Replacing Defective Processor Modules - Carrier AquaEdge 19XR series Start-Up, Operation And Maintenance Instructions Manual

Replacing Defective Processor Modules —
The module replacement part number is printed on a small
label on the rear of the ICVC module. The chiller model and
serial numbers are printed on the chiller nameplate located on
an exterior corner post. The proper software is factory-installed
by Carrier in the replacement module. When ordering a
replacement chiller visual control (ICVC) module, specify the
complete replacement part number, full chiller model number,
and chiller serial number. The installer must configure the new
module to the original chiller data. Follow the procedures
described in the Software Configuration section on page 74.
CAUTION
Electrical shock can cause personal injury. Disconnect all
electrical power before servicing.
INSTALLATION
1. Verify the existing ICVC module is defective by using the
procedure described in the Troubleshooting Guide sec-
tion, page 99, and the Control Modules section, page 117.
Do not select the ATTACH TO NETWORK DEVICE ta-
ble if the ICVC indicates a communication failure.
2. Data regarding the ICVC configuration should have been
recorded and saved. This data must be reconfigured into
the new ICVC. If this data is not available, follow the
procedures described in the Software Configuration sec-
tion. If the module to be replaced is functional, configura-
tions may also be copied manually. The data sheets on
pages CL-3 through CL-12 are provided for this purpose.
Default values are shown so that only deviations from
these need to be recorded.
If a CCN Building Supervisor or Service Tool is avail-
able, the module configuration should have already been
uploaded into memory. When the new module is in-
stalled, the configuration can be downloaded from the
computer.
Any communication wires from other chillers or CCN
modules should be disconnected to prevent the new
ICVC module from uploading incorrect run hours into
memory.
3. To install this module, record values for the TOTAL
COMPRESSOR STARTS and the COMPRESSOR
ONTIME from the MAINSTAT screen on the ICVC.
4. Power off the controls.
5. Remove the old ICVC.
6. Install the new ICVC module. Turn the control power
back on.
7. The ICVC now automatically attaches to the local net-
work device.
8. Set the current time and date in the SERVICE/TIME
AND DATE screen. Set the CCN Bus and Address in the
SERVICE / ICVC CONFIGURATION screen. Press the
alarm RESET softkey (from the default screen). Upload
via Service Tool or manually reenter all non-default con-
figuration values. (Refer to pages CL-3 through CL-12.)
If the correct VFD Configuration values are displayed in
the ISM_CONF table when that table is viewed, simply
press EXIT then SAVE to reload all of them. Use Service
Tool or manually reenter TOTAL COMPRESSOR
STARTS, SERVICE ONTIME and COMPRESSOR ON-
TIME. If forced using Service Tool, release the force on
SERVICE ONTIME after the desired value has been set.
9. Perform the guide vane calibration procedure (in Control
Test). Check and recalibrate pressure transducer readings
(refer to pages 98 and 99). Check that the CURRENT
TIME and DATE in the TIME AND DATE screen are
correct.
Solid-State Starters —
taining to the Benshaw, Inc., solid-state starter may be found
in the following paragraphs and in the Carrier RediStart MX3
Instruction Manual supplied by the starter vendor.
Attempt to solve the problem by using the following prelim-
inary checks before consulting the troubleshooting tables found
in the Benshaw manual.
1. Motor terminals or starter output lugs or wire should
not be touched without disconnecting the incoming
power supply. The silicon control rectifiers (SCRs)
although technically turned off still have AC mains
potential on the output of the starter.
2. Power is present on all yellow wiring throughout the
system even though the main circuit breaker in the
unit is off.
With power off:
• Inspect for physical damage and signs of arcing, over-
heating, etc.
• Verify the wiring to the starter is correct.
• Verify all connections in the starter are tight.
• Check the control transformer fuses.
TESTING SILICON CONTROL RECTIFIERS IN THE
BENSHAW, INC., SOLID-STATE STARTERS — If
SCR is suspected of being defective, use the following proce-
dure as part of a general troubleshooting guide.
1. Verify power is applied.
2. Verify the state of each SCR light-emitting diode (LED)
on the micropower card.
NOTE: All LEDs should be lit. If any red or green side of
these LEDs is not lit, the line voltage is not present or one
or more SCRs has failed.
3. Check incoming power. If voltage is not present check
the incoming line. If voltage is present, proceed to Steps 4
through 11.
NOTE: If after completing Steps 4 - 11 all measurements
are within specified limits, the SCRs are functioning nor-
mally. If after completing Steps 4 - 11 resistance measure-
ments are outside the specified limits, the motor leads on
the starter power lugs T1 through T6 should be removed
and the steps repeated. This will identify if abnormal re-
sistance measurements are being influenced by the motor
windings.
4. Remove power from the starter unit.
5. Using an ohmmeter, perform the following resistance
measurements and record the results:
MEASURE
BETWEEN
T1 AND T6
T2 AND T4
T3 AND T5
If all measured values are greater than 5000 ohms, pro-
ceed to Step 10. If any values are less than 5000 ohms,
one or more of the SCRs in that pair is shorted.
6. Remove both SCRs in the pair (See SCR Removal/
Installation).
7. Using an ohmmeter, measure the resistance (anode to
cathode) of each SCR to determine which device has
failed.
120
Troubleshooting information per-
WARNING
SCR PAIRS
RECORDED
BEING
VALUE
CHECKED
3 and 6
2 and 5
1 and 4
an