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Carrier AquaEdge 19XRV series User Manual

Carrier AquaEdge 19XRV series
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45
and below the CONTROL POINT. The CONTROL POINT set-
ting range is 0.5 to 2° F. If temperature control is satisfactory
and the guide vanes are stable, do not change the setting.
When very close temperature control is required, as for
some process applications, the deadband may be reduced.
When constant small load changes occur in a system and
the vanes will not stabilize, increase the size of the deadband.
The deadband must always be smaller than the allowable drift
in leaving water temperature.
PROPORTIONAL BANDS The proportional bands con-
trol how far the guide vanes will move in response to a specific
change in leaving water temperature. Increasing the propor-
tional band increases the amount that the water temperature
must move away from the control point in order to move the
guide vanes a specific amount. Decreasing the proportional
band allows the vanes to move the same amount with a smaller
change in water temperature.
If the proportional band is too large, the leaving water tem-
perature will increase or decrease slowly enough that the tem-
perature moves away from the control point by an unaccept-
able amount. A proportional band set too low will cause the
leaving temperature to overshoot the control point and cause
the guide vanes to “hunt.”
The PIC controls have separate proportional bands for in-
creasing and decreasing capacity. The PROPORTIONAL IN-
CREASE BAND should be set as described above. The PRO-
PORTIONAL DECREASE BAND should be set at a typically
smaller value than the increasing band so that the guide vanes
can close quickly enough on a sudden drop in load to prevent a
low temperature safety trip.
Proportional Entering Chilled Water Gain
— When Entering
Chilled Water Control is enabled the controls are resetting the
Leaving Chilled Water (LCW) control point every 10 seconds
in order to keep the ENTERING CHILLED WATER TEMP at
the ENTERING CHILLED WATER (ECW) SETPOINT.
The ECW GAIN affects the size of the LCW CONTROL
POINT change in proportion to the difference between the
ECW SETPOINT and ECW TEMPERATURE.
NOTE: Before enabling the ENTERING CHILLED WATER
CONTROL and before tuning the ECW GAIN, the LCW
PROPORTIONAL BANDS and LCW DEADBAND should be
adjusted satisfactorily.
Increase the ECW GAIN if the ENT CHILLED WATER
TEMP drifts away from the ECW SETPOINT. Reduce the
ECW GAIN if the ENT CHILLED WATER TEMP swings
above and below the ECW SETPOINT. Because the water must
travel around the entire loop before the controls receive feed-
back on the effect of the LCW CONTROL POINT, the chilled
water loop should be given the opportunity to stabilize before
the gain is adjusted. The following example shows how the En-
tering Chilled Water Control works to move the vanes based on
the rate of change of the ENT CHILLED WATER TEMP as
well as the by the difference between ENT CHILLED WATER
TEMP and ECW SETPOINT.
Effect of Proportional Entering Chilled Water Band (ECW
Gain) (See Fig. 25)
Error = the contribution of the ECW control to the total er-
ror that inputs to the guide vane control. Positive error drives
the vanes open. Negative error drives the vanes closed.
ECW set point = 47 F
ECW = Entering Chilled Water
ECW-10 = Entering Chilled Water 10 seconds previous
Example 1 — The first section of Fig. 25 shows the entering
water dropping with a constant rate. The ECW algorithm is
reducing its effort to open the guide vanes. After the entering
water temperature drops below the set point the error drops
below zero and thus is trying to close the vanes.
Example 2 — The second section shows the water temperature
dropping but at a decreasing rate as shown by the reduction in
the difference between ECW and ECW-10. The error value is
leveling at zero but takes a dip because the entering water tem-
perature drops below the set point.
Example 3 — The third section of Fig. 25 shows the entering
chilled water temperature increasing. Again the error starts to
level off or drop as the temperature change over 10 seconds
becomes smaller.
-1
-0.5
0
0.5
1
1.5
2
2.5
3
46.4
46.6
46.8
SET POINT = 47
47.2
47.4
47.6
47.8
48
48.2
TOTAL ERROR
°F
EXAMPLE 1
ECW(°F)
ECW-10 sec
Error, Gain = 1
Error, Gain = 3
EXAMPLE 2 EXAMPLE 3
X
X
X
X
X
X
X
X
X
X
X
X
MPLE 1
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Fig. 25 — Transient Example of ECW Gain
a19-1957

Table of Contents

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Carrier AquaEdge 19XRV series Specifications

General IconGeneral
BrandCarrier
ModelAquaEdge 19XRV series
CategoryAir Conditioner
LanguageEnglish

Summary

Start-Up, Operation, and Maintenance Instructions

SAFETY CONSIDERATIONS

General safety precautions for operating centrifugal liquid chillers and handling equipment.

INTRODUCTION

CHILLER FAMILIARIZATION

System Components

Lists and describes the main components of the chiller system.

Cooler

Description of the cooler vessel, also known as the evaporator.

Condenser

Description of the condenser vessel and its function.

