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Carrier AquaEdge 19XRV series, Start-Up, Operation And Maintenance Instructions Manual

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Carrier AquaEdge 19XRV series Start-Up, Operation And Maintenance Instructions Manual Download Page 37

37

MONITORED PARAMETER

ALARM/ALERT LIMIT

COMMENTS

Temperature Sensors Out of Range 260-271,140,141 0.06 > Voltage Ratio > 0.98 or – 40 F > Temperature > 

118°C for 3 seconds

Preset Alarm, Voltage Ratio  = Input Voltage/ Voltage 

Reference (5 V)

Pressure Transducers Out of 

Range

260-271

0.06 > Voltage Ratio > 0.98 for 3 seconds

Preset Alarm, Voltage Ratio = Input Voltage/ Voltage 

Reference (5 V)

High Compressor Discharge 

Temperature

231

COMP DISCHARGE TEMP > 104°C

Preset Alarm, Configure COMP DISCHARGE ALERT in 

SETUP1 screen

167

COMP DISCHARGE TEMP > COMP DISCHARGE 

ALERT

Configure COMP DISCHARGE ALERT in SETUP1 

screen

103

COMP DISCHARGE TEMP > COMP DISCHARGE 

ALERT – 5.6°C

Prestart Alert, Configure COMP DISCHARGE ALERT in 

SETUP1 screen

High Motor Temperature

233

COMP MOTOR WINDING TEMP > 104°C

Preset Alarm, Configure COMP MOTOR TEMP 

OVERRIDE in SETUP1 screen

102

COMP MOTOR WINDING TEMP > COMP MOTOR 

TEMP OVERRIDE – 5.6 K

Prestart Alert, Configure COMP MOTOR TEMP 

OVERRIDE in SETUP1 screen

Compressor Thrust Bearing 

Temperature

101

COMP THRUST BRG TEMP > COMP THRUST BRG 

ALERT – 5.6°C

Preset Alert, Configure COMP THRUST BRG ALERT in 

SETUP1 screen

234

COMP THRUST BRG TEMP > 85°C

Preset Alarm

Low Evaporator Temperature 

(Freeze Protection)

243

Chiller in RECYCLE SHUTDOWN and EVAP TEMP< 

EVAP REFRIG TRI 0.5°C

Preset Alarm, configure EVAP REFRIG TRIPPOINT in 

SETUP1 screen

232

EVAP REFRIG TEMP < 0.5°C (water) and EVAP 

APPROACH > EVAP APPROACH ALERT

Preset Alarm, Configure EVAP APPROACH ALERT in 

SETUP1 screen

-17.8°C < EVAP REFRIG TEMP < 4.4°C (brine) and 

EVAP APPROACH > EVAP APPROACH ALERT

Configure EVAP REFRIG TRIP POINT and CHILLED 

MEDIUM in SETUP1 screen

104

EVAPORATOR REFRIG TEMP < 0.5°C + REFRIG 

OVERRIDE DELTA T (water)

Prestart Alert, Configure REFRIG OVERRIDE DELTA T 

in SETUP1 screen

EVAPORATOR REFRIG TEMP < EVAP REFRIG 

TRIPPOINT (brine)

Prestart Alert, Configure EVAP REFRIG TRIPPOINT and 

CHILLED MEDIUM in SETUP1 screen

Transducer Voltage Fault

239

5.5 V d.c. < Voltage Reference < 4.5 V d.c.

Preset Alarm

High Condenser Pressure

- Control

235

CONDENSER PRESSURE > 1137 kPa

Preset Alarm, Configure COND PRESS OVERRIDE in 

SETUP1 screen

- Switch

207

High Pressure Switch Open (1137 ± 35 kPa) & VFD 

START = YES

Preset Alarm, Switch closes at 758 kPa

- Prestart

106

CONDENSER PRESSURE > COND PRESS 

OVERRIDE – 137 kPa

Prestart Alert, Configure COND PRESS OVERRIDE in 

SETUP1 screen

CONDENSER PRESSURE > 1000 kPa

Prestart Alert

Low Condenser Pressure

(Freeze Protection)

244

Chiller in PUMPDOWN mode and CONDENSER 

REFRIG TEMP < CONDENSER FREEZE POINT

Preset Alarm, Configure CONDENSER FREEZE POINT 

in SETUP1 screen. 

154

Energises condenser pump relay if CONDENSER 

REFRIG TEMP < CONDENSER FREEZE POINT. 

