Carrier 19DV User Manual

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Page 1

AquaEdge® 19DV

Two-Stage Back-to-Back Centrifugal Liquid

Chillers with PIC6 Controls and HFO R-1233zd(E)

50/60 Hz

Start-Up, Operation, and Maintenance

Instructions

SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . 2

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

ABBREVIATIONS AND EXPLANATIONS . . . . . . . . . . 4

CHILLER FAMILIARIZATION (FIG. 1 AND 2) . . . . . . . 4

Chiller Information Nameplate . . . . . . . . . . . . . . . . . . 4

System Components . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Evaporator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Economizer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Motor-Compressor. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Purge Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Variable Frequency Drive (VFD) . . . . . . . . . . . . . . . . . 4

Refrigerant Lubrication System . . . . . . . . . . . . . . . . . 4

Chiller Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Purge Control Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . 5

PIC6 Touch Screen HMI. . . . . . . . . . . . . . . . . . . . . . . . 5

REFRIGERATION CYCLE . . . . . . . . . . . . . . . . . . . . . . 7

REFRIGERANT LUBRICATION CYCLE . . . . . . . . . . . 8

Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Inhibitor Reclaim System . . . . . . . . . . . . . . . . . . . . . . 9

Motor Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . 9

VFD Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . 9

VFD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Purge System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Definitions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

PIC6 System Components . . . . . . . . . . . . . . . . . . . . 12

START-UP/SHUTDOWN/

RECYCLE SEQUENCE. . . . . . . . . . . . . . . . . . . . . . 13

Local Start/Stop Control . . . . . . . . . . . . . . . . . . . . . . 13

Lubrication Control . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

BEFORE INITIAL START-UP . . . . . . . . . . . . . . . . . . . 15

Job Data Required . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Equipment Required . . . . . . . . . . . . . . . . . . . . . . . . . 15

Remove Shipping Packaging . . . . . . . . . . . . . . . . . . 15

Tighten All Gasketed Joints . . . . . . . . . . . . . . . . . . . 15

Check Chiller Tightness . . . . . . . . . . . . . . . . . . . . . . 15

Refrigerant Tracer . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Leak Test Chiller . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Standing Vacuum Test . . . . . . . . . . . . . . . . . . . . . . . 18

Check the Installation . . . . . . . . . . . . . . . . . . . . . . . . 20

Inspect Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Chiller Dehydration . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Inspect Water Piping . . . . . . . . . . . . . . . . . . . . . . . . . 21

Check Safety Valves . . . . . . . . . . . . . . . . . . . . . . . . . .21

Check Purge Compressor Operation . . . . . . . . . . . .21

Ground Fault Troubleshooting . . . . . . . . . . . . . . . . . 22

Carrier Comfort Network® Interface . . . . . . . . . . . . .22

Inhibitor Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Software Configuration . . . . . . . . . . . . . . . . . . . . . . . 23

Charge Unit with Refrigerant . . . . . . . . . . . . . . . . . . . 23

Field Set Up and Verification . . . . . . . . . . . . . . . . . . . 31

Perform a Controls Test

(Quick Calibration/Quick Test) . . . . . . . . . . . . . . .32

INITIAL START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

Check Motor Rotation. . . . . . . . . . . . . . . . . . . . . . . . . 33

Check Refrigerant Lube . . . . . . . . . . . . . . . . . . . . . . . 33

To Prevent Accidental Start-Up . . . . . . . . . . . . . . . . . 33

Check Chiller Operating Condition . . . . . . . . . . . . . .33

Instruct the Customer Operator(s) . . . . . . . . . . . . . . 34

OPERATING INSTRUCTIONS. . . . . . . . . . . . . . . . . . .36

Operator Duties. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Prepare the Chiller for Start-Up . . . . . . . . . . . . . . . . . 36

To Start the Chiller . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Check the Running System . . . . . . . . . . . . . . . . . . . . 36

To Stop the Chiller . . . . . . . . . . . . . . . . . . . . . . . . . . .36

After Limited Shutdown . . . . . . . . . . . . . . . . . . . . . . . 36

After Extended Shutdown . . . . . . . . . . . . . . . . . . . . . 36

Cold Weather Operation. . . . . . . . . . . . . . . . . . . . . . .37

Manual Guide Vane Operation. . . . . . . . . . . . . . . . . .37

Refrigeration and Service Log. . . . . . . . . . . . . . . . . .37

PUMPOUT AND REFRIGERANT

TRANSFER PROCEDURES . . . . . . . . . . . . . . . . . .39

Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

GENERAL MAINTENANCE. . . . . . . . . . . . . . . . . . . . . 42

Refrigerant Properties . . . . . . . . . . . . . . . . . . . . . . . .42

Adding Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Adjusting the Refrigerant Charge . . . . . . . . . . . . . . . 42

Refrigerant Leak Testing . . . . . . . . . . . . . . . . . . . . . .42

Leak Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Test After Service, Repair, or Major Leak. . . . . . . . .42

Repair Leaks, Retest, Standing Vacuum Test . . . . .42

Checking Guide Vanes . . . . . . . . . . . . . . . . . . . . . . . . 42

Trim Refrigerant Charge. . . . . . . . . . . . . . . . . . . . . . . 44

WEEKLY MAINTENANCE . . . . . . . . . . . . . . . . . . . . . .44

Check the Refrigerant Lubrication System . . . . . . . 44

Check for Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44

SCHEDULED MAINTENANCE . . . . . . . . . . . . . . . . . .44

Service Ontime . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Inspect the Control Panel. . . . . . . . . . . . . . . . . . . . . . 44

Inspect the Purge . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Catalog No. 04-53190056-01 Printed in U.S.A. Form 19DV-CLT-2SS Pg 1 6-19 Replaces: 19DV-CLT-1SS

Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.

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Changing Refrigerant Lubrication Filters . . . . . . . . 45

Inspect Refrigerant Float System . . . . . . . . . . . . . . . 45

Inspect Safety Relief Devices and Piping . . . . . . . . 45

Compressor Bearing Maintenance . . . . . . . . . . . . . . 46

Inspect the Heat Exchanger Tubes

and Flow Devices . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Water Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Water Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Inspect the VFD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Recalibrate Pressure Transducers . . . . . . . . . . . . . . 47

Recalibrate Temperature Thermistors . . . . . . . . . . . 47

Ordering Replacement Chiller Parts . . . . . . . . . . . . . 47

TROUBLESHOOTING GUIDE. . . . . . . . . . . . . . . . . . . 47

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Checking Display Messages . . . . . . . . . . . . . . . . . . . 47

Checking Temperature Sensors . . . . . . . . . . . . . . . . 47

Checking Pressure Transducers . . . . . . . . . . . . . . . 50

High Altitude Locations . . . . . . . . . . . . . . . . . . . . . . . 51

Quick Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Quick Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Pumpdown/Lockout . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Physical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

APPENDIX A — PIC6 SCREEN AND MENU

STRUCTURE APPENDIX B — CCN COMMUNICATION WIRING

FOR MULTIPLE CHILLERS (TYPICAL) . . . . . . 75

APPENDIX C — MAINTENANCE SUMMARY AND

LOG SHEETS . . . . . . . . . . . . . . . . . . . . . . . . . . 76

APPENDIX D — REMOTE CONNECTIVITY

COMMISSIONING . . . . . . . . . . . . . . . . . . . . . . . . . . 77

INDEX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

INITIAL START-UP CHECKLIST . . . . . . . . . . . . . . CL-1

. . . . . . . . . . . . . . . . . . . . . . . . 72

SAFETY CONSIDERATIONS

Centrifugal liquid chillers are designed to provide safe and reliable service 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.

Be sure you understand and follow the procedures and safety precautions contained in the chiller instructions as well as those listed in this guide.

DANGER

Failure to follow these procedures will result in severe personal injury or death.

DO NOT VENT refrigerant relief valves within a building. Outlet from rupture disc or relief valve must be vented outdoors in accordance with the latest edition of ANSI/ ASHRAE 15 (American National Standards Institute/ American Society of Heating, Refrigerating, and AirConditioning Engineers). The accumulation of refrigerant in an enclosed space can displace 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. 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 chiller for any purpose. Oxygen gas reacts violently with oil, grease, and other common substances.

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 USE air for leak testing. Use only refrigerant or dry nitrogen.

DO NOT VALVE OFF any safety device. BE SURE that all pressure relief devices are properly in-

stalled and functioning before operating any chiller. RISK OF INJURY OR DEATH by electrocution. High

voltage can be present on motor leads even though the motor is not running. Open the power supply disconnect before touching motor leads or terminals.

WARNING

Failure to follow these procedures may result in personal injury or death.

DO NOT USE TORCH to remove any component. System contains refrigerant which may be under pressure.

To remove a component, wear protective gloves and goggles and proceed as follows:

a. Shut off electrical power to unit. b. Recover or isolate refrigerant from system using high-

pressure and low pressure ports as appropriate. Note that R-1233zd(E) will be less than atmospheric pressure until a temperature of about 65°F (18.5°C).

c. 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.

d. Cut component connection tubing with tubing cutter

and remove component from unit.

e. Carefully unsweat remaining tubing stubs when necessary.

DO NOT USE eyebolts or eyebolt holes to rig chiller sections or the entire assembly.

DO NOT work on high-voltage equipment unless you are a qualified electrician.

DO NOT WORK ON electrical components, including control panels, switches, or starters, until you are sure ALL POWER IS OFF and no residual voltage can leak from capacitors or solid-state components.

(Warnings continued on next page.)

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WARNING

LOCK OPEN AND TAG electrical circuits during servicing. IF WORK IS INTERRUPTED, confirm that all circuits are de-energized 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 overpressure can result. When it is necessary to heat refrigerant, use only warm (110°F [43°C]) water.

VERIFY that refrigerant storage cylinders are clean with no residual moisture, oil, or refrigerant that can contaminate the refrigerant charge.

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 chiller. The introduction of the wrong refrigerant can cause damage or malfunction to this chiller.

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 chiller with other refrigerants.

DO NOT ATTEMPT TO REMOVE fittings, covers, etc., while chiller is refrigerant charged or at any time while chiller is running. Be sure pressure is at 0 psig (0 kPa) before breaking any refrigerant connection. Note that chiller will be in a vacuum condition when temperature is below normal room temperature.

CAREFULLY INSPECT all rupture discs and other relief devices AT LEAST ONCE A YEAR. If chiller operates in a corrosive atmosphere, inspect the devices at more frequent intervals.

DO NOT ATTEMPT TO REPAIR OR RECONDITION any relief device when corrosion or build-up of foreign material (rust, dirt, scale, etc.) is found within the valve body or mechanism. Replace the device.

DO NOT install relief devices in series or backwards. USE CARE when working near or in line with a com-

pressed spring. Sudden release of the spring can cause it and objects in its path to act as projectiles.

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 chiller. 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 fans, or pumps.

USE only repair 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.

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 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 contamination when timely repairs cannot be completed.

INTRODUCTION

Prior to initial start-up of the 19DV unit, those involved in the start-up, operation, and maintenance should be thoroughly familiar with these instructions and other necessary job data. Procedures in this manual are arranged in the sequence required for proper chiller start-up and operation. This book also outlines the control system for those involved in the start-up, operation and maintenance of the unit before performing startup procedures. It is intended to be used in combination with the 19DV Semi-Hermetic Centrifugal Liquid Chillers Controls Operation and Troubleshooting manual that describes the controls in detail.

CAUTION

Do NOT punch holes or drill into the top surface of the control or VFD enclosure for field wiring. Knockouts are provided for field wiring connections. Drilling holes through the top of the cabinet can result in a loss of warranty on the starter assembly because of metal particulate falling on and into electronic components.

CAUTION

PROVIDE MACHINE PROTECTION. Store machine and starter indoors, protected from construction dirt and moisture. Inspect under shipping tarps, bags, or crates to be sure water has not collected during transit. Keep protective shipping covers in place until machine is ready for installation. Follow latest Water-Cooled Chillers Long Term Storage document located in Chiller Builder Library.

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CAUTION

WHEN FLUSHING THE WATER SYSTEMS isolate the chiller from the water circuits to prevent damage to the heat exchanger tubes.

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 connections. Always touch a chassis (grounded) part to dissipate body electrostatic charge before working inside control center or use a grounding strap before handling printed circuit boards.

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 PIC6 control boards have been tested and found to comply with the limits for a Class A computing device pursuant to International Standard in North America EN 610002/3 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.

ABBREVIATIONS AND EXPLANATIONS

Frequently used abbreviations in this manual include:

AWG — American Wire Gage BMS — Building Management System CCN — Carrier Comfort Network DCIB — Digital Control Interface Board DVM — Digital Volt-Ohmmeter EC — Envelope Control ECDW — Entering Condenser Water ECW — Entering Chilled Water EMS — Energy Management System HMI — Human Machine Interface HVIB — High Voltage Interface Board I/O — Input/Output IGBT — Insulated-Gate Bipolar Transistor IGV — Inlet Guide Vane IOB — Input Output Board LCDW — Leaving Condenser Water LCW — Leaving Chilled Water LED — Light-Emitting Diode MAWP — Maximum Allowable Working Pressure NSTV — Network Service Tool V OLTA — Overload Trip Amps PIC — Product Integrated Controls PPE — Protective Personal Equipment PWM — Pulse Width Modulating RLA — Rated Load Amps RMS — Root Mean Square SCCR — Short Circuit Current Rating SCR — Silicon Controlled Rectifier SIOB — Starfire 2 Input Output Board TXV — Thermostatic Expansion Valve VFD — Variable Frequency Drive VPF — Variable Primary Flow

Factory-installed additional components are referred to as options in this manual; factory-supplied but field-installed additional components are referred to as accessories.

CHILLER FAMILIARIZATION (Fig. 1 and 2)

Chiller Information Nameplate

The information nameplate is located on the left side of the chiller control panel.

System Components

The main components include the evaporator and condenser heat exchangers in separate vessels, motor-compressor, refrigerant, lubrication package, control panels, PIC6 Touch Screen HMI, economizer, VFD, and purge system.

Evaporator

This vessel is located underneath the compressor. The evaporator is maintained at a lower temperature/pressure so evaporating refrigerant can remove heat from water flowing through its internal tubes. Water flows through the internal tubes to provide comfort or process cooling.

Condenser

The condenser operates at a higher temperature/pressure than the evaporator and has water flowing through its internal tubes in order to remove heat from the refrigerant. It contains a metering device that regulates the flow of refrigerant into the economizer.

Economizer

This chamber reduces the refrigerant pressure to an intermediate level between the evaporator and condenser vessels. In the economizer, vapor is separated from the liquid, the separated vapor flows to the second stage of the compressor, and the liquid flows into the evaporator. The energy removed from the vaporized refrigerant in the economizer allows the liquid refrigerant in the evaporator to absorb more heat when it evaporates and benefits the overall cooling efficiency cycle. It contains a float assembly that regulates the flow of refrigerant into the evaporator.

Motor-Compressor

This component maintains system temperature and pressure differences and moves the heat-carrying refrigerant from the evaporator to the condenser. The 19DV utilizes a two-stage back to back direct drive configuration.

Purge Unit

This is a small independent condensing unit with compressor, separator, regenerative carbon filters, heater and vacuum pump. The purge extracts gas from condenser (or from compressor if unit is not in operation) and purifies it by removing non-condensable gases and any water vapor that may be present.

Variable Frequency Drive (VFD)

The VFD variable frequency is a voltage source design that converts line voltage into PWM (pulse width modulating) motor input for motor speed and torque control.

Refrigerant Lubrication System

This system provides lubrication to the compressor bearing by means of a refrigerant pump.

Chiller Control Panel

This control panel includes the input and output boards (IOBs), control transformer, relays, contactors, and circuit breakers. It provides the power distribution and protection to the electrical components installed on chiller and has the following functions:

• Communication with PIC6 touch screen

• Communication with purge panel

• Communication with VFD

• Sensor input and outputs

• Actuators control

• Refrigerant pump control

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Purge Control Panel

Description

19 —

High Efficiency Semi-Hermetic Centrifugal Chiller

19 G 4

–

V — Variable Speed Drive

Evaporator Frame Size, Length, Pass Arrangement, and Tube Count

Condenser Frame Size, Length, Pass Arrangement, and Tube Count

Compressor Frame Size

Compressor Impeller Diameter Code

Motor Voltage Code

Code Volts-Phase-Hertz

3 — 380-3-60 4 — 416-3-60 5 — 460-3-60 9 — 400-3-50

Special Order Indicator – — Standard S — Special Order

VFD Code* 5 — 850 Amp Std Tier VFD

Compressor Shroud Code 3 — Smallest shroud 4 — Small-Mid shroud 5 — Mid-Large shroud 6 — Largest shroud

Motor Code* B — Smallest HP D — Small-Mid HP F — Mid-Large HP H — Largest HP

2 — Small diameter 4 — Large diameter

G20 - G4K — Frame G H20 - H4K — Frame H

G22 - G4K — Frame G H22 - H4K — Frame H

*Refer to 19DV NG E-Cat Builder for motor and VFD size details.

4 — 500-800 nominal tons (1758-2813 kW)

D — Low Pressure

The purge panel includes the input and output boards, control

transformer, relays, and fuse. It provides the power distribution

and protection to the electrical components which installed in

the purge system and has the following functions:

• Communication with PIC6 touch screen

• Sensor input and outputs

• Solenoid valve control

• Control of purge compressor, vacuum pump, heater, and fan.

PIC6 Touch Screen HMI

This panel is the user interface for controlling the chiller and has the following functions:

• Chiller operation

• Chiller diagnostic

• Chiller status display

• Chiller parameter configuration

• Provide open protocol interface to outside BMS (Building Management System)

Week of Year

Ye ar of Manufacture

Fig. 1 — 19DV Chiller Model Number Identification

SERIAL NUMBER STRUCTURE

12 17 Q 26788

Unique Number

Place of Manufacture

a19-2271

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1—Interconnecting Compressor Piping 2—VFD Drain (Field Drain Piping Required) 3—Condenser 4—Condenser Waterbox Return End 5—Economizer Isolation Valve (Option) 6—Economizer 7—Evaporator Waterbox Return End 8—Vacuum/Charging Valve (Hidden)

9—PIC6 HMI Touchscreen Panel 10 — Evaporator Bundle Sight Glasses 11 — Rupture Disc 12 — Suction Elbow 13 — Evaporator Charging Valve and

Evaporator Pressure Transducer

14 — First Stage Guided Vane Actuator 15 — Compressor Motor 16 — Moisture Indicator (Hidden) 17 — Evaporator 18 — Second Stage Guided Vane Actuator 19 — Evaporator Waterbox Nozzles

20 — Condenser Waterbox Nozzles 21 — Condenser Pressure Transducer 22 — Condenser Charging Valve 23 — Envelope Stability Control Pipe 24 — Purge Assembly 25 — Purge Vent (Hidden) 26 — Motor VFD Cooling Moisture Indicator

(Hidden)

27 — Control Panel 28 — Chiller Name Plate Label 29 — Lubrication Assembly 30 — Economizer Pipe 31 — VFD 32 — Discharge Pipe

FRONT VIEW

REAR VIEW

Fig. 2 — Typical 19DV 500-800 Ton Two-Stage Compressor Chiller Components

(DV4 Shown)

Page 7

REFRIGERATION CYCLE

HIGH SIDE FLOAT

CHAMBER

COOLER

ECONOMIZER

LOW SIDE

FLOAT CHAMBER

CONDENSER

COMPRESSOR

The compressor continuously draws refrigerant vapor from the evaporator at a rate set by the amount of first stage guide vane opening and motor speed. As the compressor suction reduces the pressure in the evaporator, the remaining refrigerant boils at a fairly low temperature (typically 38 to 42°F [3 to 6°C]). The energy required for boiling is obtained from the water flowing through the evaporator tubes. With heat energy removed, the water becomes cold enough to use in an air-conditioning circuit or process liquid cooling.

After taking heat from the water, the refrigerant vapor is compressed by a back-to-back compression connected by means of interstage piping. Compression adds heat energy and the refrigerant is quite warm (typically 98 to 102°F [37 to 40°C]) when it is discharged from the compressor into the condenser.

