Carrier AquaEdge 23XRV User guide

Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Catalog No. 04-53230017-01 Printed in U.S.A. Form 23XRV-8SS Pg 1 6-22 Replaces: 23XRV-7SS
AquaEdge® 23XRV
High-Efficiency Variable Speed Screw Chiller
with Greenspeed®Intelligence and PIC6 Controls
50/60 Hz
R-134a
Start-Up, Operation and Maintenance
Instructions
CONTENTS
Page
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . 2
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
ABBREVIATIONS AND EXPLANATIONS . . . . . . . . . . 4
23XRV CHILLER FAMILIARIZATION. . . . . . . . . . . . . . 4
Chiller Identification Nameplate . . . . . . . . . . . . . . . . . 4
System Components . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Motor-Compressor. . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Control Center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Storage Vessel (Optional) . . . . . . . . . . . . . . . . . . . . . 11
REFRIGERATION CYCLE . . . . . . . . . . . . . . . . . . . . . 12
MOTOR COOLING CYCLE. . . . . . . . . . . . . . . . . . . . . 15
LUBRICATION CYCLE . . . . . . . . . . . . . . . . . . . . . . . . 15
Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Oil Reclaim System . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Capacity Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Definitions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
PIC6 System Components . . . . . . . . . . . . . . . . . . . . 17
START-UP/SHUTDOWN/RECYCLE SEQUENCE . . . 22
Local Start/Stop Control . . . . . . . . . . . . . . . . . . . . . . 23
Shutdown Sequence . . . . . . . . . . . . . . . . . . . . . . . . . 23
BEFORE INITIAL START-UP . . . . . . . . . . . . . . . . . . . 24
Job Data Required . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Equipment Required . . . . . . . . . . . . . . . . . . . . . . . . . 24
Remove Shipping Packaging . . . . . . . . . . . . . . . . . . 24
Open Oil Circuit Valves . . . . . . . . . . . . . . . . . . . . . . . 24
Oil Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Tighten All Gasketed Joints . . . . . . . . . . . . . . . . . . . 24
Check Chiller Tightness . . . . . . . . . . . . . . . . . . . . . . 25
Refrigerant Tracer . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Leak Test Chiller . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Chiller Dehydration . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Inspect Liquid Piping. . . . . . . . . . . . . . . . . . . . . . . . . 32
Inspect Refrigerant Cooling Lines . . . . . . . . . . . . . . 32
Check Optional Pumpout Compressor Piping . . . . 32
Check Relief Valves . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Identify the VFD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Check Control Center . . . . . . . . . . . . . . . . . . . . . . . . 34
Input Power Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Checking the Installation . . . . . . . . . . . . . . . . . . . . . .34
Inspect Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Ground Fault Troubleshooting . . . . . . . . . . . . . . . . .35
CCN Interface and LEN Interface. . . . . . . . . . . . . . . .35
Power Up Controls and Check Oil Heater . . . . . . . .35
Software Configuration . . . . . . . . . . . . . . . . . . . . . . .36
Input the Design Set Points . . . . . . . . . . . . . . . . . . . .36
Input the Local Occupancy Schedule . . . . . . . . . . . .36
Input Configurations. . . . . . . . . . . . . . . . . . . . . . . . . .37
Perform a Control Test . . . . . . . . . . . . . . . . . . . . . . . .37
Check Optional Pumpout System Controls and
Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
High Altitude Locations . . . . . . . . . . . . . . . . . . . . . . .38
Charge Refrigerant into Chiller . . . . . . . . . . . . . . . . .38
INITIAL START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Check Oil Pressure and Compressor Stop . . . . . . .41
To Prevent Accidental Start-Up . . . . . . . . . . . . . . . . .41
Check Chiller Operating Condition . . . . . . . . . . . . . .41
Instruct the Customer Operator . . . . . . . . . . . . . . . .41
OPERATING INSTRUCTIONS. . . . . . . . . . . . . . . . . . .42
Operator Duties. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
Prepare the Chiller for Start-Up . . . . . . . . . . . . . . . . .42
To Start the Chiller . . . . . . . . . . . . . . . . . . . . . . . . . . .42
Check the Running System . . . . . . . . . . . . . . . . . . . .42
To Stop the Chiller . . . . . . . . . . . . . . . . . . . . . . . . . . .42
After Limited Shutdown . . . . . . . . . . . . . . . . . . . . . . .43
Preparation for Extended Shutdown. . . . . . . . . . . . .43
After Extended Shutdown . . . . . . . . . . . . . . . . . . . . .43
Cold Weather Operation. . . . . . . . . . . . . . . . . . . . . . .43
Refrigeration Log . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
PUMPOUT AND REFRIGERANT
TRANSFER PROCEDURES . . . . . . . . . . . . . . . . . .45
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
Operating the Optional Pumpout Unit . . . . . . . . . . .45
Chillers with Storage Tanks. . . . . . . . . . . . . . . . . . . .46
GENERAL MAINTENANCE. . . . . . . . . . . . . . . . . . . . .52
Refrigerant Properties . . . . . . . . . . . . . . . . . . . . . . . .52
Adding Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . .52
Removing Refrigerant . . . . . . . . . . . . . . . . . . . . . . . .52
Adjusting the Refrigerant Charge . . . . . . . . . . . . . . .52
Refrigerant Leak Testing . . . . . . . . . . . . . . . . . . . . . .52
Refrigerant Leak Rate. . . . . . . . . . . . . . . . . . . . . . . . .53
Test After Service, Repair, or Major Leak. . . . . . . . .53
Repair the Refrigerant Leak, Retest, and Apply
Standing Vacuum Test. . . . . . . . . . . . . . . . . . . . . .53
Trim Refrigerant Charge. . . . . . . . . . . . . . . . . . . . . . .53