Deenergises condenser pump relay when 

CONDENSER REFRIG TEMP > CONDENSER 

FREEZE POINT + 2.8 K and ENTERING COND 

LIQUID > CONDENSER FREEZE POINT

Configure CONDENSER FREEZE POINT in SETUP1 

screen

Oil

- Low Pressure

228

OIL PRESSURE DELTA P < 90 kPa and VFD START 

= TRUE

Preset Alarm

- Low Pressure

OIL PRESSURE DELTA P < 124 kPa and startup 

complete after OIL PRESS VERIFY TIME elapsed

Preset Alarm, Configure OIL PRESS VERIFY TIME in 

SETUP1 screen

- Low Pressure

142

OIL PRESSURE DELTA P < 124 kPa and startup 

complete

Preset Alert

- Pressure Sensor Fault

227

OIL PRESSURE DELTA P > 28 kPa immediately 

before oil pump turned on

Preset Alarm

- Low Temperature

105

OIL SUMP TEMP < 66°C and OIL SUMP TEMP < 

EVAP REFRIG TEMP + 27.8°C

Prestart Alert

Line Voltage

- High

211/145

Line voltage > approximately 528 V, limits are 

calculated by VFD

Preset Alarm/Alert

- High

108

PERCENT LINE VOLTAGE > Overvoltage threshold

Preset Prestart Alert

- Low

212/146

DC BUS VOLTAGE < approximately 408 V, limits are 

calculated by a VFD

Preset Alarm/Alert

- Low

107

PERCENT LINE VOLTAGE < Undervoltage threshold Preset Prestart Alert

- Imbalance

216

LINE VOLTAGE IMBALANCE > LINE VOLTAGE % 

IMBALANCE

Configure LINE VOLTAGE % IMBALANCE and LINE 

VOLT IMBALANCE TIME in VFD CONF screen

Line Current - Single Cycle Dropout 210/144

Line Voltage on 2 Phases < 50% for 1 Cycle

Preset Alarm

- Imbalance

209/143

LINE CURRENT IMBALANCE>LINE CURRENT % 

IMBALANCE

Configure LINE CURRENT % IMBALANCE and LINE 

CURRENT IMBALANCE TIME in VFD_CONF screen

Power - Line Frequency Out of 

Range

222

47 Hz < LINE FREQUENCY < 63 Hz

Preset Alarm

- ICVC Power on Reset

214/148

Loss of control power to ICVC for excessive time 

period

Preset Alarm

Motor - Surge

238

> 5 surge events within SURGE TIME PERIOD and 

VFD SPEED > 90%

Preset Alarm, Configure SURGE DELTA% AMPS and 

SURGE TIME PERIOD in OPTIONS screen

Surge

236

> 5 surge events within SURGE TIME PERIOD and 

VFD SPEED < 90%

Preset Alarm, Configure SURGE DELTA% AMPS and 

SURGE TIME PERIOD in OPTIONS screen

Current Imbalance

225

MOTOR CURRENT IMBALANCE > MOTOR 

CURRENT % IMBALANCE

Configure MOTOR CURRENT % IMBALANCE and 

MOTOR CURRENT IMBAL TIME in VFD_CONF screen

Overload Trip

217

Any LOAD CURRENT PHASE > 108% for Excessive 

Time Period

Preset Alarm, Configure MOTOR LOAD ACTIVE 

DEMAND LIMIT in MAINSTAT screen

Excessive Amps

208

PERCENT LOAD CURRENT > 110% for 30 seconds. Preset Alarm

Acceleration Fault

203

PERCENT LOAD CURRENT > 95% and VFDSTART 

= TRUE for 5 to 40 seconds

Preset Alarm, PERCENT LOAD CURRENT = AVERAGE 

LOAD CURRENT/MOTOR RATED LOAD AMPS

Amps Not Sensed

202

PERCENT LOAD CURRENT < 5% for 3 seconds and 

VFD START=TRUE for 20 seconds

Preset Alarm, PERCENT LOAD CURRENT = AVERAGE 

LOAD CURRENT/MOTOR RATED LOAD AMPS

Table 5 - Protective limits and control settings

Summary of Contents for AquaEdge 19XRV series

Page 1: ...19XRV PIC III Control Hermetic Centrifugal Liquid Chillers Start up operation and maintenance instructions ...

Page 2: ...ter 35 5 3 Occupancy schedule 35 5 4 Safety controls 36 5 5 Shunt trip 36 5 6 Default screen freeze 36 5 7 Ramp loading control 38 5 8 Capacity override Table 6 39 5 9 High discharge temperature control 39 5 10 Oil sump temperature and pump control 39 5 11 Oil cooler 39 5 12 Remote start stop controls 40 5 13 Spare safety and spare temperature inputs 40 5 14 Alarm trip output contacts 40 5 15 Kilo...

Page 3: ...tart up 51 6 2 Shutdown sequence 52 6 3 Chilled water recycle mode 53 7 TROUBLESHOOTING GUIDE 54 7 1 Overview 54 7 2 Checking display messages 54 7 3 Checking temperature sensors 54 7 4 Checking pressure transducers 55 7 5 Control algorithms checkout procedure 56 7 6 Control test 56 8 Control Modules 69 APPENDIX 19XRV LIQUIFLO 2 ICVC PARAMETER INDEX 70 ...

Page 4: ...ire assembly DO NOT work on high voltage equipment unless you are a qualified electrician DO NOT WORK ON electrical components including control panels switches starters or oil heater until you are sure ALL POWER IS OFF and no residual voltage can leak from capacitors or solid state components LOCK OPEN AND TAG electrical circuits during servicing IF WORK IS INTERRUPTED confirm that all circuits a...