Motor-Compressor

Details the motor-compressor unit and its role in refrigerant circulation.

Economizer (Optional)

Explains the function of the optional economizer.

Control Panel

Describes the control panel as the user interface for chiller operation.

Variable Frequency Drive (VFD)

Explains the VFD's function in controlling compressor speed and energy usage.

Storage Vessel (Optional)

Details the optional storage vessels and their features.

REFRIGERATION CYCLE

MOTOR AND LUBRICATING OIL COOLING CYCLE

VFD COOLING CYCLE

LUBRICATION CYCLE

Bearings

Details the types and functions of bearings used in the compressor assemblies.

Oil Reclaim System

STARTING EQUIPMENT

Unit-Mounted VFD

Details the unit-mounted Variable Frequency Drive and its function.

CONTROLS

Definitions

Defines analog and discrete signals used in control systems.

General (controls)

Describes the microprocessor control system and its operation.

PIC III System Components

Identifies the modules within the PIC III chiller control system.

INTERNATIONAL CHILLER VISUAL CONTROLLER (ICVC)

Describes the ICVC as the system's brain, managing operations and displaying information.

CHILLER CONTROL MODULE (CCM)

Explains the CCM module's role in controlling the chiller and its inputs/outputs.

OIL HEATER CONTACTOR (1C)

Details the oil heater contactor and its function during shutdown.

OIL PUMP CONTACTOR (2C)

Describes the oil pump contactor that operates the oil pumps.

HOT GAS BYPASS CONTACTOR RELAY (3C) (OPTIONAL)

Explains the function of the optional hot gas bypass relay.

SENSORS

Details the various sensors used for monitoring chiller conditions.

GENERAL

Describes the default behavior of the ICVC display and softkey operations.

ALARMS AND ALERTS

Explains how alarms and alerts are indicated and managed on the ICVC.

ICVC MENU ITEMS

Lists the available menus for interacting with the PIC III system via ICVC.

BASIC ICVC OPERATIONS (USING THE SOFT KEYS)

Details the fundamental operations using the ICVC softkeys for navigation and control.

SERVICE TABLE

Provides access to various service-related tables for diagnostics and configuration.

CONTROL TEST

Describes how to perform control tests to verify system operation and safety devices.

CONTROL ALGORITHM STATUS

Displays status information for various control algorithms for diagnostics.

EQUIPMENT CONFIGURATION

Allows modification of equipment configuration parameters.

VFD CONFIG DATA

Provides access to VFD configuration data for verification and adjustment.

TIME AND DATE

Details how to set and verify the chiller's time and date settings.

ATTACH TO NETWORK DEVICE

Explains how to connect the ICVC to other network devices for data exchange.

LOG OUT OF DEVICE

Describes the procedure to log out of a network device connection.

ICVC CONFIGURATION

Allows configuration of ICVC settings, including language and address.

TO VIEW STATUS (FIG. 22)

Instructions on how to view the status tables for various chiller parameters.

FORCING OPERATIONS

Details how to manually override (force) values or statuses within the control system.

TIME SCHEDULE OPERATION (Fig. 23)

Explains how to view and modify time schedules for chiller operation.

TO VIEW AND CHANGE SET POINTS (Fig. 24)

Instructions for viewing and changing set points for chiller operation.

EXAMPLE 1 — CHILLER DISPLAY DEFAULT SCREEN

Shows the typical data displayed on the ICVC default screen.

EXAMPLE 2 — MAINTSTAT DISPLAY SCREEN

Illustrates the information presented in the MAINTSTAT display screen.

EXAMPLE 3 — STARTUP DISPLAY SCREEN

Shows the data displayed during the chiller's startup sequence.

EXAMPLE 4 — COMPRESS DISPLAY SCREEN

Details the information available in the COMPRESS display screen.

EXAMPLE 5 — HEAT_EX DISPLAY SCREEN

Presents the data related to heat exchanger performance on the ICVC.

EXAMPLE 6 — POWER DISPLAY SCREEN

Shows operational data related to power consumption and VFD status.

EXAMPLE 7 — VFD_STAT DISPLAY SCREEN

Displays status information and fault codes related to the VFD.

EXAMPLE 8 — ICVC_PWD DISPLAY SCREEN

Details the screen for managing ICVC passwords and security settings.

EXAMPLE 9 — SETPOINT DISPLAY SCREEN

Illustrates the screen for viewing and adjusting set points.

EXAMPLE 10 — CAPACITY DISPLAY SCREEN

Shows parameters related to the chiller's capacity control.

EXAMPLE 11 — OVERRIDE DISPLAY SCREEN

Details the override status for various control parameters.

EXAMPLE 12 — SURGPREV DISPLAY SCREEN

Provides information related to surge prevention and its parameters.

EXAMPLE 13 — LL_MAINT DISPLAY SCREEN

Shows the status and maintenance details for lead/lag operation.

EXAMPLE 14 — VFD_HIST DISPLAY SCREEN

Displays historical VFD data and fault codes.

