Carrier PIC 5+ User manual
CONTROL USER MANUAL
PIC 5+ Control for 19 Series Centrifugal Chiller
Original document
2
CONTENTS
1 - SAFETY CONSIDERATIONS ............................................................................................................................................... 4
1.1 - General Description................................................................................................................................................................. 4
1.2 - Avoid Electrocution ................................................................................................................................................................. 4
2 - GENERAL DESCRIPTION.................................................................................................................................................... 4
2.1 - General Description................................................................................................................................................................. 4
2.2 - Abbreviations Used ................................................................................................................................................................. 4
3 - HARDWARE DESCRIPTION............................................................................................................................................... 5
3.1 - General Description................................................................................................................................................................. 5
3.2 - Sensors....................................................................................................................................................................................... 7
3.3 - Controls Outputs...................................................................................................................................................................... 8
3.4 - Connections at the User’s Terminal Block............................................................................................................................ 8
3.5 - LEN/CCN Communication Cable Cequirements:............................................................................................................. 11
4 - SETTING UP THE USER INTERFACE ............................................................................................................................ 12
4.1 - User Interface......................................................................................................................................................................... 12
4.2 - Web Connection ..................................................................................................................................................................... 12
4.3 - General Features.................................................................................................................................................................... 12
4.4 - Welcome Screen......................................................................................................................................................................12
4.5 - Synoptic Screen ...................................................................................................................................................................... 13
4.6 - Setpoint Screen....................................................................................................................................................................... 13
4.7 - On/Off Screen......................................................................................................................................................................... 13
4.8 - Password/Language Screen................................................................................................................................................... 14
4.9 - Menu Screen ........................................................................................................................................................................... 14
4.10 - Conguration Screen ........................................................................................................................................................... 14
4.11 - Time Schedule Screen.......................................................................................................................................................... 15
4.12 - 19XR6/7 Status Display Screens.........................................................................................................................................15
4.13 - 19XR2~E/V/D Status Display Screens.............................................................................................................................. 17
4.14 - 19DV Status Display Screens.............................................................................................................................................. 18
5 - 19 SERIES PIC 5+ CONTROL OPERATION ................................................................................................................... 20
5.1 - Start/Stop Control ................................................................................................................................................................. 20
5.2 - Compressor Run Status......................................................................................................................................................... 20
5.3 - Chiller Start-up Sequence ..................................................................................................................................................... 20
5.4 - Chiller Shutdown Sequence.................................................................................................................................................. 21
5.5 - Oil Lubrication Control......................................................................................................................................................... 21
5.6 - Refrigerant Lubrication Control.......................................................................................................................................... 22
5.7 - Control Point........................................................................................................................................................................... 22
5.8 - Capacity Control .................................................................................................................................................................... 23
5.9 - Ramp Loading ........................................................................................................................................................................ 24
5.10 - Surge Correction Control.................................................................................................................................................... 24
5.11 - Envelope Control Valve (EC) Control............................................................................................................................. 25
5.12 - Economizer Damper Valve Control...................................................................................................................................25
5.13 - Damper Vapor Source ......................................................................................................................................................... 25
5.14 - Demand Limit....................................................................................................................................................................... 25
5.15 - Override Control.................................................................................................................................................................. 26
5.16 - Recycle Control.................................................................................................................................................................... 27
5.17 - Running Timers and Counters............................................................................................................................................ 27
5.18 - Water Pumps Control .......................................................................................................................................................... 27
5.19 - Controls Test ......................................................................................................................................................................... 28
5.20 - Swift Restart ......................................................................................................................................................................... 29
5.21 - Cooling Tower Control ........................................................................................................................................................29
5.22 - Head Pressure Control ........................................................................................................................................................ 29
5.23 - Ice Build Option................................................................................................................................................................... 29
5.24 - Time Schedule....................................................................................................................................................................... 29
5.25 - Black Box .............................................................................................................................................................................. 29
5.26 - Pressure Transducer Calibration ........................................................................................................................................ 29
5.27 - Temperature Sensor Calibration ........................................................................................................................................ 29
5.28 - ISM Calibration ................................................................................................................................................................... 30
5.29 - Alarm Email.......................................................................................................................................................................... 30
