO.

ADDRESS MODEL
CITY STATE ZIP S/N
DESIGN CONDITIONS
TONS FLOW TEMPERATURE TEMPERATURE PRESSURE SUCTION CONDENSER
BRINE PASS
(kW) RATE IN OUT DROP TEMPERATURE TEMPERATURE
COOLER ******
CONDENSER ******
From Chiller Nameplate: Line Voltage Rated Line Amps Overload Trip Amps
From VFD Nameplate: I.D. No.: Input Rating
VFD Serial Number ___________________________________________
Mfd in _____________________________________ on _____________
REFRIGERANT: Type: Charge

CARRIER OBLIGATIONS: Assemble. . . . . . . . . . . . . . . . . . . Yes  No
Leak Test . . . . . . . . . . . . . . . . . . . Yes  No
Dehydrate . . . . . . . . . . . . . . . . . . Yes  No
Charging . . . . . . . . . . . . . . . . . . . Yes  No
Operating Instructions Hrs.
START-UP TO BE PERFORMED IN ACCORDANCE WITH APPROPRIATE MACHINE START-UP INSTRUCTIONS

JOB DATA REQUIRED:
1. Machine Installation Instructions . . . . . . . . . . . . . . . . . . Yes  No 
2. Machine Assembly, Wiring and Piping Diagrams . . . . . . Yes  No 
3. Starting Equipment Details and Wiring Diagrams . . . . . . Yes  No 
4. Applicable Design Data (see above). . . . . . . . . . . . . . . . Yes  No 
5. Diagrams and Instructions for Special Controls . . . . . . . Yes  No 
INITIAL MACHINE PRESSURE:
YES NO
Was Machine Tight?
If Not, Were Leaks Corrected?
Was Machine Dehydrated After Repairs?
Catalog No. 04-53230011-01 Printed in U.S.A. Form 24XRV-5SS Pg CL-1 1016 11-14 Replaces: 23XRV-4SS
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CHECK OIL LEVEL AND RECORD: 3/4 ADD OIL: Yes  No 
1/2 Oil sump sight glass
1/4
Amount:
3/4
1/2 Strainer housing sight glass
1/4
RECORD PRESSURE DROPS: Cooler Condenser
CHARGE REFRIGERANT: Initial Charge Final Charge After Trim
INSPECT WIRING AND RECORD ELECTRICAL DATA:

Verify 6 clearance surrounding all Control Center louvers Yes  No 
Visually inspect down through top of power module for debris Yes  No 
RATINGS:
Motor Voltage Motor(s) Amps Oil Pump Voltage Starter LRA Rating
Line Voltages: Motor Oil Pump Controls/Oil Heater
RECORD THE FOLLOWING POWER ON CHECKS:
CUT ALONG DOTTED LINE

Line Voltage: Phase - Phase A-B: B-C: A-C:
Line Voltage: Phase - Ground A-G: B-G: C-G:
What type and size of transformer supplies power to the unit?
Delta with No Ground _____
Corner Grounded Delta _____
Wye with Center Ground _____
Wye with No Ground _____
Transformer Size _____kVa
FIELD-DISASSEMBLED CHILLERS ONLY:
Megger Test Motor if the VFD is removed from the chiller.
Check continuity T1 to T1, etc. (Motor to starter, disconnect motor leads T1, T2, T3.) Do not megger VFD;
disconnect leads to motor and megger the leads.
“PHASE TO PHASE” “PHASE TO GROUND”
MEGGER MOTOR
T1-T2 T1-T3 T2-T3 T1-G T2-G T3-G
10-Second Readings:

60-Second Readings:
Polarization Ratio:
CONTROLS: SAFETY, OPERATING, ETC.

Verify parameters in VFD_conf screen. Yes  No 
Perform Controls Test Yes  No 
PIC III CAUTION
COMPRESSOR MOTOR AND CONTROL CENTER MUST BE PROPERLY AND INDIVIDUALLY Yes
CONNECTED BACK TO THE EARTH GROUND IN THE STARTER (IN ACCORDANCE WITH
CERTIFIED DRAWINGS).
Water/Brine Pump Control