2
WEEKLY MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . 53
Check the Lubrication System . . . . . . . . . . . . . . . . . 53
SCHEDULED MAINTENANCE . . . . . . . . . . . . . . . . . . 53
Service Ontime . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Inspect the Control Center . . . . . . . . . . . . . . . . . . . . 53
Changing Oil and Oil Filter . . . . . . . . . . . . . . . . . . . . 54
Oil Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Oil Heater. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Refrigerant Filter/Drier . . . . . . . . . . . . . . . . . . . . . . . . 55
Oil Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
VFD Refrigerant Strainer . . . . . . . . . . . . . . . . . . . . . . 55
Vaporizer Refrigerant Return Line Orifice . . . . . . . . 55
Compressor Inlet Bearing Oil Orifice . . . . . . . . . . . . 55
Inspect Condenser Refrigerant Float System
(Frame 3-5 Heat Exchangers) . . . . . . . . . . . . . . . . 55
Inspect Variable Frequency Drive. . . . . . . . . . . . . . . 57
Inspect Relief Valves and Piping . . . . . . . . . . . . . . . 57
Compressor Bearing Maintenance . . . . . . . . . . . . . . 57
Compressor Rotor Check . . . . . . . . . . . . . . . . . . . . . 57
Motor Insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Inspect the Heat Exchanger Tubes. . . . . . . . . . . . . . 58
Water/Brine Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Water/Brine Treatment . . . . . . . . . . . . . . . . . . . . . . . . 58
Inspect the Control Center . . . . . . . . . . . . . . . . . . . . 58
Recalibrate Pressure Transducers . . . . . . . . . . . . . . 58
Optional Pumpout System Maintenance . . . . . . . . . 58
Verify Thermistor Readings. . . . . . . . . . . . . . . . . . . . 58
Ordering Replacement Chiller Parts. . . . . . . . . . . . . 59
TROUBLESHOOTING GUIDE. . . . . . . . . . . . . . . . . . . 59
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Checking Display Messages . . . . . . . . . . . . . . . . . . . 59
Checking Temperature Sensors . . . . . . . . . . . . . . . . 59
Checking Pressure Transducers . . . . . . . . . . . . . . . 59
Quick Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Control Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Gateway Status LEDs. . . . . . . . . . . . . . . . . . . . . . . . . 63
End of Life and Equipment Disposal . . . . . . . . . . . . 65
Physical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
APPENDIX A — PIC6 SCREEN AND MENU
STRUCTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
APPENDIX B — MAINTENANCE SUMMARY
AND LOG SHEETS . . . . . . . . . . . . . . . . . . . . . . . . 83
INDEX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
INITIAL START-UP CHECKLIST . . . . . . . . . . . . . . CL-1
SAFETY CONSIDERATIONS
Installation and servicing of air-conditioning equipment can be
hazardous due to system pressure and electrical components. Only
trained and qualified service personnel should install, repair, or
service air-conditioning equipment.
Untrained personnel can perform basic maintenance functions of
cleaning coils and filters and replacing filters. All other operations
should be performed by trained service personnel. When working
on air-conditioning equipment, observe precautions in the
literature, tags and labels attached to the unit, and other safety
precautions that may apply.
Follow all safety codes. Wear safety glasses and work gloves. Use
quenching cloth for unbrazing operations. Have fire extinguisher
available for all brazing operations.
It is important to recognize safety information. This is the safety-
alert symbol . When you see this symbol on the unit and in
instructions or manuals, be alert to the potential for personal
injury.
Understand the signal words DANGER, WARNING, CAUTION,
and NOTE. These words are used with the safety-alert symbol.
DANGER identifies the most serious hazards which will result in
severe personal injury or death. WARNING signifies hazards
which could result in personal injury or death. CAUTION is used
to identify unsafe practices, which may result in minor personal
injury or product and property damage. NOTE is used to highlight
suggestions which will result in enhanced installation, reliability,
or operation.
Screw liquid chillers are designed to provide safe and reliable ser-
vice when operated within design specifications. When operating
this equipment, use good judgment and safety precautions to avoid
damage to equipment and property or injury to personnel.
DANGER
Failure to follow these procedures will result in severe per-
sonal injury or death.
DO NOT VENT refrigerant relief devices within a building.
Outlet from rupture disc or relief valve must be vented out-
doors in accordance with the latest edition of ANSI/ASHRAE
15 (American National Standards Institute/American Society
of Heating, Refrigerating, and Air-Conditioning Engineers).
The accumulation of refrigerant in an enclosed space can dis-
place oxygen and cause asphyxiation.
PROVIDE adequate ventilation in accordance with
ANSI/ASHRAE 15, especially for enclosed and low overhead
spaces. Inhalation of high concentrations of vapor is harmful
and may cause heart irregularities, unconsciousness, or death.
Intentional misuse can be fatal. Vapor is heavier than air and
reduces the amount of oxygen available for breathing. Product
causes eye and skin irritation. Decomposition products are
hazardous.
DO NOT USE OXYGEN to purge lines or to pressurize a
machine for any purpose. Oxygen gas reacts violently with oil,
grease, and other common substances.
DO NOT USE air for leak testing. Use only refrigerant or dry
nitrogen.
NEVER EXCEED specified test pressures, VERIFY the
allowable test pressure by checking the instruction literature
and the design pressures on the equipment nameplate.
DO NOT VALVE OFF any safety device.
BE SURE that all pressure relief devices are properly installed
and functioning before operating any machine.
RISK OF INJURY OR DEATH by electrocution. High (or
medium) voltage is present on motor leads even though the
motor is not running. Open the power supply disconnect
before touching motor leads or terminals.
UNIT AND ELECTRICAL CONSTRUCTION is designed
for use in a non-hazardous environment (non-flammable and
non-explosive). DO NOT install the chiller in a hazardous
(flammable or explosive) location or environment.