EXAMPLE 15 — WSMDEFME DISPLAY SCREEN

Shows the status of the Water System Manager module.

EXAMPLE 16 — NET_OPT DISPLAY SCREEN

Allows configuration of network options and communication settings.

EXAMPLE 17 — VFD_CONF DISPLAY SCREEN

Details VFD configuration parameters for setup and verification.

EXAMPLE 18 — OPTIONS DISPLAY SCREEN

Lists and allows modification of various optional chiller features and settings.

EXAMPLE 19 — SETUP1 DISPLAY SCREEN

Contains setup parameters for safety limits and alarm configurations.

EXAMPLE 20 — SETUP2 DISPLAY SCREEN

Provides setup parameters for capacity control and VFD speed settings.

EXAMPLE 21 — SETUP3 DISPLAY SCREEN

Contains setup parameters for auto-restart and gas torque factors.

EXAMPLE 22 — LEADLAG DISPLAY SCREEN

Allows configuration of lead/lag control parameters for multiple chillers.

EXAMPLE 23 — RAMP_DEM DISPLAY SCREEN

Details parameters for ramp loading and demand limiting.

EXAMPLE 24 — TEMP_CTL DISPLAY SCREEN

Contains setup parameters for temperature control and reset options.

PIC III System Functions

Details the core operational functions managed by the PIC III control system.

CAPACITY CONTROL

Explains how the PIC III system controls chiller capacity based on load conditions.

Variable Speed (VFD) Application

Describes how the VFD modulates motor speed for capacity control and efficiency.

ECW CONTROL OPTION

Explains the option to use Entering Chilled Water temperature for capacity control.

CONTROL POINT DEADBAND

Defines the tolerance range for maintaining the control point temperature.

PROPORTIONAL BANDS

Explains how proportional bands affect guide vane movement in response to temperature changes.

Proportional Entering Chilled Water Gain

Details how ECW Gain affects the LCW control point change for temperature regulation.

Effect of Proportional Entering Chilled Water Band (ECW Gain) (See Fig. 25)

Illustrates the effect of ECW Gain on guide vane response to entering water temperature.

DIFFUSER CONTROL

Describes the control of the diffuser actuator based on guide vane position for optimized performance.

DEMAND LIMITING

Explains how the system limits capacity to control average line current or kilowatts.

Demand Limit Control Option

Details the use of a 4-20mA signal for external demand limit control.

CHILLER TIMERS AND STARTS COUNTER

Describes the timers for compressor ontime, service ontime, and total starts.

Safety Controls

Lists safety inputs monitored by PIC III to protect the chiller.

Shunt Trip (Option)

Explains the function and conditions for initiating a shunt trip or gate kill.

Default Screen Freeze

Describes how the ICVC display freezes upon an alarm to aid in troubleshooting.

Capacity Override

Explains how capacity overrides prevent shutdowns due to operational limits.

Ramp Loading

Details methods to slow compressor loading to reduce demand charges.

Rampdown

Describes the process of reducing VFD speed after ramp loading is complete.

High Discharge Temperature Control

Explains how the system responds to high discharge temperatures.

Compressor Bearing Temperature

Describes the monitoring and control of compressor bearing temperatures.

Oil Sump Temperature and Pump Control

Details the regulation of oil sump temperature and oil pump operation.

High Compressor Lift (Surge Prevention)

Explains how the system responds to high compressor lift conditions to prevent surge.

Kilowatt Output

Describes the CCM module's output for representing chiller power consumption.

Remote Reset of Alarms

Explains the feature allowing remote resetting of chiller alarms.

Pump and Fan Control

Details how the PIC controls cooler/condenser water pumps and tower fans.

Condenser Pump Control

Describes the chiller's monitoring of condenser pressure to control the condenser pump.

Condenser Freeze Prevention

Explains the control algorithm to prevent condenser tube freeze-up by energizing the pump.

Evaporator Freeze Protection

Details the protection mechanism against evaporator freeze-up due to low refrigerant temperatures.

Tower Fan Relay Low and High

Describes the function of tower fan relays in controlling chiller efficiency and preventing low water temperatures.

Auto. Restart After Power Failure

Explains the auto-restart feature for chillers without an uninterruptable power supply.

Water/Brine Reset

Describes the water/brine reset options for controlling chiller capacity based on water temperature.

Surge Prevention

Details the algorithm and functions to prevent chiller surge.

Surge Prevention Algorithm

Explains the operator-configurable feature for surge prevention.

Lead/Lag Control

Explains the system for automatically starting and stopping chillers in a lead/lag configuration.

Lead/Lag System Requirements

Lists the requirements for implementing the lead/lag function.

Operation Features

Details the operational features of the lead/lag system.

COMMON POINT SENSOR USAGE AND INSTALLATION

Explains the usage and installation of common point sensors for lead/lag systems.

CHILLER COMMUNICATION WIRING

Provides information on wiring for chiller communication.