Relatively cool (typically 65 to 90°F [18 to 32°C]) water flowing into the condenser tubes removes heat from the refrigerant, and the vapor condenses to liquid. The liquid drains into a high side float valve chamber between the condenser and the economizer. The refrigerant is then metered into the economizer. In the economizer, due to lower pressure, as liquid enters the

chamber, some liquid will flash into a vapor and cool the remaining liquid. The separated vapor flows to the second stage of the compressor for greater cycle efficiency. The second stage guide vane on the compressor acts as a pressure regulating device to stabilize operating conditions. At part load the second stage guide vane will back up gas flow and thereby raises the economizer pressure to allow appropriate refrigerant flow from economizer to the compressor.

The cooled liquid left in the economizer flows through a low side float valve and then into the evaporator. The float valve forms a liquid seal to keep vapor from entering the evaporator. The refrigerant is now at a temperature and pressure at which the cycle began. Figure 3 summarizes the refrigeration cycle.

The 19DV unit utilizes R-1233zd(E) refrigerant. At atmospheric pressure its boiling point is 65.5°F (18.6°C). The result is that at normal operating conditions the evaporator typically will be in a vacuum condition and the condenser will operate at a pressure above atmospheric pressure. Unit near room temperature will be close to atmospheric pressure.

Fig. 3 — Refrigeration Cycle — 19DV Two-Stage Compressor

Page 8

CAUTION

PURGE SYSTEM

CONDENSER

HIGH SIDE FLOAT

CHAMBER

REFRIGERANT

LUBRICATION

SYSTEM

VENT LINE

COOLER

ECONOMIZER

LOW SIDE

FLOAT CHAMBER

COMPRESSOR

EDUCTOR

= PURGE

= LUBE SYSTEM

= MAIN REFRIGERANT SYSTEM

LEGEND

To avoid adverse effects on chiller operation, considerations must be made to condenser water temperature control. For steady state operation, the minimum operating refrigerant pressure differential between evaporator and condenser is approximately 7 psid (48 kPa) with a maximum evaporator refrigerant temperature of 65°F (18°C). Consult Chiller Builder for required steady state operational limits and low lift options. Inverted start conditions are acceptable for short durations of time, but for periods exceeding 5 minutes, a special control solution strategy should be used to allow the chiller to establish a minimum refrigerant pressure differential (and thereby adequate equipment cooling).

REFRIGERANT LUBRICATION CYCLE

Summary

The 19DV Series chiller uses refrigerant to lubricate the bearings. The lubrication control is automatically controlled by the chiller controls. In normal RUN mode refrigerant is pumped by means of a refrigerant pump from the high side condenser float chamber to the bearings. Prior to start-up, liquid level in the high side condenser float chamber is maintained by pumping refrigerant liquid

from the evaporator to the high side float chamber until level sensor is satisfied. If liquid high side float level is not satisfied, the pump will move refrigerant from the evaporator to the condenser. During pre-lube and post-lube cycles, refrigerant is drawn from the evaporator for bearing lubrication.

Figures 4 and 5 identify the refrigerant lubrication assembly. Supply refrigerant is pulled through a filter drier by the refrigerant pump and is pumped to the bearings through two protective filters and then returned to the evaporator.

There are two pressure sensors located across the refrigerant pump. During RUN mode a minimum of 12 psid is required for the refrigerant pump delta difference. An alert will trigger if this value is less than 13 psid while the machine is in normal operating mode. Consult the 19DV with PIC6 Controls Operation and Troubleshooting manual for details.

Bearings

The 19DV motor-compressor assembly includes two matched sets of refrigerant-lubricated bearings. The motor shaft is supported by a combination set of journal bearing and roller element bearings on each end of compressor. The refrigerant lubrication pressure difference is defined as the bearing input pressure minus the bearing output pressure plus the Refrigerant Delta P Offset.

Fig. 4 — Refrigerant Lubrication Cycle

Page 9

STRAINER

PUMP

SUCTION

DISCHARGE

ACTUATOR

Fig. 5 — Refrigerant Lubrication Assembly

Inhibitor Reclaim System

The inhibitor reclaim system moves inhibitor from the evaporator and returns it to the first stage suction inlet which allows it to be mixed in the system since it has a tendency to have higher concentration in the evaporator compared with the rest of the system. The reclaim is powered by an eductor driven by the gas pressure difference between first stage suction and discharge of second stage.

Motor Cooling System

The motor is cooled by liquid refrigerant taken from the bottom of the high side condenser float chamber. Refrigerant flow is maintained by the pressure differential that exists due to compressor operation. After the refrigerant flows past an isolation valve, an in-line filter drier, and a sight glass/moisture indicator, it is directed over the motor by spray nozzles. The refrigerant collects in the bottom of the motor casing and is then drained back into the evaporator through the motor refrigerant drain line. The motor is protected by temperature thermistors embedded in the stator windings. An increase in motor winding temperature past the motor override set point overrides the temperature capacity control to hold, and if the motor temperature exceeds 10°F (5.5°C) above this set point, the controls close the inlet guide vanes. If the temperature rises above 122°F (50°C), the compressor shuts down. See Fig. 6.

VFD Cooling System

The VFD enclosure is sealed from the atmosphere to protect electronics from outside contaminants. Refrigerant is routed through a coil in the VFD enclosure to regulate enclosure temperature while still maintaining a temperature high enough to prevent condensation. The VFD cooling line is branched off the motor cooling supply. The refrigerant is then drained back into the evaporator through the motor/VFD drain line. Rectifier and inverter sections are air-cooled and protected by temperature sensors embedded in the inverter. An increase in inverter temperature past the override set point overrides the temperature capacity control to hold, and if the temperature exceeds 10°F (5.5°C) above this set point, the controls close the inlet guide vanes. If the IGBT temperature rises above 144°F (80°C), the compressor shuts down. See Fig. 6.

NOTE: VALVES SHUT AT FACTORY TO CONTAIN INHIBITOR IN LUBRICATION ASSEMBLY. IMPORTANT: OPEN THESE VALVES PRIOR TO STARTUP.

FROM EVAPORATOR

TO COMPRESSOR/ MOTOR BEARINGS

REFRIGERANT

PUMP

ILTER

FROM HIGH SIDE FLOAT CHAMBER

VFD

All 19DV units are equipped with a VFD to operate the centrifugal semi-hermetic compressor motor. The VFD and control panel are the main field wiring interfaces for the installing contractor. The VFD and control panel are mounted on the chiller. See Manufacturer VFD specific information and VFD schematics.

VFD model 32VS is designed to operate in an ambient range of up to 104°F (40°C). The drive has two control circuit boards.

The Digital Control Interface Board (DCIB) controls the fans for cooling operation, controls insulated-gage bipolar transistors (IGBTs), measures three phase line current, controls temperature input and cooling solenoid, controls outputs for pilot relays, and controls communication with HMI controller.

The High Voltage Interface Board (HVIB) steps down incoming voltage to 24 VAC and sends this to the DCIB for monitoring. The HVIB measures DC Bus voltage, controls the precharge circuit, and controls SCR gating. It contains watchdog LED to confirm DC Bus potential is depleted.

If the drive needs to be removed, use the 4 lifting lugs. See Fig. 7. A 32VS 850A weighs approximately 1500 lbs. The drive is compatible with the Network Service Tool V (NSTV) for diagnostics.

Purge System

The purge system is located under the condenser. See Fig. 8. It has two gas inlets coming from condenser and compressor. When chiller is running, the condenser line is active/open and non-condensable gas is pulled out from condenser; when chiller is idle the compressor line is active and non-condensables are pulled out from compressor volute. This is implemented due to non-condensable gas density being less than refrigerant and therefore it will accumulate at the highest point when chiller is not running.

In the purge tank the purge gas is cooled by a separate integral R-134a cooling system. The cooling system consists of an compressor, an air cooled condenser coil, an expansion valve, and a cooling coil in purge tank. Cooling the purge gas results in condensation of R-1233zd(E) vapor as it touches the coil, resulting in a vacuum with the result that more refrigerant is pushed to the coil. As the purge tank fills up with refrigerant it will be drained through the purge drain to the refrigerant pump assembly. See Fig. 9.

Page 10

SOLENOID VALVE

VFD

COOLER

COMPRESSOR

LIFTING LUGS

MOISTURE

INDICATOR

MOISTURE

INDICATOR

Fig. 6 — Motor/VFD Cooling System

CONDENSER

MOTOR COOLING

SYSTEM

Fig. 7 — 32VS 850A

LIFTING LUGS

Page 11

COMPRESSOR VOLUTE (SV02)

CONDENSER (SV01)

MOTOR DRAIN (SV05)

VENTING (SV06)

PURGE TANK

PURGE PUMPOUT (SV03)

VACUUM PUMP

COMPRESSOR SUCTION

CONTROL PANEL

PURGE DRAIN (SV04) (REFRIGERANT PUMP INLET)

COMPRESSOR

CONDENSER ASSEMBLY

STRAINER

EXTRA FILTERS WITH STRAP HEATERS (NOT SHOWN)

CONDENSER

COMPRESSOR

SV01

SV02

COMPRESSOR VALVE

COMPRESSORSUCTION TEMP

STRAINER

134A CIRCUIT

LEVEL

SV04

PURGE DRAIN

CARBON FILTERS VACCUM PUMP SV06

SV05

STRAINER

SIGHT GLASS

CONDENSER ASSY

REGULATOR

SV03

PUMP OUT

VALV E

CHECK VALVE

(TO MOTOR DRAIN)

(TO LUBE ASSY)

FIELD CONNECTION / PURGE VENT

3/8 SAE FLARE

SWITCHES

VENT LINE

REGENERATED

REFRIGERANT

THROTTLE

DEVICE

CONDENSER VALVE

Fig. 8 — Purge System

Fig. 9 — Purge Tank

Page 12

Non-condensables that come into contact with the cold coil in the purge tank will not condense and will accumulate at the top of the purge tank, raising the pressure and reducing the flow of refrigerant vapor. When the controls sense that there is sufficient non-condensable gas in the purge tank, the control will open the pumpout valve, activate the purge evacuation pump, and force the gas through the active carbon filters. To capture any remaining refrigerant the gas is routed through two active carbon filters that will absorb the refrigerant. As the carbon filters become saturated the system will regenerate the filters by applying heat to the filters while under vacuum and then disperse the regenerated refrigerant back to the evaporator while releasing the non-condensables to atmosphere.

The 19DV purge control is automatic. Purge control should be active when purge inlet temperature (evaporator refrigerant liquid temp when chiller compressor OFF or condenser saturated temperature when chiller compressor ON) is greater than purge active temperature set point (65°F default [18.3°C)].

If chiller compressor is running, condenser solenoid valve should be opened to purge refrigerant from condenser.

If chiller compressor is not running, open the compressor solenoid valve to purge refrigerant from compressor. If Purge Comp Suction Temp is less than purge compressor off temp (default to 4°F [–15.5°C]) and the refrigerant level flag is ON, close compressor solenoid valve and condenser solenoid valve, and open pump out solenoid valve. Purge vent valve and purge vacuum pump shall be kept ON for about 10s. After 10s discharge, pump out solenoid valve, purge vent valve, and purge vacuum pump shall be kept OFF. Condenser solenoid valve shall be opened if chiller compressor is running or compressor solenoid valve shall be opened if chiller compressor is not running. After 10s discharge, it will start 20s delay. Then, check purge compressor suction temperature again; if it is less than 6°F (–14°C), it will continue cycle as before.

If refrigerant level in the purge tank is high (both PGLE_HI and PGLE_LO are ON), or purge compressor suction temperature is less than 12°F (–11°C) and PGLE_LO is ON, then drainage solenoid valve should be opened to drain refrigerant from purge tank to evaporator (open CV1, SV04, SV01, SV02 when chiller is off, open SV04, SV01 when chiller is on). After PGLE_LO is OFF, keep drain process for another 1s, then set the refrigerant level flag to ON. If purge level in the purge tank is low (both PGLE_HI and PGLE_LO are OFF), drainage solenoid valve should be closed.

If pump out solenoid valve is accumulated ON for 100 minutes, purge system should do regeneration process for reg_tim minutes (default = 120 minutes – 19DV Configuration Menu), regardless whether purge is active. When regeneration process is active, the Purge Regeneration Valve and Purge Heater should be on for reg_tim minutes, purge vacuum pump should be on for 3 minutes and then 10 minutes off, alternating during reg_tim minutes.

Upon regeneration completion, purge system will wait for another 4 hours to let carbon filter cool down before it will operate normally.

WARNING

The main circuit breaker (if equipped) on the front of the starter disconnects the main motor power only. Power may be still energized for other circuits. Always check wiring diagrams before initiating any work on the chiller and follow applicable lock-out/tag-out procedures. Failure to disconnect power will result in personal injury.

CONTROLS

Definitions

ANALOG SIGNAL

An analog signal varies in proportion to the monitored source. It quantifies values between operating limits. (Example: A temperature sensor is an analog device because its resistance changes in proportion to the temperature, generating many values.)

DISCRETE SIGNAL

A discrete signal is a 2-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 boundary by generating an on/off, high/low, or open/closed signal.)

General

The 19DV centrifugal liquid chiller contains a microprocessorbased 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 load within the set point plus the deadband by sensing the leaving chilled water or brine temperature and regulating the inlet guide vanes and compressor speed. The guide vane is a variable flow pre-whirl assembly that controls the refrigeration effect in the evaporator by regulating the amount of refrigerant vapor flow 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. The variable frequency drive (VFD) allows compressor start-up and capacity control by modulating the motor frequency based on the operating condition.

PIC6 System Components

The chiller control system is called the PIC6 (Product Integrated Control 6). See Table 1. As with previous PIC versions, the PIC6 system controls the operation of the chiller by monitoring all operating conditions. The PIC6 control system can diagnose a problem and let the operator know what the problem is and what to check. It positions the guide vanes and VFD speed to maintain leaving chilled water temperature. It controls the refrigerant pump providing compressor bearing lubrication and 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 regulates the envelope control valve for stabilized aerodynamic operation, if installed. The PIC6 controls offer an operator trending function to help the operator monitor the chiller status more easily and for critical compressor motor protection. The PIC6 system provides open protocols to support the competitive BMS system and can be integrated into Carrier’s Lifecycle System Management for remote monitoring and data management.

Table 1 — Major Controls Components and

Panel Locations

PIC6 COMPONENT PANEL LOCATION Variable Frequency Drive Top of condenser Purge Panel Under condenser Remote Monitoring Control Panel

NOTE: For detailed information about the PIC6 HMI (human machine interface), see the 19DV with PIC6 Controls Operation and Troubleshooting manual.

Page 13

START-UP/SHUTDOWN/

RECYCLE SEQUENCE

Local Start/Stop Control

Local start-up (or manual start-up) is initiated by pressing the gray Start/Stop icon on the HMI interface. See Fig. 10.

Fig. 10 — Chiller Start/Stop Icon

This initiates the PIC6 starting sequence by displaying the list of operating modes. Press Local On to initiate start-up. See Fig. 11.

Fig. 11 — Local On

Prior to start-up the start-to-start timer and the stop-to-start timer must have elapsed and all alarms must be cleared (see Troubleshooting Guide section).

When start-up is initiated the status screen displays the start-up progress and the Start/Stop icon blinks green.

Once local start-up begins, the PIC6 control system performs a series of prestart tests to verify that all prestart alerts and safeties are within acceptable limits. Table 2 shows appropriate Prestart Alerts/Alarms conditions. If a test is not successful, the start-up is delayed or aborted. If the tests are successful, the start-up will be in progress and the COMPRESSOR RUN STATUS will be “Startup.” The control will then energize the chilled water/brine pump relay.

Five seconds later, the condenser pump relay energizes. Thirty seconds later the PIC6 control system monitors the chilled water and condenser water flow devices and waits until the WATER FLOW VERIFY TIME (operator-configured, default 5 minutes) expires to confirm flow. After flow is verified, the chilled water temperature is compared to CONTROL POINT plus 1/2 CHILLED WATER DEADBAND. If the temperature is less than

or equal to this value, the PIC6 control system turns off the condenser pump relay and goes into a Recycle mode.

If the water/brine temperature is high enough, the start-up sequence continues and checks the guide vane position. If the guide vanes are more than 4% open, the start-up waits until the PIC6 control system closes the vanes. If the vanes are closed and the refrigerant pump pressure difference is less than

2.5 psid (17.2 kPa), the refrigerant pump relay energizes. The PIC6 control system then waits until the refrigerant pressure (REF PRESS VERIFY TIME, operator-configured, default of 40 seconds) reaches 12 psid (82.7 kPa). After refrigerant pressure is verified, if high side float chamber has adequate liquid level, refrigerant pump will be kept ON for 20 seconds for prelube; if not, refrigerant pump will be kept ON pumping refrigerant from evaporator to the high side float chamber until liquid level is satisfied. Upon pre-lube satisfied the compressor start relay is energized.

Compressor ontime and service ontime timers start, and the compressor STARTS IN 12 HOURS counter and the number of starts over a 12-hour period counter advance by one.

Failure to verify any of the requirements up to this point will result in the PIC6 control system aborting the start and displaying the applicable prestart alert alarm state number near the bottom of the home screen on the HMI panel. A prestart failure does not advance the STARTS IN 12 HOURS counter. Any failure after the 1CR relay has energized results in a safety shutdown, advances the starts in 12 hours counter by one, and displays the applicable shutdown status on the display.

The minimum time to complete the entire prestart sequence is approximately 185 seconds. See Fig. 12 for normal start-up timing sequence. See Table 2 for a list of prestart checks.

Lubrication Control

For the 19DV system, refrigerant is used to lubricate and cool the compressor bearings. The refrigerant lubrication system includes refrigerant pump pressure transducers, control valves, filters, liquid level switch and inhibitor reclaim system. See Fig. 13 for the lube assembly schematic.

When the chiller is powered on, the controller will maintain the liquid level in the condenser float chamber. If liquid level is low, refrigerant will be pumped from evaporator to the condenser high side float chamber until the liquid level switch is ON. Once the operator pushes the start button, the system will go into prestart check process.

When Refrigerant Pump request is on for pre-lube and the bearing pressure difference is OK for start, if evaporator temperature plus leaving condenser water temperature is less than 10°F (–12.2°C), pump refrigerant from evaporator to condenser until compressor is ON. Else, if evaporator temperature plus leaving condenser water is equal or larger than 10°F (–12.2°C), pump refrigerant from condenser to bearing and drain to condenser until compressor is ON.

During pre-lubrication, if the bearing pressure difference is less than 8 psid (55.2 kPa) for 8 seconds continuously, the chiller will shut down. To proceed to start-up, the bearing pressure difference needs to exceed 12 psid (82.7 kPa) during the pressure verification time. The compressor will run after the pre-lubrication process. Refrigerant from the high side condenser float chamber will be pumped to bearings and will drain to evaporator. When chiller shuts down, the condenser control valve will be opened and the refrigerant evaporator control valve will open (3-way valve will connect evaporator to pump suction). This position allows refrigerant to be pumped from evaporator to condenser high side float chamber. When the chiller is OFF, always open evaporator control valve. While running, if compressor is ON and the bearing pressure difference is less than 10 psid (68.9 kPa) for 10 seconds continuously, the chiller will shut down.

Page 14

Table 2 — Prestart Checks

START INITIATED: prestart checks are made; evaporator pump started.*

B Condenser water pump started (5 seconds after A).

Water flows verified (30 seconds to 5 minutes maximum after B). Chilled water temperatures checked against control point. Guide vanes checked for closure. Refrigerant pump started; tower fan control enabled.

Ref pressure verified (15 seconds minimum, 300 seconds maximum after C).

Compressor motor starts; compressor on-time and service on-time start, 15-minute inhibit timer starts (10 seconds after D), total compressor starts advances by one, and the number of starts over a 12-hour period advances by one.

SHUTDOWN INITIATED; Compressor motor stops; compressor on-time and service on-time stop, and 2-minute inhibit timer starts.

Refrigerant pump and evaporator pumps de-energized (120 seconds after F).Condenser pump and tower fan control may continue to operate if condenser pressure is high. Evaporator pump may continue if in RECYCLE mode.

O/A

Restart permitted (both inhibit timers expired: minimum of 15 minutes after E; minimum of 2 minutes after F).

* Auto Restart After Power Failure Timing sequence will be faster.