3
WARNING
Failure to follow these procedures may result in personal
injury or death.
DO NOT USE TORCH to remove any component. System
contains oil and refrigerant under pressure.
To remove a component, wear protective gloves and goggles
and proceed as follows:
Shut off electrical power to unit.
Recover refrigerant to relieve all pressure from system using
both high-pressure and low pressure ports.
Traces of vapor should be displaced with nitrogen and the
work area should be well ventilated. Refrigerant in contact
with an open flame produces toxic gases.
Cut component connection tubing with tubing cutter and
remove component from unit. Use a pan to catch any oil that
may come out of the lines and as a gage for how much oil to
add to the system.
Carefully unsweat remaining tubing stubs when necessary. Oil
can ignite when exposed to torch flame.
DO NOT USE eyebolts or eyebolt holes to rig heat exchangers
or the entire assembly.
DO NOT work on high (or medium) voltage equipment unless
you are a qualified electrician.
DO NOT WORK ON electrical components, including
control panels, switches, starters, or oil heater until you are
sure ALL POWER IS OFF and no residual voltage can leak
from capacitors or solid-state components.
LOCK OPEN AND TAG electrical circuits during servicing.
IF WORK IS INTERRUPTED, confirm that all circuits are
deenergized before resuming work.
AVOID SPILLING liquid refrigerant on skin or getting it into
the eyes. USE SAFETY GOGGLES. Wash any spills from the
skin with soap and water. If liquid refrigerant enters the eyes,
IMMEDIATELY FLUSH EYES with water and consult a
physician.
NEVER APPLY an open flame or live steam to a refrigerant
cylinder. Dangerous over pressure can result. When it is
necessary to heat refrigerant, use only warm (110 F [43 C])
water.
DO NOT REUSE disposable (nonreturnable) cylinders or
attempt to refill them. It is DANGEROUS AND ILLEGAL.
When cylinder is emptied, evacuate remaining gas pressure,
loosen the collar, and unscrew and discard the valve stem. DO
NOT INCINERATE.
CHECK THE REFRIGERANT TYPE before adding
refrigerant to the machine. The introduction of the wrong
refrigerant can cause machine damage or malfunction.
Operation of this equipment with refrigerants other than those
cited herein should comply with ANSI/ASHRAE 15 (latest
edition). Contact Carrier for further information on use of this
machine with other refrigerants.
DO NOT ATTEMPT TO REMOVE fittings, covers, etc.,
while machine is under pressure or while machine is running.
Be sure pressure is at 0 psig (0 kPa) before breaking any
refrigerant connection.
CAREFULLY INSPECT all relief valves, rupture discs, and
other relief devices AT LEAST ONCE A YEAR. If machine
operates in a corrosive atmosphere, inspect the devices at more
frequent intervals.
DO NOT ATTEMPT TO REPAIR OR RECONDITION any
relief valve when corrosion or build-up of foreign material
(rust, dirt, scale, etc.) is found within the valve body or
mechanism. Replace the valve.
WARNING
DO NOT install relief devices in series or backwards.
USE CARE when working near or in line with a compressed
spring. Sudden release of the spring can cause it and objects in
its path to act as projectiles.
SOME MODELS MAY EXCEED 85 dBA. Hearing
protection should be worn when working in the vicinity of
such chillers.
CAUTION
Failure to follow these procedures may result in personal
injury or damage to equipment.
DO NOT STEP on refrigerant lines. Broken lines can whip
about and release refrigerant, causing personal injury.
DO NOT climb over a machine. Use platform, catwalk, or
staging. Follow safe practices when using ladders.
USE MECHANICAL EQUIPMENT (crane, hoist, etc.) to lift
or move inspection covers or other heavy components. Even if
components are light, use mechanical equipment when there is
a risk of slipping or losing your balance.
BE AWARE that certain automatic start arrangements CAN
ENGAGE THE STARTER, TOWER FAN, OR PUMPS.
Open the disconnect ahead of the starter, tower fan, and
pumps. Shut off the machine or pump before servicing
equipment.
USE only repaired or replacement parts that meet the code
requirements of the original equipment.
DO NOT VENT OR DRAIN waterboxes containing industrial
brines, liquid, gases, or semisolids without the permission of
your process control group.
DO NOT LOOSEN waterbox cover bolts until the waterbox
has been completely drained.
DOUBLE-CHECK that coupling nut wrenches, dial
indicators, or other items have been removed before rotating
any shafts.
DO NOT LOOSEN a packing gland nut before checking that
the nut has a positive thread engagement.
PERIODICALLY INSPECT all valves, fittings, and piping for
corrosion, rust, leaks, or damage.
PROVIDE A DRAIN connection in the vent line near each
pressure relief device to prevent a build-up of condensate or
rain water.
DO NOT re-use compressor oil or any oil that has been
exposed to the atmosphere. Dispose of oil per local codes and
regulations.
DO NOT leave refrigerant system open to air any longer than
the actual time required to service the equipment. Seal circuits
being serviced and charge with dry nitrogen to prevent oil
contamination when timely repairs cannot be completed.
Chiller must be installed in an indoor environment where the
ambient temperature is between 40 to 104°F (4 to 40°C) with a
relative humidity (non-condensing) of 95% or less. To ensure
that electrical components operate properly and to avoid
equipment damage, do not locate chiller in an area exposed to
dust, dirt, corrosive fumes, or excessive heat and humidity.