LEAD/LAG OPERATION

Describes how the lead/lag system operates to manage chiller capacity.

Lead/Lag Chiller Configuration and Operation

Details the configuration and operation of lead, lag, and standby chillers.

Lead/Lag Shutdown Requirements

Outlines the conditions necessary for stopping a lag chiller.

FAULTED CHILLER OPERATION

Describes how the system operates when the lead chiller experiences a fault.

Ice Build Control

Explains the function and configuration of the ice build control mode.

ICE BUILD INITIATION

Describes the process for initiating the ice build cycle.

TERMINATION OF ICE BUILD

Details the conditions under which the ice build function terminates.

RETURN TO NON-ICE BUILD OPERATIONS

Explains how the chiller returns to normal operation after ice build termination.

START-UP/RECYCLE OPERATION

Describes the sequence of operations during chiller start-up and recycle.

TEMPERATURE CONTROL DURING ICE BUILD

Explains temperature control adjustments during the ice build phase.

Service Operation

Provides guidance on accessing and performing service operations through the ICVC.

TO ACCESS THE SERVICE SCREENS

Details the steps to access the service screens and enter the password.

HOLIDAYS

Explains how to configure holiday schedules for chiller operation.

BRODEF

Describes the BRODEF screen for daylight savings time and broadcast settings.

ALARM ROUTING

Explains how to configure alarm routing for CCN network communication.

DAYLIGHT SAVING TIME CONFIGURATION

Details the configuration of daylight saving time settings.

START-UP/SHUTDOWN/ RECYCLE SEQUENCE (FIG. 32)

Illustrates the timing sequence for start-up and shutdown operations.

Local Start-Up

Describes the procedure for initiating a local start-up of the chiller.

Shutdown Sequence

Details the steps involved in shutting down the chiller system.

Chilled Water Recycle Mode

Explains the recycle mode for chillers operating under lightly loaded conditions.

Automatic Soft Stop Amps Threshold

Describes the feature that closes guide vanes to shut down the compressor based on amps.

Safety Shutdown

Explains the process and indicators for a safety shutdown.

BEFORE INITIAL START-UP

Lists the required data and equipment for initial chiller start-up.

Job Data Required

Specifies the essential job data needed before starting the chiller.

Equipment Required

Lists the necessary tools and equipment for chiller installation and start-up.

Using the Optional Storage Tank and Pump out System

Provides guidance on using the optional storage tank and pumpout system.

Remove Shipping Packaging

Details the steps for removing shipping materials from chiller components.

Open Oil Circuit Valves

Instructs on opening oil circuit valves for proper system operation.

Oil Charge

Describes the procedure for charging the chiller with the correct oil.

Tighten All Gasketed Joints and Guide Vane Shaft Packing

Explains how to tighten gasketed joints and guide vane shaft packing for a leak-tight seal.

Check Chiller Tightness

Outlines the procedure for checking the chiller's overall tightness and performing leak tests.

Refrigerant Tracer

Recommends using a refrigerant tracer for leak testing.

Leak Test Chiller

Provides a detailed procedure for testing the chiller for refrigerant leaks.

Standing Vacuum Test

Describes the procedure for performing a standing vacuum test to check for leaks.

Chiller Dehydration

Explains when and how to perform dehydration on the chiller.

Check Optional Pumpout Compressor Water Piping

Details the piping requirements for the optional pumpout system's condenser water.

Check Relief Valves

Instructs on checking relief valves for proper installation and compliance.

Identify the VFD

Guides the user on identifying the VFD based on its part number and model.

Input Power Wiring

Provides instructions for connecting AC input power to the VFD.

Checking the Installation

Details steps to verify the proper installation of the VFD and associated wiring.

Inspect Wiring

Provides guidance on inspecting wiring for conformance to diagrams and codes.

Ground Fault Troubleshooting

Outlines the procedure for troubleshooting ground faults.

Carrier Comfort Network® Interface

Describes the wiring and connection requirements for the CCN communication bus.

Power Up the Controls and Check the Oil Heater

Explains the procedure for powering up controls and checking the oil heater.

SOFTWARE VERSION

Details where to find the software part number and version.

Software Configuration

Guides on configuring software settings and recording them.

Input the Design Set Points

Explains how to access and modify set points for chiller control.

Input the Local Occupied Schedule (OCCPC01S)

Describes how to set up the local occupied time schedule.

Input Service Configurations

Lists configurations requiring access to the SERVICE menu.

CHANGE ICVC CONFIGURATION IF NECESSARY

Details how to change ICVC settings like address, units, and password.

TO CHANGE THE PASSWORD

Step-by-step instructions for changing the ICVC password.

TO CHANGE THE ICVC DISPLAY FROM ENGLISH TO METRIC UNITS

Guides on switching the ICVC display units from English to Metric.

CHANGE LANGUAGE

Explains how to change the language displayed on the ICVC.

MODIFY CONTROLLER IDENTIFICATION IF NECESSARY

Describes how to change the ICVC module address for network identification.