Can the Carrier controls independently start the pumps?
Condenser Liquid Pump Yes  No 
Chilled Liquid Pump Yes  No 
CL-2
INITIAL START:
Check Position of all Valves:
Isolation Valves (See Fig. 2-4, 41-43, and 45)
VALVE LOCATION OPEN
Discharge Under Muffler ________
Cooler Inlet Next to economizer or under cooler ________
Hot Gas Bypass Between cooler and condenser ________
Vaporizer Condenser Gas Between cooler and condenser ________
Oil Pump Next to oil pump inlet ________
Oil Filter Downstream of oil filter ________
Oil Pressure Regulator Under oil sump next to oil pressure regulator ________
Filter/Drier Next to condenser float chamber ________
Filter/Drier Under condenser near filter/drier ________
VFD Refrigerant Cooling Inlet Under compressor discharge ________
VFD Refrigerant Cooling Drain Between cooler and condenser ________
Relief Valve Three-Way Valves
Cooler (if installed) Fully Front Seated or Fully Back Seated ________
Condenser Fully Front Seated or Fully Back Seated ________
Service Valves CLOSED
Cooler Refrigerant Charging Valve On cooler relief valve tree ________
Cooler Refrigerant Pumpout Valve Under cooler ________
Condenser Refrigerant Charging Valve On condenser relief valve tree ________
Condenser Refrigerant Pumpout Valve On condenser float valve chamber ________
Oil Sump Charging/Drain Valve Under oil sump ________
Start Liquid Pumps and Establish Liquid Flow

Oil Level OK and Oil Temperature OK Oil Pressure
Restart Compressor, Bring Up To Speed. Shut Down. Any Abnormal Coastdown Noise? Yes*  No 
*If yes, determine cause.
START MACHINE AND OPERATE. COMPLETE THE FOLLOWING:

A: Trim charge and record under Charge Refrigerant Into Chiller section on page 79.
B: Inspect refrigerant cooling lines for condensation (Q,R compressors only). See page 71.
B: Complete any remaining control calibration and record under Controls section (pages 18-60).
C: Take at least two sets of operational log readings and record.
D: After machine has been successfully run and set up, shut down and mark shutdown oil levels.
E: Give operating instructions to owner’s operating personnel. Hours Given: Hours
F: Call your Carrier factory representative to report chiller start-up.
G: Rockwell/Allen Bradley VFD: Register drive start-up at www.automation.rockwell.com/warp.
Eaton VFD: Complete Eaton Warranty Registration Form TD08H28TE and send to:
VFDAftermarketEG@eaton.com
NOTE: To extend drive warranty, registration should be performed by a Rockwell or Eaton Certified Technician as
applicable.
H: Return a copy of this completed checklist to the local Carrier Service office.
SIGNATURES:
CARRIER CUSTOMER
TECHNICIAN REPRESENTATIVE
DATE DATE
CL-3
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23XRV PIC III SETPOINT TABLE CONFIGURATION SHEET
DESCRIPTION RANGE UNITS DEFAULT VALUE
Base Demand Limit 40 to 100 % 100
LCL Setpoint 10 to 60 (-12.2 to 15.6) ° F (° C) 50.0 (10.0)
ECL Setpoint 15 to 65 (-9.4 to 18.3) ° F (° C) 60.0 (15.6)
Ice Build Setpoint 15 to 60 (-9.4 to 15.6) ° F (° C) 40 (4.4)
Tower Fan High Setpoint 55 to 105 (13 to 41) ° F (° C) 75 (23.9)
Upload all Control Configuration tables via Service Tool Yes  No 

ICVC Software Part # (See ICVC CONFIGURATION Screen):
ICVC Controller Identification (See ICVC CONFIGURATION Screen): BUS: ADDRESS:
VFD Gateway Version # (See VFD_STAT Screen):
VFD Inverter Version # (See VFD_STAT Screen):
VFD Rectifier Version # (See VFD_STAT Screen):

23XRV PIC III LOCAL TIME SCHEDULE CONFIGURATION SHEET OCCPC01S
Day Flag Occupied Unoccupied

M T W T F S S H Time Time
Period 1:
Period 2:
Period 3:
Period 4:
Period 5:
Period 6:
Period 7:
Period 8:

NOTE: Default setting is OCCUPIED 24 hours/day.
ICE BUILD 23XRV PIC III TIME SCHEDULE CONFIGURATION SHEET OCCPC02S

Period 1:
Period 2:
Period 3:
Period 4:
Period 5:
Period 6:
Period 7:
Period 8:
NOTE: Default setting is UNOCCUPIED 24 hours/day.
CL-4
23XRV PIC III CCN TIME SCHEDULE CONFIGURATION SHEET OCCPC03S