4
INTRODUCTION
Prior to initial start-up of the 23XRV chiller, those involved in
the start-up, operation, and maintenance should be thoroughly
familiar with these instructions and other necessary job data.
This book is outlined to familiarize those involved in the start-
up, operation and maintenance of the unit with the control sys-
tem before performing start-up procedures. Procedures in this
manual are arranged in the sequence required for proper chiller
start-up and operation.
Factory-installed additional components are referred to as options
in this manual; factory-supplied but field-installed additional com-
ponents are referred to as accessories.
ABBREVIATIONS AND EXPLANATIONS
Frequently used abbreviations in this manual include:
23XRV CHILLER FAMILIARIZATION
See Fig. 1-7 for 23XRV details.
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.
CAUTION
This unit uses a microprocessor control system. Do not short
or jumper between terminations on circuit boards or modules;
control or board failure may result.
Be aware of electrostatic discharge (static electricity) when
handling or making contact with circuit boards or module con-
nections. Always touch a chassis (grounded) part to dissipate
body electrostatic charge before working inside control center.
Use extreme care when handling tools near boards and when
connecting or disconnecting terminal plugs. Circuit boards can
easily be damaged. Always hold boards by the edges and
avoid touching components and connections.
This equipment uses, and can radiate, radio frequency energy.
If not installed and used in accordance with the instruction
manual, it may cause interference to radio communications.
The chiller control boards have been tested and found to com-
ply with the limits for a Class A computing device pursuant to
International Standard in North America EN 61000-2/3 which
are designed to provide reasonable protection against such
interference when operated in a commercial environment.
Operation of this equipment in a residential area is likely to
cause interference, in which case the user, at his own expense,
will be required to take whatever measures may be required to
correct the interference.
Always store and transport replacement or defective boards in
anti-static shipping bag.
CCN — Carrier Comfort Network®
CCW — Counterclockwise
CSM — Chillervisor System Manager
CW — Clockwise
DPI — LF2 VFD Drive Peripheral Interface Board
ECDL — Entering Condenser Liquid
ECL — Entering Chilled Liquid
EMS — Energy Management System
EXV — Electronic Expansion Valve
HGBP — Hot Gas Bypass
HMI — Human Machine Interface
IGBT — Insulated Gate Bipolar Transistor
I/O — Input/Output
IOB — Input/Output Board
KAIC — Kiloamps Interrupt Capacity
LCD — Liquid Crystal Display
LCDL — Leaving Condenser Liquid
LCL — Leaving Chilled Liquid
LED — Light-Emitting Diode
LEI — Local Equipment Interface Translator
LEN — Local Equipment Network
LF2 — Reliance LiquiFloa2 VFD with Active Rectifier
NOTE(S):
a. LiquiFlo and Reliance are trademarks of Rockwell Automation.
OIM — Reliance Operator Interface Module
OLTA — Overload Trip Amps
PIC6 — Product Integrated Control 6
RLA — Rated Load Amps
RS485 — Communications Type used by PIC
SCR — Silicon Controlled Rectifier
SI — International System of Units
SIOB — Starfire Input Output Board
TB1 — Control Center Terminal Block 1
TB2 — Control Center Terminal Block 2
VFD — Variable Frequency Drive
VFG — Variable Frequency Gateway Module

5
Fig. 1 — Model Number Identification
23XRV – High Efficiency
Variable Speed Screw Chiller
Evaporator Size*
A1-A6
B1-B6
30-32
35-37
40-42
45-47
50-52
55-57
Condenser Size*
A1-A6
B1-B6
30-32
35-37
40-42, 4D
45-47, 4E
50-52
55-57
Economizer Option
E– With Economizer
N– No Economizer
Voltage Code
3–380-3-60
4–416-3-60
5–460-3-60
7–575-3-60
9 –380/415-3-50
––Not Used
Compressor Option
0– Full Load Optimized
1– Part Load Optimized
Drive Code**
AA – LF-2, 440 Amps In, 442 Amps Out
BA – LF-2, 520 Amps In, 442 Amps Out
CC – LF-2, 608 Amps In, 608 Amps Out
R1 – Std Tier, 575-v, 269 Amps In, 269 Amps Out
R2 – Std Tier, 230 Amps In, 230 Amps Out
R3 – Std Tier, 335 Amps In, 335 Amps Out
R4 – Std Tier, 445 Amps In, 445 Amps Out
23XRV 40 42 N R V AA 5 0 – –
Compressor Code†
P
Q
R
Motor Code
H
J
P
Q
R X
S
T
U
V
S–Special
––Standard
* First character 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.

6
Fig. 2 — Typical 23XRV Components (Units with P Compressor)
1—Discharge Pipe
2—Variable Frequency Drive
3—Cooler Relief Valve
4—Compressor Discharge Pipe
5—PIC6 Controller
6—Refrigerant Charging Valve
7—ASME Nameplate, Evaporator
8—Condenser Relief Valves
9—Tubesheet Mounting Brackets
10 — Condenser
11 — ASME Nameplate, Condenser
12 — Level Sensing Chamber
13 — Condenser Refrigerant Pumpout Valve
14 — Refrigerant Strainer
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
34
5
6
7
8
9
10
11
12
13
14
15
16
18
17
19 20
21 — Tubesheet Mounting Brackets
22 — Vaporizer Sight Glass
23 — Vaporizer Drain Sight Glass (Hidden)
24 — Oil Sump Heater (Hidden)
25 — Oil Sump
26 — Oil Sump Sight Glass (Hidden)
27 — Oil Pump Outlet Filter
28 — Oil Pump
29 — ASME Nameplate Oil Concentrator
30 — Vaporizer Sight Glass
31 — Hot Gas Bypass Line
32 — Oil Charging Drain Valve
33 — Typical Waterbox Drain Coupling (Hidden)
34 — Condenser Supply/Return End Waterbox
35 — Variable Orifice
36 — Oil Reclaim Actuator
37 — Cooler Supply/Return End Waterbox
38 — Oil Pump Inlet Filter
21
22
23
24
25
26
30 28
29 27
33 31
32
34
35
36
37
38
39
41
42
43
39 — Discharge Isolation Valve Assembly
(Option or Accessory)
40 — Machine Electrical Data Nameplate
41 — Main EXV
42 — Economizer Gas EXV (Option)
43 — Economizer (Option)
44 — Economizer Muffler (Hidden)
40
44