INPUT JOB SITE PARAMETERS

Instructs on inputting job-specific parameters for chiller configuration.

INPUT EQUIPMENT SERVICE PARAMETERS IF NECESSARY

Guides on inputting and verifying VFD configuration parameters.

VERIFY VFD CONFIGURATION AND CHANGE PARAMETERS IF NECESSARY (Fig. 40)

Details steps for verifying VFD configuration against machine data.

VFD CHILLER FIELD SET UP AND VERIFICATION

Covers procedures for setting up and verifying the VFD installation.

Label Locations

Specifies the locations of key labels for VFD and chiller configuration.

Check VFD_CONFIG TABLE

Explains how to access and verify VFD configuration parameters via the ICVC.

SURGE PREVENTION CONFIGURATIONS

Details the parameters and effects related to surge prevention configurations.

Fine Tuning VPF Surge Prevention

Provides instructions for fine-tuning surge prevention parameters for optimal performance.

CONFIGURE DIFFUSER CONTROL IF NECESSARY

Guides on configuring diffuser control if the compressor is equipped with a variable diffuser.

MODIFY EQUIPMENT CONFIGURATION IF NECESSARY

Instructs on modifying equipment configuration parameters as per job data.

Owner-Modified CCN Tables

Describes the CCN tables that can be modified by the owner.

OCCDEFCS

Details the Local and CCN time schedules that can be modified.

HOLIDAYS

Explains how to configure holiday schedules for chiller operation.

BRODEF

Describes the BRODEF screen for daylight savings time and broadcast settings.

ALARM ROUTING

Explains how to configure alarm routing for CCN network communication.

PRESSURE TRANSDUCER CALIBRATION

Provides instructions for calibrating pressure transducers for accurate readings.

Zero Point Calibration

Details the procedure for calibrating pressure transducers at zero psig.

High End Calibration

Describes the procedure for high-end calibration of pressure transducers.

CHILLER EQUALIZATION WITHOUT A PUMPOUT UNIT

Explains how to equalize refrigerant pressure without a pumpout unit.

CHILLER EQUALIZATION WITH PUMPOUT UNIT

Details the procedure for equalizing refrigerant pressure using a pumpout unit.

Charge Refrigerant into Chiller

Provides instructions for charging the chiller with refrigerant.

TRIMMING REFRIGERANT CHARGE

Describes how to adjust the refrigerant charge for optimal performance.

INITIAL START-UP

Lists the essential steps and checks for initiating the chiller's first start-up.

Preparation

Specifies the pre-start checks required before operating the chiller.

To Start the Chiller

Details the procedure for starting the chiller from the ICVC.

Check the Running System

Guides on monitoring the chiller's operation and parameters after start-up.

Check Motor Rotation

Explains how to check the motor's rotation direction for proper operation.

Check Oil Pressure and Compressor Stop

Details how to check oil pressure and observe compressor behavior during shutdown.

To Prevent Accidental Start-Up

Describes how to configure a safety override to prevent accidental start-ups.

Check Chiller Operating Condition

Instructs on verifying the chiller's operating condition and fluid levels.

Instruct the Customer Operator

Provides guidance on instructing the customer's operating personnel.

To Stop the Chiller

Describes the procedure for stopping the chiller using the ICVC or occupancy schedule.

After Limited Shutdown

Outlines procedures for chillers after a limited shutdown period.

Preparation for Extended Shutdown

Details steps for preparing the chiller for an extended shutdown.

Cold Weather Operation

Provides guidance for operating the chiller during cold weather conditions.

Manual Guide Vane Operation

Explains how to manually operate the guide vanes for control or emergency purposes.

Refrigeration Log

Describes the purpose and use of the refrigeration log for tracking chiller performance.

PUMPOUT AND REFRIGERANT TRANSFER PROCEDURES

Provides procedures for transferring refrigerant and performing pumpout operations.

Preparation

Specifies the necessary preparations for pumpout and refrigerant transfer.

Operating the Optional Pumpout Unit

Details the operation of the optional pumpout unit.

POSITIVE PRESSURE CHILLERS WITH STORAGE TANKS

Provides information specific to chillers with positive pressure storage tanks.

Transfer Refrigerant from Storage Tank Vessel to Chiller

Step-by-step instructions for transferring refrigerant from storage to the chiller.

Transfer Refrigerant from Chiller to Storage Tank Vessel

Instructions for transferring refrigerant from the chiller to the storage tank.

Transfer Refrigerant from Cooler to Condenser

Details the procedure for transferring refrigerant from the cooler to the condenser.

Transfer Refrigerant from Condenser to Cooler

Explains how to transfer refrigerant from the condenser to the cooler.

GENERAL MAINTENANCE

Provides guidelines for routine maintenance tasks.

Refrigerant Properties

Describes the properties of the standard refrigerant HFC-134a.

Adding Refrigerant

Provides instructions for adding refrigerant to the chiller.