5.30 - Prognostic.............................................................................................................................................................................. 30
5.31 - Master Slave Control ........................................................................................................................................................... 31
5.32 - Oil EXV Control.................................................................................................................................................................. 31
5.33 - Pumpdown/Lockout............................................................................................................................................................. 31
5.34 - Trending................................................................................................................................................................................. 31
3
5.35 - Electronic Document........................................................................................................................................................... 32
5.36 - Hydraulic Option Control................................................................................................................................................... 32
5.37 - Marine Option ...................................................................................................................................................................... 33
5.38 - Extended Open Protocol Connector ................................................................................................................................. 33
5.39 - Purge Control ....................................................................................................................................................................... 33
5.40 - Motor Rotation Check ........................................................................................................................................................ 34
5.41 - Heat Reclaim UI .................................................................................................................................................................. 34
5.42 - Onboard Service Log........................................................................................................................................................... 34
5.43 - Carrier Smart Password....................................................................................................................................................... 34
5.44 - Heat Exchange Performance Plot...................................................................................................................................... 34
6 - DIAGNOSTICS – TROUBLESHOOTING......................................................................................................................... 34
6.1 - General.................................................................................................................................................................................... 34
6.2 - Displaying Alarms.................................................................................................................................................................. 34
6.3 - Resetting Alarms.................................................................................................................................................................... 34
6.4 - Alarm Codes ........................................................................................................................................................................... 35
6.5 - Event States ............................................................................................................................................................................ 46
7 - COLOUR TOUCH SCREEN INTERFACE PARAMETER SETTING....................................................................... 47
7.1 - Main Conguration Menu..................................................................................................................................................... 47
7.2 - Find and Modify the Unit IP Address ................................................................................................................................. 47
7.3 - Conguration of the Web Connection................................................................................................................................. 47
7.4 - System Conguration ............................................................................................................................................................ 48
7.5 - Display Conguration (Contrast, Ccreensaver, Calibration)............................................................................................ 49
7.6 - Languages Available for the Touch Screen Conguration................................................................................................ 49
8 - DIAGNOSTICS AND COMMUNICATION PROBLEM TROUBLESHOOTING ................................................... 50
8.1 - Hardware Problems ............................................................................................................................................................... 50
8.2 - Problems with the Use of the Web Interface ...................................................................................................................... 50
8.3 - Ethernet/IP Connection ........................................................................................................................................................ 50
9 - SCREEN STRUCTURE......................................................................................................................................................... 53
9.1 - Detailed Menu Description .................................................................................................................................................. 54
4
Installation, start-up and servicing of equipment can be
hazardous if certain factors particular to the installation are
not considered: operating pressures, presence of electrical
components and voltages and the installation site (elevated
plinths and built-up up structures). Only properly qualied
installation engineers and highly qualied installers and
technicians, fully trained for the product, and are authorized
to install and start-up the equipment safely. During all
servicing operations all instructions and recommendations
which appear in the installation and service instructions for
the product, as well as on tags and labels fixed to the
equipment, components and accompanying parts supplied
separately, must be read, understood and followed.
-Apply all standard safety codes and practices.
-Wear safety glasses and gloves.
-Use the proper tools to move heavy objects. Move units
carefully and set them down gently.
Only personnel qualified in accordance with IEC
(International Electro technical Commission)
recommendations may be permitted access to electrical
components. It is particularly recommended that all sources
of electricity to the unit should be shut off before any work
is begun. Remember to shut off the main power supply at
the main circuit breaker or isolator.
CAUTION: The equipment uses and emits electromagnetic
signals. Tests have shown that the equipment conforms to
all applicable codes with respect to electromagnetic
compatibility.
RISK OF ELECTROCUTION:Even when the main circuit
breaker or isolator is switched off, certain circuits may still
be energized, since they may be connected to a separate
power source.
RISK OF BURNS: Electrical currents cause components
to get hot either temporarily or permanently. Handle power
cable, electrical cables and conduits, terminal box covers
and motor frames with great care.
PIC 5+ control is a control system for controlling 19 Series
which include both legacy and next generation centrifugal
water-cooled chillers. The control system monitors and
controls all operations of the chiller. The microprocessor
control system matches the cooling or heating capacity of the
chiller to the cooling or heating load while providing state-
of-the-art chiller protection. The system controls cooling or
heating load within the set point plus and minus the dead
band by sensing the water or brine temperature and regulating
the inlet guide vane via a mechanically linked actuator motor
and regulating VFD speed if the compressor is a variable
speed compressor.The guide vane is a variable ow pre-whirl
assembly that controls the refrigeration effect in the cooler
by regulating the amount of refrigerant vapor ow into the
compressor. An increase in guide vane opening increases
capacity.A decrease in guide vane opening decreases capacity.
The microprocessor-based control center protects the chiller
by monitoring the digital and analog inputs and executing
capacity overrides or safety shutdowns, if required.
PIC 5+ control also gives access to a Control Test function
covering all outputs except compressor relay outputs.
The following abbreviations are used frequently:
Carrier Comfort Network
Operating mode: CCN
Entering Condenser Water
Entering Chilled Water
Envelope Control
Leaving Condenser Water
Leaving Chilled Water
Light Emitting Diode
Local Equipment Network
(internal communication linking the main board to slave boards)
Rated Load Amps
Variable Frequency Drive
Integrated Starter Module
Main Control Board
Input/Output Board
5
The 19 Series PIC 5+ control system consists of one main
control board (SAIA board), an ISM (Integrated Starter
Module) and three basic IOBs (Input/output Board Module)
and optional IO boards per system requirements.All boards
communicate via an internal LEN bus. If a Rockwell or Eaton
Unit Mounted VFD is installed, a LEN-MODBUS protocol
converter module is required.
3.1.1 - Main Control Board
Figure 1: 19 Series PIC 5+ Control Interface
Figure 2: 19 Series PIC 5+ Control Interface
(View From Below)
BCDEF
1. Power supply connector (24 VAC)
2. LEN connector
3. CCN connector
4. Ethernet connector
5. USB connector
The main control board is supplied from a 24 VAC supply
referred to earth.
CAUTION: Maintain the correct polarity when connecting
the power supply to the boards; otherwise the boards may
be damaged.
In the event of a power supply interrupt, the unit restarts
automatically without the need for an external command.
However, any faults active when the supply is interrupted
are saved and may in certain cases prevent a circuit or unit
from restarting.
3.1.2 - ISM (Integrated Starter Module)
ISM is motor control module, and it is supplied from an
115VAC supply referred to earth.