7
Fig. 3 — Typical 23XRV Components (Units with Q Compressor)
3
2
1
8
7
5
18 17 16
14 13 12
11 10 9
20
19
21
6
4
15
1 — Motor Terminal Cover Plate
2 — Variable Frequency Drive
3 — PIC6 Controller
4 — Discharge Pipe Relief Valve
5 — Condenser
6 — Oil Reclaim Actuator
7 — Vaporizer Sight Glass
8 — Oil Filter Assembly
9 — Oil Sump Temperature (hidden)
10 — Oil Sump
11 — Condenser Refrigerant Pumpout Valve
12 — Condenser Float Chamber
13 — Cooler Inlet Isolation Valve (Hidden)
14 — ASME Nameplate, Economizer (Hidden)
15 — Oil Sump Heater
16 —FilterDrier
17 — Vaporizer Heater
18 — Condenser Supply/Return End Waterbox
19 — Cooler Supply/Return End Waterbox
20 — Motor Cooling Supply Line
21 — VFD Disconnect
27
28
29
32
40
41
42
43
22 23
24
25
26
39 37 36
38 35 34 33 31
30
22 — Discharge Pipe
23 — Compressor Discharge Check Valve Access Cover
24 — Condenser Relief Valves
25 — Refrigerant Charging Valves
26 — Cooler Relief Valve
27 — Tubesheet Mounting Brackets
28 — Typical Waterbox Drain Coupling
29 — ASME Nameplate, Condenser
30 — Oil Drain
31 — ASME Nameplate Oil Concentrator
32 — Discharge Isolation Valve (Option or Accessory)
33 — Suction Oil Filter
34 — Oil Pump
35 — Discharge Oil Filter
36 — Oil Sump Sight Glass
37 — Refrigeration Machine Nameplate
38 — Filter Drier Isolation Valve with Schrader Valve
39 — Machine Electrical Data Nameplate
40 —Economizer
41 — Motor Cooling Sight Glass
42 — Motor Cooling Isolation Valve
43 — Vaporizer Drain Sight Glass
51
50
53
52
49
48
47
46
45
44
44 — VFD Cold Plate Refrigeration Inlet Connection (Outlet Hidden)
45 — VFD Cold Plate Orifice
46 — Compressor Nameplate
47 — Compressor Lubrication Block
48 — Economizer Muffler
49 — Vaporizer Condenser Gas Isolation Valve
50 — Hot Gas Bypass Isolation and Trim Valve
51 — VFD Cooling Refrigerant Strainer
52 — Cooler Refrigerant Pumpout Valve
53 — ASME Nameplate, Cooler

8
Fig. 4 — Typical 23XRV Components (Units with R Compressor)
20
19
18
12 11 10
9
8
7
6
5
4
3
2
1
21
14
17
13
16 15
1 — Motor Terminal Cover Plate
2 — Variable Frequency Drive
3 — PIC6 Controller
4 — Discharge Pipe Relief Valve
5 — Condenser
6 — Oil Reclaim Actuator
7 — Vaporizer Sight Glass
8 — Oil Filter Assembly
9 — Oil Sump Temperature
10 —OilSump
11 — Condenser Refrigerant Pumpout Valve
12 — Condenser Float Chamber
13 — Cooler Inlet Isolation Valve (Hidden)
14 — ASME Nameplate, Economizer (Hidden)
15 — Oil Sump Heater
16 —FilterDrier
17 — Vaporizer Heater
18 — Condenser Supply/Return End Waterbox
19 — Cooler Supply/Return End Waterbox
20 — Motor Cooling Supply Line
21 — VFD Disconnect
23 26
27
29
31 30
32
35 34
22 24 25
28
33
36
40
41
42
43
39 37
38
22 — Discharge Pipe
23 — Compressor Discharge Check Valve Access Cover
24 — Condenser Relief Valves
25 — Refrigerant Charging Valves
26 — Cooler Relief Valve
27 — Tubesheet Mounting Brackets
28 — Typical Waterbox Drain Coupling
29 — ASME Nameplate, Condenser
30 — Oil Drain
31 — ASME Nameplate Vaporizer
32 — Discharge Isolation Valve (Option or Accessory)
33 — Suction Oil Filter
34 — Oil Pump
35 — Discharge Oil Filter
36 — Oil Sump Sight Glass
37 — Refrigeration Machine Nameplate
38 — Filter Drier Isolation Valve with Schrader Valve
39 — Machine Electrical Data Nameplate
40 —Economizer
41 — Motor Cooling Sight Glass
42 — Motor Cooling Isolation Valve
43 — Vaporizer Drain Sight Glass
50
51
52
53
47
48 49
46
45
44
44 — VFD Cold Plate Refrigeration Inlet Connection (Outlet Hidden)
45 — VFD Cold Plate Orifice
46 — Compressor Nameplate
47 — Compressor Lubrication Block
48 — Economizer Muffler
49 — Vaporizer Condenser Gas Isolation Valve
50 — Hot Gas Bypass Isolation and Trim Valve
51 — VFD Cooling Refrigerant Strainer
52 — Cooler Refrigerant Pumpout Valve
53 — ASME Nameplate, Cooler

9
Fig. 5 — Typical 23XRV Installation — Sensor Locations (Units with P Compressor)
1
9
8
7
2
3
4
5
6
1— Compressor Motor Winding Temperature (Hidden)
2— Vaporizer Temperature
3— Evaporator Return Liquid Temperature (Hidden)
4—OilSumpPressure
5— Oil Sump Temperature
6— Supply Oil Pressure
7— Condenser Liquid Temperature (Hidden)
8— Evaporator Liquid Flow (Optional)
9— Evaporator Liquid Temperature (Hidden)
10 — Compressor Discharge Temperature
11 — Compressor Discharge Pressure
12 — Compressor Discharge High Pressure Switch
10
11 12
13 — Inductor Temperature Switch (Inside VFD Enclosure)
14 — VFD Rectifier Temperature (Inside Power Module)
15 — VFD Heat Sink Temperature (Inside VFD Enclosure)
16 — VFD Inverter Temperature (Inside Power Module)
17 — Evaporator Temperature
18 — Condenser Pressure
19 — Condenser Liquid Level Sensor
20 — Economizer Pressure (Optional)
21 — Economizer Temperature (Optional)
13 14 15
16
19
17
18
20 21

10
Fig. 6 — Typical 23XRV Installation — Sensor Locations (Units with Q Compressor)
4
3
2
1
7
6
5
8
9
1—Condenser Pressure
2—Evaporator Pressure
3—Compressor Discharge Temperature
4—Compressor Discharge Pressure
5—Compressor Discharge High Pressure Switch
6—Compressor Motor Winding Temperature (Hidden)
7—Evaporator Refrigerant Liquid Temperature (Hidden)
8—Condenser Liquid Temperature
9—Condenser Liquid Flow (Optional)
13
12
10
18
17
15
14
20
19
11
16
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 LF2 VFD Enclosure)
15 — Oil Pressure Leaving Filter (Hidden)
16 — Oil Sump Pressure (Hidden)
17 — Oil Sump Temperature (Hidden)
18 — Vaporizer Temperature
19 — Evaporator Liquid Temperature
20 — Evaporator Liquid Flow (Optional)