Removing Refrigerant

Details procedures for removing refrigerant from the chiller.

Adjusting the Refrigerant Charge

Explains how to adjust the refrigerant charge for optimal chiller performance.

Refrigerant Leak Testing

Provides recommendations for leak testing refrigerant systems.

Leak Rate

Specifies recommended leak rates for chillers based on ASHRAE guidelines.

Test After Service, Repair, or Major Leak

Outlines pressure and leak testing procedures after service or major leaks.

TESTING WITH REFRIGERANT TRACER

Describes using refrigerant tracer for leak detection.

TESTING WITHOUT REFRIGERANT TRACER

Details leak testing methods without using refrigerant.

TO PRESSURIZE WITH DRY NITROGEN

Explains the procedure for pressurizing the chiller with dry nitrogen for leak testing.

Checking Guide Vane Linkage

Provides instructions for adjusting the guide vane actuator's chain tension and position.

Trim Refrigerant Charge

Describes the procedure for removing excess refrigerant.

WEEKLY MAINTENANCE

Specifies maintenance tasks to be performed weekly.

Check the Lubrication System

Instructs on checking the oil level in the reservoir sight glass weekly.

Service Ontime

Explains how to reset the Service Ontime value for tracking major service work.

Inspect the Control Panel

Details maintenance steps for the control panel, including cleaning and tightening.

Check Safety and Operating Controls Monthly

Specifies monthly checks for safety and operating controls, including automated tests.

Changing Oil Filter

Provides instructions for changing the oil filter on a yearly basis or after repairs.

Oil Specification

Lists Carrier's specifications for oil type and ISO viscosity grade.

Oil Changes

Recommends yearly oil analysis and provides guidelines for oil change intervals.

TO CHANGE THE OIL

Step-by-step instructions for changing the chiller's oil.

Refrigerant Filter

Describes the refrigerant filter/drier and when it should be changed.

Oil Reclaim Filter

Details the replacement schedule for the oil reclaim system's strainer and filter.

VFD Refrigerant Strainer

Explains the location and replacement frequency for the VFD refrigerant strainer.

Inspect Refrigerant Float System

Provides instructions for inspecting the refrigerant float system every five years.

ECONOMIZER FLOAT SYSTEM (TWO-STAGE COMPRESSORS)

Describes the economizer float system used in two-stage compressors.

ECONOMIZER DAMPER VALVE (TWO-STAGE COMPRESSORS)

Details the inspection and cleaning of the economizer damper valve.

Inspect Relief Valves and Piping

Explains the maintenance required to keep relief valves in peak operating condition.

Compressor Bearing and Gear Maintenance

Provides guidelines for maintaining compressor bearings and gears for proper lubrication.

Inspect the Heat Exchanger Tubes and Flow Devices

Describes inspection and cleaning procedures for heat exchanger tubes and flow devices.

COOLER AND OPTIONAL FLOW DEVICES

Details inspection and cleaning procedures for cooler tubes and flow devices.

CONDENSER AND OPTIONAL FLOW DEVICES

Describes inspection and cleaning procedures for condenser tubes and flow devices.

Water Leaks

Explains how the refrigerant moisture indicator shows water leakage.

Water Treatment

Recommends using qualified specialists for water treatment programs.

Inspect the VFD

Provides instructions for periodic inspection and cleaning of the VFD.

Recalibrate Pressure Transducers

Describes the annual procedure for checking and recalibrating pressure transducers.

Optional Pumpout System Maintenance

Provides maintenance details for the optional pumpout system compressor.

OPTIONAL PUMPOUT COMPRESSOR OIL CHARGE

Details the oil charge requirements for the optional pumpout compressor.

OPTIONAL PUMPOUT SAFETY CONTROL SETTINGS (FIG. 54)

Explains the high-pressure switch settings for the optional pumpout system.

Ordering Replacement Chiller Parts

Specifies the information required when ordering replacement chiller parts.

TROUBLESHOOTING GUIDE (TABLES 15-18B)

Provides guidance for diagnosing and resolving chiller issues.

Overview

Introduces the PIC III features that aid in troubleshooting the chiller.

Checking Display Messages

Guides on checking ICVC display messages to identify fault conditions.

Checking Temperature Sensors

Details how to check temperature sensors by resistance and voltage drop.

RESISTANCE CHECK

Describes the procedure for checking sensor resistance.

VOLTAGE DROP

Explains how to check sensor voltage drop.

CHECK SENSOR ACCURACY

Guides on checking sensor accuracy by comparing readings to known temperatures.

DUAL TEMPERATURE SENSORS

Describes the dual sensor setup for bearing and motor temperature sensors.

Checking Pressure Transducers

Details how to check and calibrate pressure transducers.

COOLER CONDENSER PRESSURE TRANSDUCER AND OPTIONAL WATERSIDE FLOW DEVICE CALIBRATION

Explains how to check and calibrate cooler/condenser pressure transducers and flow devices.