Page 5: ...e disconnect switch es in the control box es If any maintenance operations are carried out on the unit lock the power supply circuit in the open position ahead of the machine If the work is interrupted always ensure that all circuits are still deenergised before resuming the work ATTENTION Even if the unit has been switched off the power circuit remains energised unless the unit or circuit disconn...

Page 6: ...tart up procedures Procedures in this manual are arranged in the sequence required for proper chiller start up and operation 2 1 Light emitting diodes on boards All boards continuously check and indicate the proper operation of their electronic circuits A light emitting diode LED lights on each board when it is operating properly The red LED flashing for a 2 second period on the NRCP BASE board in...

Page 7: ...g chilled water temperature The control panel registers cooler condenser and lubricating system pressures shows chiller operating condition and alarm shutdown conditions records the total chiller operating hours sequences chiller start stop and recycle under micro processor control displays the status of the VFD provides access to other CCN Carrier Comfort Network devices and energy management sys...

Page 8: ...ure differential that exists due to compressor operation After the refrigerant flows past an isolation valve an in line filter and a sight glass moisture indicator the flow is split between motor cooling and oil cooling systems Flow to the motor flows through an orifice and into the motor Once past the orifice the refrigerant is directed over the motor by a spray nozzle The refrigerant collects in...

Page 9: ...frequency drive motor controller mounted on the condenser This VFD is used with low voltage motors between 380 and 460 V a c It reduces the starting current inrush by controlling the voltage and frequency to the compressor motor Once the motor has accelerated to minimum speed the PIC III modulates the compressor speed and guide vane position to control chilled water temperature Operational paramet...

Page 10: ...ring Forward motor bearing Labyrinth gas line Oil supply to forward high speed bearing Isolation valve Filter Sight glass Isolation valve Oil skimmer line Filter Eductor Sight glass Oil pump Oil pump motor Oil cooler Isolation valves Pressure transducer TXV bulb Oil filter ...

Page 11: ...e oil heater while the compressor is off and regulates the hot gas bypass valve if installed The PIC III controls provide critical protection for the compressor motor and control the VFD The PIC III can interface with the Carrier Comfort Network CCN system if desired It can communicate with other PIC I PIC II or PIC III equipped chillers and other CCN devices The PIC III consists of three modules ...

Page 12: ...r thermistor is located in the base of the evaporator sensing refrigerant temperature directly Evaporator and condenser water side differential pressure transducers are not standard and are not required The ICVC software uses the evaporator satu ration refrigerant temperature in place of differential pres sure flow detection to provide evaporator freeze protection Approach temperatures are shown i...

Page 13: ...DISPLAY is enabled but the standard CCM connection is retained a differential value of approximately 197 kPa will always be displayed If water side differential pressure transducers are used flow is detected from differential pressure between sensors pressure transducers located in water inlet and outlet nozzles for each heat exchanger The thresholds for flow determination EVAP FLOW DELTA P CUTOUT...

Page 14: ...wing and modifica tion of the local and CCN time schedules and Ice Build time schedules The SETPOINT menu allows set point adjustments such as the entering chilled water and leaving chilled water set points The SERVICE menu can be used to view or modify information on the Alarm History Control Test Control Algorithm Status Equipment Configuration VFD Configuration data Equipment Service Time and D...

Page 15: ...CPC01S LOCAL TIME SCHEDULE OCCPC02S ICE BUILD TIME SCHEDULE OCCPC03S CCN TIME SCHEDULE Select a Schedule NEXT PREVIOUS SELECT EXIT 1 2 3 4 5 6 7 8 Override Select a Time Period Override NEXT PREVIOUS SELECT EXIT Modify a Schedule Time INCREASE DECREASE ENTER EXIT ANALOGUE VALUES Add Eliminate a Day ENABLE DISABLE ENTER EXIT DISCRETE VALUES Base Demand Limit LCW Setpoint ECW Setpoint Ice Build Setp...

Page 16: ...ag Status VFD_HIST VFD Alarm History LOADSHED CUR ALRM Chiller Alarm History WSMDEFME Water System Manager Control Status OCCDEFCM Time Schedule Status Select a table NEXT PREVIOUS SELECT EXIT Select a test NEXT PREVIOUS SELECT EXIT CAPACITY Capacity Control Algorithm OVERRIDE Override Status EXIT LL_MAINT LEADLAG Status WSMDEFME Water System Manager Control Status Maintenance Table Data OCCDEFM T...

Page 17: ...S NO ENTER EXIT DISCRETE VALUES ATTACH TO NETWORK DEVICE List Network Devices Local Device 6 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...

Page 18: ...NSTAT table shows the actual value of overall chiller status such as CONTROL MODE RUN STATUS AUTO CHILLED WATER RESET and REMOTE RESET SENSOR 1 On the menu screen press STATUS to view the list of point status tables STATUS SCHEDULE SETPOINT SERVICE 2 Press NEXT or PREVIOUS to highlight the desired status table The list of tables is MAINSTAT Overall chiller status STARTUP Status required to perform...