11
Fig. 7 — Typical 23XRV Installation — Sensor Locations (Units with R Compressor)
Cooler
The cooler (also known as the evaporator) is maintained at low
temperature/pressure so that evaporating refrigerant can remove
heat from the liquid flowing through its internal tubes.
Condenser
This vessel is located underneath the compressor. The condenser
operates at a higher temperature/pressure than the cooler and has
liquid flowing through its internal tubes to remove heat from the
refrigerant.
Motor-Compressor
The motor-compressor maintains system temperature/pressure
differences and moves the heat carrying refrigerant from the cool-
er to the condenser. See Fig. 8.
Muffler
The muffler provides acoustical attenuation. A check valve just
downstream of the muffler prevents reverse compressor rotation
during shutdown.
Control Center
The control center is the user interface for controlling the chiller
and regulating the chiller’s capacity to maintain the proper chilled
liquid temperature.
The control center:
• registers cooler, condenser, and lubricating system pressures
• shows chiller operating condition and alarm shutdown
conditions
• records the total chiller operating hours, starts, and the
number of hours the chiller has been currently running
• sequences chiller start, stop, and recycle under micropro-
cessor control
• provides access to other Carrier Comfort Network®devices
• provides machine protection
Storage Vessel (Optional)
Two sizes of storage vessels are available. The vessels have
double relief valves, a magnetically coupled dial-type refriger-
ant level gage, a 1-in. FPT drain valve, and a 1/2-in. male flare
vapor connection for the pumpout unit. A 30-in.-0-400 psi
(–101-0-2750 kPa) gage is also supplied with each unit.
NOTE: If a storage vessel is not used at the jobsite, factory-in-
stalled optional isolation valves may be used to isolate the chiller
charge in either the cooler or condenser. An optional pumpout
compressor system is used to transfer refrigerant from vessel to
vessel.
6
4
2
1
3
5
9
7
8
1—Condenser Pressure
2—Evaporator Pressure
3—Compressor Discharge Temperature
4—Compressor Discharge Pressure
5—Compressor Discharge High Pressure Switch
6—Compressor Motor Winding Temperature (Hidden)
7—Evaporator Refrigerant Liquid Temperature (Hidden)
8—Condenser Liquid Temperature
9—Condenser Liquid Flow (Optional)
19
17
16
15
20
10 11 12 13 14
18
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 LF2 VFD Enclosure)
15 — Oil Pressure Leaving Filter
16 — Oil Sump Pressure (Hidden)
17 — Oil Sump Temperature (Hidden)
18 — Vaporizer Temperature
19 — Evaporator Liquid Temperature
20 — Evaporator Liquid Flow (Optional)

12
Fig. 8 — Compressor (Typical, R Compressor Shown)
REFRIGERATION CYCLE
The compressor continuously draws refrigerant vapor from the
cooler. As the compressor suction reduces the pressure in the cool-
er, the remaining refrigerant boils at a fairly low temperature (typ-
ically 38 to 42°F [3 to 6°C]). The energy required for boiling is ob-
tained from the liquid flowing through the cooler tubes. With heat
energy removed, the liquid becomes cold enough for use in an air-
conditioning circuit or process liquid cooling.
After absorbing heat from the chilled liquid, the refrigerant vapor
is compressed. Compression adds still more energy, and the refrig-
erant is quite warm (typically 90 to 130°F [32 to 54°C]) when it is
discharged from compressor into condenser.
Relatively cool (typically 65 to 85°F [18 to 29°C]) liquid flowing
into the condenser tubes removes heat from the refrigerant and the
vapor condenses to liquid, refrigerant.
For heat exchangers frame sizes 3-5, the liquid refrigerant in the
condenser passes through orifices into the FLASC (Flash Sub-
cooler) chamber (Fig. 9). Since the FLASC chamber is at a low-
er pressure, part of the liquid refrigerant flashes to vapor, thereby
cooling the remaining liquid. The FLASC vapor is recondensed
on the tubes which are cooled by entering condenser liquid. The
liquid then passes through a float valve assembly which forms a
liquid seal to keep FLASC chamber vapor from entering the
cooler.
Heat exchanger frame sizes A and B incorporate a sensible sub-
cooler instead of the FLASC, and the liquid seal and throttle level
control are performed by an electronic expansion valve instead of
a float valve. See Fig. 10.
An optional economizer can be installed between the condenser
and cooler. Pressure in this chamber is intermediate between con-
denser and cooler pressures. At this lower pressure, some of the
liquid refrigerant flashes to gas, cooling the remaining liquid. For
heat exchanger frame sizes 3-5, an in-line orifice on the economiz-
er drain flange meters the refrigerant liquid into the cooler. For
size A and B heat exchangers, the flash gas to the compressor is
produced in a brazed plate heat exchanger where some of the con-
denser liquid prior to throttling is diverted through the economizer
electronic expansion valve (EXV). The EXV control logic is
based on economizer saturated temperature, superheat and com-
pressor speed. The flash gas, having absorbed heat, is returned di-
rectly to the compressor at a point after suction cutoff (Fig. 11 and
12). Here it is mixed with gas from the suction cut-off point to pro-
duce an increase in the mass flow of refrigerant transported and
compressed without either an increase in suction volume or a
change in suction temperature.
DISCHARGE
COMPRESSOR LUBRICATION BLOCK MOTOR TERMINAL
ACCESS COVER
MOTOR COOLING
DRAIN
MOTOR TERMINALS ECONOMIZER
PORT
MOTOR
COOLING
INLET
FLANGE
a23-1619

13
Fig. 9 — Refrigerant Flow Schematic, Q and R Compressors (Without Optional Flash Economizer)
a23-1668
REFRIGERANT
VAPOR
REFRIGERANT
LIQUID
REFRIGERANT
LIQUID/VAPOR

14
Fig. 10 — Refrigerant Flow Schematic, P Compressor (Without Optional Economizer)
Fig. 11 — Refrigerant Flow Schematic, Q and R Compressors (With Optional Flash Economizer)
a23-1727
a23-1669
REFRIGERANT
VAPOR
REFRIGERANT
LIQUID
REFRIGERANT
LIQUID/VAPOR