MACHINE SAFETIES EVAPORATOR PUMP

CONDENSER WATER PUMP

WATER FLOW, CHILLED WATER TEMP, GUIDE VANES, REF PUMP, TOWER FAN CONTROL

REF PUMP

COMPRESSOR, COMPRESSOR ONTIME, SERVICE ONTIME

15-MINUTE START-TO-STA RT

2-MINUTE STOP-TO-START

PUMP

REFRIGERANT FILTER

PURGE DRAIN

COOLER

SIGHT GLASSSTRAINER

STRAINER

PUMPOUT DRAIN

BEARING FILTER

BEARING SUPPLY

HS FLOAT CHAMBER

2-WAY

ACTUATED VALVE

3-WAY

ACTUATED

VALV E

PRESTART CHECK CONDITION* STATE NUMBER

STARTS IN 12 HOURS 8 (not counting recycle restarts or auto restarts after power failure) Alert – 100 COND PRESSURE COND PRESS OVERRIDE – 20 psi Alert – 102 #RECYCLE RESTARTS LAST 4 HOURS > 5 Alert – 103 COMP BEARING TEMP >= COMP BEARING ALERT– 10°F (5.6°C) Alarm – 230 COMP MOTOR WINDING TEMP COMP MOTOR WINDING– 10°F (5.6°C) Alarm – 231 COMP DISCHARGE TEMPERATURE COMP DISCHARGE ALERT– 10°F (5.6°C) Alarm – 232 EVAP_SAT <Evap trip point** + EVAP OVERRIDE DELTA T Alarm – 233 EVAP REFRIG LIQUID TEMP <Evap trip point** + EVAP OVERRIDE DELTA T Alarm – 233 AVERAGE LINE VOLTAGE UNDERVOLTAGE THRESHOLD AVERAGE LINE VOLTAGE OVERVOLTAGE THRESHOLD CHECK FOR GUIDE VANE 1 CALIBRATION Alarm – 236 CHECK FOR GUIDE VANE 2 CALIBRATION Alarm – 238

* If Prestart Check Condition is True, then resulting State is as indi-

cated in the State Number column.

† See the Controls Operation and Troubleshooting guide for alarm

and alert codes.

††

Alarm – 234 Alarm – 235

** Evap trip point = 33°F (0.6°C) (water) or EVAP REFRIG TRIP-

POINT (brine).

†† Condition ignored for Eaton/Rockwell VFDs.

†

Fig. 12 — Control Timing Sequence for Normal Start-Up

Fig. 13 — Lube Assembly Schematic

Page 15

Shutdown

Unit Start/Stop

The unit can be stopped locally using the HMI by pressing the green Start/Stop icon . The Unit Start/Stop screen is displayed. Press Confirm Stop (see Fig. 14).

Fig. 14 — Confirm Stop

Chiller shutdown begins if any of the following occurs:

• Local OFF button is pressed

• A recycle condition is present

• The time schedule has gone into unoccupied mode when in Network or Local Schedule control mode

• The chiller protective limit has been reached and chiller is in alarm

• The start/stop status (CHIL_S_S) is overridden to stop from the network when in Network mode

If the chiller is normally shut down from running, soft stop shutdown will be performed. The soft stop feature closes the guide vanes of the compressor automatically if a non-alarm stop signal occurs before the compressor motor is de-energized.

Any time the compressor is directed to stop (except in the cases of a fault shutdown), the guide vanes are directed to close and VFD is directed to minimum speed for variable speed compressor, and the compressor shuts off when any of the following is true:

• PERCENT LOAD CURRENT (%) drops below the SOFT STOP AMPS THRESHOLD

• ACTUAL GUIDE VANE OPENING drops below 4%

• 4 minutes have elapsed after initializing stop.

When any one of the above conditions is true, the shutdown sequence stops the compressor by deactivating the compressor start relay. Then the guide vane shall be closed and stay at the fully closed position, the refrigerant pump relay will be turned off after 120 seconds post lube, and the chilled water/brine pump and condenser water pump will be shut down.

BEFORE INITIAL START-UP

Job Data Required

• list of applicable design temperatures and pressures (product data submittal)

• chiller certified prints

• VFD details and wiring diagrams

• diagrams and instructions for special controls or options

• 19DV Installation Instructions

Equipment Required

• mechanic’s tools (refrigeration)

• digital volt-ohmmeter (DVM)

• true RMS (root mean square) digital multimeter with clamp-on current probe or true RMS digital clamp-on ammeter rated for at least 480 vac

• electronic refrigerant leak detector

• absolute pressure manometer or electronic micron gage (see Fig. 15)

• drum charging valve (unless refrigerant bottles already have charging valves)

• charging hose

Fig. 15 — Digital Vacuum Gage

Remove Shipping Packaging

Remove any packaging material from the unit, VFD, and control panels. Inspect the unit for damage that occurred during shipping or installation. Document any damage that was identified.

Tighten All Gasketed Joints

Gaskets normally relax by the time the chiller arrives at the jobsite. Tighten all gasketed joints to ensure a leak-tight chiller (does not apply to refrigerant joints covered by factory insulation). Gasketed joints (excluding O-rings) may include joints at some or all of the following:

• Waterbox covers

• Compressor first suction elbow flanges (at compressor and at the evaporator)

• Compressor secondary suction flanges (at compressor and low side float chamber)

• Compressor discharge flange

• Evaporator inlet line spacer (both sides)

• Envelope control flange (both sides of valve)

• ICP piping flange

• High and low side float chamber covers

See Tables 3 and 4 for bolt torque requirements.

Check Chiller Tightness

Figure 16 outlines the proper sequence and procedures for leak testing.

The 19DV chillers are shipped without the refrigerant charge. The chiller is shipped with a 15 psig (103 kPa) dry nitrogenholding charge.

If the 15 psig factory nitrogen charge is present, then release pressure and proceed to pull a deep vacuum on the unit. Vacuum should be pulled through 1 tom of first stage side of the evaporator. Upon completion of pulling the required vacuum the chiller can be charged with refrigerant. The

-in. charging valve on top of the evaporator shell should

-in. female NPT located under bot-

Page 16

be used for charging by lifting charge cylinder and gravity feed into the evaporator. The chiller should be charged with refrigerant. If the holding charge is not present, the chiller must be examined for leaks. To test for leaks add a small refrigerant holding charge to unit and pressurize with nitrogen up to 20 psig to determine and correct the origin of the leak. Use an electronic leak detector to check all flanges and solder joints after the chiller is pressurized. If the 15 psig factory nitrogen charge is present, then release pressure and proceed to pull a vacuum on the unit. The chiller should

Table 3 — Bolt Torque Requirements, Foot Pounds

be charged with refrigerant. Follow the leak test chiller procedure (page 18).

If the chiller is spring isolated, keep all springs blocked in both directions to prevent possible piping stress and damage during the transfer of refrigerant from vessel to vessel during the leak test process, or any time refrigerant is being transferred. Adjust the springs when the refrigerant is in operating condition and the water circuits are full. Any piping weights are to be separately supported.

SAE 8

HEX HEAD

SA354 GR BD

BOLT SIZE

(in.)

SAE 2, A307 GR A

HEX HEAD

NO MARKS

LOW CARBON STEEL

SOCKET HEAD OR HEX

WITH 3 RADIAL LINES, OR SA499

MEDIUM CARBON STEEL

SAE 5

WITH 6 RADIAL LINES OR

MEDIUM CARBON STEEL

MINIMUM MAXIMUM MINIMUM MAXIMUM MINIMUM MAXIMUM

46 69913

8 11 13 18 20 28 13 19 22 31 32 46 21 30 35 50 53 75 32 45 53 75 80115 46 65 75 110 115 165 65 95 105 150 160 225

105 150 175 250 260 370 140 200 265 380 415 590

1 210 300 410 580 625 893

330 475 545 7809851,410 460 660 770 1,100 1,3801,960 620 885 1,020 1,460 1,840 2,630

740 1060 1,220 1,750 2,200 3,150 1010 1450 1,670 2,390 3,020 4,310 1320 1890 2,180 3,110 3,930 5,610 1630 2340 2,930 4,190 5,2807,550

2 1900 2720 3,150 4,500 5,670 8,100

2180 3120 4,550 6,500 8,200 11,710 3070 4380 5,000 7,140 11,350 16,210 5120 7320 8,460 12,090 15,710 22,440

3 6620 9460 11,040 15,770 19,900 28,440

Table 4 — Bolt Torque Requirements, Foot Pounds (Metric Bolts)

BOLT SIZE

(METRIC)

MINIMUM MAXIMUM MINIMUM MAXIMUM M4 1.75 2.5 2.5 3.5 M6 698 12 M8 14 20 20 30

M10 28 40 40 57 M12 48 70 70 100 M16 118 170 170 240 M20 230 330 330 470 M24 400 570 570 810 M27 58 0 830 820 1175

CLASS 8.8 CLASS 10.9

Page 17

19DV Field Procedure for new units with less than 15 psig holding charge or units

suspected of leaking.

1. Attach compound gage to vessel

2. Note ambient temperature

Raise pressure to 20 psig (138 kPa) using Nitrogen with added tracer gas for electronic leak detection

Leak check

Pass

Evacuate vessel and perform standing vacuum test

Locate and mark all leak sources

Dehydrate

Pass

Charge unit NOTE: Be sure to add refrigerant as gas until chiller pressure exceeds 15 in Hg (vac) / 380 mmHg (vac) to avoid possible tube freezing.

Repair all leaks

Yes

Fig. 16 — 19DV Leak Test Procedures

Page 18

Refrigerant Tracer

Carrier recommends the use of an environmentally acceptable refrigerant tracer for leak testing with an electronic refrigerant detector.

Ultrasonic leak detectors can also be used if the chiller is under pressure.

WARNING

Do not use air or oxygen as a means of pressurizing the chiller. Mixtures of HFO R-1233zd(E) and air at elevated pressure can undergo combustion, resulting in equipment damage and possible personal injury.

Leak Test Chiller

Due to regulations regarding refrigerant emissions and the difficulties associated with separating contaminants from the refrigerant, Carrier recommends the following leak test procedure. Refer to Table 5 for refrigerant pressure/temperature values.

1. If the pressure readings are normal for the chiller condition: a. Evacuate the charge from the vessels, if present. b. Raise the chiller pressure, if necessary, by adding

refrigerant until pressure is at the equivalent saturated pressure for the surrounding temperature.

CAUTION

Never charge liquid refrigerant into the chiller if the pressure in the chiller is less than 15 in. Hg (vac) / 380 mm Hg (vac) for HFO R-1233zd(E). Charge as a gas only, with the evaporator and condenser pumps running, until this pressure is reached, using PUMPDOWN/LOCKOUT (located in the Maintenance menu) and END LOCKOUT mode on the PIC6 control interface. Flashing of liquid refrigerant at low pressures can cause tube freeze-up and considerable damage.

c. Leak test chiller as outlined in Steps 3 to 7.

2. If the pressure readings are abnormal for the chiller condition: a. Prepare to leak test chiller. b. For cooling machines, check for leaks by connecting a

nitrogen bottle with added tracer to allow for electronic leak detection if possible; otherwise, soap bubble solution is to be used. Raise the pressure to 20 psig (138 kPa). If electronic leak detector is avail-

able, ensure small amount of tracer material is added. c. Plainly mark any leaks that are found. d. Release the pressure in the system. e. Repair all leaks. f. Retest the joints that were repaired.

NOTE: Suggested test pressure is 20 psig (138 kPa); maximum allowable test pressure 45 psig (310 kPa).

3. Check the chiller carefully with an electronic leak detector or soap bubble solution.

4. Leak Determination — If an electronic leak detector indicates a leak, use a soap bubble solution, if possible, to confirm. Total all leak rates for the entire chiller. Leakage at rates greater than 0.1% of the total charge per year should be repaired. Local regulation governs the requirements for when repair of leaks become mandatory. Note the total chiller leak rate as well as the full charge amount on the start-up report.

5. If no leak is found during the initial start-up procedures, complete the transfer of refrigerant gas from the storage tank to the chiller. Recover any gas used for leak detection purposes as required per local jurisdiction.

6. If no leak is found after a retest: a. Perform a standing vacuum test as outlined in the

Standing Vacuum Test section, below.

b. If the chiller fails the standing vacuum test, repeat

leak test and repair.

c. If the chiller passes the standing vacuum test, dehy-

drate the chiller. Follow the procedure in the Chiller Dehydration section, page 20. Charge the chiller with refrigerant.

7. If the chiller is opened to the atmosphere for an extended period, evacuate it before repeating the leak test. A nitrogen purge should be maintained to reduce the potential for corrosion when open to the atmosphere.

NOTE: Alternate optional leak testing method is to isolate the water circuits and use a portable water heater to raise the temperature of the evaporator and condenser water circuits to approximately 100°F (38°C) which corresponds to a pressure of approximately

14.40 psig (99.3 kPag).

Standing Vacuum Test

When performing the standing vacuum test or chiller dehydration, use a manometer or a wet bulb indicator. Dial gages cannot indicate the small amount of acceptable leakage during a short period of time.

1. Attach an absolute pressure manometer or wet bulb indicator to the chiller.

2. Evacuate the vessel to at least 18 in. Hg vac (41 kPa [abs]), using a vacuum pump or a pumpout unit.

3. Valve off the pump to hold the vacuum and record the manometer or indicator reading. a. If the leakage rate is less than 0.05 in. Hg (0.17 kPa

in 24 hours, the chiller is sufficiently tight.

b. If the leakage rate exceeds 0.05 in. Hg (0.17 kPa)

24 hours, re-pressurize the vessel and test for leaks.

4. Repair the leak, retest, and proceed with dehydration.

)

Page 19

Table 5 — HFO R-1233zd(E) Pressure and Temperature

TEMP. PRESSURE

F C PSIA PSIG IN HG KPAG KPA ABS MMHG (VAC) % VACUUM

20.0 –6.7

22.0 –5.6

24.0 –4.4

26.0 –3.3

28.0 –2.2

30.0 –1.1

32.0 0.0

34.0 1.1

36.0 2.2

38.0 3.3

40.0 4.4

42.0 5.6

44.0 6.7

46.0 7.8

48.0 8.9

50.0 10.0

52.0 11.1

54.0 12.2

56.0 13.3

58.0 14.4

60.0 15.6

62.0 16.7

64.0 17.8

66.0 18.9

68.0 20.0

70.0 21.1

72.0 22.2

74.0 23.3

76.0 24.4

78.0 25.6

80.0 26.7

82.0 27.8

84.0 28.9

86.0 30.0

88.0 31.1

90.0 32.2

92.0 33.3

94.0 34.4

96.0 35.6

98.0

100.0 37.8

102.0 38.9

104.0 40.0

106.0 41.1

108.0 42.2

110.0 43.3

112.0 44.4

114.0 45.6

116.0 46.7

118.0 47.8

120.0 48.9

122.0 50.0

124.0 51.1

126.0 52.2

128.0 53.3

130.0 54.4

36.7

5.16

5.43

5.72

6.01

6.32

6.64

6.98

7.33

7.69

8.06

8.45

8.86

9.28

9.72

10.17

10.64

11.13

11.63

12.15

12.69

13.25

13.83

14.43

15.05

15.69

16.34

17.03

17.73

18.46

19.20

19.98

20.77

21.59

22.44

23.31

24.21

25.13

26.08

27.06

28.07

29.10

30.17

31.26

32.39

33.54

34.73

35.95

37.20

38.48

39.80

41.16

42.54

43.97

45.42

46.92

48.45

–9.54

–9.27

–8.98

–8.69

–8.38

–8.06

–7.72

–7.37

–7.01

–6.64

–6.25

–5.8

–5.42

–4.98

–4.53

–4.06

–3.57

–3.07

–2.55

–2.01

–1.45

–0.87

–0.27

0.35

0.99

1.64

2.33

3.03

3.76

4.50

5.28

6.07

6.89

7.74

8.61

9.51

10.43

11.38

12.36

13.37

14.40

15.47

16.56

17.69

18.84

20.03

21.25

22.50

23.78

25.10

26.46

27.84

29.27

30.72

32.22

33.75

–19.4 –65.8 35.6 493.5 65

–18.9 –63.9 37.4 479.4 63

–18.3 –61.9 39.4 464.6 61

–17.7 –59.9 41.5 449.3 59

–17.1 –57.8 43.6 433.3 57

–16.4 –55.6 45.8 416.7 55

–15.7 –53.2 48.1 399.3 53

–15.0 –50.8 50.5 381.3 50

–14.3 –48.3 53.0 362.6 48

–13.5 –45.8 55.6 343.2 45

–12.7 –43.1 58.3 323.0 42

–11.9 –40.3 61.1 302.0 40

–11.0 –37.4 64.0 280.2 37

–10.1 –34.3 67.0 257.6 34

–9.2 –31.2 70.1 234.2 31

–8.3 –28.0 73.4 209.9 28

–7.3 –24.6 76.7 184.8 24

–6.2 –21.2 80.2 158.7 21

–5.2 –17.6 83.8 131.7 17

–4.1 –13.887.5 103.8 14

–2.9 –10.0 91.4 74.9 10

–1.8 –6.0 95.4 45.0 6

–0.6 –1.9 99.5 14.0 2

0.7 2.4 103.7 — —

2.0 6.8 108.1 — —

3.3 11.3 112.7 — —

4.7 16.0 117.4 — —

6.2 20.9 122.2 — —

7.6 25.9 127.2 — —

9.2 31.1 132.4 — —

10.7 36.4 137.7 — —

12.4 41.9 143.2 — —

14.0 47.5 148.9 — —

15.8 53.4 154.7 — —

17.5 59.4 160.7 — —

19.4 65.6 166.9 — —

21.2 71.9 173.3 — —

23.2 78.5 179.8 ——

25.2 85.2 186.6 — —

27.2 92.2 193.5 — —

29.3 99.3 200.7 — —

31.5 106.7 208.0 — —

33.7 114.2 215.5 — —

36.0 122.0 223.3 — —

38.4 129.9 231.3 — —

40.8 138.1 239.5 — —

43.3 146.5 247.9 — —

45.8 155.1 256.5 — —

48.4 164.0 265.3 — —

51.1 173.1 274.4 — —

53.9 182.4 283.8 ——

56.7 192.0 293.3 — —

59.6 201.8 303.1 — —

62.6 211.8 313.2 — —

65.6 222.1 323.5 — —

68.7 232.7 334.1 — —

Page 20

Check the Installation

Use the following instructions to verify the condition of the installation. Note that the contractor should not apply power to the chiller before the Carrier Start-up Technician arrives at the job site.

1. Inspect the water piping to the chiller to confirm it is correct. Confirm it is adequately supported from the chiller and there are isolation valves installed.

2. Turn off, lock out, and tag the input power to the drive.

3. Wait a minimum of 5 minutes for the DC bus to discharge.

4. All wiring should be installed in conformance with the applicable local, national, and international codes (e.g., NEC/CSA).

5. Remove any debris, such as metal shavings, from the enclosure.

6. Check that there is adequate clearance around the machine.

7. Verify that the wiring to the terminal strip and the power terminals is correct and that no external voltage potential is connected to any of the inputs.

8. Verify that all of the VFD power module circuit board connectors are fully engaged and taped in place.

9. Check that the field-installed wire size is within terminal specifications and that the wires are tightened properly and adequately supported.

10. Check that specified branch circuit protection is installed and correctly rated.

11. Check that the incoming power is within ±10% of chiller nameplate voltage.

12. Verify that a properly sized ground wire is installed and a suitable earth ground is used. Check for and eliminate any grounds between the power leads. Verify that all ground leads are unbroken to the power supply. Only a wye secondary power supply transformer with solidly grounded neutral is acceptable as a power supply to this chiller. If a ground wire is not present or the transformer secondary is any other type than a wye with solidly grounded delta, please contact the Technical Service Manager or Service Engineering.

Inspect Wiring

WARNING

Do not check the voltage supply without proper equipment and precautions. Serious personal injury may result. Follow power company recommendations.

CAUTION

Do not apply any kind of test voltage, even for a rotation check, if the chiller is under a dehydration vacuum. Insulation breakdown and serious damage may result.

WARNING

Do not apply power unless a qualified Carrier technician is present. Serious personal injury may result.

1. Examine the wiring for conformance to the job wiring diagrams and all applicable electrical codes.

2. Ensure that the VFD is protected by fused disconnects or circuit breakers as per electrical code.

3. Compare the ampere rating on the VFD nameplate to rating on the compressor nameplate.

4. Check that there is adequate service clearance around the machine.

5. Check that specified branch circuit protection is installed and correctly rated.

6. Ensure there is capability to turn off, lock out, and tag the input power to the drive.

7. If power is applied to the drive then wait a minimum of 5 minutes for the DC bus to discharge and check DC bus voltage prior to starting any work.

