Start-Up, Operation, and Maintenance Instructions

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G. NORMAL RUN WITH OVERRIDES PRIMARY STATE MESSAGE 120 RUN CAPACITY LIMITED 121 RUN CAPACITY LIMITED 122 RUN CAPACITY LIMITED 123 RUN CAPACITY LIMITED 124 RUN CAPACITY LIMITED 125 RUN CAPACITY LIMITED Table 11 — CVC/ICVC Primary and Secondary Messages and Custom Alarm/Alert Messages with Troubleshooting Guides (cont) *[LIMIT] is shown on the CVC/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 STATE MESSAGE 260 SENSOR FAULT 261 SENSOR FAULT 262 SENSOR FAULT 263 SENSOR FAULT 264 SENSOR FAULT 265 SENSOR FAULT 266 SENSOR FAULT 267 SENSOR FAULT 268 SENSOR FAULT 269 SENSOR FAULT 270 SENSOR FAULT 271 SENSOR FAULT 273 SENSOR FAULT SECONDARY ALARM MESSAGE ADDITIONAL MESSAGE PRIMARY CAUSE CAUSE/REMEDY HIGH CONDENSER 120->Condenser Pressure Check for high condenser water temperatures. PRESSURE [VALUE] exceeded limit of [LIMIT]*. Check setting in SETUP1. HIGH MOTOR 121->Comp Motor Winding Temp Check motor cooling lines. TEMPERATURE [VALUE] exceeded limit of [LIMIT]*. Check for closed valves. Check setting in SETUP1. LOW EVAP 122->Evaporator Refrig Temp Check refrigerant charge. REFRIG TEMP [VALUE] exceeded limit of [LIMIT]*. Check for low entering cooler temperatures. HIGH COMPRESSOR 123->Surge Prevention Override: Check for high condenser water temperatures or LIFT Lift Too High For Compressor. low suction temperature. MANUAL GUIDE 124->Run Capacity Limited: Target guide vane point has been forced in VANE TARGET Manual Guide Vane Target. MAINSTAT screen. Release force to continue normal operation. LOW DISCHARGE No messages. Check oil charge. SUPERHEAT Check refrigerant charge. SECONDARY ALARM MESSAGE MESSAGE PRIMARY CAUSE LEAVING CHILLED 260->Sensor Fault: WATER Leaving Chilled Water ENTERING CHILLED 261->Sensor Fault: WATER Entering Chilled Water CONDENSER 262->Sensor Fault: PRESSURE Condenser Pressure EVAPORATOR 263->Sensor Fault: PRESSURE Evaporator Pressure COMPRESSOR 264->Sensor Fault: BEARING TEMP Comp Thrust Bearing Temp COMPRESSOR 265->Sensor Fault: MOTOR TEMP Comp Motor Winding Temp COMP DISCHARGE 266->Sensor Fault: TEMP Comp Discharge Temp OIL SUMP TEMP 267->Sensor Fault: Oil Sump Temp COMP OIL 268->Sensor Fault: PRESS DIFF Oil Pump Delta P CHILLED WATER 269->Sensor Fault: FLOW Chilled Water Delta P COND WATER 270->Sensor Fault: FLOW Cond Water Delta P VFD SPEED SENSOR 271->Sensor Fault: OUT OF RANGE Check Actual VFD Speed Sensor VFD SPEED OUT OF 273->Sensor Fault: RANGE Check Actual VFD Speed Sensor 80 ADDITIONAL CAUSE/REMEDY Check sensor resistance or voltage drop. Check for proper wiring. Check sensor resistance or voltage drop. Check for proper wiring. Check sensor wiring. Check sensor wiring. Check sensor resistance or voltage drop. Check for proper wiring. Check sensor resistance or voltage drop. Check for proper wiring. Check sensor resistance or voltage drop. Check for proper wiring. Check sensor resistance or voltage drop. Check for proper wiring. Check sensor wiring and accuracy. Check sensor wiring and accuracy. Check sensor wiring and accuracy. Check voltage input on terminals J6-1 and J6-2 on the ISM module. Check wiring. Check VFD feedback 0-5 vac. Calibrate VFD speed reference signal.