15
Fig. 12 — Refrigerant Flow Schematic, P Compressor (With Optional Economizer)
MOTOR COOLING CYCLE
For Q and R compressors, one half of the motor is cooled by suc-
tion gas while the other half is cooled by liquid refrigerant taken
from the bottom of the condenser vessel. The P compressor has
two spray nozzles that cool the motor by injecting liquid refriger-
ant. The flow of liquid refrigerant is maintained by the pressure
differential that exists due to compressor operation. The refriger-
ant flows through an isolation valve, in-line filter/drier, and a sight
glass/moisture indicator (dry-eye), into the motor through the mo-
tor spray nozzle. See Fig. 9-12.
The motor spray nozzle is orificed to control refrigerant flow
through the gaps between the rotor and stator. The refrigerant col-
lects in the bottom of the motor casing and then drains into the
cooler through the motor cooling drain line.
The motor is protected by a temperature sensor and a temperature
switch embedded in the stator windings. If motor thermistor tem-
perature exceeds 197°F (88°C) the override function will start un-
loading the compressor. If the motor winding temperature rises
above the 200°F (93°C) safety limit, the compressor will shut
down.
LUBRICATION CYCLE
Summary
The 23XRV chiller requires an oil pump. Oil flow is provided by a
magnetically coupled, motor-driven oil pump. Oil flows through
the oil filter into the compressor rotors and bearings. The cycle is
referred to as a “low side” oil system. See Fig. 13.
Details
The oil system:
• lubricates the roller bearings which support the male and
female rotors, and the ball bearings of the 23XRV com-
pressor.
• lubricates the male and female rotors.
Oil is charged into the system through a hand valve located on the
bottom of the oil sump. Sight glasses on the oil sump permit oil
level observation. When the compressor is shut down, an oil level
should be visible in the oil sump sight glass. During operation, the
oil level should always be visible in the oil sump sight glass. Ap-
proximately 10 gal. (37.9 L) of oil is charged into the sump.
Oil from the compressor bearing drain is drained directly into the
oil sump. Refrigerant is driven from the oil as it flows around the
oil sump heater and into the strainer housing. The oil pump draws
the oil through a strainer and forces it through an oil filter.
The filter housing is capable of being isolated by upstream and
downstream valves to permit filter replacement. An oil pressure
regulator valve directs excessive oil back into the oil sump. Oil
supplied to the compressor is monitored by an oil pressure sensor.
The Oil Delta P value is equal to the difference between the oil
pressure leaving the filter and the oil sump pressure. It is read di-
rectly from the PIC6 home screen.
a23-1728
IMPORTANT: To avoid adverse effects on chiller operation,
consideration must be made to condenser water temperature
control. Consult the Chiller Builder for required steady state
operational limits. Inverted start conditions are acceptable for
short durations; generally, for periods exceeding 5 minutes,
special control strategy solutions are to be used to allow the
chiller to build minimum refrigerant pressure differential (and
thereby adequate equipment cooling).

16
Oil is supplied to the compressor through two separate inlets. One
inlet leads to the suction bearings, the other leads to the discharge
bearings. Most of the oil drains back into the sump while a small
amount is used to lubricate the rotors. Rotor lubrication oil leaves
the compressor mixed with the compressed discharge refrigerant
vapor.
The oil sump contains temperature and pressure sensors and an oil
heater. (In some cases a two-stage heater is supplied, with 500 W
for the first stage and 1000 W for the second stage.) The oil sump
is vented to the compressor suction to minimize the amount of re-
frigerant absorbed by the oil. Oil Sump T is displayed on the PIC6
home screen. The oil sump pressure is used to calculate the Oil
Delta P value.
Operating Oil Delta P must be at least 18 psid (124 kPa) after the
Oil Pressure Verify Time has elapsed. Under normal full load con-
ditions, oil pressure is typically 20 to 28 psid (138 to 193 kPa). If
sufficient oil pressure is not established or maintained the chiller
will shut down. An oil pressure delta P sensor fault will be de-
clared if the OIL DELTA P is not less than 4 psid (27.6 kPa) prior
to start-up.
If the oil pressure falls below the values specified in Table 1
during start-up, the PIC6 control will shut down the chiller.
Table 1 — Oil Pressure Requirements
Fig. 13 — Oil Flow Schematic
TIME
(SEC)
MINIMUM START-UP OIL
PRESSURE REQUIREMENT
R-134a/R-513A
PSID kPa
Before Oil Pump On < 6 41.4
After Oil Press Verify Time 18 124
During Start/Run 15 103
DUAL STAGE
OIL HEATER
VAPORIZER
HEATER
SKIMMER LINE
VAPORIZER
RETURN GAS
VENT LINE
OIL SUPPLY
VAPORIZER
SUPPLY GAS
OIL DRAIN
CONDENSER
EVAPORATOR
VA PORIZER/OIL SUM P