8. Inspect the control panels and VFD enclosure to ensure that the contractor has used the knockouts or provided top hat to feed the wires into the enclosures. Generally, wiring into the top of the enclosures can allow debris to fall into the enclosures. Clean and inspect the interior of the power panel and VFD enclosure if this has occurred. If metal particulate has fallen into the rectifier or inverter assemblies contact Service Engineering or your Technical Service Manager for further instructions.

9. Check that the incoming power is within ±10% of chiller nameplate voltage.

10. Check that the room environmental conditions match the chiller enclosure type.

11. Ensure the customer’s contractor has verified proper operation of the pumps, cooling tower fans, and associated auxiliary equipment. This includes ensuring motors are properly lubricated and have proper electrical supply and proper rotation. Carrier must maintain pump control for freeze protection algorithm.

12. Verify that the incoming source does not exceed the SCCR (short circuit current rating) of the equipment marking.

13. Ensure all electrical equipment and controls are properly grounded in accordance with the job drawings, certified drawings, and all applicable electrical codes.

CAUTION

Disconnect leads to VFD prior to megohm test. The voltage generated from the tester can damage VFD components.

Test #1: For 3-lead motor, tie terminals 1, 2, and 3 together and test between the group and ground.

1. With the tester connected to the motor leads, take 10-second and 60-second megohm readings.

2. Divide the 60-second resistance reading by the 10-second reading. The ratio, or polarization index, must be one or higher. Both the 10 and 60-second readings must be at least 50 megohms. If the readings on a field-installed starter are unsatisfactory, repeat the test at the motor with the power leads disconnected. Satisfactory readings in this second test indicate the fault is in the power leads.

Test #2: Only perform this test if the unit has been disassembled at the job site, if the starter has been removed, or during annual maintenance.

Perform a megohm test from each terminal to ground. The megohm value should be greater than 20 megohm. Note that if a megohm test is performed between the terminals it will show a direct short and is not a valid test because of the 3 terminal motor internal delta configuration.

Chiller Dehydration

Dehydration is recommended if the chiller has been open for a considerable period of time, if the chiller is known to contain moisture, or if there has been a complete loss of chiller holding charge or refrigerant pressure.

Page 21

CAUTION

Do not start or megohm-test the compressor motor or any other pump motor, even for a rotation check, if the chiller is under dehydration vacuum. Insulation breakdown and severe damage may result.

WARNING

Power to the motor and VFD must be disconnected by an isolation switch before placing the machine under a vacuum. To be safe, isolate input power before evacuating the chiller if you are not sure if there are live leads to the hermetic motor.

Dehydration can be done at room temperatures. Using a cold trap (Fig. 17) may substantially reduce the time required to complete the dehydration and is recommended should the unit be exposed to liquid moisture. The higher the room temperature, the faster dehydration takes place. At low room temperatures, a very deep vacuum is required to boil off any moisture and heating of the water in the water circuits of the chiller to approximately 100°F (38°C) may be required.

pockets of moisture can turn into ice. The slow rate of evaporation (sublimation) of ice at these low temperatures and pressures greatly increases dehydration time.

6. Valve off the vacuum pump, stop the pump, and record the instrument reading.

7. After a 2-hour wait, take another instrument reading. If the reading has not changed, dehydration is complete. If the reading indicates vacuum loss, repeat Steps 4 and 5.

8. If the reading continues to change after several attempts, perform a leak test (maximum 45 psig [310 kPa] pressure). Locate and repair the leak, and repeat dehydration.

9. Once dehydration is complete, the evacuation process can continue. The final vacuum prior to charging the unit with refrigerant should in all cases be 29.9 in. Hg (500 microns,

0.07 kPa [abs]) or less.

Inspect Water Piping

Refer to piping diagrams provided in the certified drawings and the piping instructions in the 19DV Installation Instructions manual. Inspect the piping to the evaporator and condenser. Be sure that the flow directions are correct and that all piping specifications have been met.

Piping systems must be properly vented with no stress on waterbox nozzles and covers. Water flows through the evaporator and condenser must meet job requirements. Measure the pressure drop across the evaporator and the condenser.

Fig. 17 — Dehydration Cold Trap

Perform dehydration as follows:

1. Connect a high capacity vacuum pump (5 cfm [.002 m or larger is recommended) to the refrigerant vacuum/ charging valve (Fig. 2). Tubing from the pump to the chiller should be as short in length with a minimum diameter of 0.5 in. (13 mm) and as large in diameter as possible to provide least resistance to gas flow.

2. Use an absolute pressure manometer or a electronic micron gage to measure the vacuum. Open the shutoff valve to the vacuum indicator only when taking a reading. Leave the valve open for 3 minutes to allow the indicator vacuum to equalize with the chiller vacuum.

3. If the entire chiller is to be dehydrated, open all isolation valves (if present).

4. With the chiller ambient temperature at 60°F (15.6°C) or higher, operate the vacuum pump until the manometer reads 29.8 in. Hg (vac), –14.63 psig (–100.9 kPag), or a vacuum indicator reads 35°F (1.7°C). Operate the pump an additional 2 hours.

5. Do not apply a greater vacuum than 29.82 in. Hg vac (757.4 mm Hg) or go below 33°F (0.56°C) on the wet bulb vacuum indicator. At this temperature and pressure, isolated

/s]

CAUTION

Water must be within design limits, clean, and treated to ensure proper chiller performance and to reduce the potential of tube damage due to corrosion, scaling, or erosion. Carrier assumes no responsibility for chiller damage resulting from untreated or improperly treated water.

Check Safety Valves

Be sure safety valves have been piped to the outdoors in compliance with the latest edition of ANSI/ASHRAE Standard 15 and applicable local safety codes. Piping connections must allow for access to the valve mechanism for periodic inspection and leak testing.

The standard 19DV relief devices are set to relieve at 57 psig (393 kPa) chiller design pressure. To avoid potential rupture the chiller should never be pressurized above 45 psig (310 kPa) for any testing purpose.

Check Purge Compressor Operation

Enter Quick Test menu (under Main Menu) and select “Quick Test Purge Comp.” Connect a pressure gage to purge compressor inlet Schrader valve (suction is top fitting).

The purge system is shown in Fig. 18. The reading should be about 0 ± 0.25 psig (–15.6 to –14.3°F) [0 ± 1.724 kPa (–26.5 to –25.7°C)]. If not, adjust the purge expansion valve in the R-134a purge compressor circuit until the reading is correct.

NOTE: This step should only be performed if the purge is not working correctly. The installation of the gage will result in a loss of refrigerant and the charge of R-134a is a very small quantity affecting the operation of the purge. The charge should be weighed into this circuit using a charging cylinder or similar device.

Page 22

NOTE: CLOCKWISE ROTATION OF EXPANSION VALVE ADJUSTMENT

SCREW INCREASES THE PRESSURE SETTING AND COUNTERCLOCKWISE ROTATION DECREASES PRESSURE SETTING.

EXPANSION VALVE

Fig. 18 — Purge System

Ground Fault Troubleshooting

Follow this procedure only if ground faults are declared by the chiller controls. Test the chiller compressor motor and its power lead insulation resistance with a 500-v insulation tester such as a megohmmeter.

1. Open the VFD main disconnect switch and follow lockout/ tagout rules.

CAUTION

The motor leads must be disconnected from the VFD before an insulation test is performed. The voltage generated from the tester can damage the VFD.

2. Perform test #1: For 3-lead motor, tie terminals 1, 2, and 3 together and test between the group and ground. a. With the tester connected to the motor leads, take 10-

second and 60-second megohm readings.

b. Divide the 60-second resistance reading by the 10-

second reading. The ratio, or polarization index, must be one or higher. Both the 10 and 60-second readings must be at least 50 megohms. If the readings are

SUCTION SCHRADER

VALVE

unsatisfactory, repeat the test at the motor with the power leads disconnected. Satisfactory readings in this second test indicate the fault is in the power leads.

3. Perform test #2: Only perform this test if the unit has been disassembled at the job site, if the starter has been removed, or during annual maintenance. Perform a megohm test from each terminal to ground. The megohm value should be greater than 20 megohm. Note that if a megohm test is performed between the terminals it will show a direct short and is not a valid test because of the 3 terminal motor internal delta configuration.

Carrier Comfort Network® Interface

The Carrier Comfort Network (CCN) communication bus wiring is supplied and installed by the electrical contractor. It consists of shielded, 3-conductor cable with drain wire.

The system elements are connected to the communication bus in a daisy chain arrangement. The positive pin of each system element communication connector must be wired to the positive pins of the system element on either side of it. The negative pins must be wired to the negative pins. The signal ground pins must be wired to the signal ground pins. See installation manual.

Page 23

NOTE: Conductors and drain wire must be 20 AWG (American Wire Gage) minimum stranded, tinned copper. Individual conductors must be insulated with PVC, PVC/nylon, vinyl,

, or polyethylene. An aluminum/polyester 100% foil

Tefl on shield and an outer jacket of PVC, PVC/nylon, chrome vinyl, or Teflon with a minimum operating temperature range of –4°F to 140°F (–20°C to 60°C) is required. See Table 6 for cables that meet the requirements.

Table 6 — Manufacturers and Cable Numbers

MANUFACTURER CABLE NO.

ALPHA 2413 or 5643

AMERICAN A22503

BELDEN 8772

COLUMBIA 02525

When connecting the CCN communication bus to a system element, a color code system for the entire network is recommended to simplify installation and checkout. The color code shown in Table 7 is recommended.

Table 7 — Recommended Color Code

SIGNAL

TYPE

+ Red Red (+)

GROUND White White (G)

– Black Black (–)

CCN BUS CONDUCTOR

INSULATION COLOR

CCN TERMINAL

CONNECTION

WARNING

BE AWARE that certain automatic start arrangements can engage the starter. Open the disconnect ahead of the starter

in addition to shutting off the chiller or pump. Failure to follow this procedure may result in personal injury by electric shock.

WARNING

The main disconnect on the starter front panel may not deenergize all internal circuits. Open all internal and remote disconnects before servicing the starter. Failure to follow this procedure may result in personal injury by electric shock.

Inhibitor Charge

The inhibitor charge is included with the 19DV unit supplied from the factory. No action associated with inhibitor is required unless a new refrigerant charge is added or the inhibitor has been distilled out of the existing refrigerant charge.

If the unit needs to be disassembled, add 1% (mass of total refrigerant charge) of inhibitor PP23BZ110001 (part number is for 1 Gal. Inhibitor Density is 8.2202 lb/Gal [0.985 Kg/L]). For example, see Tables 8 and 9; sum up the evaporator, condenser, and economizer charge; take 1% of total charge; then calculate required inhibitor volume. For a G20 evaporator with G22 condenser this yields: (700+413+342)lb*0.01/(8.2202 lb/Gal)=1.77 Gal (1 Gal + 99 oz) [6.70 L]. See Fig. 19 for field inhibitor addition assuming compressor running and negative evaporator pressure. A dose of Carrier inhibitor is supplied with the unit by the factory.

Suggested Procedure:

1. Ensure availability of appropriate PPE such as protective gloves/protective clothing/eye protection/face protection and wash throughly after handling.

2. If new inhibitor charge is required, a refrigerant charge hose can be used for this purpose or a hard pipe creating a funnel using a 90 degree 2-in. x

-in. NPT female elbow reducer

along with a 2-in. NPT pipe to create a reservoir (add inhibitor as it is being sucked into the evaporator and close

-in.

charging ball valve prior to air being sucked into chiller). Ensure that parts used to add inhibitor are clean to avoid any chiller contamination.

Software Configuration

WARNING

Do not operate the chiller before the control configurations have been checked and a Calibration and Control Test has been satisfactorily completed. Protection by safety controls cannot be assumed until all control configurations have been confirmed.

See the 19DV with PIC6 Controls Operation and Troubleshooting manual for instructions on using the PIC6 interface to configure the 19DV unit. As the unit is configured, all configuration settings should be written down. A log, such as the one shown starting on page CL-1, provides a list for configuration values.

Charge Unit with Refrigerant

IMPORTANT: Turn on the chilled water and condenser water pumps to prevent freezing.

CAUTION

Always operate the condenser and chilled water pumps whenever charging, transferring, or removing refrigerant from the chiller. Always confirm that water flow is established. Failure to follow this procedure may result in equipment damage.

CAUTION

The transfer, addition, or removal of refrigerant in spring isolated chillers may place severe stress on external piping if springs have not been blocked in both up and down directions. Failure to block springs in both up and down directions could result in severe personal injury and equipment damage.

CAUTION

Always operate the condenser and chilled water pumps during charging operations to prevent freeze-ups. Damage could result to equipment if condenser and chilled water pumps are not operated during pumpdown or charging.

WARNING

Always charge refrigerant gas into unit until pressure exceeds water freeze temperature using PUMPDOWN/LOCKOUT (located in the Maintenance menu) and TERMINATE LOCKOUT mode on the PIC6. Evaporator and condenser water pumps must be running to prevent tube freezing.

For R-1233zd(E) water freeze point is exceeded at -15 in. Hg (-51 kPa).

1. Teflon is a registered trademark of DuPont.

Page 24

All 19DV units are field charged. Charge the unit from refrigerant cylinders. Use Tables 8 and 9 to find expected approximate charge by adding evaporator and condenser charge together. Refer to unit nameplate and E-Cat output for certified values.

Prior to charging ensure the following:

1. Standing vacuum test completed.

2. Only initiate refrigerant charging into a deep vacuum.

3. Adequate refrigerant supply is available as per unit nameplate.

CAUTION

Do not apply power to the VFD or motor when in a dehydration vacuum because it will result in equipment damage.

charging gas until the pressure is greater than the above saturation pressure temperature to avoid refrigerant flashing and potential tube freezing. Once required pressure is reached, switch over to charge liquid either by lifting refrigerant cylinder above charging valve to allow for gravity feed or, if charge is isolated in storage tank, by using pumpout equipment suited for low pressure refrigerant.

After the machine has been started, adjust charge for optimum machine performance. Operate the chiller at design load and then add or remove refrigerant slowly until the difference between the leaving chilled water temperature and the evaporator refrigerant temperature reaches design conditions or becomes a minimum. Do not overcharge.

Use the evaporator sight glass (see Fig. 20) to determine the correct refrigerant at all times. During steady state operation at full load, the boiling pool tubes under compressor suction

With water pumps running, connect charging hose from refrigerant cylinder to chiller evaporator charging valve. Start with

Table 8 — Refrigerant Charge — English (lbs)

G H

EVAPORATOR HXREFRIGERANT

G20 through

G2K

G40 through

G4K

— — G24, G29 402 H22, H27 763 H24, H29 507

WT [lbs]

700

840

CONDENSER

G22, G27, G2C,

G2H

G23, G28, G2D,

G2J

REFRIGERANT

WT [lbs]

413 H20, H25 741 H22, H27 484

405 H21, H26 752 H23, H28 495

should be covered with liquid refrigerant. There is no benefit to a refrigerant liquid level higher than the tubes.

DV4

EVAPORATOR HXREFRIGERANT

WT [lbs]

CONDENSER

REFRIGERANT

WT [lbs]

— — G2E, G2K 397 H23, H28 778 H2C, H2H 431

——

— — G44, G49 455 H2B, H2G 707 H42, H47 563

— — G4E, G4K 448 H2C, H2H 716 H43, H48 576

————H2D, H2J726H44, H49590

————H2E, H2K736H4C, H4H499

————H40, H45841 H4D, H4J 508

————H41, H46853 H4E, H4K 518

————H42, H47866 — —

————H43, H48883— —

————H44, H49900——

————H4A, H4F795——

————H4B, H4G803 — —

————H4C, H4H813 — —

————H4D, H4J824 — —

————H4E, H4K836 — —

G42, G47, G4C,

G4H

G43, G48, G4D,

G4J

468 H24, H29 792 H2D, H2J 439

458 H2A, H2F 700 H2E, H2K 448

* The economizer factor for Frame G, H is 342 lbs, so for example the charge for

a G20 evaporator coupled with G22 condenser is: 700 lbs + 413 lbs + 342 lbs = 1455 lbs

Page 25

Table 9 — Refrigerant Charge — SI (kg)

Cooler

½" NPT charging valve

½" x 2" NPT reducer elbow or alternate adapter

2" NPT pipe

or alternate container

DV4

G H

EVAPORATOR HXREFRIGERANT

G20 through

G2K

G40 through

G4K

— — G24, G29 182 H22, H27 346 H24, H29 230

— — G2E, G2K 180 H23, H28 353 H2C, H2H 195

——

— — G44, G49 206 H2B, H2G 321 H42, H47 255

— — G4E, G4K 203 H2C, H2H 325 H43, H48 261

————H2D, H2J329H44, H49268

————H2E, H2K334H4C, H4H226

————H40, H45381H4D, H4J230

WT [kg]

318

381

CONDENSER

G22, G27, G2C,

G2H

G23, G28, G2D,

G2J

G42, G47, G4C,

G4H

G43, G48, G4D,

G4J

REFRIGERANT

WT [kg]

187 H20, H25 336 H22, H27 220

184 H21, H26 341 H23, H28 225

212 H24, H29 359 H2D, H2J 199

208 H2A, H2F 318 H2E, H2K 203

EVAPORATOR HXREFRIGERANT

WT [kg]

CONDENSER

REFRIGERANT

WT [kg]

————H41, H46387H4E, H4K235

————H42, H47393——

————H43, H48 401 — —

————H44, H49408 ——

————H4A, H4F361——

————H4B, H4G364——

————H4C, H4H369——

————H4D, H4J374——

————H4E, H4K379——

* The economizer factor for Frame G, H is 155 kg, so for example the charge for

a G20 evaporator coupled with G22 condenser is: 318 kg + 187 kg + 155 kg = 660 kg

Fig. 19 — Inhibitor Addition

Page 26

/2" NPT COOLER

CHARGING VALVE

Fig. 20 — Evaporator Charging Valve and Sight Glasses

HOME SCREEN

The home screen is the first screen shown after switching the unit on. See Fig. 21. Note the Globe and Lock icons.

COOLER SIGHT GLASSES (APPLY LIGHT TO ONE AND VIEW THROUGH OTHER)

The Lock icon on the Home screen allows access to the password menu and displays current software version. See Fig. 23.

Fig. 21 — Home Screen

The Globe icon on the Home screen allows access to language and measurement settings. See Fig. 22.

Fig. 22 — Language and Units Selection Screen

Fig. 23 — Login Screen

CHANGE THE SET POINTS

To access the set point screen, press the lock icon on the Main Menu. In the User Login menu, enter the password (default USER password = 1111), and click accept. The screen will then default back to the home screen. See Fig. 24. The Service Login access is reserved for access to equipment service tables.

Fig. 24 — Home Screen

Page 27

The Main Menu screen is displayed. See Fig. 25. Press the Setpoint Table icon.

Fig. 25 — Main Menu

The Setpoint screen is displayed. See Fig. 26. Set the base demand limit, and either the LCW set point or the ECW set point. To set a value, press the appropriate set point, enter the value, and press OK. For more information, see the PIC6 Control User Manual.

5. Equipment configuration

6. Automated control quick test

PA SS WO R D

The PIC6 provides a smart factory password for better security and the password changes periodically. With a smart password, only authorized users can log into the controller factory tables to access key product configuration and maintenance data.

A password must be entered to access the Set Point or other common user tables. See Fig. 28. User password can be changed from the General Configuration Menu. USER CONFIGURATION allows change of the User access password.

IMPORTANT: Be sure to remember the password. Retain a copy for future reference. Without the password, access will not be possible unless accessed by a Carrier representative. Factory password is required to enter configuration menus required for chiller setup.

Fig. 26 — Setpoint Menu

INPUT THE LOCAL OCCUPIED SCHEDULE

Access the schedule menu (Main Menu→Configuration Menu→Schedule Menu) and set up the occupied time schedule according to the customer’s requirements. If no schedule is available, the default is factory set for 24 hours occupied, 7 days per week including holidays. When the control mode is LOCAL SCHEDULE, the chiller will be automatically started if the configured local schedule is occupied and will be automatically shut down by the unoccupied schedule.

The Network Schedule should be configured if a CCN system is being installed. When control mode is NETWORK, the chiller can be started and stopped by the CHIL_S_S software point as written by other equipment through the network command and network schedule. The Schedule Menu contains a table to set the Network Schedule if required.

For more information about setting time schedules, please refer to the PIC6 Control User Manual.