Page 19: ...ELEASE ENTER Override indication An override value is indicated by SUPVSR SERVC or BEST flashing next to the point value on the STATUS table 4 4 3 Time schedule operation Fig 8 1 On the Menu screen press SCHEDULE STATUS SCHEDULE SETPOINT SERVICE 2 Press NEXT or PREVIOUS to highlight the de sired schedule OCCPC01S LOCAL Time Schedule OCCPC02S ICE Build Schedule OCCPC03S CCN Time Schedule NEXT PREVI...

Page 20: ...e CONTROL POINT SOURCES LCW or ECW can be active at one time The setpoint that is active is deter mined from the SERVICE menu See the Service Operation section page 49 The ice build ICE BUILD function is also activated and configured from the SERVICE menu 3 Press NEXT or PREVIOUS to highlight the desired setpoint entry NEXT PREVIOUS SELECT EXIT 4 Press SELECT to modify the highlighted setpoint NEX...

Page 21: ...oint Names preceded by two asterisks can be changed only from the ICVC Reference Point Names in lower case type can be viewed by CCN or BS only by viewing the whole table 7 Alarms and Alerts An asterisk in the far right field of an ICVC status screen indicates that the chiller is in an alarm state an exclamation mark in the far right field of the ICVC screen indicates an alert state The asterisk o...

Page 22: ...gramming 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 devices Exampl...

Page 23: ...en To access this display from the ICVC default screen 1 Press MENU 2 Press STATUS 3 Scroll down to highlight HEAT_EX 4 Press SELECT DESCRIPTION STATUS UNITS POINT Chilled Water Delta P Entering Chilled Water Leaving Chilled Water Chilled Water Delta T Chill Water Pulldown Min Evaporator Refrig Temp Evaporator Pressure Evaporator Approach Condenser Water Delta P Entering Condenser Water Leaving Co...

Page 24: ...Inverter Temperature Rectifier Temperature VFD Enclosure Temp VFD Cold Plate Temp Humidity Sensor Input Relative Humidity VFD Coolant Flow Actual VFD Speed 0 to 999 0 to 99999 0 to 999 0 to 99999 0 0 to 2 0 0 to 99999 0 to 99999 0 to 99999 0 to 99999 0 0 to 2 0 0 to 99999 0 to 99999 0 to 99999 0 to 99999 0 to 99999 0 to 99999 0 to 99999 0 to 99999 0 to 99999 0 to 99999 0 to 99999 0 to 99999 0 to 9...

Page 25: ...ALARM NORMAL ALARM NORMAL ALARM NORMAL ALARM NORMAL ALARM NORMAL ALARM NORMAL ALARM NORMAL ALARM NORMAL ALARM NORMAL ALARM FALSE TRUE FALSE TRUE NORMAL ALARM NORMAL ALARM NORMAL ALARM NORMAL ALARM NORMAL ALARM NORMAL ALARM NORMAL ALARM NORMAL ALARM VFD_FLT CYCLE_1 LINEIM_I LINEIM_V PH_REV HI_VOLT LOW_VOLT HI_DCBUS LO_DCBUS MOTIM_I MOTOR_OV RECT_OI RECT_OT RECT_PU INV_OI INV_OT INV_PU GRND_FLT FREQ...

Page 26: ...1 Press MENU 2 Press SERVICE 3 Scroll down to highlight CONTROL ALGORITHM STATUS 4 Press SELECT 5 Scroll down to highlight CAPACITY DESCRIPTION STATUS UNITS POINT Entering Chilled Water Leaving Chilled Water Capacity Control Control Point Control Point Error ECW Delta T ECW Reset LCW Reset Total Error Resets Guide Vane Delta Target Guide Vane Pos Actual Guide Vane Pos Target VFD Speed Actual VFD S...

Page 27: ... display from the ICVC default screen 1 Press MENU 2 Press SERVICE 3 Scroll down to highlight CONTROL ALGORITHM STATUS 4 Press SELECT 5 Scroll down to highlight LL_MAINT DESCRIPTION STATUS UNITS POINT Lead Lag Control LEADLAG Configuration Current Mode Load Balance Option LAG Start Time LAG Stop Time Prestart Fault Time Pulldown Delta T Min Satisfied LEAD CHILLER in Control LAG CHILLER Mode Run St...

Page 28: ... Voltage Reference Flux Current Torque Current Inverter Temperature Rectifier Temperature VFD Enclosure Temp VFD Cold Plate Temp Actual VFD Speed Chiller Fault State VFD Fault Code 0 to 99999 0 to 99999 0 to 99999 0 to 99999 0 to 99999 0 to 99999 0 to 99999 0 to 99999 0 to 99999 0 to 999 0 to 99 0 to 2 0 0 to 100 0 to 100 0 to 2 0 0 to 100 0 to 100 0 to 99999 0 to 99999 0 to 99999 0 to 99999 0 to ...