ISM input / output description is as below:
STARTER FAULT STARTFLT Dry Contact J2-7,8
COMPRESSOR START CONTACT STAR_AUX Dry Contact J2-9,10
COMPRESSOR RUN CONTACT RUN_AUX Dry Contact J2-11,12
LINE VOLTAGE V1 LN_VOLT1 0-5 Volt J3-1
LINE VOLTAGE V2 LN_VOLT2 0-5 Volt J3-2
LINE VOLTAGE V3 LN_VOLT3 0-5 Volt J3-3
LINE CURRENT C1 LN_AMPS1 0-5 Volt J4-1,2
LINE CURRENT C2 LN_AMPS2 0-5 Volt J4-3,4
LINE CURRENT C3 LN_AMPS3 0-5 Volt J4-5,6
GROUND FAULT PHASE 1 GRFLT_31 0-5 Volt J5-1,2
GROUND FAULT PHASE 2 GRFLT_23 0-5 Volt J5-3,4
GROUND FAULT PHASE 3 GRFLT_12 0-5 Volt J5-5,6
VFD SPEED FEEDBACK VFD_IN 0-10 Volt/ 0-5 Volt J6-1,2
VFD TARGET SPEED VFD_OUT 0-20 mA J8-1,2
COMPRESSOR START RELAY COMP_SR Relay J9-1,2
COMPRESSOR TRANS RELAY TRANS Relay J9-3,4
SHUNT TRIP RELAY TRIPR Relay J9-5,6
6
3.1.3 - IO Board
IO Board is Input/output Board, and it is supplied from a 24VAC supply referred to earth.
For the IOB input / output description, please refer to section 3.4.
3.1.4 - LEN -> MODBUS Protocol Converter
PIC5 Port LED1
SEND
LED2
RECEIVE
LED3
POWER
LED4
RUNNING
LED5
ERROR
LED6
SEND
LED7
RECEIVE
VFD Port
+
-
GND
+
-
Unused
Unused
GND
24V AC
GND
24V
8
7
6
5
1
ON
RS-232
RS-485
2 Wire
4 Wire
OFF
2
3
4
LEN -> MODBUS Protocol converter is connected between IOBs and VFD. Please refer the decription in the above picture.
7
Pressure transducers:
Pressure transducers are used to measure and control the pressures in the unit.These electronic sensors deliver 0 to 5 VDC.
The transducers can be calibrated through the controller. The pressure transducers are connected to the IOBs.
This transducer measures the pressure of the evaporator. Standard for 19XR2~E/V/D, 19XR6/7 and 19DV
This transducer measures the pressure of the condenser Standard for 19XR2~E/V/D, 19XR6/7 and 19DV
This transducer measures the pressure of the economizer Standard for 19XR6/7
This transducer measures the oil pressure in the oil discharge piping Standard for 19XR2~E/V/D and 19XR6/7
This transducer measures the Oil pressure in the oil sump Standard for 19XR2~E/V/D and 19XR6/7
This transducer measures the pressure of pump output Standard for 19DV
This transducer measures the pressure of bearing outlet Standard for 19DV
This transducer measures the pressure of bearing inlet Standard for 19DV
This transducer measures the pressure of pump input Standard for 19DV
This optional transducer measures the evaporator pressure dierence
between entering and leaving water.
Optional for 19XR2~E/V/D, 19XR6/7 and 19DV
This optional transducer measures the condenser pressure dierence
between entering and leaving water.
Optional for 19XR2~E/V/D, 19XR6/7 and 19DV
This is an option transducer, and it measures the pressure of evaporator
entering water
Optional for 19XR2~E/V/D, 19XR6/7 and 19DV
This is an optional transducer, and it measures the pressure of
evaporator leaving water
Optional for 19XR2~E/V/D, 19XR6/7 and 19DV
This is an optional transducer, and it measures the pressure of
condenser entering water
Optional for 19XR2~E/V/D, 19XR6/7 and 19DV
This is an optional transducer, and it measures the pressure of
condenser leaving water
Optional for 19XR2~E/V/D, 19XR6/7 and 19DV
Temperature sensors:
The system uses electronic sensors to measure and control the temperatures in the unit.
There are three types of temperature sensors, 5K thermistor, 10K thermistor and RTD (three wirings, MINCO S100308)
based on the IOB channel congurations.
measures the temperature of entering evaporator water. Standard for 19XR2~E/V/D, 19XR6/7 and 19DV
measures the temperature of leaving evaporator water. Standard for 19XR2~E/V/D, 19XR6/7 and 19DV
measures the temperature of entering condenser water. Standard for 19XR2~E/V/D, 19XR6/7 and 19DV
measures the temperature of leaving condenser water. Standard for 19XR2~E/V/D, 19XR6/7 and 19DV
measures the temperature of evaporator refrigerant liquid. Standard for 19XR2~E/V/D, 19XR6/7 and 19DV
measures the Compressor discharge temperature. Standard for 19XR2~E/V/D, 19XR6/7 and 19DV
measure the low speed motor end bearing temperature Standard for 19XR6/7
measure the low speed compressor end bearing temperature Standard for 19XR6/7
measure the high speed motor end bearing temperature Standard for 19XR6/7
measure the high speed compressor end bearing temperature Standard for 19XR6/7
Measure the compressor thrust bearing oil temperature Standard for 19XR2~E/V/D
Measure the 1st stage bearing temperature Standard for 19DV
Measure the 2nd stage bearing temperature Standard for 19DV
Measure the bearing ref supply temperature Standard for 1-9DV
The 3 sensors measure the temperature of compressor motor windings Standard for 19XR2~E/V/D, 19XR6/7 and 19DV
19XR2~E/V/D and 19DV only has 1 sensor.
measures the compressor sump temperature of oil Standard for 19XR2~E/V/D and 19XR6/7
measures the oil temperature in the oil discharge piping Standard for 19XR2~E/V/D and 19XR6/7
The temperature sensor range is -40 ~ +245°F.