INPUT SERVICE CONFIGURATIONS

See Fig. 27 for 19DV Configuration Tables. For specific values for the following configurations, refer to the chiller performance data or job-specific data sheet:

1. Password

2. Log in/log out

3. Input time and date

4. Service parameters

Fig. 27 — 19DV Configuration Tables

Fig. 28 — User Login Screen

INPUT TIME AND DATE

Set day and time and, if applicable, holidays through MAIN MENU SYSTEM CONFIGURATION and then select Date/ Time Configuration. See the Controls Operation and Troubleshooting guide for details. Because a schedule is integral to the chiller control sequence, the chiller will not start until the time and date have been set.

MODIFY CONTROLLER IDENTIFICATION IF NECESSARY

The CCN address can be changed from the Configuration Menu. Change this address under CONTROL IDENTIFICATION for each chiller if there is more than one chiller at the jobsite. Write the new address on the PIC6 Touch Screen module for future reference.

Page 28

CONFIGURE TABLES

Access the related tables through MAIN MENU CONFIGURATION MENU (Fig. 27) to modify or view job site parameters

Table 10 — Factory Parameters

DESCRIPTION RANGE UNITS DEFAULT VALUE

Factory Password

Chiller Type 19XR6/7=0, 19XR2~E/D/V=1, 19DV=2

Unit Type Cool Only=0, Heat Mach=1

Comp (Single=0, Dual=1)

Chilled Medium Type Water/Brine

Cond Shell Side MAWP 185PSI=0, 300PSI=1

19DV Comp Design Press 44PSI=0, 72PSI=1

Country Code

Free Cooling Option

VFD Option No=0,FS VFD=1,Carrier=2, Rockwell LF2=3, Eaton=4, Rockwell STD=5

IOB3 Option (19XR2~E/D/V)

IOB4 Option

Guide Vane1 Type, Digital=0, Analog=1

VFD Feedback Voltage Sel, 0-5V=0, 0-10V=1

Marine Option

Power Request Option

Cont. Power Request

Purge System Option

Liquid Bypass Option

Heat Reclaim Option No=0, Full=1, Partial=2

0 to 65535 4444 n/a

0 to 2 0 2

0 to 1 0 Per selection

0 to 1 1 1

Water/Brine Water Per selection

0 to 1 1 n/a

0 to 1 0 1

0 to 999 8601

No/Yes No Per selection

0 to 5 0 2

0 to 1 0 n/a

No/Yes No Yes

0 to 1 0 1

0 to 1 0 n/a

Dsable/Enable Dsable Enable

Dsable/Enable Dsable Per selection

0 to 2 0 n/a

Table 11 — General VFD Config

Main Menu

Configuration MenuGeneral VFD Config [CFGGEVFD]

shown in 19DV Configuration tables. Tables 10-16 should be verified or configured during startup/commissioning. Consult chiller nameplates as indicated.

DESCRIPTION RANGE UNITS DEFAULT VALUE VFD Gain 0.10 to 1.50 — 0.75 0.75 VFD Max Speed Per 90.0 to 110.0 % 100 100 VFD Min Speed Per 45.0 to 89.0 % 70 60 VFD Start Speed Per 65.0 to 100.0 % 100 100 VFD Current Limit 0.0 to 99999.0 AMPS 250 Nameplate VFD Load Current 20mA 10.0 to 5000.0 AMPS 200 n/a Comp Frequency 100% 45.0 to 62.0 Hz 50 Nameplate VFD Load Current Input Enable/Dsable — Enable Dsable

Table 12 — 19DV Configuration

Main Menu

DESCRIPTION RANGE UNITS DEFAULT VALUE Motor Pole Pair 1, 2 — 1 1 IGV2 Travel Limit 30 to 100% % 96 93.6 IGV2 minimum Degree 0 to 20 Degree 2 2 IGV2 Fully Open Degree 10 to 100 Degree 90 88 IGV2 Actuator Max Deg. 90 to 120 Degree 94 94 IGV2 Deg@IGV1 20 Deg 10 to 30 Degree 28.1 28.1 IGV2 Deg@IGV1 30 Deg 10 to 50 Degree 37.2 37.2 IGV2 Deg@IGV1 50 Deg 10 to 80 Degree 71.6 71.6 VFD Rate Speed Hz 10 to 200 Hz 8 Purge Regen Lasting Time 0 to 65535 minutes 120 120 Daily PG Pumpout Limit 20 to 200 minutes 50 50

Configuration Menu19DV Configuration [Table = CFG_19DV]

0.5 80.5

Page 29

Table 13 — UM VFD Config

Main Menu

DESCRIPTION RANGE UNITS DEFAULT VALUE

Compressor Speed 100% 47 to 110 Hz 50 Nameplate Rated Line Voltage 200 to 13800 Volts 460 Nameplate Motor Nameplate Current 10 to 1500 AMPS 200 Nameplate Motor Rated Load Current 10 to 2000 AMPS 200 Nameplate Motor Nameplate Voltage 200 to 13800 Volts 460 Nameplate Motor Nameplate RPM 1500 to 3600 rpm 3000 Nameplate Motor Nameplate KW 0 to 5600 KW 1500 Nameplate Skip Frequency 1 0.0 to 102.0 Hz 30 30 Skip Frequency 2 0.0 to 102.0 Hz 30 30 Skip Frequency 3 0.0 to 102.0 Hz 30 30 Skip Frequency Band 0.0 to 102.0 Hz 0 0 Increase Ramp Time 5 to 60 sec 30 30 Decrease Ramp Time 5 to 60 sec 30 30 Line Voltage Imbalance% 1 to 10 % 10 10 Line Volt Imbalance Time 1 to 10 sec 10 10 Line Current Imbalance% 5 to 40 % 40 40 Line Current Imbal Time 1 to 10 sec 10 10 Motor Current Imbalance% 5 to 40 % 40 40 Motor Current Imbal Time 1 to 10 sec 10 10 Single Cycle Dropout Dsable/Enable — Dsable Dsable PWM Switch Frequency

0=2 KHZ, 1=4 KHZ Restore Defaults No/Yes — No No LEN Comm Timeout 0 to 255 sec 10 10 Modbus Comm Timeout 0 to 255 sec 2 2 Gateway Modbus Baud Rate

4800=1, 9600=2, 19200=3, 38400=4

Configuration MenuUM VFD Configuration [CFGUMVFD]

0 to 1 — 0 1

1 to 4 — 2 2

Table 14 — Surge Correction Config

DESCRIPTION MENU NAME RANGE UNITS DEFAULT VALUE

Surge Line Configuration PR = 0, Delta T = 1

IGV1 Pos Configuration Degree =0, Percentage =1

Surge Delta Tsmax dts_max 0.0 to 150.0 ^F 70 Nameplate Surge Delta Tsmin dts_min 0.0 to 150.0 ^F 45 Nameplate PR at Full Load Opening pr_ful 1.0000 to 5.0000 — 3 3 PR at Minimum Opening pr_min 1.0000 to 5.0000 — 1.5 1.5 IGV1 Full Load Open Deg gv1_dful 80 to 120.0 — 88 88 Sound Ctrl IGV1 Open Deg gv1_dmed 10.0 to 40.0 — 27 27 IGV1 Minimum Open Deg gv1_dmin 0.0 to 10.0 — 2 2 IGV1 Maximum Open Deg gv1_dmax 90 to 120.0 — 109 94 IGV1 Minimum Position gv1_pmin 0.0 to 100.0 % 5 5 IGV1 Full Load Position gv1_pful 0.0 to 100.0 % 100 93.6 Envelop Line Offset sgl_off 1.0 to 3.0 ^F 2 1 Envelop Lower Deadband sgl_loff 0.5 to 3.0 ^F 1.5 1.5 Envelop Upper Deadband sgl_hoff 0.1 to 3.0 ^F 1.5 1.5 Surge Line Shape Factor sgl_shfh –1.000 to 0.000 — –0.01 Nameplate Sound Line Shape Factor sgl_shfl 0.000 to 1.000 — 0.01 Nameplate Envelop Speed Factor sgl_spdf 0.00 to 3.00 — 2 Nameplate Surge Delay Time surg_del 0 to 120 sec 15 15 Surge Time Period surge_t 7 to 10 min 8 8 Surge Delta Amps % surge_a 5.0 to 40.0 % 20 20 GV1 Close Step Surge gvstp_sg 1.0 to 3.0 % 2 2 VFD Speed Step Surge EC Valve Step Surge hgbpstsg 1.0 to 10.0 % 4 4 Surge Profile Offset sgl_pro 0.00 to 5.0 ^F 0 0 High Efficiency Mode high_eff Dsable/Enable — Enable Enable High Noise Alert noi_alt Dsable/Enable — Enable Enable

sgl_cfg 0 to 1 — 0 1

gv1c_sel 0 to 1 — 0 0

vfdstpsg 1.0 to 5.0 % 1.5 1.5

Page 30

]

Table 15 — Option Configuration

Main Menu

DESCRIPTION RANGE UNITS DEFAULT VALUE

Auto Restart Option

Common Sensor Option

EC Valve Option No=0, Cont.=1,ON/OFF=2, mA=3

EC Selection Disable=0, Surge=1, Low Load=2, Comb=3

ECV Open IGV1 Position

ECV Close IGV1 Position

ECV Off DT for Low Load

ECV On DT for Low Load

ECV Low Load DB

Head Pres Valve Option

Head Pres Delta P 0%

Head Pres Delta P 100%

Head Pressure Min Output

Tower Fan High Setpoint

Refrig Leakage Option

Refrig Leakage Alarm mA

Oil EXV Option

Oil Temp High Threshold

Oil Temp Low Threshold

Gas Torque Factor

Guide Vane/SRD Factor

Power Recovery Timeout

Condenser Flush Alert

Customer Alert Option

Ice Build Option

Ice Build Recycle

Ice Build Termin Source Temp=0,Contact=1,Both=2

Water Pressure Option No=0, Pres.=1, Pres.D=2

Water Flow Measurement No=0, Flow Meter=1,Water Pres. D=2

Water Flow Determination Sat Temp=0,Flow Switch=1

Water Flow at 4mA

Water Flow at 20mA

Evap Flow Rate Baseline

Evap Pres Drop Baseline

Cond Flow Rate Baseline

Cond Pres Drop Baseline

Water Pres Drop @20mA

Max Oil Pressure Diff

Oil Pump VFD Max Step

Vapor Source SV Delay

Vapor Source SV Option

Liquid Bypass Selection

Purge On Idle Option

Evap Liquid Temp Opt

Evap App Calc Selection Sat Temp=0, Ref Temp=1



Configuration Menu Option Configuration [CONF_OPT

Dsable/Enable — Dsable Jobsite specific

0 to 3 — 0 2 (if selected)

0 to 3 — 0 Jobsite specific

0.5 to 10.0 % 5 5 (adjust as required)

1.5 to 20.0 % 10 10 (adjust as required)

0.5 to 10 ^F 4 4 (adjust as required)

0.5 to 10 ^F 2 2 (adjust as required)

0.5 to 2.0 ^F 1 1 (adjust as required)

Dsable/Enable — Dsable Jobsite specific

20 to 85 PSI 25 25 (adjust as required)

20 to 85 PSI 50 50 (adjust as required)

0 to 100 % 0 0 (adjust as required)

55 to 105 °F 75 75 (adjust as required)

Dsable/Enable — Dsable Jobsite specific

4 to 20 mA 20 20 (adjust as required)

Dsable/Enable — Dsable Dsable

100 to 140 °F 122 n/a

90 to 130 °F 113 n/a

0.25 to 3.00 — 1 1

0.70 to 1.20 — 0.95 0.95

0 to 60 min 15 15

Dsable/Enable — Dsable Dsable

Dsable/Enable — Dsable Jobsite specific

0 to 2 — 0 Jobsite specific

0 to 1 — 0 Jobsite specific

0 to 200 GPS 0 (adjust as required)

0 to 150 GPS 0 (adjust as required)

0 to 20 PSI 0 (adjust as required)

0 to 150 GPS 0 (adjust as required)

0 to 20 PSI 0 (adjust as required)

10 to 40 PSI 10 (adjust as required)

35 to 60 PSI 50 n/a

0 to 10 % 7 n/a

0 to 10 min 5 n.a

Dsable/Engale — Dsable n.a

Dsable/Enable — Dsable Per selection

Dsable/Enable — Dsable (adjust as required for force)

Dsable/Enable — Enable n/a

0 to 1 — 1 1

Page 31

Table 16 — Service Parameters Table

Configuration MenuService Parameters [SERVICE]

DESCRIPTION Menu name RANGE DEFAULT UNITS VALUE* Service Password ser_pass 0 to 65535 2222 — Atmospheric Pressure atom_pre 8 to 15 14.5 PSI GV1 Travel Limit gv1_lim 30 to 100 80.7 % GV1 Closure at Startup gv1stpos 0 to 40 4 % Controlled Fluid DB ctrl_db 0.5 to 2 1 ^F Derivative EWT Gain ewtdgain 1 to 3 2 — Proportional Dec Band gv1decdb 2 to 10 6 — Proportional Inc Band gv1incdb 2 to 10 6.5 — Maximum GV Movement max_gv 1.0 to 4.0 2 % Demand Limit At 20 mA dem_20ma 10 to 100 40 % Demand Limit Prop Band dem_pdb 3 to 15 10 % Amps or KW Ramp per Min ldramprt 5 to 20 5 % Temp Ramp per Min tmramprt 1 to 10 3 ^F Recycle Shutdown Delta T rcysh_dt 0.5 to 4 1 ^F Recycle Restart Delta T rcyst_dt 2 to 10 5 ^F Damper Valve Act Delay dmp_dly 1 to 5 2 min Damper Valve Close DB dmp_cldb 2 to 10 5 PSI Damper Valve Open DB dmp_opdb 10 to 20 13 PSI Damper Action Delta T dmp_dt 4 to 10 7 ^F Lub Press Verify Time oilpvr_t 15 to 300 40 sec Soft Stop Amps Threshold sf_st_th 40 to 100 70 % Water Flow Verify Time wflow_t 0.5 to 5 5 min Power Calibration Factor mbb_pfcl 0.5 to 2 1 — Enable Excessive Starts ex_start No/Yes No — Purge Active Temp SP pgt_set 30 to 90 65 — Oil Stir Cycle(19XR6/7)

No Stir=0, 30s/30m=1, 1m/4h=2, Comb. 0&1=3

* Most Service Parameters do not require any change from default.

Adjust as required.

oilstiro 0 to 3 1 —

Field Set Up and Verification

IMPORTANT: Some parameters are specific to the chiller configuration and will need to be verified prior to operation. All command functions must be initiated from the HMI.

Use the HMI touch screen to confirm that the VFD values match the chiller parameter labels and Chiller Builder design data sheet. The VFD values can be located from Main Menu



Configuration Menu.

LABEL LOCATIONS

Verify the following labels have been installed properly and match the chiller requisition:

• Surge Parameters — Located inside the HMI chiller control panel.

• Chiller identification nameplate — Located on the left side of the control panel. See Fig. 29.

• VFD Nameplate data - located on the right side of the VFD. See Fig. 29.

MODIFY EQUIPMENT CONFIGURATION IF NECESSARY

The EQUIPMENT SERVICE table has screens to select, view, or modify parameters. Carrier’s certified drawings have the configuration values required for the jobsite. Modify these values only if requested. Modifications can include:

• Chilled water reset

• Entering chilled water control (Enable/Disable)

• 4 to 20 mA demand limit

• Auto restart option (Enable/Disable)

• Remote contact option (Enable/Disable)

See the 19DV with PIC6 Controls Operation and Troubleshooting guide for more details about these functions; see the Control Panel Schematic for field wiring.

Fig. 29 — Machine Identification Nameplate and VFD

Electrical Nameplate

Page 32

Perform a Controls Test (Quick Calibration/Quick Test)

NOTE: The QUICK TEST screens can only be accessed when the chiller is in STOP mode.

Check the safety controls status by performing an automated controls test. First, perform a Quick Calibration Test (Path Main Menu → Quick Calibration). This is required for all modulating analog actuators. Upon successful calibration, use Quick Test (Main Menu → Quick Test) to verify operation on desired components. Note that this is a very useful feature for troubleshooting. On the QUICK TEST table screen, select a test to be performed.

The Quick Test checks all outputs and inputs for proper functionality. In order to successfully proceed with the controls test, the compressor must be off with no alarms showing, and voltage should be within ±10% of rating plate value. Each test asks the operator to confirm the operation is occurring and whether or not to continue. If an error occurs, the operator can try to address the problem as the test is being done or note the problem and proceed to the next test.

NOTE: The refrigerant pump test will not energize the pump if evaporator pressure is below –13 psig (–90 kPa).

When the controls test is finished the test stops and the QUICK TEST menu displays. If a specific automated test procedure is not completed, access the particular control test to test the function when ready. Disable the Quick Test feature when testing is complete. For information about calibration, see the sections Checking Pressure Transducers, page 50, and High Altitude Locations, page 51.

EVAPORATOR AND CONDENSER PRESSURE TRANSDUCER AND WATERSIDE FLOW DEVICE CALIBRATION

(Waterside Device Optional with IOB Inputs Available) Calibration can be checked by comparing the pressure readings

from the transducer to an accurate refrigeration gage reading. The transducer can be checked and calibrated at 2 pressure points. These calibration points are 0 psig (0 kPa) and between 10 psig (68.9 kPa) and 30 psig (206.8 kPa). To calibrate these transducers:

1. Shut down the compressor and the evaporator and condenser pumps.

NOTE: There should be no flow through the heat exchangers.

2. Disconnect the transducer in question from its Schrader fitting for evaporator or condenser transducer calibration. For pump pressure or bearing pressure or flow device calibration keep transducer in place.

NOTE: If the evaporator or condenser vessels are at 0 psig (0 kPa) atmospheric pressure, the transducers can be calibrated for zero without removing the transducer from the vessel.

3. Access the PRESSURE screen from the Main Menu and view the particular transducer reading (the evaporator pressure, condenser pressure, economizer pressure, pump inlet pressure, pump outlet pressure, bearing inlet pressure, bearing outlet pressure).

4. To calibrate a device, view the particular reading on the screen. It should read 0 kPa. If the reading is not 0 kPa, but within 35 kPa, the value may be set to zero while the appropriate transducer parameter is highlighted. The value will now go to zero. No high end calibration is necessary for REF PUMP DELTA P or flow devices. If the transducer value is not within the calibration range, the transducer will return to the original reading. If the pressure is within the allowed range (noted above), check the voltage ratio of the transducer. To obtain the voltage ratio, divide the voltage (dc) input from the transducer by the supply voltage signal (see Maintenance Others in Maintenance

Menu) or measure across the positive (+ red) and negative (– black) leads of the transducer. The voltage ratio must be between 0.80 and 0.11 for the software to allow calibration. Rotate the waterside flow pressure device from the inlet nozzle to the outlet nozzle and repeat this step. If rotating the waterside flow device does not allow calibration then pressurize the transducer until the ratio is within range. Then attempt calibration again.

5. A high pressure point can be calibrated between 10 and 30 psig (68.9 and 206.8 kPa) by attaching a regulated pressure source (usually from a nitrogen cylinder with high resolution pressure gage). The high pressure point can be calibrated by accessing the appropriate transducer parameter on the PRESSURES screen, highlighting the parameter, then increasing or decreasing the value to the exact pressure on the refrigerant gage.

Pressures at high altitude locations must be compensated for, so the chiller temperature/pressure relationship is correct. This is set in the Service Parameters (Configuration Menu).

The PIC6 does not allow calibration if the transducer is too far out of calibration. In this case, a new transducer must be installed and re-calibrated.

IMPORTANT: When screen display calibration is complete, do not press Calibration Enable/Dsable since the new values will be deleted. Values are kept by exiting the pressure sensor table.

OPTIONAL THERMAL DISPERSION FLOW SWITCH CALIBRATION

Set the flow through the water circuit to the minimum safe flow that will be encountered.

Reduce the sensitivity of the switch by turning the adjustment counter-clockwise until the yellow LED turns off. This indicates that the switch is now open.

Increase the sensitivity of the flow switch by turning the adjustment potentiometer clockwise until the yellow LED is lit.

In case of nuisance trips at low flow, increase the sensitivity of the switch by turning the potentiometer clockwise.