TRANSDUCER REPLACEMENT

Provides instructions for replacing pressure transducers.

Control Algorithms Checkout Procedure

Guides on using the Control Algorithm Status screens to diagnose problems.

Control Test

Explains how to use the Control Test feature to check system outputs and inputs.

A. MANUAL STOP

Details the manual stop procedure and probable causes/remedies.

B. READY TO START

Lists conditions and causes for the 'Ready to Start' status.

C. IN RECYCLE SHUTDOWN

Describes the 'In Recycle Shutdown' state and its causes/remedies.

D. PRE-START ALERTS

Lists pre-start alerts that delay chiller start-up until corrected.

E. START-UP IN PROGRESS

Details messages and causes related to the start-up phase.

F. NORMAL RUN

Lists messages and causes related to normal chiller operation.

G. NORMAL RUN WITH OVERRIDES

Describes messages and causes for normal operation with overrides active.

H. OUT-OF-RANGE SENSOR

Lists sensor faults when readings are outside the expected range.

I. CHILLER PROTECTIVE LIMIT FAULTS

Details protective limit faults that can cause chiller shutdowns.

I. CHILLER PROTECTIVE LIMIT FAULTS (cont)

Continues listing protective limit faults and their causes/remedies.

I. CHILLER PROTECTIVE LIMIT FAULTS (cont)

Continues listing protective limit faults and their causes/remedies.

I. CHILLER PROTECTIVE LIMIT FAULTS (cont)

Continues listing protective limit faults and their causes/remedies.

I. CHILLER PROTECTIVE LIMIT FAULTS (cont)

Continues listing protective limit faults and their causes/remedies.

J. CHILLER ALERTS

Lists various alerts that indicate abnormal chiller conditions.

J. CHILLER ALERTS (cont)

Continues listing chiller alerts and their causes/remedies.

J. CHILLER ALERTS (cont)

Continues listing chiller alerts and their causes/remedies.

Control Modules

Describes the ICVC and CCM modules and their operational indicators.

Notes on Module Operation

Provides notes on module operation, including LED indicators and communication status.

Replacing Defective Processor Modules

Provides instructions for replacing defective ICVC modules.

INSTALLATION

Details the installation procedure for a replacement ICVC module.

DPI Communications Interface Board Status LEDs

Explains the status LEDs on the DPI board for VFD status indication.

Gateway Status LEDs

Describes the status LEDs on the Gateway for communication link indication.

INVERTER STATUS LIGHT

Details the status light patterns for the inverter module.

RECTIFIER STATUS LIGHT

Details the status light patterns for the rectifier module.

INVERTER AND RECTIFIER CONTROL BOARD FAILURE STATUS LIGHT PATTERNS

Describes failure status light patterns for inverter and rectifier control boards.

DRIVE STATUS INDICATOR

Explains the meaning of the drive status indicator LEDs on the Gateway.

MS STATUS INDICATOR

Describes the MS status indicator LEDs on the Gateway.

NET A STATUS INDICATOR

Explains the NET A status indicator LEDs on the Gateway.

NET B STATUS INDICATOR

Describes the NET B status indicator LEDs on the Gateway.

End of Life and Equipment Disposal

Provides information on the equipment's lifespan and proper disposal methods.

Physical Data

Provides additional information on component weights and clearances.

19XRV COMPRESSOR FRAME 2 THROUGH FRAME 5 FITS AND CLEARANCES (in.)

Details the fits and clearances for compressor frames 2 through 5.

19XRV COMPRESSOR FRAME E FITS AND CLEARANCES

Provides fits and clearances for the 19XRV compressor frame E.

MOTOR LEAD INSTALLATION LABELS

Describes the labels related to motor lead installation.

19XRV COMPRESSOR ASSEMBLY TORQUES

Lists the torque specifications for compressor assembly components.

19XRV COMPRESSOR ASSEMBLY TORQUES FRAME E

Provides torque specifications for Frame E compressor assembly components.

APPENDIX A — 19XRV LIQUIFLO™ 2 ICVC PARAMETER INDEX

An index of parameters available on the 19XRV LiquiFlo™ 2 ICVC.

APPENDIX B — LEAD/LAG WIRING

Provides wiring schematics for lead/lag configurations.

19XRV Lead Lag Schematic Series Cooler Flow

Illustrates the series cooler flow wiring for lead/lag systems.

19XRV Lead Lag Schematic Parallel Cooler Flow

Shows the parallel cooler flow wiring for lead/lag systems.

APPENDIX C — MAINTENANCE SUMMARY AND LOG SHEETS

Provides a summary of maintenance intervals and log sheets.

19XRV Maintenance Interval Requirements

Outlines the required maintenance intervals for the 19XRV chiller.

19XRV Weekly Maintenance Log

A log sheet for recording weekly maintenance activities.

19XRV Maintenance Log

A log sheet for recording various maintenance actions.

19XRV Seasonal Shutdown Log

A log sheet for recording tasks performed during seasonal shutdown.