I. CHILLER PROTECT LIMIT FAULTS STATE PRIMARY MESSAGE 200 PROTECTIVE LIMIT 201 PROTECTIVE LIMIT 202 PROTECTIVE LIMIT 203 FAILURE TO START 204 FAILURE TO STOP 205 FAILURE TO STOP 206 PROTECTIVE LIMIT 207 PROTECTIVE LIMIT 208 PROTECTIVE LIMIT 209 PROTECTIVE LIMIT 210 PROTECTIVE LIMIT 211 PROTECTIVE LIMIT 212 PROTECTIVE LIMIT 213 PROTECTIVE LIMIT 214 PROTECTIVE LIMIT 215 PROTECTIVE LIMIT 216 PROTECTIVE LIMIT 217 PROTECTIVE LIMIT 218 PROTECTIVE LIMIT 219 PROTECTIVE LIMIT 220 PROTECTIVE LIMIT 221 PROTECTIVE LIMIT 222 PROTECTIVE LIMIT 223 PROTECTIVE LIMIT Table 11 — CVC/ICVC Primary and Secondary Messages and Custom Alarm/Alert Messages with Troubleshooting Guides (cont) SECONDARY MESSAGE 1M CONTACT FAULT 2M CONTACT FAULT MOTOR AMPS NOT SENSED EXCESS ACCELERATION TIME 1M/2M CONTACT FAULT MOTOR AMPS WHEN STOPPED STARTER FAULT HIGH CONDENSER PRESSURE EXCESSIVE MOTOR AMPS LINE PHASE LOSS LINE VOLTAGE DROPOUT HIGH LINE VOLTAGE LOW LINE VOLTAGE ALARM MESSAGE PRIMARY CAUSE 200->1M Aux Contact Fault; Check 1M Contactor and Aux 201->2M Aux Contact Fault; Check 2M Contactor and Aux 202->Motor Amps Not Sensed — Average Line Current [VALUE] 203->Motor Acceleration Fault — Average Line Current [VALUE] 204->1M/2M Aux Contact Stop Fault; Check 1M/2M Contactors and Aux 205->Motor Amps When Stopped — Average Line Current [VALUE] 206->Starter Fault Cutout; Check Optional Starter Contacts 207->High Cond Pressure cutout. [VALUE] exceeded limit of [LIMIT]*. 208->Compressor Motor Amps [VALUE] exceeded limit of [LIMIT]*. 209->Line Phase Loss; Check ISM Fault History to Identify Phase 210->Single Cycle Line Voltage Dropout 211->High Average Line Voltage [VALUE] 212->Low Average Line Voltage [VALUE] STARTER MODULE 213->Starter Module Power- RESET On Reset When Running POWER LOSS 214->Power Loss: Check voltage supply LINE CURRENT IMBALANCE LINE VOLTAGE IMBALANCE MOTOR OVERLOAD TRIP MOTOR LOCKED ROTOR TRIP 215->Line Current Imbalance; Check ISM Fault History to Identify Phase 216->Line Voltage Imbalance; Check ISM Fault History to Identify Phase 217->Motor Overload Trip; Check ISM configurations 218->Motor Locked Rotor Amps exceeded; Check Motor & ISM Config 219->Starter Locked Rotor Amps Rating exceeded STARTER LOCK ROTOR TRIP GROUND FAULT 220->Ground Fault Trip; Check Motor and Current Transformers PHASE REVERSAL 221->Phase Reversal Trip; TRIP Check Power Supply LINE FREQUENCY 222->Line Frequency — TRIP [VALUE] exceeded limit of [LIMIT]. Check Power Supply. STARTER MODULE 223->Starter Module FAILURE Hardware Failure 81 ADDITIONAL CAUSE/REMEDY Check for wiring of current transformers to the ISM. Check main circuit breaker for trip. Check to be sure that the inlet guide vanes are closed at start-up. Check starter for proper operation. Reduce unit pressure if possible. For Benshaw Inc. RediStart MICRO starters, view fault code at RediStart MICRO display. Press FAULT RESET to clear faults. Check for high condenser water temperatures, low water flow, fouled tubes. Check for division plate/gasket bypass. Check for noncondensables. Check transducer wiring and accuracy. If [VALUE] is less than Limit then check the 1CR Starting Circuit. Check motor current for proper calibration. Check inlet guide vane actuator. Check transformers to ISM. Check power distribution bus. Consult power company. Check transformers to ISM. Check distribution bus. Consult power company. Check transformers to ISM. Check distribution bus. Consult power company. Check transformers to ISM. Check distribution bus. Consult power company. Check upstream equipment. Check upstream equipment. Check ISM configuration. Check ISM configuration. Check ISM configuration.