Period 1:
Period 2:
Period 3:
Period 4:
Period 5:
Period 6:
Period 7:
Period 8:
NOTE: Default setting is OCCUPIED 24 hours/day.
23XRV PIC III VFD_CONF TABLE CONFIGURATION SHEET

Motor Nameplate Voltage 380 to 480 VOLTS 480
54 to 110 (Q,R Compressors)
Compressor 100% Speed Hz 70
54 to 140 (P Compressor)
Rated Line Voltage 208 to 600 VOLTS 460
Rated Line Amps 10 to 5000 AMPS 200
Rated Line Kilowatts 0 to 999999 KW 100
Motor Rated Load KW 0 to 999999 KW 100
Motor Rated Load Amps 10 to 5000 AMPS 200
Motor Nameplate Amps 10 to 5000 AMPS 100
1500 to 3500 (Q,R Compressors) 2672
Motor Nameplate RPM
1500 to 3960 (P Compressor) 3750
Motor Nameplate KW 0 to 999999 KW 100
Inverter PWM Frequency
0/1 0
(0=4 k Hz, 1=2 k Hz)
Skip Frequency 1 0.0 to 102 Hz 102
Skip Frequency Band 0.0 to 102 Hz 0
Line Voltage % Imbalance 1 to 10 % 10
Line Volt Imbalance Time 1 to 10 SEC 10
Line Current % Imbalance 5 to 40 % 40
Line Current Imbal Time 1 to 10 SEC 10
Motor Current % Imbalance 5 to 40 % 40
Motor Current Imbal Time 1 to 10 SEC 10
Increase Ramp Time SEC 30
Decrease Ramp Time SEC 30
Single Cycle Dropout 0/1 DSABLE/ DSABLE
ENABLE
CL-5
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23XRV PIC III OPTIONS TABLE CONFIGURATION SHEET
Auto Restart Option 0/1 DSABLE/ENABLE DSABLE
Remote Contacts Option 0/1 DSABLE/ENABLE DSABLE
Soft Stop Amps Threshold 40 to 100 % 100
Hot Gas Bypass

HGBP Option 0,1,2 0=DSABLE DSABLE
1=HGBP
2=LOW LOAD HGBP
Min. Load Point (T1, P1)
0.5 to 20 ˆF 1.5
HGBP Delta T1
(.3 to 11.1) (ˆC) (.8)
10 to 170 PSI 150
HGBP Delta P1 (68.9 to 1172.2) (kPa) (1034.2)
Full Load Point (T2, P2)
0.5 to 20 ˆF 4
HGBP Delta T2
(.3 to 11.1) (ˆC) (2.2)

30 to 250 PSI 200
HGBP Delta P2
(206.9 to 1724) (kPa) (1379)
HGBP Deadband 0.5 to 3 ˆF 1
(.3 to 1.7) (ˆC) (.6)
HGBP On Delta Speed 0.0 to 20.0 % 5.0
HGBP Off Delta Speed 0.0 to 20.0 % 3.0
Stall Protection
Stall Delta % Amps 5 to 20 % 10
Stall Time Period 7 to 10 MIN 8
Ice Build Control

Ice Build Option 0/1 DSABLE/ENABLE DSABLE
Ice Build Termination 0 to 2 0
(0=TEMP, 1=Contact, 2=Both)
Ice Build Recycle 0/1 DSABLE/ENABLE DSABLE
Refrigerant Leak Option 0/1 DSABLE/ENABLE DSABLE
PPM at 20 mA 0 to 99999 1000
Refrigerant Leak Alarm PPM 0 to 99999 500

Head Pressure Reference
20 to 85 PSI 25
Delta P at 0% (4 mA)
(138 to 586) (kPa) (172)
20 to 85 PSI 50
Delta P at 100% (20 mA)
(138 to 586) (kPa) (345)
Minimum Output 0 to 100 % 0
CL-6
23XRV PIC III SETUP1 TABLE CONFIGURATION SHEET
150 to 200 °F 200
Comp Motor Temp Override
(66 to 93) (° C) (93)
145 to 166 PSI 145
Cond Press Override
(1000 to 1145) (kPa) (1000)
125 to 160 °F 140
Comp Discharge Alert
(52 to 71) (° C) (60)
Rectifier Temp Override, 155 to 170 °F 160
Q,R Compressors (68 to 77) (° C) (71)
Rectifier Temp Override, 155 to 190 °F 180
P Compressor (68 to 88) (° C) (82)
Inverter Temp Override, 155 to 170 °F 160
Q,R Compressors (68 to 77) (° C) (71)
Inverter Temp Override, 155 to 190 °F 180
P Compressor (68 to 88) (° C) (82)
Chilled Medium 0/1 WATER/BRINE WATER