8
Evaporator / Condenser water pump
The controller can regulate an optional evaporator /
condenser water pump.
Inlet Guide Vane
The Inlet Guide vane (IGV) is used to adjust the refrigerant
vapor flow into compressor to change in the operating
conditions of the machine.To adjust the refrigerant ow, the
guide vane moves open or close to vary the cross-section of
the refrigerant path.The high degree of accuracy with which
the guide vane is positioned ensures that the flow of
refrigerant is precisely controlled.
Economizer Damper valve (used for NGC chiller or the
chiller which is equipped with electrical damper valve)
The economizer damper control positions the economizer
damper valve open or closed to maintain a minimum
refrigerant pressure difference between the evaporator and
economizer.
Damper vapor source solenoid valve (used for 19XRC)
Damper vapor sorce solenoid valve adjusts the pressure
difference between Economizer and Evaporator according
to pressure difference between damper cap and ow passage.
EC Valve
The envelope control function is used to articially load the
chiller and keep it running under low load conditions or to
prevent surge conditions. Since this also reduces the operating
efciency of the machine, this is a user selectable option.
VFD
The VFD allows compressor start-up and capacity control
by modifying the motor frequency. The aviator continually
monitors many compressor parameters in order to ensure its
protection.If a problem occurs, the frequency aviator triggers
an alarm and, if necessary, stops the compressor.
The components listed below are available at the user’s
terminal block on the IOB. Some of them can only be used
if the unit operates in the remote operating type (Remote
mode).
The following table summarizes the connections at the I/O
boards.
19XR6/7 I/O Mapping:
Entering Chilled
Water Temperature
AI1 IOB1
Leaving Chilled Water
Temperature
AI2 IOB1
Entering Condenser
Water Temp
AI3 IOB1
Leaving Condenser
Water Temp
AI4 IOB1
Evap. Refrigerant
Liquid Temperature
AI5 IOB1
Comp Discharge
Temperature
AI6 IOB1
Condenser Pressure AI7 IOB1
Evaporator Pressure AI8 IOB1
Economizer Pressure AI9 IOB1
FS VFD Load Current AI10 IOB1 For Freestanding VFD
option
Chiller Status
Output mA
AO1 IOB1 User option, 4~20mA
4mA=OFF 8mA=Tripout
12mA=Shutdown
20mA=Running
Oil EXV Output
(4-20ma)
AO2 IOB1 Factory option, 4~20mA
Evap Wate
Flow Switch
DI1 IOB1 User option, dry contact,
“Closed” indicates “FLOW”
Cond Water
Flow Switch
DI2 IOB1 User option, dry contact,
“Closed” indicates “FLOW”
Remote Contact Input DI3 IOB1 User option, dry contact,
“Closed” indicates Turn ON
the chiller
Remote Emergency
Stop Input
DI4 IOB1 User option, dry contact,
“Closed” indicates chiller
emergency stop
Stage 1 IGV Increase DO1 IOB1 Used for ON/OFF type
guide vane actuator
Stage 1 IGV
Decrease
DO2 IOB1 Used for ON/OFF type
guide vane actuator
Chiller Alarm Relay DO3 IOB1 User option, 24VAC output,
recommend with external
power supply
Chiller Alert Relay DO4 IOB1 User option, 24VAC output,
recommend with external
power supply
Motor Winding
Temperature 1
AI1 IOB2
Motor Winding
Temperature 2
AI2 IOB2
Motor Winding
Temperature 3
AI3 IOB2
Oil Supply
Temperature
AI4 IOB2 Factory option
Oil Sump
Temperature
AI5 IOB2
Oil Supply Pressure AI6 IOB2
Oil Sump Pressure AI7 IOB2
Auto Demand Limit
Input
AI8 IOB2 User option, 4~20mA
Refrigerant Leak
Sensor
AI9 IOB2 User option, 4~20mA
Displacement Switch AI10 IOB2
Guide Vane1 Output AO1 IOB2
Damper Valve
Feedback Fully Open
DI1 IOB2
9
Damper Valve
Feedback Fully Close
DI2 IOB2
High Pressure Switch DI3 IOB2
Ice Build Contact DI4 IOB2 User option, dry contact
Oil Heater Relay DO1 IOB2
Oil Pump Relay DO2 IOB2
Economizer Damper
Valve Open
DO3 IOB2
Economizer Damper
Valve Close
DO4 IOB2
Low Speed ME Brg
Temp
AI1 IOB3
Low Speed CE Brg
Temp
AI2 IOB3
High Speed ME Brg
Temp
AI3 IOB3
High Speed CE Brg
Temp
AI4 IOB3
Remote Reset Sensor AI5 IOB3 User option, 5K thermistor
Guide Vane 1 Actual
Pos
AI6 IOB3
Common CHWS
Temp
AI7 IOB3 Used for lead lag option
Auto Water Temp
Reset
AI8 IOB3 User option, 4~20mA
Common CHWR
Temp
AI9 IOB3 Used for lead lag option
Head Pressure
Output
AO1 IOB3 Factory option
EC Valve Feedback
Fully Open
DI1 IOB3 Factory option
EC Valve Feedback