HYDRAULIC STATUS

The HYDRAULIC STATUS screen (access from the Main Menu) provides a convenient way to detect if any of the evaporator/condenser pressure switches (if installed) are in need of calibration. See Fig. 30 for the hydraulic status menu. With no flow the water delta should read 0 kPa. If it does not, the value may be set to zero using PRESSURE SENSOR CALIB located in the Maintenance Menu. See Fig. 31 for the pressure sensor calibration menu. High end calibration is not necessary.

Fig. 30 — Hydraulic Status Menu

Page 33

IMPORTANT: When screen display calibration is complete, do not press Calibration Enable/Dsable since the new values will be deleted. Values are kept by exiting the pressure sensor table.

Fig. 31 — Pressure Sensor Calibration Menu

INITIAL START-UP

Preparation

Before starting the chiller, verify:

1. Power is on to the VFD, chiller control panel, water pumps, and other equipment as required.

2. Cooling tower water is at proper level and at-or-below design entering temperature.

3. Chiller is charged with refrigerant and all refrigerant valves are in their proper operating positions.

4. Valves in the evaporator and condenser water circuits are open and flow is as per design.

NOTE: If the pumps are not automatic, ensure water is circulating properly.

b. Open evaporator control valve, open condenser drain

valve, close condenser control valve, and close evapora-

tor control valve. Run refrigerant pump for 30 seconds. c. Start the motor and ramp to 5 Hz in 10 seconds. d. Once the motor speed reaches 5 Hz, stop motor. e. Stop refrigerant pump 1 minute after motor speed

reaches 5 Hz, then reset all 4 refrigerant lubrication

valves to close. f. Three minutes after motor speed reaches 5 Hz, close

first IGV. Status can be followed in Quick Test as

Check State IDLE=0, PreLub=1, Rotat=2, PosLub=3,

End=4.

6. When the VFD is energized and the motor begins to turn, check for clockwise motor rotation through first stage sight glasses. See Fig. 32.

IMPORTANT: Do not check motor rotation during coastdown. Rotation may have reversed during equalization of vessel pressures.

CORRECT MOTOR ROTATION

IS CLOCKWISE WHEN VIEWED

THROUGH SUCTION PIPE

LEADING TO COMPRESSOR

1ST STAGE SIGHT GLASS

CAUTION

Do not permit water or brine that is warmer than 150°F (65°C) to flow through the evaporator or condenser. Refrigerant overpressure may discharge through the relief device and result in the loss of refrigerant charge (applicable only with standard Charlotte rupture disk).

5. Access the PUMPDOWN/LOCKOUT feature from the Maintenance Menu. Press the End Lockout button on the touch screen and accept the “press OK to Terminate Lockout?” prompt. The unit is reset to operating mode. The chiller is locked out at the factory to prevent accidental start-up.

Check Motor Rotation

1. Close the starter enclosure door.

2. Apply 3-phase power to drive.

3. The VFD checks for proper phase rotation as soon as power is applied to the starter and the PIC6 controls power up.

4. An alarm message will appear on the HMI screen if the phase rotation is incorrect. If this occurs reverse any 2 of the 3 incoming power leads to the starter and reapply power. The motor is now ready for a rotation check.

5. Go to Main Menu, Quick Test and Enable Quick Test following by enabling Motor Rotation Check. This starts the following sequence: a. Fully open the first IGV (inlet guide vane).

Fig. 32 — Correct Motor Rotation

Check Refrigerant Lube

1. In Quick Test the refrigerant lube pressure can be checked. Open evaporator control valve, then run the refrigerant pump. Pressure drop across the refrigerant pump must exceed 8 psig (55 kPa). If pressure drop is negative, check the pump rotation. If pressure drop is below 8 psig (55 kPa), check for clogged filter drier or bearing supply filter.

2. Press the Stop button and listen for any unusual sounds from the compressor as it coasts to a stop.

To Prevent Accidental Start-Up

A chiller STOP override setting may be entered to prevent accidental start-up during service or whenever necessary. From the Main Menu, access the General Parameters Menu and use the down arrow to reach Stop Override on the GENUNIT table. Change Stop Override to Yes; then execute the command by touching the lightning button. The message “ALM-276 Protective Limit - Stop Override” will appear in the Home Screen message area. To restart the chiller, access the same screen and change the Stop Override option to No.

Check Chiller Operating Condition

Check to be sure that chiller temperatures, pressures, water flows, and refrigerant levels indicate the system is functioning properly.

Page 34

Instruct the Customer Operator(s)

Ensure the operator understands all operating and maintenance procedures. Point out the various chiller parts and explain their function as part of the complete system.

EVAPORATOR-CONDENSER

High side float chamber, relief devices, refrigerant charging valve, temperature sensor locations, pressure transducer locations, Schrader fittings, waterboxes and tubes, and vents and drains.

MOTOR COMPRESSOR ASSEMBLY

Guide vane actuator, transmission, motor cooling system, temperature and pressure sensors, sight glasses, motor temperature sensors, and compressor serviceability.

COMPRESSOR LUBRICATION SYSTEM

Valves, dryers and filters, liquid level switch and inhibitor reclaim system.

ECONOMIZER

Float valve, drain valve, Schrader fitting, damper valve.

CONTROL SYSTEM

CCN and LOCAL start, reset, menu, softkey functions, HMI operation, occupancy schedule, set points, safety controls, and auxiliary and optional controls.

PURGE

Check for potential leaks by monitoring purge hours in RUNTIME. Note changes over time.

AUXILIARY EQUIPMENT

Starters and disconnects, separate electrical sources, pumps, and cooling tower.

DESCRIBE CHILLER CYCLES

Refrigerant, motor cooling, lubrication, and liquid reclaim.

REVIEW MAINTENANCE

Scheduled, routine, and extended shutdowns, importance of a log sheet, importance of water treatment and tube cleaning, and importance of maintaining a leak-free chiller.

SAFETY DEVICES AND PROCEDURES

Electrical disconnects, relief device inspection, and handling refrigerant.

CHECK OPERATOR KNOWLEDGE

Start, stop, and shutdown procedures, safety and operating controls, refrigerant charging, and job safety.

REVIEW THE START-UP, OPERATION, AND MAINTENANCE MANUAL.

FINE TUNING VPF (VARIABLE PRIMARY FLOW) SURGE PREVENTION

Figures 33-36 show how the parameters defined below will affect the configured surge line. The menu can be found under

Main Menu Config.

NOTE: Before tuning surge prevention, check for VFD (variable frequency drive) speed limitation or capacity overrides. If the



Configuration Menu Surge Correction

source of low capacity is found in one of these places, do not proceed with an attempt to tune the Surge Prevention configurations.

If capacity is not reached and

1. ACTUAL GUIDE VANE POSITION < GUIDE VANE TRAVEL RANGE

and

2. SURGE PREVENTION ACTIVE = YES (can be identified in Main Menu

and

3. PERCENT LINE CURRENT < 100%

then the surge line is probably too conservative. Note the following parameters from HMI when maximum

ACTUAL LINE CURRENT is achieved:

• EVAPORATOR REFRIGERANT TEMP

• EVAPORATOR PRESSURE

• CONDENSER REFRIG TEMP

• CONDENSER PRESSURE

• ACTUAL GUIDE VANE POSITION

• ACTUAL LINE CURRENT

The ACTIVE DELTA TSAT and the CALC REF DELTA TSAT can be monitored on the Maintenance Menu Correction screen. When ACTUAL DELTA TSAT exceeds CALC REF DELTA TSAT + ENVELOPE LINE OFFSET surge prevention will occur.

If ACTUAL GUIDE VANE POSITION is less than 30%, then increase SURGE DELTA TSMIN in steps of 2ºF (1.2ºC) until one of the three conditions listed above no longer applies. Do not change SURGE DELTA TSMAX.

If ACTUAL GUIDE VANE POSITION is greater than 60%, then increase SURGE DELTA TSMAX in steps of 2ºF (1.2ºC) until cooling capacity is reached or one of conditions listed above no longer applies. Do not change SURGE/HGBP DELTA TSMIN.

If ACTUAL GUIDE VANE POSITION is more than 30% AND less than 60%, then:

1. Increase SURGE DELTA TSMIN in steps of 2ºF (1.2ºC).

2. Increase SURGE DELTA TSMAX in steps of 2ºF (1.2ºC).

3. Repeat Steps 1 and 2 until one of the conditions listed above no longer applies.

NOTE: DELTA TSMIN should seldom need to be increased more than 10 degrees above the selection program value. Likewise, DELTA TSMAX rarely requires more than a 2ºF (1.2ºC) increase.

If surge is encountered then the controls surge prevention algorithm surge line is probably too optimistic or high. Note following parameters from HMI at surge:

• EVAPORATOR REFRIGERANT TEMP

• EVAPORATOR PRESSURE

• CONDENSER REFRIG TEMP

• CONDENSER PRESSURE

• ACTUAL GUIDE VANE POSITION

• AVERAGE LINE CURRENT



Maintenance Menu Surge Correction)



Surge

Page 35

Fig. 33 — Effect of SURGE DELTA TSMIN on Surge

0 10 20 30 40 50 60 70 80 90 100 110

Tsmin= 30

Tsmin= 40

Tsmin= 50

GV_POS

Delta Tsat

0 102030405060708090100110

Tsmax= 60

Tsmax= 70

Tsmax= 80

GV_POS

Delta Tsat

0.00

5.00

10.00

15.00

20.00

25.00

30.00

35.00

40.00

45.00

50.00

55.00

60.00

0 102030405060708090100110

Shape factor = -0.020

Shape factor = -0.040

Shape factor = -0.050

GV_POS

Delta Tsat

0 102030405060708090100110

Speed Factor =1.60

Speed Factor =1.85

Speed Factor =2.00

GV_POS

Delta Tsat

Prevention

Fig. 34 — Effect of SURGE DELTA TSMAX on Surge

Prevention

Fig. 35 — Effect of SURGE LINE SHAPE FACTOR on

Surge Prevention

Fig. 36 — Effect of SURGE LINE SPEED FACTOR on

Surge Prevention

If ACTUAL GUIDE VANE POSITION is less than 30%, go to Step 1. If ACTUAL GUIDE VANE POSITION is greater than 60%, then go to Step 3.

1. Do not change SURGE LINE SHAPE FACTOR from the value selected by Chiller Builder (ECAT). Decrease SURGE DELTA TSMIN in 1°F steps up to 5 times. Monitor chiller for surge.

2. If ACTUAL GUIDE VANE POSITION is still less than 30% and Step 1 failed, increase the value of SURGE LINE SHAPE FACTOR in steps of 0.01 up to 2 times. For example, if surge is encountered when shape factor is –0.06, increase the SURGE LINE SHAPE FACTOR to –0.05. If this does not solve the problem, go to Step 5, even if ACTUAL GUIDE VANE POSITION is less than 30%.

3. Do not change SURGE LINE SHAPE FACTOR from the value selected by Chiller Builder (ECAT). Decrease SURGE DELTA TSMAX by 1°F steps up to 5 times. Monitor chiller for surge.

4. If ACTUAL GUIDE VANE POSITION is greater than 60% and Step 3 failed to eliminate surge, then set SURGE DELTA TSMAX to 5°F below the value specified by Chiller Builder (ECAT). Increase the value of the SURGE LINE SHAPE FACTOR in steps of 0.01 up to 2 times. For example, if surge is encountered when the SURGE LINE SHAPE FACTOR is –0.06, increase the SURGE LINE SHAPE FACTOR to –0.05. If this does not solve the problem, go to Step 5, even if ACTUAL GUIDE VANE POSITION is greater than 60%.

5. If ACTUAL GUIDE VANE POSITION is greater than 30% but less than 60% or if Step 2 failed (with ACTUAL GUIDE VANE POSITION less than 30) or if Step 4 failed (with ACTUAL GUIDE VANE POSITION greater than 60), then perform this step. Do not change SURGE LINE SHAPE FACTOR from the value specified by Chiller Builder (ECAT). Reset SURGE DELTA TSMIN and SURGE DELTA TSMAX to the value specified by Chiller Builder (ECAT). Decrease SURGE DELTA TSMIN and SURGE DELTA TSMAX in steps of 1°F up to 5 times. Monitor chiller for surge.

If the drive does not slow down adequately at part load, then the machine may be operating at a point above the configured “software” surge line and the machine is in surge prevention mode. Check for a surge protection message on the HMI. If the unit is not in a surge protection state, then the ENVELOPE SPEED FACTOR may need to be increased (more aggressive surge line protection) in combination with a decrease in the SURGE LINE SHAPE FACTOR.

Page 36

OPERATING INSTRUCTIONS

Operator Duties

1. Become familiar with the chiller and related equipment before operating the chiller.

2. Prepare the system for start-up, start and stop the chiller, and place the system in a shutdown condition.

3. Maintain a log of operating conditions and document any abnormal readings.

4. Inspect the equipment, make routine adjustments, and perform a Control Test. Maintain the proper refrigerant levels.

5. Protect the system from damage during shutdown periods.

6. Maintain the set point, time schedules, and other PIC functions.

Prepare the Chiller for Start-Up

Follow the steps described in the Initial Start-Up section, page 33.

To Start the Chiller

1. Start the water pumps, if they are not automatic.

2. Press the Start/Stop icon on the HMI home screen to start the system. If the chiller is in the OCCUPIED mode and the start timers have expired, the start sequence will start. Follow the procedure described in the Start-Up/Shutdown/ Recycle Sequence section, page 13.

can be overridden to limit the compressor kW, or the pulldown rate can be decreased to avoid a high demand charge for the short period of high demand operation. Pulldown rate can be based on load rate or temperature rate and is viewed at Maintenance Menu RAMP_DEM (Ramping Demand Limit Value). Configuration is done in General Config and rate is done in Service Parameters.

9. High and low float chambers each provide two sight glasses for looking into the float chamber to confirm proper float operation. Note that the sight glasses on the float covers are used to diagnose a float operation failure of fully closed, stuck in one position, or fully open. The sight glasses are not used to identify correct refrigerant charge.



Capacity Controls



To Stop the Chiller

The occupancy schedule starts and stops the chiller automatically once the time schedule is configured.

The unit can be stopped manually using the HMI by pressing the green Start/Stop icon . The Unit Start/Stop screen is displayed. Press Confirm Stop. The compressor will then follow

the normal shutdown sequence as described in the Start-Up/ Shutdown/Recycle Sequence section on page 13. The chiller is now in the OFF control mode.

Check the Running System

After the compressor starts, the operator should monitor the display and observe the parameters for normal operating conditions:

1. The normal bearing temperature should be about 95°F (35°C). Alert will initiate at 104°F (40°C) and Alarm will be initiated at 122°F (50°C).

2. The First Stage and Second Stage Bearing Temperatures can be accessed from the Temperatures menu. If the bearing temperature is high or in Alarm/Alert state with the refrigerant pump running, stop the chiller and determine the cause of the high temperature. Do not restart the chiller until corrected.

3. The liquid level sensor on the condenser float chamber should indicate Closed in the INPUT menu.

4. The bearing pressure drop should exceed 13 psid (90 kPa) when the compressor is ON, as seen on the HMI Transmission Status screen. If not, an alert will be generated. Typically the reading will be slightly lower at initial start-up. There will be an alarm if compressor is ON and the bearing pressure drop is less than 10 psid for 10 seconds.

5. The moisture indicator sight glass on the refrigerant motor cooling line should indicate single phase refrigerant flow and a dry condition; i.e., solid liquid with no turbulent bubbles.

6. The condenser pressure and temperature varies with the chiller design conditions. Typically the pressure will range from –1.5 to 17.5 psig (–10.3 to 120.6 kPa). with a corresponding temperature range of 60 to 105°F (15 to 41°C). The condenser entering water temperature should be controlled below the specified design entering water temperature to save on compressor kilowatt requirements.

7. Evaporator pressure and temperature also will vary with the design conditions. Typical pressure range will be between –7.7 to –5.0 psig (–50.8 kPa to –35 kPa), with temperature ranging between 34 and 45°F (1.1 and 7.2°C).

8. The compressor may operate at full capacity for a short time after the pulldown ramping has ended, even though the building load is small. The active electrical demand setting

IMPORTANT: Do not attempt to stop the chiller by opening an isolating knife switch. High intensity arcing may occur.

If the chiller is stopped by an alarm condition, do not restart the chiller until the problem is diagnosed and corrected.

After Limited Shutdown

No special preparations should be necessary. Follow the regular preliminary checks and starting procedures.

PREPARATION FOR EXTENDED SHUTDOWN

If freezing temperatures are likely to occur in the chiller area, drain the chilled water, condenser water, and pumpout condenser water circuits to avoid freeze-up. Keep the waterbox drains open. Ensure that chiller is powered up so purge can automatically remove non-condensables from the low pressure chiller system during the shutdown. It is recommended not to store the refrigerant in the unit if below-freezing temperatures are anticipated or if the extended shutdown extends past a normal seasonal shutdown. In that case both refrigerant and water side should be purged with positive pressure of dry nitrogen.

After Extended Shutdown

Ensure the water system drains are closed. It may be advisable to flush the water circuits to remove any soft rust that may have formed. This is a good time to brush the tubes and inspect the Schrader fittings on the waterside flow devices for fouling, if necessary.

Match the actual to the recorded nitrogen pressure prior to the extended shutdown to determine if a leak is present. Check the evaporator pressure on the HMI panel and compare it to the original holding charge that was left in the chiller. If, after adjusting for ambient pressure changes, any change in pressure is indicated, check for refrigerant leaks. See Check Chiller Tightness section, page 15.

If charge was removed, recharge the chiller by transferring refrigerant from the pumpout storage tank (if supplied). Follow the Pumpout and Refrigerant Transfer Procedures section on page 39. Observe freeze-up precautions.

Carefully make all regular preliminary and running system checks.

Page 37

Cold Weather Operation

When the entering condenser water temperature drops very low, the operator should automatically cycle the cooling tower fans off to keep the temperature up and tower bypass piping or condenser water flow modulation may be required. Economizer bypass option may be required for units operating at low lift outside of the selected lift as identified in the Carrier Equipment Selection Program.

IMPORTANT: A field-supplied water temperature control system for condenser water should be installed. The system should be able to maintain the leaving condenser water temperature at design conditions.

Manual Guide Vane Operation

It is possible to manually operate the guide vanes in order to check control operation or to control the guide vanes in an emergency. Manual operation is possible by overriding the target guide vane position.

NOTE: Manual control overrides the configured pulldown rate during start-up and permits the guide vanes to open at a faster rate. Motor current above the electrical demand setting, capacity overrides, and chilled water temperature below the control point override the manual target and close the guide vanes. For descriptions of capacity overrides and set points, see the 19DV with PIC6 Controls Operation and Troubleshooting guide.

Refrigeration and Service Log

A refrigeration log (as shown in Fig. 37), is a convenient checklist for routine inspection and maintenance and provides a continuous record of chiller performance. It is also an aid when scheduling routine maintenance and diagnosing chiller problems.

Keep a record of the chiller pressures, temperatures, and liquid levels on a sheet similar to the one in Fig. 37. Automatic recording of data is possible by using CCN devices such as the Data Collection module and a Building Supervisor. Contact a Carrier representative for more information.

Page 38

REFRIGERATION LOG CARRIER 19DV SEMI-HERMETIC CENTRIFUGAL REFRIGERATION MACHINE

PLANT______________________ MACHINE MODEL NO.______________________ MACHINE SERIAL NO. _______________________

EVAPORATOR

CONDENSER

COMPRESSOR

DESCRIPTION

REFRIGERANT

WATER

REFRIGERANT

WATER

CAPACITY

BEARINGS

DATE

PRESSURE SAT

LIQUID TEMP

LEVEL

FLOW

TEMP IN

TEMP OUT

PRESSURE

TEMP SAT

FLOW

TEMP IN

TEMP OUT

GV1 ACTUAL POS

GV2 ACTUAL POS

1ST STAGE TEMP

2ND STAGE TEMP

REFRIGERANT LUBE

MOTOR

DRIVE TRAIN

VFD ACTUAL SPEED

PURGE RUNTIME AV DAILY PURGE IN 7 DAYS

REMARKS: Indicate shutdowns on safety controls, repairs made, and inhibitor or refrigerant added or removed. Include amounts.