0.5 to 2.0 ˆF 1.0
Chilled Liquid Deadband
(0.3 to 1.1) (ˆC) (0.6)
10 to 40.0 °F 33
Evap Refrig Trippoint
(–12.2 to 4.4) (° C) (0.6)
Refrig Override Delta T 2.0 to 5.0 ˆF 3
Q,R Compressors (1.1 to 2.8) (ˆ C) (1.7)
Refrig Override Delta T 2.0 to 10.0 ˆF 5
P Compressor (1.1 to 5.6) (ˆC) (2.8)
Evap Approach Alert 0.5 to 30.0 ˆF 5
Q,R Compressors (0.3 to 16.6) (ˆC) (2.8)
Evap Approach Alert 0.5 to 10.0 ˆF 4
P Compressor (0.3 to 5.6) (ˆC) (2.2)
0.5 to 30.0 ˆF 6
Cond Approach Alert
(0.3 to 16.6) (ˆC) (3.3)
–20 to 35 °F 34
Condenser Freeze Point
(–28.9 to 1.7) (° C) (1.1)
Flow Delta P Display 0/1 DSABLE/ENABLE DSABLE

0.5 to 50.0 PSI 5.0
Evap Flow Delta P Cutout
(3.4 to 344.8) (kPa) (34.5)
0.5 to 50.0 PSI 5.0
Cond Flow Delta P Cutout (3.4 to 344.8) (kPa) (34.5)
Oil Press Verify Time 15 to 300 SEC 45
Liquid Flow Verify Time 0.5 to 5 MIN 5
Recycle Control
2.0 to 10.0 ˆF 5
Restart Delta T
(1.1 to 5.6) (ˆ C) (2.8)
Shutdown Delta Speed
0.0 to 20.0 % 2.0
(Q, R Compressors)
Shutdown Delta Speed
–10.0 to 20.0 % 0.5
(P Compressor)
2.0 to 10.0 ˆF 5
Shutdown Delta T
(1.1 to 5.6) (ˆ C) (2.8)
SPARE ALERT/ALARM ENABLE

Disable=0, Lo=1/3, Hi=2/4
Spare Temp #1 Enable 0 to 4 0

–40 to 245 °F 245
Spare Temp #1 Limit
(–40 to 118) (° C) (118)
Spare Temp #2 Enable 0 to 4 0
Spare Temp #2 Limit –40 to 245 °F 245
(–40 to 118) (° C) (118)
CL-7 516
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23XRV PIC III SETUP2 TABLE CONFIGURATION SHEET
DESCRIPTION STATUS UNITS DEFAULT VALUE
Capacity Control
Proportional Inc Band 6.5
2 to 10
Q,R Compressors
 Proportional Inc Band
P Compressor 2 to 15 12
Proportional Dec Band 2 to 10 6.0
Proportional ECL Gain 1 to 3 2.0
VFD Control
VFD Gain 0.1 to 1.5 0.75
VFD Minimum Speed 15 to 50 % 20
VFD Maximum Speed 50 to 100 % 100
Vaporizer Heater Mode 0 to 1 0
0 = Normal, 1 = Service
Oil Reclaim Min Output 0 to 25 % 25

23XRV PIC III SETUP3 TABLE CONFIGURATION SHEET
Oil Sump and Vap. Heater Control
Vap. Heater Turn On Speed 550 to 950 RPM 595
Vap. Heater Turn Off Speed 600 to 2500 RPM 625
Vap. Heater Turn On Lift 18 to 30 (10 to 17) ^F (^C) 22.5 (12.5)
Vap. heater Turn Off Lift 25 to 30 (14 to 19) ^F (^C) 26 (14.4)
Cond. Refrig Temp Low Limit 55 to 80 (33 to 27) °F (°C) 70 (21)
Sump Heater Turn On Speed 550 to 850 RPM 700
Sump Heater Turn Off Speed 600 to 2500 RPM 750
Sump Heater Turn On Lift 18 to 30 (10 to 17) ^F (^C) 22.0 (12)
Sump Heater Turn Off Lift 20 to 60 (11 to 33) ^F (^C) 40 (22)
23XRV PIC III SETUP4 DISPLAY SCREEN (P COMPRESSOR ONLY)