Page 29: ...nt names are available for CCN read operation Forcing shall not be supported on maintenance screens Example 15 NET_OPT display screen To access this display from the ICVC default screen 1 Press MENU 2 Press SERVICE 3 Scroll down to highlight EQUIPMENT CONFIGURATION 4 Press SELECT 5 Scroll down to highlight NET_OPT DESCRIPTION STATUS UNITS POINT DEFAULT Loadshed Function Group Number Demand Limit D...

Page 30: ...lineim_t motim_i motim_t ramp_inc ramp_dec cycdrop 460 60 YES 460 200 100 100 200 100 3456 100 0 102 0 102 0 102 0 0 0 10 10 40 10 40 10 30 30 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 Example 17 OPTIONS display screen To access this display from the ICVC default screen 1 Press MENU 2 Press SERVI...

Page 31: ...RT TB_ALERT MEDIUM CWDB ERT_TRIP REF_OVER EVAP_AL COND_AL CDFREEZE FLOWDISP EVAP_CUT COND_CUT WFLOW_T oilpr_t rcycr_dt rcycs_dt sp1_en sp1_lim sp2_ en sp2_ lim 93 3 861 71 2 71 2 93 3 79 5 WATER 0 6 0 6 1 7 2 8 3 3 1 1 DSABLE 3 4 3 4 5 40 2 8 0 6 0 118 0 118 Note No variables are available for CCN read or write operation Forcing shall not be supported on service screens Example 19 SETUP2 display s...

Page 32: ...own to highlight RAMP_DEM DESCRIPTION STATUS UNITS POINT DEFAULT Pulldown Ramp Type Select Temp 0 kW 1 Demand Limit and kW Ramp Demand Limit Source Select Amps 0 kW 1 Amps or kW Ramp Min Demand Limit Prop Band Demand Limit At 20 mA 20 mA Demand Limit Opt Demand Watts Interval 0 1 0 1 5 to 20 3 to 15 40 to 100 0 1 5 to 60 DSABLE ENABLE Minutes ramps1ct dem_src kw_ramp dem_app dem_20ma dem_sel dw_in...

Page 33: ...city by modulating both motor speed and inlet guide vanes in response to chilled water temperature deviation from the CONTROL POINT see above During operation when the CONTROL POINT is not met within 1 3 of the width of the CHILLED WATER DEADBAND the controller will calculate a GUIDE VANE DELTA which will effect a percentage change to either the guide vane position or TARGET VFD SPEED Factors cons...

Page 34: ...s is the tolerance range on the chilled water brine temperature control point If the water temperature goes outside the CHILLED WATER DEADBAND the PIC III opens or closes the guide vanes until the temperature is within tolerance The PIC III may be configured with a 0 3 to 1 1 K deadband CHILLED WATER DEADBAND may be viewed or modified on the SETUP1 screen which is accessed from the EQUIPMENT SERVI...

Page 35: ...WATTS INTERVAL in the SERVICE EQUIPMENT SERVICE RAMP_DEM screen 5 2 Chiller timers and starts counter The PIC III maintains two run time clocks COMPRESSOR ONTIME and SERVICE ONTIME COMPRESSOR ONTIME indicates the total lifetime compressor run hours SERVICE ONTIME is a resettable timer that can be used to indicate the hours since the last service visit or any other event A separate counter tallies ...

Page 36: ... can define alert limits on various monitored inputs in the SETUP1 screen A partial list of protective safety and alert limits is provided in Table 5 A complete list of alarm and alert messages is provided in the Troubleshooting Guide section page 54 5 5 Shunt trip The function of the shunt trip on the PIC III is to act as a safety trip The shunt trip is wired from the standard I O board to a VFD ...

Page 37: ...condenser pump relay if CONDENSER REFRIG TEMP CONDENSER FREEZE POINT Deenergises condenser pump relay when CONDENSER REFRIG TEMP CONDENSER FREEZE POINT 2 8 K and ENTERING COND LIQUID CONDENSER FREEZE POINT Configure CONDENSER FREEZE POINT in SETUP1 screen Oil Low Pressure 228 OIL PRESSURE DELTA P 90 kPa and VFD START TRUE Preset Alarm Low Pressure OIL PRESSURE DELTA P 124 kPa and startup complete ...

Page 38: ...rature 158 159 248 249 SPARE TEMPERATURE SPARE TEMP LIMIT Optional Alarm Alert Configure SPARE TEMP ENABLE and SPARE TEMP LIMIT in SETUP1 screen Guide Vane Position 253 ACTUAL GUIDE VANE POS 4 after 4 minutes of closing Preset Alarm ACTUAL GUIDE VANE POSITION 0 045 V after startup complete Preset Alarm ACTUAL GUIDE VANE POSITION 3 15 V after startup complete Preset Alarm ACTUAL GUIDE VANE POSITION...

Page 39: ...e the Surge Prevention Algorithm section page 43 5 9 High discharge temperature control If the COMP DISCHARGE TEMP increases above 71 1 C the guide vanes are proportionally opened to increase gas flow through the compressor If the LEAVING CHILLED WATER temperature decreases 2 8 K below the control set point temperature as a result of opening the guide vanes the PIC III will bring the chiller into ...