APPENDIX D — BACNET COMMUNICATION OPTION

Details the configuration and operation of the BACnet communication option.

TO ADDRESS THE UPC OPEN CONTROLLER

Explains how to assign a unique address to the UPC Open controller for BACnet network.

BACNET DEVICE INSTANCE ADDRESS

Defines the BACnet Device Instance address and its uniqueness requirement.

CONFIGURING THE BAS PORT FOR BACNET MS/TP

Guides on configuring the BAS Port for BACnet MS/TP communication.

WIRING THE UPC OPEN CONTROLLER TO THE MS/TP NETWORK

Provides specifications and recommendations for wiring UPC Open controllers to MS/TP networks.

COMMUNICATION LEDS

Explains the function of communication LEDs on the UPC Open controller.

REPLACING THE UPC OPEN BATTERY

Provides instructions for replacing the UPC Open controller's battery.

NETWORK POINTS LIST

Lists the network points available for the controller for monitoring and configuration.

INITIAL START-UP CHECKLIST

A checklist for initial start-up procedures, including machine information and job data.

MACHINE INFORMATION

Fields for recording essential machine details like name, address, and model.

DESIGN CONDITIONS

Section for recording chiller design conditions such as TONS, FLOW RATE, and TEMPERATURE.

CHILLER LINE SIDE

Fields for recording chiller line voltage, FLA, and OLTA ratings.

OIL PUMP

Fields for recording oil pump voltage, RLA, and OLTA ratings.

REFRIGERANT

Fields for recording refrigerant type and charge.

CARRIER OBLIGATIONS

Checks for Carrier's responsibilities during initial start-up.

START-UP TO BE PERFORMED IN ACCORDANCE WITH APPROPRIATE MACHINE START-UP INSTRUCTIONS

Confirms that start-up procedures align with machine instructions.

JOB DATA REQUIRED

Lists essential job data that must be available before proceeding with start-up.

INITIAL MACHINE PRESSURE

Section to record initial machine pressures after installation.

RECORD PRESSURE DROPS

Fields for recording pressure drops in the cooler and condenser.

CHARGE REFRIGERANT

Sections for recording initial and final refrigerant charge.

INSPECT WIRING AND RECORD ELECTRICAL DATA

Guides on inspecting wiring and recording electrical data from VFD and other components.

RATINGS

Details the motor voltage, RLA, LRA, and VFD ratings.

FIELD-INSTALLED VFDs ONLY

Specific instructions for field-installed VFDs regarding continuity checks and meggering.

CONTROLS: SAFETY, OPERATING, ETC.

Checks related to controls, safety, and operating parameters.

Perform Controls Test (Yes/No)

Confirms whether a controls test has been performed.

INITIAL START

Steps to initiate the chiller's start-up sequence.

WATER/BRINE PUMP CONTROL

Checks if Carrier controls can independently start pumps.

RUN MACHINE

Confirms if safeties shut down the machine.

START MACHINE AND OPERATE. COMPLETE THE FOLLOWING:

Final steps to complete after starting the machine.

19XRV PIC III SETPOINT TABLE CONFIGURATION SHEET

Configuration sheet for PIC III setpoints like demand limit and temperatures.

19XRV PIC III LOCAL TIME SCHEDULE CONFIGURATION SHEET OCCPC01S

Configuration sheet for the local time schedule.

ICE BUILD 19XRV PIC III TIME SCHEDULE CONFIGURATION SHEET OCCPC02S

Configuration sheet for the ice build time schedule.

19XRV PIC III CCN TIME SCHEDULE CONFIGURATION SHEET OCCPC03S

Configuration sheet for the CCN time schedule.

19XRV PIC III VFD_CONF TABLE CONFIGURATION SHEET

Configuration sheet for VFD parameters.

19XRV PIC III OPTIONS TABLE CONFIGURATION SHEET

Configuration sheet for various chiller options.

19XRV PIC III SETUP1 TABLE CONFIGURATION SHEET

Setup sheet for safety limits and alarm configurations.

19XRV PIC III SETUP2 TABLE CONFIGURATION SHEET

Setup sheet for capacity control and VFD speed settings.

19XRV PIC III SETUP3 TABLE CONFIGURATION SHEET

Setup sheet for auto-restart and gas torque factors.

19XRV PIC III LEADLAG TABLE CONFIGURATION SHEET

Configuration sheet for lead/lag control parameters.

19XRV PIC III RAMP_DEM TABLE CONFIGURATION SHEET

Configuration sheet for ramp loading and demand limiting parameters.

19XRV PIC III TEMP_CTL TABLE CONFIGURATION SHEET

Configuration sheet for temperature control and reset options.

BROADCAST (BRODEF) CONFIGURATION SHEET

Configuration sheet for broadcast settings, including daylight savings.

ICVC DISPLAY AND ALARM SHUTDOWN STATE RECORD SHEET

A sheet for recording ICVC display information and alarm states.

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