17
Oil Reclaim System
The oil reclaim system recovers oil from the cooler, removes the
refrigerant, filters and returns the oil back to the compressor.
One or more oil reclaim nozzles are positioned along the length
of the cooler to draw the oil and refrigerant mixture from the sur-
face of the refrigerant level. The mixture passes through an oil
reclaim modulating valve and into the vaporizer. The flow of re-
frigerant and oil is regulated to prevent the vaporizer from be-
coming overloaded with liquid refrigerant. The modulating
valve position is adjusted in accordance with the difference be-
tween the Vaporizer Temp and the Evap Sat Temp. The oil re-
claim modulating valve closes when chiller is shut down to pre-
vent vaporizer and oil sump from being flooded with refrigerant.
Do not manually open the oil reclaim modulating valve when the
chiller is shut down. Doing so will severely degrade the viscosity
of the oil in the sump. Flow of refrigerant and oil from the cooler
can be observed through a sight glass on top of the vaporizer.
Viscosity of compressor oil is significantly reduced when it ab-
sorbs refrigerant. A combination of heat and low pressure is used
to vaporize refrigerant that has been absorbed by the oil mixture
reclaimed from the cooler. Condenser gas is used to warm the re-
frigerant and oil mixture in the vaporizer. Warm refrigerant is bled
from the condenser top, directed through tubes that line the bottom
of the vaporizer, and discharged into the cooler. A 1500 W electric
heater provides supplemental heat to the vaporizer when the com-
pressor is operating at lower loads. Refrigerant boiled out of the
reclaimed mixture is vented to the compressor suction. The con-
centrated oil mixture drains out of the vaporizer, through a sight
glass, past the vaporizer temperature sensor, and into the oil sump.
The oil sump heaters maintain the temperature of the reclaimed oil
and the oil returned from the compressor at approximately 90°F
(32.2°C) when the chiller is running and 140°F (60°C) when the
chiller is off. The oil sump is also vented to compressor suction to
increase oil viscosity by boiling off additional refrigerant.
Capacity Control
The PIC6 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 re-
sponse to the difference between the CONTROL POINT and the
LEAVING CHILL WATER TEMP or ENT CHILL WATER
TEMP temperatures.
The PIC6 controls respond to the difference between the CON-
TROL POINT and LEAVING CHILL WATER TEMP tempera-
tures when the EWT CONTROL OPTION is DISABLED.
The PIC6 controls respond to the difference between the CON-
TROL POINT and ENT CHILL WATER TEMP temperatures
when the EWT CONTROL OPTION is ENABLED.
The chiller capacity is controlled by varying the TGT. VFD
SPEED from 0% to 100%. The PIC6 controls monitor the com-
pressor oil properties and set a Compressor Minimum Speed to
ensure sufficient compressor bearing lubrication under all operat-
ing conditions. It will limit the circuit capacity to Circuit Capacity
Limit% in the General Configuration Table.
CONTROLS
Definitions
ANALOG SIGNAL
An analog signal varies in proportion to the monitored source. It
quantifies values between operating limits. (Example: A tempera-
ture sensor is an analog device because its resistance changes in
proportion to the temperature, generating many values.)
DISCRETE SIGNAL
A discrete signal is a two-position representation of the value of a
monitored source. (Example: A switch produces a discrete signal
indicating whether a value is above or below a set point or bound-
ary by generating an on/off, high/low, or open/closed signal.)
General
The 23XRV hermetic screw liquid chiller contains a touch screen
microprocessor-based control center that monitors and controls all
operations of the chiller. The microprocessor control system
matches the cooling capacity of the chiller to the cooling load
while providing state-of-the-art chiller protection. The system
controls cooling capacity within the set point plus the deadband by
sensing the leaving chilled liquid or brine temperature (see Fig. 14
and 15) and regulating the compressor speed. Reducing the com-
pressor speed decreases the volume flow rate of refrigerant
through the compressor. Chiller protection is provided by the PIC6
processor, which monitors the digital and analog inputs and exe-
cutes capacity overrides or safety shutdowns, if required.
Fig. 14 — Control Sensors (Temperature)
Fig. 15 — Control Sensors (Pressure Transducers)
PIC6 System Components
The chiller control system is called PIC6. See Fig. 16-21 and Ta-
ble 2. The PIC6 system controls the chiller by monitoring all oper-
ating conditions. The PIC6 control system can diagnose a problem
and let the operator know what the problem is and what to check.
It promptly adjusts compressor speed to maintain leaving chilled
liquid temperature. It can interface with auxiliary equipment such
as pumps and cooling tower fans to turn them on when required. It
continually checks all safeties to prevent any unsafe operating
condition. It also regulates the oil heater and regulates the hot gas
bypass valve, if installed. The PIC6 control system provides criti-
cal protection for the compressor motor and control of the variable
frequency drive.
The PIC6 control system supports native CCN and LEN protocols
and can communicate via CCN to other PIC I, PIC II, PIC III, and
PIC6 equipped chillers or other CCN devices. PIC6 has native ca-
pability to communicate with building automation system via
BACnet1MS/TP, BACnet/IP, Modbus2RTU, and Modbus
TCP/IP. The PIC6 controls are housed inside the control center en-
closure. See Fig. 2-4. The component names are listed in Table 2.
1. BACnet is a trademark of ASHRAE.
2. Modbus is a registered trademark of Schneider Electric.
SHRINK WRAP
STRAIN RELIEF
1/8” NPT
THERMOWELL
REMOVABLE
TEMPERATURE
SENSOR

18
p
Fig. 16 — PIC6 Wiring
Fig. 17 — Control Center VFD Input Components (LF-2 VFD)
CCN LABEL
LEN LABEL
4
13
8
16
17
18
19
1
2
376
22
5
12
11
15
16
8
9
10
14
8
21 20
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, 25A
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, 25A (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)
FUSE
REF
FUSE
DESCRIPTION
FU1 CLASS CC, 1A/600V
FU2 CLASS CC, 1A/600V
FU3 CLASS CC, 1A/600V
FU4 150A/600V
FU5 150A/600V
FU6 150A/600V
FU7 CLASS CC, 20A/600V
FU8 CLASS CC, 20A/600V
FU9 CLASS CC, 20A/600V
FU10 CLASS CC, 5A/600V
FU11A&B CLASS CC, 25A/600V
A2–F1 3AG SLO–BLO

19
Fig. 18 — Control Center VFD Input Components (Std Tier VFD)
FRONT VIEW – DOORS REMOVED
2
13
7
8
6
9
10
5
LEGEND
CONTROL PANEL
ASSEMBLY
EXPANDED
VIEW
4
1— Input Circuit Breaker
2— Power Module
3— Control Relays (CR1 - CR6)
4— Location of Control Panel Assembly - see expanded view
5— Drive Status Indicator
6— Ground Lug
7— 120V Control Transformer
8— 120V Vaporizer Heater Transformer
9— 15 Amp Control Circuit Breaker
10 — Cooling Fan

20
Fig. 19 — Power Module Components (LF2 shown)
Fig. 20 — Control Panel (TB1-15,16 is the high pressure switch)
25
1
2
4
3
15
14
13
11 8
1
4
12
10
8
3
7
11
6
10
9
5
6
7
8
22
20
19
21
18
16
17
23
24
20
25
26
LEGEND
*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.
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
Door Open Door Closed
a23-1627
ADDITIONAL PLUG CN3
(NOT SHOWN)
CONNECTS VFD RS485
COMMUNICATION
TO PIC6 J10 (MODBUS).
ADDITIONAL CN4
(RUN PERMISSIVE)
HARNESS NOT SHOWN.