Fully Close
DI2 IOB3 Factory option
Spare Safety DI3 IOB3 User option, dry contact,
normal open
Power Request
Feedback
DI4 IOB3 Marine option
EC Valve Solenoid /
Open
DO1 IOB3 Factory option
EC Valve Close DO2 IOB3 Factory option
Free Cooling Mode DO3 IOB3 Factory option
Power Request
Output
DO4 IOB3 Marine option
Entering Evap Water
Pressure
AI3 IOB4 User option, if IOB4
installed, same as follows
Leaving Evap Water
Pressure
AI4 IOB4 User option
Entering Cond Water
Pressure
AI5 IOB4 User option
Leaving Cond Water
Pressure
AI6 IOB4 User option
Evap Water Flow
Measurement
AI8 IOB4 User option, 4~20mA
Cond Water Flow
Measurement
AI9 IOB4 User option, 4~20mA
Chilled Water Pump
(Variable)
AO1 IOB4 User option, 4~20mA/0~5V
Condenser Water
Pump (Variable)
AO2 IOB4 User option, 4~20mA/0~5V
Tower Fan (Variable) AO3 IOB4 User option, 4~20mA/0~5V
Customer Alert DI3 IOB4 Marine option, dry contact
Free Cooling Start
Switch
DI4 IOB4 Marine option, dry contact
Chilled Water Pump DO1 IOB4 User option
Condenser Water
Pump
DO2 IOB4 User option
Tower Fan High DO3 IOB4 User option
Tower Fan Low DO4 IOB4 User option
19XR2~E/V/D I/O, 19XRC mapping:
Entering Chilled
Water Temperature
AI1 IOB1
Leaving Chilled Water
Temperature
AI2 IOB1
Entering Condenser
Water Temperature
AI3 IOB1
Leaving Condenser
Water Temperature
AI4 IOB1
Evap. Refrigerant
Liquid Temperature
AI5 IOB1
Comp Discharge
Temperature
AI6 IOB1
Condenser Pressure AI7 IOB1
Evaporator Pressure AI8 IOB1
FS VFD Load Current AI10 IOB1 For free standing VFD
Variable Speed Oil
Pump
AO1 IOB1 Factory option
Oil EXV Output AO2 IOB1 Factory option, 4~20mA
EC Valve Output mA AO3 IOB1 Factory option, 4~20mA
Chiller Lockout Input DI1 IOB1 User option, dry contact,
normal open
Spare Safety DI2 IOB1 User option, dry contact,
normal open
Remote Contact Input DI3 IOB1 User option, dry contact,
“Closed” indicates Turn ON
the chiller
Remote Emergency
Stop Input
DI4 IOB1 User option, dry contact,
“Closed” indicates chiller
emergency stop
Stage 1 IGV Increase DO1 IOB1
Stage 1 IGV
Decrease
DO2 IOB1
Chiller Alarm Relay DO3 IOB1 User option, 24VAC output,
recommend with external
power supply
Motor Winding
Temperature 1
AI1 IOB2
Thrust Bearing Oil
Temperature
AI2 IOB2
Oil Sump
Temperature
AI3 IOB2
Oil Supply
Temperature
AI4 IOB2 Factory option
Guide Vane 1 Actual
Pos
AI5 IOB2
Oil Supply Pressure AI6 IOB2
Oil Sump Pressure AI7 IOB2
EC Valve Feedback AI8 IOB2 Factory option, 4~20mA
Motor Winding
Temperature 2
AI9 IOB2 For high voltage motor
Motor Winding
Temperature 3
AI10 IOB2 For high voltage motor
Diuser Pressure AI11 IOB2 Factory option
Guide Vane1 Output AO1 IOB2 Factory option, for 4~20mA
type guide vane
Diuser Output AO2 IOB2 Factory option
Evap Water Flow
Switch
DI1 IOB2 User option, dry contact,
“Closed” indicates “FLOW”
Cond Water Flow
Switch
DI2 IOB2 User option, dry contact,
“Closed” indicates “FLOW”
Ice Build Contact DI4 IOB2 User option, dry contact
Oil Heater Relay DO1 IOB2
Oil Pump Relay DO2 IOB2
EC Valve Soleniod /
Open
DO3 IOB2 Factory option
Vapor Source SV DO4 IOB2 Factory option, for 19XRC
Heat Reclaim
Entering Temp
AI3 IOB3 Heat reclaim option
Heat Reclaim Leaving
Temp
AI4 IOB3 Heat reclaim option
Remote Reset Sensor AI5 IOB3 User option, 5K thermistor
10
Auto Water Temp
Reset
AI6 IOB3 User option, 4~20mA
Common CHWS
Temp
AI7 IOB3 Used for lead lag option
Auto Demand Limit
Input
AI8 IOB3 User option, 4~20mA
Common CHWR
Temp
AI9 IOB3 Used for lead lag option
Refrigerant Leak
Sensor
AI10 IOB3 User option, 4~20mA
Chiller Status Output
mA
AO1 IOB3 User option, 4~20mA
4mA=OFF 8mA=Tripout
12mA=Shutdown
20mA=Running
Fire Security Interlock DI1 IOB3 User option, dry contact,
normal open
Customer Alert DI2 IOB3 Marine option, dry contact
Free Cooling Start
Switch
DI3 IOB3 Marine option, dry contact
Power Request
Feedback
DI4 IOB3 Marine option
Chiller Alert Relay DO2 IOB3 User option, 24VAC output,
recommend with external
power supply
Free Cooling Mode DO3 IOB3 Marine option
Power Request
Output
DO4 IOB3 Marine option
Entering Evap Water
Pressure
AI3 IOB4 User option, if IOB4
installed, same as follows
Leaving Evap Water
Pressure
AI4 IOB4 User option
Entering Cond Water
Pressure
AI5 IOB4 User option
Leaving Cond Water
Pressure
AI6 IOB4 User option
Evap Water Flow