BEARING DELTA P

REF PUMP DELTA P

RUNNING AMPS

TEMPERATURE

Fig. 37 — Refrigeration and Service Log

Page 39

PUMPOUT AND REFRIGERANT

STORAGE TANK LIQUID VALV E

OIL SEPARATOR

PUMPOUT CONDENSER WATER SUPPLY AND RETURN

PUMPOUT CONDENSER

STORAGE TANK VAPOR VALVE

PRESSURE RELIEF SAFETY VALV E

PUMPOUT COMPRESSOR

REFRIGERANT CHARGING VALVE

LIQUID LINE SERVICE VALV E

CHILLER CONDENSER VESSEL

CHILLER COOLER VESSEL

SERVICE VALVE ON PUMPOUT UNIT

SERVICE VALVE ON CHILLER (FIELD SUPPLIED)

MAINTAIN AT LEAST 2 FT (610mm) CLEARANCE AROUND STORAGE TANK FOR SERVICE AND OPERATION WORK.

REFRIGERANT CHARGING VALVE

TRANSFER PROCEDURES

Preparation

For refrigerant side service work the refrigerant can be isolated in a storage tank. The following procedures and Fig. 38 and 39 describe how to transfer refrigerant from vessel to vessel and perform chiller evacuation.

CAUTION

If equipped, the power to the pumpout compressor oil heater must be on whenever any valve connecting the pumpout compressor to the chiller or storage tank is open. Leaving the heater off will result in oil dilution by refrigerant and can lead to compressor failure. Similarly a recovery unit suited for low pressure refrigerant should be used.

WARNING

During transfer of refrigerant into and out of the optional storage tank, carefully monitor the storage tank level gage. Do not fill the tank more than 90% of capacity to allow for refrigerant expansion. Overfilling may result in damage to the tank or the release of refrigerant which will result in personal injury or death.

CAUTION

Do not mix refrigerants from chillers that use different compressor oils and ensure that tanks previously used with a different refrigerant have been cleaned in order to avoid refrigerant contamination. Compressor and heat exchanger damage can result.

CAUTION

Always run the chiller evaporator and condenser water pumps and always charge or transfer refrigerant as a gas when the chiller pressure is less than –15 in. Hg (–51 kPa). Below this pressure, liquid refrigerant flashes into gas, resulting in extremely low temperatures in the evaporator/ condenser tubes and possibly causing tube freeze-up.

CAUTION

Transfer, addition, or removal of refrigerant in spring-isolated chillers may place severe stress on external piping if springs have not been blocked in both up and down directions.

Fig. 38 — Typical Optional Pumpout System Piping Schematic with Storage Tank

Page 40

PUMP-OUT WITH STORAGE TANK

ECONOMIZER AND LS FLOAT

CONDENSER

COOLER

HS FLOAT

PUMP-OUT COMPRESSOR

RELIEF VALVE

OIL SEPARATOR

PUMP-OUT CONDENSER

CHECK VALVE

STORAGE VESSEL

Fig. 39 — Refrigerant Transfer Schematic

The following procedures assume that system is piped in agreement with Fig. 39. Use the PIC6 Pumpdown/Lockout feature under the Maintenance menu.

NOTE: Instructions assume pumpout unit with four control valves oriented as shown. Actual equipment may have a different design, in which case the procedure changes.

Transfer Refrigerant from Storage Tank Vessel to Chiller

1. Equalize refrigerant pressure. a. Turn on chiller water pumps, establishing water flow

(assumes vacuum condition in chiller system).

b. Open (O) and close (C) pumpout and storage tank

valves according to below table.

VALVE 1A1B2345678910

CONDITION OOCOCCOCCCC

c. Gradually open valve 5 to allow vapor pressure to

equalize between storage tank and chiller system.

d. Open valve 5 fully after the chiller pressure exceeds

–12.7 in. Hg (58.3 kPa abs) corresponding to a saturation temperature of 40°F (4.4°C). The chiller water

pumps can be turned off (if desired). When vacuum pressure is fully equalized, close valve 5.

VALVE 1A1B2345678910

CONDITION O O COCCOCCC C

e. Open valve 7 and 10 to prepare to let higher pressure

in the recovery tank push liquid refrigerant into the chiller through the evaporator charging/vacuum valve.

VALVE 1A1B2345678910

CONDITION O O COCCOOCC O

2. Push liquid to chiller; then remove remaining vapor from storage tank. a. Open valve 4. b. Ensure pumpout condenser water is off; then turn on

the pumpout compressor in manual mode to push liquid to chiller. Monitor the storage tank level until tank is empty of liquid refrigerant.

c. Close charging valves 7 and 10.

Page 41

d. Turn off the pumpout compressor.

VALVE 1A1B2345678910

CONDITION OOCOOCOCCCC

e. To prepare for removal of remaining refrigerant vapor

in storage tank, close pumpout valves 3 and 4 and open valves 2 and 5.

VALVE 1A1B2345678910

CONDITION O O OCCOOCCCC

f. Turn on the pumpout condenser water. g. Run pumpout unit in auto until the vacuum switch is sat-

isfied. This occurs approximately at 15 in. Hg vacuum (48 kPa absolute or 7 psia), removing the residual refrigerant vapor from the recovery tank and condensing the a liquid in the chiller. Close valves 1a, 1b, 2, 5, 6.

VALVE 1A1B2345678910

CONDITION C C CCCCCCCCC

h. Turn off pumpout condenser water.

Transfer Refrigerant from Chiller to Storage Tank Vessel

1. Equalize refrigerant pressure. Be sure to run pumps if saturated refrigerant temperature is near the freezing point to avoid potential tube freeze up. a. Dehydrate the refrigerant storage vessel and con-

nected hoses/piping so there are no non-condensables mixed with the refrigerant.

b. Open (O) and close (C) pumpout and storage tank

valves according to below table.

VALVE 1A1B2345678910

CONDITION OOCOCCOCCCC

c. Gradually open valve 5 to allow vapor pressure to equal-

ize between chiller system and storage tank, and open valve 7 and 10 to allow liquid refrigerant to drain by gravity.

VALVE 1A1B2345678910

CONDITION OOCOCCOOCCO

2. Push remaining liquid, followed by refrigerant vapor removal from chiller. Open valve 7 and 10 to prepare to let higher pressure in the recovery tank push liquid refrigerant into the chiller through the evaporator charging/vacuum valve. a. To prepare for liquid push, turn off the pumpout con-

denser water. Place valves in the following positions.

VALVE 1A1B2345678910

CONDITION OOOCCOOOCCO

b. Run the pumpout compressor in manual until all liquid is

pushed out of the chiller (approximately 45 minutes). To drain remaining liquid in HS and LS float chambers refrigerant hoses can be connected to valve 8 and 9 and this liquid can be drained (or pushed) to the storage tank prior to next step. Close valves 2, 5, 7 and 10, then stop compressor.

VALVE 1A1B2345678910

CONDITION OOCCCCOCCCC

c. Turn on pumpout condenser water. d. Open valves 3 and 4, and place valves in the follow-

ing positions.

e. Run the pumpout compressor until the chiller pressure

reaches –7.5 psig (49.5 kPa abs), followed by turning off the pumpout compressor. Note it is possible that the pressure switch is satisfied before this condition. Warm chiller condenser water will boil off any entrapped liquid refrigerant, and chiller pressure will rise.

f. When chiller pressure increases to –5.5 psig (63 kPa

abs) turn on the pumpout compressor until the pressure reaches 7.5 psig (49.5 kPa abs) again; then turn off the pumpout compressor. Repeat this process until the chiller pressure no longer rises.

g. Start the chiller water pumps (condenser and evapora-

tor), establish water flow. At this point turn on the pumpout compressor in auto until the vacuum switch is satisfied. This occurs at approximately 15 in. Hg vacuum (48 kPa abs, 7 psia).

h. Close all valves.

VALVE 1A1B2345678910

CONDITION C C CC CC CCCC C

i. Turn off the pumpout condenser water.

DISTILLING THE REFRIGERANT

1. Transfer the refrigerant from the chiller to the pumpout storage tank as described in the Transfer Refrigerant from Chiller to Storage Tank Vessel section.

2. Equalize the refrigerant pressure a. Turn on chiller water pumps and monitor chiller

pressures.

b. Close pumpout and storage tank valves 2, 4, 5, 7 and

10. Open any isolation valves, if present. Open pumpout and storage tank valves 3 and 6; open chiller valves 1a and 1b.

VALVE 1A1B2345678910

CONDITION O O COCCOCCC C

c. Gradually crack open valve 5 to increase chiller pres-

sure to –7.5 psig (49.5 kPa abs). Slowly feed refrigerant to prevent freeze-up.

d. Open valve 5 fully after the chiller pressure rises

above the freezing point. Let the storage tank and chiller pressure equalize.

3. Transfer remaining refrigerant. e. Set valves as per below table and turn on the pumpout

condenser water.

VALVE 1A1B2345678910

CONDITION O O OCCOOCCCC

f. Run the pumpout compressor until all refrigerant is

removed from the storage tank (remaining content in tank is non-condensables).

g. Turn off the pumpout compressor, close all valves,

and turn off the pumpout condenser water.

VALVE 1A1B2345678910

CONDITION C C CC CC CCCC C

4. Drain the contaminants from the bottom of the storage tank into a container and dispose of it safely.

VALVE 1A1B2345678910

CONDITION OOCOOCOCCCC

Page 42

GENERAL MAINTENANCE

Refrigerant Properties

The standard refrigerant for the 19DV chiller is HFO R-1233zd(E). At normal atmospheric pressure, HFO R-1233zd(E) will boil at 65°F (18°C) and must, therefore, be kept in pressurized containers or storage tanks. The refrigerant is practically odorless when mixed with air and is noncombustible at atmospheric pressure. Read the Material Safety Data Sheet and the latest ASHRAE Safety Guide for Mechanical Refrigeration to learn more about safe handling of this refrigerant.

DANGER

HFO R-1233zd(E) in heavy concentrations may displace enough oxygen to cause asphyxiation. When handling this refrigerant, protect the hands and eyes and avoid breathing fumes.

Adding Refrigerant

Follow the procedures described in the Trim Refrigerant Charge section, page 44.

CAUTION

Always use the compressor pumpdown function in the PUMPDOWN/LOCKOUT feature to turn on the evaporator pump and lock out the compressor when transferring refrigerant. Liquid refrigerant may flash into a gas and cause possible freeze-up and damage to the unit when the chiller pressure is below –15 in. Hg (–53 kPa) for HFO R-1233zd(E).

Adjusting the Refrigerant Charge

If the addition or removal of refrigerant is required to improve chiller performance, follow the procedures given under the Trim Refrigerant Charge section, page 44.

Refrigerant Leak Testing

Since parts of the refrigerant system operate in vacuum, noncondensables will enter the cooling systems. The PIC6 HMI will issue an alert indicating excessive purge operation. Leaks, which cause frequent purge cycles, should be repaired without delay. Non-condensable gas in the machine causes higher than normal condenser pressure, compressor surge at start-up, and frequent purge cycles, so locate and repair any leaks as soon as possible. Before making any necessary repairs to a leak, transfer all refrigerant from the vessel.

Leak Rate

It is recommended by ASHRAE that chillers be taken off line immediately and repaired if the refrigerant leak rate for the entire chiller is more than 10% of the operating refrigerant charge per year.

Carrier recommends that leaks totaling less than the above rate but more than a rate of 0.1% of the total charge per year should be repaired during annual maintenance or whenever the refrigerant is transferred for other service work.

Test After Service, Repair, or Major Leak

If all the refrigerant has been lost or if the chiller has been opened for service, the chiller or the affected vessels must be pressure tested and leak tested. Refer to the Leak Test Chiller section on page 18 to perform a leak test.

WARNING

HFO R-1233zd(E) should not be mixed with air or oxygen and pressurized for leak testing. In general, this refrigerant should not be present with high concentrations of air or oxygen above atmospheric pressures, because the mixture can undergo combustion.

TESTING WITH REFRIGERANT TRACER

Use an environmentally acceptable refrigerant as a tracer for leak test procedures. Use dry nitrogen to raise the machine pressure to leak testing levels.

TESTING WITHOUT REFRIGERANT TRACER

Another method of leak testing is to pressurize with nitrogen only and to use a soap bubble solution or an ultrasonic leak detector to determine if leaks are present.

TO PRESSURIZE WITH DRY NITROGEN

NOTE: Pressurizing with dry nitrogen for leak testing should not be done if the full refrigerant charge is in the vessel because purging the nitrogen is very difficult.

1. Connect a copper tube from the pressure regulator on the cylinder to the refrigerant charging valve. Never apply full cylinder pressure to the pressurizing line. Follow the listed sequence.

2. Open the charging valve fully.

3. Slowly open the cylinder regulating valve.

4. Observe the pressure gage on the chiller and close the regulating valve when the pressure reaches test level. Do not exceed maximum allowable test pressure 45 psig (310 kPa) for units marked 57 MAWP (maximum allowable working pressure) to allow for plenty of margin to avoid from bursting the rupture discs.

5. Close the charging valve on the chiller. Remove the copper tube if it is no longer required.

Repair Leaks, Retest, Standing Vacuum Test

After pressurizing the chiller, test for leaks with an electronic halide leak detector, soap bubble solution, or ultrasonic leak detector. Bring the chiller back to atmospheric pressure, repair any leaks found, and retest.

After retesting and finding no leaks, apply a standing vacuum test. Then dehydrate the chiller. Refer to the Standing Vacuum Test and Chiller Dehydration sections (pages 18 and 20) in the Before Initial Start-Up section.

Checking Guide Vanes

During normal shutdown, when the chiller is off, the guide vanes are closed. Complete the following steps to adjust position if required (see Fig. 40 and 41):

1. Remove the set screw in the guide vane coupling.

2. Loosen the holddown bolts on the guide vane actuator.

3. Pull the guide vane actuator away from the suction housing.

Page 43

Fig. 40 — Guide Vane Actuator

Page 44

Fig. 41 — Guide Vane Actuator Detail

NOTE: For first stage, rotate coupling clockwise to close guide vanes; rotate coupling counterclockwise to open guide vanes. For second stage, rotate coupling counterclockwise to close guide vanes; rotate coupling clockwise to open guide vanes.

4. If required, rotate the guide vane shaft fully clockwise for first stage and counterclockwise for second stage and spotdrill the guide vane actuator shaft. Spot-drilling is necessary when the guide vane actuator sprocket set screws on the guide vane actuator shaft need to be re-seated. (Remember: Spot-drill and tighten the first set screw before spot-drilling for the second set screw.)

Trim Refrigerant Charge

If to obtain optimal chiller performance it becomes necessary to adjust the refrigerant charge, operate the chiller at design load and then add or remove refrigerant slowly until the difference between the leaving chilled water temperature and the evaporator refrigerant temperature reaches design conditions or becomes a minimum. Do not overcharge. Use evaporator sight glasses to visually determine optimum charge. At steady state full load operation the evaporator tubes, as viewed in the boiling pool section of the evaporator, should be covered with liquid refrigerant — if tubes are covered, maximum efficiency is achieved and there is no benefit of additional refrigerant.

Refrigerant may be added either through the storage tank or directly into the chiller as described in the Charge Unit with Refrigerant section on page 23.

To remove any excess refrigerant, follow the procedure in Transfer Refrigerant from Chiller to Storage Tank Vessel section on page 41.

WEEKLY MAINTENANCE

Check the Refrigerant Lubrication System

1. Enter INPUT menu and verify that Liquid Level Switch is closed (if compressor is on).

2. Check moisture indicating sight glass on bearing supply line (Fig. 42) as well as on the motor/VFD liquid cooling line (located between vessels feeding of the high side float chamber; sight glass is located downstream of filter drier).

3. Check that pressure Ref Pump Delta P (PRESSURE Menu is above 13 psig [89.6 kPa]).

Check for Leaks

Frequent purge pumpout operation is an indication of a leak. When the daily pumpout limit is exceeded, the controls will show process Alert 148 — Purge Daily Pumpout Limit Exceeded. If no alert, the purge run-time for the past 24 hours as well as the past 7 days can be obtained from RUNTIME menu.

SCHEDULED MAINTENANCE

Establish a regular maintenance schedule based on your actual chiller requirements such as chiller load, run hours, and water quality. The time intervals listed in this section are offered as

guides to service only.

Service Ontime

The HMI will display resettable “After Service Hrs”, “Total Pumpout Numbers”, and “Total Pumpout Time” values on the

Main Menu



Run Times screen. These values should be reset to zero by the service person or the operator each time major service work is completed so that the time between service events can be viewed and tracked. Previous values and associated dates should be logged for future reference prior to resetting.

Inspect the Control Panel

Maintenance consists of general cleaning and tightening of connections. Vacuum the control cabinets to eliminate dust build-up. If the chiller control malfunctions, refer to the Troubleshooting Guide section on page 47 for control checks and adjustments.

WARNING

Ensure power to the starter is isolated when cleaning and tightening connections inside the starter enclosure. Failure to disconnect power could result in electrocution.

Page 45

Inspect the Purge

MOISTURE INDICATOR

SIGHT GLASS

FOR INSPECTION

NOTE: SECOND INDICATOR IS LOCATED IN THE MOTOR/VFD COOLING LINE (ON THE CONDENSER SIDE) COMING OFF THE BOTTOM OF THE HIGH SIDE FLOAT CHAMBER.

With unit off drain, purge tank by entering the Quick Test menu, opening Drainage Solenoid Valve and Purge Condenser Solenoid Valve, and turning the Refrigerant pump on to drain the refrigerant liquid. Let it run for about 15 minutes. Turn on Purge Compressor and verify that it runs. Close all valves using the Quick Test menu. Clean the condenser coil as required and replace the strainer as needed.

Changing Refrigerant Lubrication Filters

Change the refrigerant lubrication filter, motor cooling filter, and bearing filter on an annual basis or when the chiller is opened for repairs. The filters can be isolated so they can be changed with refrigerant remaining in the chiller. Strainers such as 2x refrigerant pump suction strainers, inhibitor reclaim, and inductor are to be replaced every 5 years or as required when the machine is open for service. These filters do not contain desiccant for moisture removal so changing the filter will not change the moisture indicator status.

Change strainers/filters by closing isolation valves and slowly opening the flare fitting with a wrench and back-up wrench to relieve pressure.

Inspect Refrigerant Float System

Perform this inspection only if the following symptoms are seen:

• There is a simultaneous drop in evaporator pressure and increase in condenser pressure. This will be accompanied by an increase in kW/Ton.

• The liquid line downstream of the float valve feels warm and float valve seems stuck based on a visual inspection through the end cover sight glass. This indicates condenser gas flowing past the float.

1. Transfer the refrigerant into a pumpout storage tank.

2. Remove the float access cover.

3. Clean the chamber and valve assembly thoroughly. Be sure the valve moves freely. Ensure that all openings are free of obstructions.

4. Examine the cover gasket and replace if necessary.

Fig. 42 — Moisture Indicator Sight Glass for inspection

This applies for both the high side float (first float downstream of condenser) and the low side float (second float downstream of condenser). The float refrigerant level can be observed through the two sight glasses located on the float cover under the condenser. See Fig. 43 for float detail. Inspect the float every five years. Clean the chamber and the float valve assembly. Be sure that the float moves freely and the ball bearings that the float moves on are clean.

Fig. 43 — Float System

Inspect Safety Relief Devices and Piping

The relief device on this chiller protects the system against the potentially dangerous effects of overpressure. To ensure against damage to the equipment and possible injury to personnel, these devices must be kept in peak operating condition.

As a minimum, the following maintenance is required.

1. At least once a year, disconnect the vent piping at the valve outlet and carefully inspect the rupture disk for any evidence of internal corrosion or rust, dirt, scale, leakage, etc. Verify that vent piping has a section leaning away from valve to avoid the valve outlet becoming a trap for dirt, condensation etc.

Page 46

2. If corrosion or foreign material is found, do not attempt to repair or recondition. Replace the safety relief device.

3. If the chiller is installed in a corrosive atmosphere or the relief devices are vented into a corrosive atmosphere, inspect the safety relief devices at more frequent intervals.

Compressor Bearing Maintenance

The key to good bearing maintenance is proper lubrication. Inspect the lubrication system regularly and thoroughly. Annual vibration measurements are recommended to monitor overall compressor status. Annual refrigerant analysis is recommended to monitor refrigerant acid and moisture levels over time.

Excessive bearing wear can often be detected through increased vibration or increased bearing temperature. To inspect the bearings, a complete compressor teardown is required. Only a trained service technician should perform a compressor disassembly. Bearings cannot be field inspected; excessive vibration is the primary sign of wear or damage. If either symptom appears, contact an experienced and responsible service organization for assistance. Annual compressor vibration analysis and trending is recommended for compressor preventative monitoring and maintenance.