Economizer Control
Economizer Option 0/1 DS/ENABLE DSABLE
Econ Activate Speed 20 to 100 % 50
Econ Activate Deadband 0 to 20 % 10
Econ EXV Max Movement 0.5 to 5.0 % 3.0
Superheat Setpoint 0.0 to 20.0 (0.0 to 11.1) ^F (^C) 6.0 (3.3)
Econ Proportional Gain 0.1 to 2.0 0.1
Econ PID Calc Time 10 to 120 SEC 25
CL-8
23XRV PIC III SETUP5 DISPLAY SCREEN (P COMPRESSOR ONLY)
Condenser Level Control
Cond EXV Max Movement 0.5 to 10.0 % 10
Cond EXV Min Position 15 to 60 % 30
Cond EXV Start Position 70 to 100 % 100
Disch Superheat Limit 2 to 10 (1.1 to 5.6) °F (°C) 6 (3.3)
Cooler Approach Limit 1.5 to 20 (0.8 to 11.1) °F (°C) 2.5 (1.4)
Start Delay 0 to 255 SEC 120
Freeze Margin at Start 0 to 10 ^F 3
Cond Loop Timer 5 to 10 SEC 5
Cond Level Setpoint 0.5 to 4.8 V 3.0
Disch Sup Ht Corr Factor 0 to 1 % .01
Evap App Corr Factor 0 to 2 % 0.5
Fine Tune Enabled? Y/N Y
Fine Tune Threshold 0.1 to 1 % 0.2
1Cond Level Deadband 0.0 to 1 V 0.4
Anti Winding Min 15 to 60 30
1Cond Level Prop Gain 0.2 to 5 3.0
Cond Level Int Gain 0.0 to 5.0 0.04
Cond Level Clamp 0.5 to 3 % 1.5
Cond Level Low Limit 0.5 to 4.8 V 1.6
Cond Level High Limit 0.5 to 4.8 V 3.2
Feed Forward Threshold 0.0 to 5.0 1.0
Feed Forward Gain 0 to 30.0 0
Evap Approach Reset Gain 0 to 15 10
23XRV PIC III LEADLAG TABLE CONFIGURATION SHEET

DESDRIPTION RANGE UNITS DEFAULT VALUE
Lead Lag Control
LEAD/LAG Configuration
DSABLE=0, LEAD=1, 0 to 3 0
LAG=2, STANDBY=3
Load Balance Option 0/1 DSABLE/ENABLE DSABLE
Common Sensor Option 0/1 DSABLE/ENABLE DSABLE
LAG % Capacity 25 to 75 % 50
LAG Address 1 to 236 92
LAG START Timer 2 to 60 MIN 10
LAG STOP Timer 2 to 60 MIN 10
PRESTART FAULT Timer 2 to 30 MIN 5
PULLDOWN Timer 1 to 30 MIN 2
STANDBY Chiller Option 0/1 DSABLE/ENABLE DSABLE
STANDBY % Capacity 25 to 75 % 50
STANDBY Address 1 to 236 93
CL-9 516
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -- - - - - - - - - - - - - - - - - - - -
23XRV PIC III RAMP_DEM TABLE CONFIGURATION SHEET
Pulldown Ramp Type:
0/1 1
Select: Temp=0, kW=1
Demand Limit and kW Ramp
Demand Limit Source
0/1 0
Select: Amps=0, kW=1
Amps or kW Ramp % Min 5 to 20 10
Demand Limit Prop Band 3 to 15 % 10
Demand Limit At 20 mA 40 to 100 % 40
20 mA Demand Limit Opt 0/1 DSABLE/ENABLE DSABLE
VFD Overload Decrease 25 to 50 % 30
VFD Overload Delta 3 to 15 % 5
Demand Watts Interval 5 to 60 MIN 15
23XRV PIC III TEMP_CTL TABLE CONFIGURATION SHEET


ECL Control Option 0/1 DSABLE/ENABLE DSABLE
2 to 10 ˆF 3
Temp Pulldown Ramp/Min
(1.1 to 5.6) (ˆC) (1.7)
Temperature Reset
RESET TYPE 1
–30 to 30 ˆF 10
Degrees Reset At 20 mA
(–17 to 17) (ˆC) (6)
RESET TYPE 2
–40 to 245 °F 85
Remote Temp (– > No Reset)
(–40 to 118) (° C) (29)
–40 to 245 °F 65
Remote Temp (– > Full Reset)
(–40 to 118) (° C) (18)
–30 to 30 ˆF 10
Degrees Reset
(–17 to 17) (ˆC) (6)
RESET TYPE 3
0 to 15 ˆF 10
CHL Delta T (– > No Reset)
(0 to 8) (ˆC) (6)