Measurement
AI8 IOB4 User option, 4~20mA
Cond Water Flow
Measurement
AI9 IOB4 User option, 4~20mA
Chilled Water Pump
(Variable)
AO1 IOB4 User option, 4~20mA/0~5V
Condenser Water
Pump (Variable)
AO2 IOB4 User option, 4~20mA/0~5V
Tower Fan (Variable) AO3 IOB4 User option, 4~20mA/0~5V
Chilled Water Pump DO1 IOB4 User option, 24VAC output,
recommend with external
power supply
Condenser Water
Pump
DO2 IOB4 User option, 24VAC output,
recommend with external
power supply
Tower Fan High DO3 IOB4 User option, 24VAC output,
recommend with external
power supply
Tower Fan Low DO4 IOB4 User option, 24VAC output,
recommend with external
power supply
19DV mapping:
Entering Chilled
Water Temperature
AI1 IOB1
Leaving Chilled Water
Temperature
AI2 IOB1
Entering Condenser
Water Temperature
AI3 IOB1
Leaving Condenser
Water Temperature
AI4 IOB1
Evap. Refrigerant
Liquid Temperature
AI5 IOB1
Comp Discharge
Temperature
AI6 IOB1
Condenser Pressure AI7 IOB1
Evaporator Pressure AI8 IOB1
FS VFD Load Current AI10 IOB1 For free standing VFD
Chiller Status Output
mA
AO1 IOB1 User option, 4~20mA
4mA=OFF 8mA=Tripout
12mA=Shutdown
20mA=Running
Evap Water Flow
Switch
DI1 IOB1 User option, dry contact,
“Closed” indicates “FLOW”
Cond Water Flow
Switch
DI2 IOB1 User option, dry contact,
“Closed” indicates “FLOW”
Remote Contact Input DI3 IOB1 User option, dry contact,
“Closed” indicates Turn ON
the chiller
Remote Emergency
Stop Input
DI4 IOB1 User option, dry contact,
“Closed” indicates chiller
emergency stop
Economizer Bypass
Valve
DO1 IOB1 x
Refrigerant Pump DO2 IOB1
Chiller Alarm Relay DO3 IOB1 User option, 24VAC output,
recommend with external
power supply
Vapor Venting Line SV DO4 IOB1 x
Motor Winding
Temperature 1
AI1 IOB2
EC Valve Feedback AI3 IOB2 Factory option
Pump Outlet Pressure AI5 IOB2
Bearing Outlet
Pressure
AI6 IOB2
Bearing Inlet Pressure AI7 IOB2
Auto Demand Limit
Input
AI8 IOB2 User option, 4~20mA
Refrigerant Leak
Sensor
AI9 IOB2 User option, 4~20mA
Pump Inlet Pressure AI10 IOB2
Guide Vane1 Output AO1 IOB2
EC Valve Output mA AO3 IOB2 Factory option
Liquid Level Switch DI2 IOB2
High Pressure Switch DI3 IOB2
Ice Build Contact DI4 IOB2 User option, dry contact
Condenser Control
Valve
DO1 IOB2 x
Evaporator Control
Valve
DO2 IOB2 x
Condenser Filling
Valve
DO3 IOB2 x
Economizer Isolation
Valve
DO4 IOB2 x
1st Stage Bearing
Temp
AI1 IOB3
2nd Stage Bearing
Temp
AI2 IOB3
Bearing Ref Supply
Temp
AI3 IOB3
Guide Vane 2 Actual
Pos
AI4 IOB3
Remote Reset Sensor AI5 IOB3 User option, 5K thermistor
Guide Vane 1 Actual
Pos
AI6 IOB3
11
Common CHWS
Temp
AI7 IOB3 Used for lead lag option
Auto Water Temp
Reset
AI8 IOB3 User option, 4~20mA
Common CHWR
Temp
AI9 IOB3 Used for lead lag option
Head Pressure
Output
AO1 IOB3 Factory option
Guide Vane 2 Output AO3 IOB3
Spare Safety DI3 IOB3 User option, dry contact,
normal open
Power Request
Feedback
DI4 IOB3 Marine option
Evaporator Drain
Valve
DO1 IOB3
Condenser Drain
Valve
DO2 IOB3
Free Cooling Mode DO3 IOB3 Factory option
Power Request
Output
DO4 IOB3 Marine option
Entering Evap Water
Pressure
AI3 IOB4 User option, if IOB4
installed, same as follows
Leaving Evap Water
Pressure
AI4 IOB4 User option
Entering Cond Water
Pressure
AI5 IOB4 User option
Leaving Cond Water
Pressure
AI6 IOB4 User option
Evap Water Flow
Measurement
AI8 IOB4 User option, 4~20mA
Conde Water Flow
Measurement
AI9 IOB4 User option, 4~20mA
Chilled Water
Pump(Variable)
AO1 IOB4 User option, 4~20mA/0~5V
Condenser Water
Pump(Variable)
AO2 IOB4 User option, 4~20mA/0~5V
Tower Fan(Variable) AO3 IOB4 User option, 4~20mA/0~5V
Customer Alert DI3 IOB4 Marine option, dry contact
Free Cooling Start
Switch
DI4 IOB4 Marine option, dry contact
Chilled Water Pump DO1 IOB4 User option
Condenser Water
Pump
DO2 IOB4 User option
Tower Fan High DO3 IOB4 User option
Tower Fan Low DO4 IOB4 User option
Purge Level Switch
Low
cDI-01 SIOB User option
Purge Level Switch
High
cDI-02 SIOB User option
Purge Comp Suction
Temp
AI-01 SIOB User option
Purge Cond Valve DO-01 SIOB User option
Purge Comp Valve DO-02 SIOB User option
Purge Pumpout Valve DO-03 SIOB User option
Purge Drainage Valve DO-04 SIOB User option
Purge Regeneration
Valve
cDO-05 SIOB User option
Purge Discharge
Valve
cDO-06 SIOB User option
Purge Vaccum Pump DO-07 SIOB User option