Page 40: ...he STARTS IN 12 HOURS parameter on the MAINSTAT screen occur not counting either recycle restarts or auto restarts after power failure an excessive starts alarm displays preventing the chiller from starting The operator must press the RESET softkey on the ICVC to override the starts counter and start the chiller If the chiller records 12 starts excluding recycle starts in a sliding 12 hour period ...

Page 41: ...denser pump will energise to try to decrease the pressure and Alert 151 will be generated The pump turns off when the condenser pressure is 24 1 kPa less than the pressure over ride and the CONDENSER REFRIG TEMP is within 1 7 K of the ENTERING CONDENSER WATER temperature 5 18 Condenser freeze prevention This control algorithm helps prevent condenser tube freeze up by energizing the condenser pump ...

Page 42: ...he oil pump will energise for one minute before energising the evaporator pump AUTO RESTART will then continue like a normal start up If power to the ICVC module has been off for more than 3 hours or the timeclock has been set for the first time start the compressor with the slowest TEMP PULLDOWN DEG MIN rate possible in order to minimise oil foaming The oil pump is energised occasionally during t...

Page 43: ... point moved directly into the surge prevention region In this case investigate the ability of the condenser cooling means e g cooling tower to provide cooling water in accordance with the design load entering condenser water temperature schedule A surge condition occurs when the lift becomes so high the gas flow across the impeller reverses This condition can eventually cause chiller damage When ...

Page 44: ...cific piece of equipment that is without further control elements or signal conditioning although it may be The head pressure reference output will be on whenever the condenser pump is operating It may also be manually operated in CONTROLS TEST When the head pressure differential is less than the value entered for DELTA P AT 0 the output will be maintained at 4 mA 5 26 Lead lag control The lead la...

Page 45: ...a designated standby chiller when either the lead or lag chiller is faulted and capacity requirements are not met The lead lag option only operates when the chillers are in CCN mode If any other chiller configured for lead lag is set to the LOCAL or OFF modes it will be unavailable for lead lag operation Lead lag chiller configuration and operation A chiller is designated the lead chiller when its...

Page 46: ... flashing next to the CHILLER START STOP parameter in the MAINSTAT screen The PIC III control then monitors the lag chiller for a successful start If the lag chiller fails to start the standby chiller if configured is started 5 27 5 Lag chiller yhutdown Requirements The following conditions must be met in order for the lag chiller to be stopped 1 Lead chillerAVERAGE LINE CURRENT or MOTOR PERCENT K...

Page 47: ...e build schedule can be viewed or modified from the SCHEDULE table From this table select the ice build schedule OCCPC02S screen See Fig 8 and the section on Time Schedule Operation page 19 for more information on modifying chiller schedules The ice build time schedule defines the period s during which ice build is active if the ice build option is enabled If the ice build time schedule overlaps o...

Page 48: ...ut Ice build operation terminates when the ICE BUILD TERMINATION parameter is set to 1 CONTACTS and the ICE BUILD CONTACTS are open and the ICE BUILD RECYCLE is set to DSABLE 0 In this case the ICE BUILD CONTACTS provide ice level termination control The contacts are used to stop the ice build function when a time period on the ice build schedule OCCPC02S is set for ice build operation The remote ...

Page 49: ... ATTACH softkey to attach to the LOCAL device and view the chiller operation Fig 13 Example of Attach to Network Device screen 5 30 Service operation An overview of the tables and screens available for the SERVICE function is shown in Fig 7 5 30 1 To access the service screens When the SERVICE screens are accessed a password must be entered 1 From the main MENU screen press the SERVICE softkey The...

Page 50: ...chiller or CCN device can be configured as the broadcast device The controller that is configured as the broadcaster is the device responsible for transmitting holi day time and daylight savings dates throughout the network To access the BRODEF screen see the SERVICE menu structure Fig 7 To view or change the holiday periods for up to 18 different holidays perform the following operation 1 At the ...

Page 51: ...ss the CLOSE softkey To end the override select REMOTE CONTACTS INPUT and press the RELEASE softkey 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 6 The RUN STATUS parameter on the MAINSTAT screen line now reads PRE START If a test is not successful the start up is delayed or aborted ...

Page 52: ...mpressor stops The condenser water pump shuts down at the same time if the ENTERING CONDENSER WATER temperature is greater than or equal to 46 1 C and the CONDENSER REFRIG TEMP is greater than the CONDENSER FREEZE POINT plus 2 8 K The stop to start timer now begins to count down If the start to start timer value is still greater than the value of the start to stop timer then this time displays on ...

Page 53: ...s the RECYCLE CONTROL RESTART DELTA T in ECW CONTROL and the ENTERING CHILLED WATER temperature is greater than the CONTROL POINT plus the RECYCLE CONTROL RESTART DELTA T Once these conditions are met the compressor initiates a start up with a normal start up sequence An alert condition may be generated if 5 or more recycle start ups occur in less than 4 hours Excessive recycling can reduce chille...