0 to 15 ˆF 0
CHL Delta T (– > Full Reset)
(0 to 8) (ˆC) (0)
–30 to 30 ˆF 5
Degrees Reset
(–17 to 17) (ˆC) (3)
Enable Reset Type 0 to 3 0
23XRV BROADCAST (BRODEF) CONFIGURATION SHEET

Time Broadcast Enable 0/1 DSABLE/ENABLE DSABLE
Daylight Savings
Start Month 1 to 12 4
Start Day of Week 1 to 7 7
Start Week 1 to 5 1
Start Time 00:00 to 24:00 HH:MM 02:00
Start Advance 0 to 360 MIN 0
Stop Month 1 to 12 10
Stop Day of Week 1 to 7 7
Stop Week 1 to 5 5
Stop Time 00:00 to 24:00 02:00
Stop Back 0 to 360 MIN 0
© Carrier Corporation 2014
Catalog No. 04-53230011-01 Printed in U.S.A. Form 23XRV-5SS Pg CL-10 1016 11-14 Replaces: 23XRV-4SS

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AquaEdge®

Start-Up, Operation and Maintenance

23XRV CHILLER FAMILIARIZATION

23XRV – High Efficiency Compressor Option

* First number denotes frame size.

 Fig. 1 — Model Number Identification

43 38 — Discharge Isolation Valve Assembly (Option or

Fig. 2 — Typical 23XRV Components (Units with P Compressor)

Fig. 3 — Typical 23XRV Components (Units with Q Compressor)

Fig. 4 — Typical 23XRV Components (Units with R Compressor)

14 14 — Inductor Temperature Switch (Inside VFD Enclosure)

Fig. 5 — Typical 23XRV Installation — Sensor Locations (Units with P Compressor)

Fig. 6 — Typical 23XRV Installation — Sensor Locations (Units with Q Compressor)

COMPRESSOR LUBRICATION BLOCK MOTOR TERMINAL

Fig. 8 — Compressor (Typical, R Compressor Shown)

Fig. 11 — Refrigerant Flow Schematic, P Compressor (Without Optional Economizer)

Fig. 13 — Refrigerant Flow Schematic, P Compressor (With Optional Economizer)

MIST ACTUATED BALL

EXTERNAL OIL HEATER

OIL REFRIGERANT OIL/REFRIGERANT MIXTURE

Fig. 14 — Oil Flow Schematic

Fig. 15 — Control Sensors (Temperature)

Fig. 18 — Control Center VFD Input Components (LF-2 VFD)

5 FRONT VIEW – DOORS REMOVED RIGHT SIDEWALL

Fig. 19 — Control Center VFD Input Components (Std Tier VFD)

Door Open Door Closed

OIL PUMP HOT GAS BYPASS

Fig. 23 — Cutaway Views of Electronic Expansion Valves (EXV) (P Compressor Only)

CCN operating mode by pressing the CCN softkey. Occupied?

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

PRIMARY STATUS COMPRESSOR DATE TIME

WHEN POWER ON)

3. Press SELECT to view the desired point status table.

4. On the point status table, press NEXT or

• Press INCREASE or DECREASE to change the high-

Start Chiller In CCN Control

Start Chiller in Local Control

Clear Alarms Access Main Menu

STATUS SCHEDULE SETPOINT SERVICE

1 1 1 1 (ENTER A 4-DIGIT PASSWORD)

Display The Setpoint Table

Modify a Discrete Point

Fig. 27 — 23XRV ICVC Menu Structure

CONTROL TEST List the Control Tests

CONTROL ALGORITHM STATUS

OCCDEFM (Time Schedule Status)

ENABLE DISABLE QUIT ENTER (DISCRETE VALUES)

Fig. 28 — 23XRV ICVC Service Menu Structure

Modify a Service Table Parameter

ENABLE DISABLE QUIT ENTER (DISCRETE VALUES)

TIME AND DATE

Display Time and Date Table:

Modify Device Address

LOG OUT OF DEVICE

Fig. 28 —23XRV ICVC Service Menu Structure (cont)

Override Indication — An override value is indicated by

For Discrete Points — Press YES or NO to

3. Press SELECT to view the desired time schedule.

4. Press NEXT or PREVIOUS to highlight the de-