Purge Compressor DO-08 SIOB User option
Purge Heater DO-10 SIOB User option
The electrical characteristics of the transmission Cables shall
be comprised of three conductors, (1.5 Pairs) two signals and
one ground of 20 AWG or larger with 100% shield plus a
tinned copper braid (65% coverage), embodied as one of the
following types is recommended by Carrier:
-Belden #8772 (for intra building, 60 deg C)
-Belden #85240 (high temperature, 150 deg C)
-Belden #89418 (plenum cable, 200 deg C)
When LEN-MODBUS gateway which described in section
3.1.4 is used in the system, the communication cable for LEN
and MODBUS sides should also follow this requirement.
The communication cable between ISM and IOB should be
as far away from high voltage cable and other disturbance
equipment as possible. The communication cable should be
as short as possible and should be separated from other
cables. Making the communication cable go through metal
shield conduct is preferred.
12
The user interface is a colorful 10.4” TFT touch screen.
Navigation is either direct from the touch screen interface
or by connecting to a web interface via the Ethenert IP port
of the controller.
The navigation menus are the same for both connection
methods. Please note that only two web connections may be
authorized at the same time.
Connection from a PC is using a web browser with Java.
In order to access the HMI , the operator should enter the
IP address of the unit in the address bar of the web browser.
The IP address can be viewed or changed from the screen
(see also section 8.2).
Minimum web browser conguration:
• Microsoft Internet Explorer (version 8 or higher) or
Mozilla Firefox (version 3.5.2 orhigher).In the advanced
connection options add the unit address to the address
list. Do not use a proxy server.
• Java platform(version6orhigher).(Inthecontrolpanel,
click the option that allows storing temporary internet
les and use a direct connection.)
For more information on the web browser and Java platform
conguration, please refer to section 8 “Diagnostics and
communication problem trouble shooting” and contact your
network administrator.
NOTE:Two users can be connected simultaneously with no
priority between users; the last modication will take effect.
4.3.1 - Buttons
Unit is
running Unit is o Home
Main menu Logged o Logged in
No alarms Alarm/ Alert
Back* Up & Down
* Note that the “Back” button is not present in the main menu.
4.3.2 - Screens
The interface includes the following screens:
• Welcome screen,
• Synoptic screen with direct display of the main
parameters,
• Menu screens for navigation,
• Data/conguration screens listing the parameters by
type,
• Operating mode selection screen,
• Password entry and language selection screen,
• Parameter modication screen,
• Time schedule screen.
NOTE: If the interface is not used for a long period, it will
go into screen saver mode with black screen. The control is
always active, the operating mode remains unchanged. The
interface screen is re-animated when the user presses the
screen. The welcome screen is displayed.
The welcome screen is the rst screen shown after switching
the unit on or after the re-animation of the screen.It displays
the application name as well as current software version
number.
To exit from this screen press the following button:
Go to Home
Screen
Software version number
13
1Synoptic screen access button
2Main Menu access button
3User Login screen access button
4Unit Start/Stop access button
5Alarm menu access button
6Setpoint
7Unit capacity percentage (motor load current percentage)
8Guide Vane Position percentage
9Oil temperature
10 Oil pressure delta
11 Condenser pump status (hydraulic System option is Enabled)
12 Evaporator pump status (hydraulic System option is Enabled)
13 Condenser water inlet and outlet temperature
14 Evaporator water inlet and outlet temperature
15 Condenser saturated temperature and pressure
16 Evaporator saturated temperature and pressure
Message: all screens described below can display an
information message in the band at the bottom.
COMMUNICATION
FAILURE!
Equipment controller did not respond while reading the
table content.
ACCESS DENIED! Equipment controller does not allow accessing one of the
table data blocks.