Page 54: ... expand on the fault description For a complete list of VFD Fault Code Descrip tions and corrective actions see Table 11 NOTE The date format in these tables is MM DD YY If the alarm light starts to flash while accessing a menu screen press the EXIT softkey to return to the default screen to read the alarm message The STATUS screen can also be accessed to determine where an alarm exists A C to the...

Page 55: ... are at 0 kPa or are open to atmospheric pressure the transducers can be calibrated for zero without removing the transducer from the vessel 3 Access the HEAT_EX screen and view the particular transducer reading the EVAPORATOR PRESSURE or CONDENSER PRESSURE parameter on the HEAT_EX screen To calibrate oil pressure or liquid side flow device view the particular reading CHILLED WATER DELTA P and CON...

Page 56: ...ntrol override values LL_MAINT LEAD LAG Status Indicates LEAD LAG operation status OCCDEFCM Time Schedules Status The Local and CCN occupied schedules are displayed here to help the operator quickly determine whether the schedule is in the occupied mode or not WSMDEFME Water System Manager Status The water system manager is a CCN module that can turn on the chiller and change the chilled water con...

Page 57: ...CONTACTS CLOSED Chiller timer countdown complete Unit will proceed to start Remote contact enabled and closed READY TO START IN XX MIN START COMMAND IN EFFECT Chiller START STOP on MAINSTAT manually forced to start Release SUPERVISOR force to start under normal control READY TO START IN XX MIN RECYCLE RESTART PENDING Chiller in recycle mode READY TO START UNOCCUPIED MODE Time schedule for PIC III ...

Page 58: ...eck for proper VFD cooling fan operation and blockage 111 PRESTART ALERT HIGH INVERTER TEMP 111 Inverter Temperature VALUE exceeded limit of LIMIT Check that VFD refrigerant isolation valves are open Check VFD refrigerant cooling solenoid and refrigerant strainer Check for proper VFD cooling fan operation and blockage LIMIT is shown on the ICVC as the temperature pressure voltage etc setpoint pred...

Page 59: ...etc setpoint 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 is tripped H OUT OF RANGE SENSOR ICVC FAULT STATE PRIMARY MESSAGE SECONDARY MESSAGE PRIMARY CAUSE ADDITIONAL CAUSE REMEDY 260 SENSOR FAULT LEAVING CHILLED WATER 260 Sensor Fault Check Leaving Chilled Water Sensor Check sensor resistan...

Page 60: ...to ground distribution bus voltage Check VFD fuses Check 24 V a c power supply to ICVC Consult power company 215 PROTECTIVE LIMIT LOW DC BUS VOLTAGE 215 Low DC Bus Voltage VALUE exceeded limit of LIMIT Verify phase to phase and phase to ground line voltage VFD Circuit Board malfunction Call Carrier Service 216 PROTECTIVE LIMIT LINE VOLTAGE IMBALANCE 216 Line Voltage Imbalance Check VFD Fault Histo...

Page 61: ... valves Confirm that TXV bulb is secured in place and insulated Check for sensor wiring and accuracy This fault can result from extended operation at low load with low water flow to the evaporator or condenser 235 PROTECTIVE LIMIT HIGH CONDENSER PRESSURE 235 Condenser Pressure VALUE exceeded limit of LIMIT Check for high condenser water temperatures low water flow fouled tubes Check for division p...

Page 62: ... CONFLICT 252 VFD Config Conflict VFD Downloaded Verify to Reset Alarm The VFD_CONF table in the Gateway does not match that which is in the ICVC 253 PROTECTIVE LIMIT GUIDE VANE CALIBRATION 253 Guide Vane Fault VALUE Check Calibration Enter CONTROL TEST and execute Guide Vane Calibration Check CCM guide vane feedback terminals J4 9 and J4 10 Check guide vane feedback potentiometer Alarm before sta...

Page 63: ...e or voltage drop Check for proper wiring Check for partially closed service valves Check oil cooler TXV Check oil level and oil temperature 151 CONDENSER PRESSURE ALERT PUMP RELAY ENERGISED 151 High Condenser Pressure VALUE Pump Energised to Reduce Pressure Check sensor wiring and accuracy Check condenser flow and water temperature Check for fouled tubes This alarm is not caused by the High Press...

Page 64: ...ondenser Check that the condenser tubes are not fouled 164 VFD SPEED ALERT LOW VFD SPEED 164 Actual VFD Speed exceeded limit of Target VFD Speed 10 Actual VFD Speed on COMPRESS screen must be at least 90 of Target VFD Speed 165 AUTORESTART PENDING LOW DC BUS VOLTAGE 165 Low DC Bus Voltage VALUE Exceeded Limit of LIMIT Verify phase to phase and phase to ground line voltage 166 AUTORESTART PENDING H...