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Start-Up, Operation, and Maintenanc
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CONTENTS (cont) Page Page Chiller D
Page 5 and 6:
Factory-installed additional compon
Page 7 and 8:
Factory-Mounted Starter or Variable
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MOTOR COOLING LINE TXV BULB PRESSUR
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OPTIONAL METER PACKAGE INTEGRATED S
Page 13 and 14:
The PIC II can interface with the C
Page 15 and 16:
CVC/ICVC Operation and Menus (Fig.
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Start Chiller In CCN Control Start
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SERVICE MENU CONTINUED FROM PREVIOU
Page 21 and 22:
7. Press ENTER to register the valu
Page 23 and 24:
Table 2 — CVC/ICVC Display Data (
Page 25 and 26:
Page 27 and 28:
Page 29 and 30: Table 2 — CVC/ICVC Display Data (
Page 31 and 32: Table 2 — CVC/ICVC Display Data (
Page 33 and 34: PIC II System Functions NOTE: Words
Page 35 and 36: Shunt Trip (Option) — The functio
Page 37 and 38: OVERRIDE CAPACITY CONTROL HIGH COND
Page 39 and 40: (see wiring diagrams or certified d
Page 41 and 42: NOTE: The lead/lag function can be
Page 43 and 44: Ice Build Control — The ice build
Page 45 and 46: Service Operation — An overview o
Page 47 and 48: Shutdown Sequence — Chiller shutd
Page 49 and 50: 49 Fig. 28 — 19XR Leak Test Proce
Page 51 and 52: Fig. 29 — Typical Optional Pumpou
Page 53 and 54: Chiller Dehydration — Dehydration
Page 55 and 56: MECHANICAL STARTER 1. Check all fie
Page 57 and 58: CHANGE THE BENSHAW INC., RediStart
Page 59 and 60: VFD Cooling System Leak Inspection
Page 61 and 62: Protecting the VFD Configuration 1.
Page 63 and 64: Check Optional Pumpout System Contr
Page 65 and 66: Dry Run to Test Start-Up Sequence F
Page 67 and 68: Leave the oil charge in the chiller
Page 69 and 70: LEGEND C — Contactor FU — Fuse,
Page 71 and 72: 2. Evacuate the refrigerant gas fro
Page 73 and 74: SCHEDULED MAINTENANCE Establish a r
Page 75 and 76: Water Treatment — Untreated or im
Page 77 and 78: TRANSDUCER REPLACEMENT — Since th
Page 79: Table 11 — CVC/ICVC Primary and S
Page 83 and 84: I. CHILLER PROTECT LIMIT FAULTS (co
Page 85 and 86: TEMPERATURE (F) PIC II VOLTAGE DROP
Page 87 and 88: Control Modules Turn controller pow
Page 89 and 90: ANALOG OUT J8 INTERGRATED STARTER M
Page 91 and 92: NOTES: 1. Cooler data: based on a c
Page 93 and 94: Table 14 — 19XR Additional Data f
Page 95 and 96: HEAT EXCHANGER COOLER/ CONDENSER HE
Page 97 and 98: Table 18 — Optional Pumpout Syste
Page 99 and 100: ITEM A B C D E F VIEW B — HIGH SP
Page 101 and 102: 101 Fig. 45 — Allen-Bradley Wye-D
Page 103 and 104: 103 LEGEND (cont) ISM — Integrate
Page 105 and 106: 105 LEGEND (cont) ISM — Integrate
Page 107 and 108: 107 LEGEND Denotes Component Termin
Page 109 and 110: AUX — Auxiliary C — Contactor C
Page 111 and 112: Fig. 53 — Benshaw, Inc. Solid-Sta
Page 113 and 114: LEGEND AUX — Auxiliary C — Cont
Page 115 and 116: 1A LEGEND AUX — Auxiliary C — C
Page 117 and 118: 117 Fig. 57 — Typical Variable Fr
Page 123 and 124: Abbreviations and Explanations, 4 A
Page 125 and 126: MACHINE INFORMATION: DESIGN CONDITI
Page 127 and 128: 19XR, XRV PIC II SETPOINT TABLE CON
Page 129 and 130: CUT ALONG DOTTED LINE CUT ALONG DOT
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CUT ALONG DOTTED LINE CUT ALONG DOT
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Copyright 2001 Carrier Corporation
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Start-Up, Operation, and Maintenance Instructions

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