LIMIT EXCEEDED! The value entered exceeds the table limits.
Save changes? Modications have been made. The web interface waits to
conrm exit by pressing Save or Cancel.
HIGHER FORCE IN
EFFECT!
Force or Auto command was rejected by the equipment
controller because the interface force level is lower than the
equipment controller’s.
The On/Off screen allows users to select the unit operating
mode.
4.7.1 - Unit Start-up
With the unit in the Local Off mode, press the button
to display the list of operating modes. Select the expected
mode to startup the chiller
Shows the
last mode
selected
Operating
mode list
4.7.2 - Unit Stop
To Stop the unit - press the following button:
Conrm the unit shut-down or return to the previous screen.
14
B
D
E
FC
1Cursor showing the activated language
2Log in
3Unit of measurement selection: Metric/Imperial
4Enter the password
5Log o
NOTE: Password validation is effective after pressing the
Log-in button.
To access Main menu, press the following button:
Navigation
through tables
Touch the items to access the corresponding table/menu.
B
D
E FC
1Save
2Cancel
3Message
4Previous page
5Next page
Below is an example to show how to force a point.
B
1Forcible point
Forced value
Force Auto
The Auto button cancels the force action on the point.
15
B
D E F G
C
1Selection of the applicable days for the time schedule
2Modication of the period start and end schedules
3Save
4Cancel
5Previous period
6Next period
The following screens are designed for end user to check the
components status.
4.12.1 - System Overview
The following screen is the system overview screen (default
screen), by clicking the component in this screen, user can
enter the specic component screen.
4.12.2 - Condenser Status
4.12.3 - Evaporator Status
4.12.4 - Compressor Status
16
4.12.5 - Motor Status
4.12.6 - Economizer Status
The pressure difference shown in this screen is the pressure
difference between economizer pressure and evaporator
pressure.
4.12.7 - Transmission Status
4.12.8 - Envelope Control Status
4.12.9 - VFD Status
4.12.10 - Startup Sequence
The following screen shows the sequence of startup check
items. Touch the mode title of main screen to access this
screen. Users are able to see which items has been checked
in startup process.
17
The following screens are designed for end user to check the
components status.
4.13.1 - System Overview
The following screen is the system overview screen (default
screen), by clicking the component in this screen, user can
enter the specic component screen.
4.13.2 - Condenser Status
4.13.3 - Evaporator Status
4.13.4 - Compressor Status – Single Stage
4.13.5 - Compressor Status – Dual Stage
4.13.6 - Motor Status
18
4.13.7 - Transmission Status
4.13.8 - Envelope Control Status
4.13.9 - VFD Status
4.13.10 - Startup Sequence
The following screen is showing the startup sequence after
user push the startup button. User can check where we are
in the startup process.
4.14.1 - System Overview
4.14.2 - Condenser Status
19
4.14.3 - Evaporator Status
4.14.4 - Compressor Status
4.14.5 - Motor Status
4.14.6 - Envelope Control Status
4.14.7. VFD Status
4.14.8. Startup Sequence
20
4.14.9. Purge System Status
This function determines the chiller STATSTOP command.
There are 4 control modes (LOCAL,LOCAL SCHEDULE,
REMOTE,NETWORK) can be selected. In a certain control
mode, only appropriate control sources are valid to start or
stop chiller.
Local
When control mode is LOCAL, the chiller can be started by
“Local ON” button on UI screen and be shut down by
“Conrm Stop” buttons on screen, EMSTOP software point.
Network
When control mode is NETWORK, chiller can be started and
stopped by the CHIL_S_S and CHIL_OCC software point
which is written by other equipment through network command
and network schedule. Only when both points are written as
“YES”, the chiller will start up. Also, chiller can be shut down
by EMSTOP software point, STOP button on UI screen.
Local Schedule
When control mode is LOCAL SCHEDULE, chiller will be
automatically started if configurable local schedule is
occupied and be shut down by unoccupied schedule,
EMSTOP software point, STOP button on UI screen.
Remote
When control mode is REMOTE,chiller will be started and shut
down by the remote discrete input (IOB1_DI3: REM_CON)
located on the I/O board. Also, chiller can be shut down by
EMSTOP point, STOP button on UI screen.
NOTE: there is a STOP OVERRIDE point in GENUNIT
table, if this point is enabled, the chiller cannot be started
and chiller should be stopped if it is running.
Compressor Run Status is shown on the top of default screen.
0 STATSTOP is STOP, no alarm.
1 Control test is active
2 Pump down is active
3 Lockout in is active
4 Recycle shutdown completed on low load in eect until
the need for cooling resumes; non-fault condition
5 Shutdown completed due to alarm fault condition.
6 The control is delaying the start sequence until the
Start to Start and Stop to Start timers have elapsed
7 The chiller is in the process of the checks prior to
energizing the compressor motor
8 Normal Startup in progress
9 Auto Restart in pending
10 Ramp loading in progress. The chiller has started
and is slowly increasing its load to control electrical
demand charges
11 The chiller has completed ramp loading following
start up. Normal running mode, no override or
demand limit
12 Running with Override active
13 Running with Demand Limit Active; The chiller is
prevented from loading further because it has
reached the an AVERAGE LOAD CURRENT Limit or
a MOTOR KILOWATTS Limit
14 Shutdown compressor in progress
15 Free Cooling in progress
16 Condenser Flush in progress
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