Page 65: ...e maximum value of 10 0 seconds Verify connection of current feedback device and motor terminals If fault repeats replace current feedback devices and or power supply 206 36 SW OverCurrent 1 The drive output current has exceeded the software current Check for excess load improper DC boost setting DC brake volts set too high 286 37 Motor I Imbalance 4 Phase current displayed in Imbalance Display 22...

Page 66: ...unexpected fault Check wiring harness 206 216 Rectifier Ground Fault Excessive ground current measured Check for grounded input wiring 220 217 Rectifier Base Temp Excessive rectifier temperature measured Check for proper temperature and flow rate of coolant 218 218 Rectifier IGBT Temp Excessive calculated IGBT temperature Check for proper temperature and flow rate of coolant 218 219 Rectifier IT O...

Page 67: ...at Voltage 4 The rectifier did not regulate to the desired bus voltage within the defined time Replace rectifier power board and or rectifier control board 206 238 Rectfr Not Log In 4 Rectifier took too long to connect to inverter a Check the cabling between the communications interface and the two control boards b Connect one DPI device at a time to see if one of the DPI devices is causing the pr...

Page 68: ...1 3 266 36 1 675 3 134 37 1 629 3 008 38 1 585 2 888 39 1 542 2 773 40 1 499 2 663 41 1 457 2 559 42 1 417 2 459 43 1 377 2 363 Temperature C PIC III voltage drop V Resistance Ohms 44 1 338 2 272 45 1 300 2 184 46 1 263 2 101 47 1 227 2 021 48 1 192 1 944 49 1 158 1 871 50 1 124 1 801 51 1 091 1 734 52 1 060 1 670 53 1 029 1 609 54 0 999 1 550 55 0 969 1 493 56 0 941 1 439 57 0 913 1 387 58 0 887 ...

Page 69: ...roperly Is lit continuously there is most likely a hardware fault that requires replacing the module Is off continuously the power should be checked Blinks 3 times per second a software error has been discovered and the module must be replaced If there is no input power check the fuses and circuit breaker If the fuse is good check for a shorted secondary of the transformer or if power is present t...

Page 70: ...S POWER Average Load Current STATUS POWER Base Demand Limit SETPOINT SETPOINT X Baud Rate SERVICE ICVC CONFIGURATION X Broadcast Option SERVICE EQUIPMENT CONFIGURATION NET_OPT X Bus Number SERVICE ICVC CONFIGURATION X Capacity Control SERVICE CONTROL ALGORITHM STATUS CAPACITY Capacity Control SERVICE EQUIPMENT SERVICE SETUP2 CCM Pressure Transducers SERVICE CONTROL TEST CCM Temperature Thermistors...

Page 71: ... STATUS CAPACITY CONTROL TEST SERVICE Current CHW Setpoint SERVICE CONTROL ALGORITHM STATUS WSMDEFME Current Date SERVICE TIME AND DATE X Current Mode SERVICE CONTROL ALGORITHM STATUS LL_MAINT Current Time SERVICE TIME AND DATE X Date SERVICE TIME AND DATE X Day of Week SERVICE TIME AND DATE X Daylight Savings SERVICE EQUIPMENT CONFIGURATION BRODEF X DC Bus Voltage STATUS POWER DC Bus Voltage SERV...

Page 72: ... MAINSTAT Ice Build Control SERVICE EQUIPMENT SERVICE OPTIONS 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 Ice Build Time Schedule SCHEDULE OCCP02S X Ice Build Time Schedule OCCPC02S SERVICE EQUIPMENT CONFIGURATION OCCDEFCS X ICVC CONFIGURAT...

Page 73: ... 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 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 CONTRO...

Page 74: ...ATUS POWER Pressure Transducers Control Test SERVICE CONTROL TEST PRESTART FAULT Time SERVICE CONTROL ALGORITHM STATUS LL_MAINT PRESTART FAULT Timer SERVICE EQUIPMENT SERVICE LEADLAG X PRIMARY MESSAGE DEFAULT SCREEN Proportional Dec Band SERVICE EQUIPMENT SERVICE SETUP2 X Proportional ECW Gain SERVICE EQUIPMENT SERVICE SETUP2 X Proportional Inc Band SERVICE EQUIPMENT SERVICE SETUP2 X Pulldown Ramp...

Page 75: ...ture 2 SERVICE CONTROL ALGORITHM STATUS LL_MAINT Spare Temperature 2 SERVICE CONTROL TEST THERMITORS 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 Advance SERVICE EQUIPMENT...

Page 76: ...NTROL ALGORITHM STATUS VFD_HIST VFD Checksum Error STATUS VFD_STAT VFD Cold Plate Temp STATUS POWER VFD Cold Plate Temp SERVICE CONTROL ALGORITHM STATUS VFD_HIST VFD Comm Fault STATUS VFD_STAT VFD CONFIG PASSWORD SERVICE VFD CONFIG DATA X VFD Coolant Flow STATUS HEAT_EX VFD Coolant Flow STATUS POWER VFD Coolant Solenoid Test SERVICE CONTROL TEST DISCRETE OUTPUTS X VFD Enclosure Temp STATUS POWER V...

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