CAUTION

If compressor requires disassembly, cleanliness is of critical importance to avoid contamination. Small amounts of contamination can result in damage to ceramic bearings.

Inspect the Heat Exchanger Tubes and Flow Devices

EVAPORATOR AND OPTIONAL FLOW DEVICES

Inspect and clean the evaporator tubes at the end of the first operating season. Because these tubes have internal ridges, a rotary-type tube cleaning system is needed to fully clean the tubes. Inspect the tubes’ condition to determine the scheduled frequency for future cleaning and to determine whether water treatment in the chilled water/brine circuit is adequate. Inspect the entering and leaving chilled water temperature sensors and flow devices for signs of corrosion or scale. Replace a sensor or Schrader fitting if corroded or remove any scale if found.

CONDENSER AND OPTIONAL FLOW DEVICES

Since this water circuit is usually an open-type system, the tubes may be subject to contamination and scale. Clean the condenser tubes with a rotary tube cleaning system at least once per year and more often if the water is contaminated. Inspect the entering and leaving condenser water sensors and flow devices for signs of corrosion or scale. Replace the sensor or Schrader fitting if corroded or remove any scale if found.

Higher than normal condenser pressures, together with the inability to reach full refrigeration load, usually indicate dirty tubes or air in the chiller. If the refrigeration log indicates a rise above normal condenser pressures, check the condenser refrigerant temperature against the leaving condenser water temperature. If this reading is more than what the design difference is supposed to be, the condenser tubes may be dirty, water flow may be incorrect, or non-condensables have contaminated the refrigerant circuit. To resolve, check the purge status. If purge is operating normally and does not have excessive run time, that may be an indication to double check pressure transducer and temperature readings along with flow.

During the tube cleaning process, use brushes specially designed to avoid scraping and scratching the tube wall. Contact your Carrier representative to obtain these brushes. Do not use wire brushes. Hard scale may require chemical treatment for its prevention or removal. Consult a water treatment specialist for proper treatment.

Water Leaks

The refrigerant moisture indicator on the refrigerant motor cooling line along with the moisture indicator located in the liquid refrigerant feeding the compressor bearings (Fig. 2) indicates whether there is water or air leakage during chiller operation. Water leaks should be repaired immediately.

CAUTION

The chiller must be dehydrated after repair of water leaks or damage may result. See Chiller Dehydration section, page 20.

Water Treatment

Untreated or improperly treated water may result in corrosion, scaling, erosion, or algae. The services of a qualified water treatment specialist should be obtained to develop and monitor a treatment program.

CAUTION

Water must be within design flow limits, clean, and treated to ensure proper chiller performance and reduce the potential of tube damage due to corrosion, scaling, erosion, and algae. Carrier assumes no responsibility for chiller damage resulting from untreated or improperly treated water. If the unit is going to be stored for an extended period of time, Carrier has specific long-term storage requirements that are documented and available from the chiller sales group.

Inspect the VFD

Before working on any starter, shut off the chiller, then open and tag all disconnects supplying power to the starter.

CAUTION

The motor leads must be disconnected from the VFD before an insulation test is performed. The voltage generated from the tester can damage the drive components.

CAUTION

Failure to follow these procedures may result in personal injury or damage to equipment.

TO AVOID an electric shock hazard, verify that the voltage on the bus capacitors has discharged completely before servicing. Check the DC bus voltage at the power terminal block by measuring between the +DC and –DC terminals, between the +DC terminal and the chassis, and between the –DC terminal and the chassis. The voltage must be zero for all three measurements.

WARNING

DC bus capacitors retain hazardous voltages after input power has been disconnected. An isolated multimeter will be needed to measure DC bus voltage and to make resistance checks.

After disconnecting input power, wait 5 minutes for the DC bus capacitors to discharge and then check the voltage with a voltmeter rated for the DC bus voltage to ensure the DC bus capacitors are discharged before touching any internal components. Failure to observe this precaution could result in severe bodily injury or loss of life.

WARNING

The disconnect on the starter front panel does not always deenergize all internal circuits. Open all internal and remote disconnects before servicing the starter. Failure to follow this procedure may result in personal injury by electric shock.

Page 47

Periodically vacuum accumulated debris on the internal parts. Use electrical cleaner for electrical parts as required. Perform visual inspection of the capacitors located on the DC bus and inductors. Check cooling fan operation. Check condensate drain for the VFD enclosure.

Power connections on newly installed starters may relax and loosen after a short period of operation. Turn power off and retighten. Recheck annually thereafter.

CAUTION

Loose power connections can cause voltage spikes, overheating, malfunctioning, or failures.

Recalibrate Pressure Transducers

Once a year, the pressure transducers should be checked against a pressure gage reading. Check all pressure transducers: evaporator pressure, condenser pressure, refrigerant pump inlet pressure, refrigerant pump outlet pressure, bearing inlet pressure, bearing outlet pressure, and optional evaporator entering and leaving water pressure, as well as condenser entering and leaving water pressure. See Fig. 31.

Recalibrate Temperature Thermistors

Entering chilled water (ECW), leaving chilled water (LCW), entering condenser water (ECDW), leaving condenser water (LCDW).

Ordering Replacement Chiller Parts

When ordering Carrier specified parts, the following information must accompany an order:

• chiller model number and serial number

• name, quantity, and part number of the part required

• delivery address and method of shipment.

TROUBLESHOOTING GUIDE

Overview

The PIC6 control system has many features to help the operator and technician troubleshoot a 19DV chiller.

• The HMI shows the chiller’s actual operating conditions and can be viewed while the unit is running.

• The HMI default screen indicates when an alarm occurs. Once all alarms have been cleared (by correcting the problems), the HMI default screen indicates normal operation. For information about displaying and resetting alarms and a list of alert codes, see the 19DV with PIC6 Controls Operation and Troubleshooting manual.

• The Configuration menu screens display information that helps to diagnose problems with chilled water temperature control, chilled water temperature control overrides, hot gas bypass, surge algorithm status, and time schedule operation.

• The quick test and quick calibration feature facilitates the proper operation and test of temperature sensors, pressure transducers, the guide vane actuator, refrigerant pump, water

pumps, tower control, and other on/off outputs while the compressor is stopped. It also has the ability to lock off the compressor and turn on water pumps for pumpout operation (Maintenance Menu). The HMI shows the temperatures and pressures required during these operations.

• If an operating fault is detected, an alarm indicator is displayed on the HMI default screen. A more detailed message — along with a diagnostic message — is also stored in the Current Alarms table.

• Review the Alarms History table to view other less critical events which may have occurred. Compare timing of relevant events and alarms.

For detailed information about alarms, see the 19DV with PIC6 Controls Operation and Troubleshooting manual. Press the bell icon in the top right corner of the home screen to access current alarms and alarm history, and to reset alarms.

Checking Display Messages

The first area to check when troubleshooting the 19DV is the HMI display. Status messages are displayed at the bottom of the screen, and the alarm icon indicates a fault. For a complete list of alarms, see the 19DV with PIC6 Controls Operation and Troubleshooting manual.

Checking Temperature Sensors

All temperature sensors are thermistor-type sensors. This means that the resistance of the sensor varies with temperature. All sensors have the same resistance characteristics. If the controls are on, determine sensor temperature by measuring voltage drop; if the controls are powered off, determine sensor temperature by measuring resistance. Compare the readings to the values listed in Tables 17 and 18.

RESISTANCE CHECK

Turn off the control power and, from the module, disconnect the terminal plug of the sensor in question. With a digital ohmmeter, measure sensor resistance between receptacles as designated by the wiring diagram. The resistance and corresponding temperature are listed in Tables 17 and 18. Check the resistance of both wires to ground. This resistance should be infinite.

VOLTAGE DROP

The voltage drop across any energized sensor can be measured with a digital voltmeter while the control is energized. Tables 17 and 18 list the relationship between temperature and sensor voltage drop (volts dc measured across the energized sensor). Exercise care when measuring voltage to prevent damage to the sensor leads, connector plugs, and modules. Sensors should also be checked at the sensor plugs.

CAUTION

Relieve all refrigerant pressure or drain the water before removing any thermowell threaded into the refrigerant pressure boundary. Failure to do so could result in personal injury and equipment damage.

Page 48

Table 17 — Thermistor Temperature (F) vs. Resistance/Voltage Drop

TEMPERATURE

(F)

PIC

VOLTAGE

DROP (V)

RESISTANCE

(OHMS)

–25 4.700 97,706 –24 4.690 94,549 –23 4.680 91,474 –22 4.670 88,480 –21 4.659 85,568 –20 4.64882,737 –19 4.637 79,988 –18 4.625 77,320 –17 4.613 74,734 –16 4.601 72,229 –15 4.588 69,806 –14 4.576 67,465 –13 4.562 65,205 –12 4.549 63,027 –11 4.535 60,930 –10 4.521 58,915

–9 4.507 56,981 –8 4.492 55,129 –7 4.477 53,358 –6 4.461 51,669 –5 4.446 50,062 –4 4.429 48,536 –3 4.413 47,007 –2 4.396 45,528 –1 4.379 44,098

0 4.361 42,715 1 4.344 41,380 2 4.325 40,089 3 4.307 38,843 4 4.288

37,639

5 4.269 36,476 6 4.249 35,354 7 4.229 34,270 8 4.209 33,224

9 4.188 32,214 10 4.167 31,239 11 4.145 30,298 12 4.123 29,389 13 4.101 28,511 14 4.079 27,663 15 4.056 26,844 16 4.033 26,052 17 4.009 25,285 18 3.985 24,544 19 3.960 23,826 20 3.936 23,130 21 3.911 22,455 22 3.886 21,800 23 3.861 21,163 24 3.835 20,556 25 3.808 19,967 26 3.782 19,396 27 3.755 18,843 28 3.727 18,307 29 3.700 17,787 30 3.672 17,284 31 3.644 16,797 32 3.617 16,325 33 3.588 15,8

34 3.559 15,426 35 3.530 14,997 36 3.501 14,582 37 3.471 14,181 38 3.442 13,791 39 3.412 13,415 40 3.382 13,050 41 3.353 12,696 42 3.322 12,353 43 3.291 12,021 44 3.260 11,699 45 3.229 11,386 46 3.198 11,082 47 3.167 10,787 48 3.135 10,500 49 3.104 10,221 50 3.074 9,949 51 3.042 9,689 52 3.010 9,436 53 2.978 9,190 54 2.946 8,951 55 2.914 8,719 56 2.882 8,494 57 2.850 8,275 58 2.819 8,062 59 2.788 7,855 60 2.756 7,655 61 2.724 7,460 62 2.692 7,271 63 2.660 7,088 64 2.628 6,909 65 2.596 6,736

TEMPERATURE

(F)

PIC

VOLTAGE

DROP (V)

RESISTANCE

(OHMS)

66 2.565 6,568 67 2.533 6,405 68 2.503 6,246 69 2.472 6,092 70 2.440 5,942 71 2.409 5,796 72 2.378 5,655 73 2.347 5,517 74 2.317 5,382 75 2.287 5,252 76 2.256 5,124 77 2.227 5,000 78 2.197 4,880 79 2.167 4,764 80 2.137 4,650 81 2.108 4,539 82 2.079 4,432 83 2.050 4,327 84 2.021 4,225 85 1.993 4,125 86 1.965 4,028 87 1.937 3,934 88 1.909 3,843 89 1.881 3,753 90 1.854 3,667 91 1.827 3,582 92 1.800 3,500 93 1.773 3,420 94 1.747 3,342 95 1.721 3,266 96 1.695 3,192 97 1.670 3,120 98 1.644 3,049

99 1.619 2,981 100 1.595 2,914 101 1.570 2,849 102 1.546 2,786 103 1.523 2,724 104 1.499 2,663 105 1.476 2,605 106 1.453 2,547 107 1.430 2,492 108 1.408 2,437 109 1.3862,384 110 1.364 2,332 111 1.343 2,282 112 1.321 2,232 113 1.300 2,184 114 1.279 2,137 115 1.259 2,092 116 1.239 2,047 117 1.219 2,003 118 1.200 1,961 119 1.180 1,920 120 1.161 1,879 121 1.143 1,840 122 1.124 1,801 123 1.106 1,764 124 1.088 1,727 125 1.070 1,691 126 1.053 1,656 127 1.036 1,622 128 1.019 1,589 129 1.002 1,556 130 0.986 1,524 131 0.969 1,493 132 0.953 1,463 133 0.938 1,433 134 0.922 1,404 135

0.907 1,376

136 0.893 1,348 137 0.878 1,321 138 0.864 1,295 139 0.849 1,269 140 0.835 1,244 141 0.821 1,219 142 0.808 1,195 143 0.795 1,172 144 0.782 1,149 145 0.769 1,126 146 0.756 1,104 147 0.744 1,083 148 0.731 1,062 149 0.719 1,041 150 0.707 1,021 151 0.696 1,002 152 0.684983 153 0.673 964 154 0.662 945 155 0.651 928 156 0.640 910

TEMPERATURE

(F)

PIC

VOLTAGE

DROP (V)

RESISTANCE

(OHMS)

157 0.630 893 158 0.619 876 159 0.609 859 160 0.599 843 161 0.589 827 162 0.579 812 163 0.570 797 164 0.561 782 165 0.551 768 166 0.542 753 167 0.533 740 168 0.524 726 169 0.516 713 170 0.508 700 171 0.499 687 172 0.491 675 173 0.484 663 174 0.476 651 175 0.468 639 176 0.460 628 177 0.453 616 178 0.445 605 179 0.438 595 180 0.431 584 181 0.424 574 182 0.418 564 183 0.411 554 184 0.404 544 185 0.398 535 186 0.392 526 187 0.385 516 188 0.379 508 189 0.373 499 190 0.367 490 191 0.361 482 192 0.356 474 193 0.350 466 194 0.344 458 195 0.339 450 196 0.333 442 197 0.328 435 198 0.323 428 199 0.318 421 200 0.313 414 201 0.308 407 202 0.304 400 203 0.299 393 204 0.294 387 205 0.290 381 206 0.285 374 207 0.281368 208 0.277 362 209 0.272 356 210 0.268 351 211 0.264 345 212 0.260 339 213 0.256 334 214 0.252 329 215 0.248 323 216 0.245 318 217 0.241 313 218 0.237 308 219 0.234 303 220 0.230 299 221 0.227 294 222 0.224 28

223 0.220 285 224 0.217 280 225 0.214 276 226 0.211 272 227 0.208 267 228 0.205 263 229 0.203 259 230 0.198 255 231 0.195 251 232 0.192 248 233 0.190 244 234 0.187 240 235 0.184 236 236 0.182 233 237 0.179 229 238 0.176 226 239 0.174 223 240 0.172 219 241 0.169 216 242 0.167 213 243 0.164 210 244 0.162 207 245 0.160 204 246 0.158 201 247 0.155 198 248 0.153 195

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Table 18 — Thermistor Temperature (C) vs. Resistance/Voltage Drop

TEMPERATURE

(C)

–33 4.722 105 616 –32 4.706 99 640 –31 4.688 93 928 –30 4.670 88 480 –29 4.650 83 297 –28 4.630 78 377 –27 4.608 73 722 –26 4.586 69 332 –25 4.562 65 205 –24 4.538 61 343 –23 4.512 57 745 –22 4.486 54 411 –21 4.458 51 341 –20 4.429 48 536 –19 4.399 45 819 –18 4.368 43 263 –17 4.336 40 858 –16 4.303 38 598 –15 4.269 36 476 –14 4.233 34 484 –13 4.196 32 613 –12 4.158 30 858 –11 4.119 29 211 –10 4.079 27 663

–9 4.037 26 208 –8 3.994 24 8 –7 3.951 23 545 –6 3.906 22 323 –5 3.861 21 163 –4 3.814 20 083 –3 3.765 19 062 –2 3.716 18 097 –1 3.667 17 185

0 3.617 16 325 1 3.565 15 513 2 3.512 14 747 3 3.459 14 023 4 3.406 13 341 5 3.353 12 696 6 3.298 12 087 7 3.242 11 510 8 3.185 10 963

9 3.129 10 444 10 3.074 9 949 11 3.016 9 486 12 2.959 9 046 13 2.901 8 628 14 2.844 8 232 15 2.788 7 855 16 2.730 7 499 17 2.672 7 160 18 2.615 6 839 19 2.559 6 535 20 2.503 6 246 21 2.447 5 972 22 2.391 5 711 23 2.335 5 463 24 2.2805 226 25 2.227 5 000 26 2.173 4 787 27 2.120 4 583 28 2.067 4 389 29 2.015 4 204 30 1.965 4 028 31 1.914 3 861 32 1.865 3 701 33 1.816 3 549 34 1.768 3 404 35 1.721 3 266 36 1.675 3 134 37 1.629 3 008 38 1.5852 888 39 1.542 2 773 40 1.499 2 663 41 1.457 2 559 42 1.417 2 459 43 1.377 2 363

PIC

VOLTAGE

DROP (V)

RESISTANCE

(OHMS)

TEMPERATURE

(C)

44 1.338 2 272 45 1.300 2 184 46 1.263 2 101 47 1.227 2 021 48 1.192 1 944 49 1.158 1 871 50 1.124 1 801 51 1.091 1 734 52 1.060 1 670 53 1.029 1 609 54 0.999 1 550 55 0.969 1 493 56 0.941 1 439 57 0.913 1 387 58 0.8871 337 59 0.861 1 290 60 0.835 1 244 61 0.811 1 200 62 0.7871 158 63 0.764 1 117 64 0.741 1 079 65 0.719 1 041 66 0.698 1 006 67 0.677 971 68 0.657 938 69 0.638 906 70 0.619 876 71 0.601 846 72 0.583 81 73 0.566 791 74 0.549 765 75 0.533 740 76 0.518 715 77 0.503 692 78 0.488 670 79 0.474 648 80 0.460 628 81 0.447 608 82 0.434 588 83 0.422 570 84 0.410 552 85 0.398 535 86 0.387518 87 0.376 502 88 0.365 487 89 0.355 472 90 0.344 458 91 0.335 444 92 0.325 431 93 0.316 418 94 0.308 405 95 0.299 393 96 0.291 382 97 0.283 371 98 0.275 360

99 0.267 349 100 0.260 339 101 0.253 330 102 0.246 320 103 0.239 311 104 0.233 302 105 0.227 294 106 0.221 286 107 0.215 278 108 0.210 270 109 0.205 262 110 0.198 255 111 0.193 248 112 0.188 242 113 0.183 235 114 0.178 229 115 0.174 223 116 0.170 217 117 0.165 211 118 0.161 205 119 0.157 200 120 0.153 195

PIC

VOLTAGE

DROP (V)

RESISTANCE

(OHMS)

Page 50

CHECK SENSOR ACCURACY

1ST STAGE BEARING TEMP SENSOR

2ND STAGE

BEARING

TEMP SENSOR

MOTOR TEMP SENSOR

ELEMENT

BLK

WHT RED

ELEMENT

Place the sensor in a medium of known temperature and compare that temperature to the measured reading. The thermometer used to determine the temperature of the medium should be of laboratory quality with 0.5F (0.25C) graduations. The sensor in question should be accurate to within 2F (1.2C).

Note that the PIC6 control module, MAINTENANCE menu, offers a temperature sensor calibration feature where the sensor temperature can be offset. Note that only the four water temperatures can be calibrated. To use this feature, place the sensor at 32°F (0C) or other known temperature. Read the raw temperature and calculate offset based on the reading seen in the TEMP_CAL menu. Enter and execute the offset, which cannot exceed ± 2F (1.2C).

See Fig. 2 for sensor locations. The sensors are immersed directly in the refrigerant or water circuits. When installing a new sensor, apply a pipe sealant or thread sealant to the sensor threads.

An additional thermistor, factory installed in the bottom of the evaporator barrel, is displayed as Evap Refrig Liquid Temp on the TEMPERATURES display screen. This thermistor provides additional protection against a loss of water flow.

DUAL TEMPERATURE SENSORS

For servicing convenience, there are 2 redundant sensors each on the bearing and motor temperature sensors. If one of the sensors is damaged, the other can be used by simply moving a wire. The number 2 terminal in the sensor terminal box is the common line. To use the second sensor, move the wire from the number 1 position to the number 3 position. See Fig. 44 or Fig. 45.

Checking Pressure Transducers

There are 6 factory-installed pressure transducers measuring refrigerant pressure: condenser pressure, evaporator pressure, refrigerant pump suction, discharge pressure, bearing inlet pressure, and bearing outlet pressure.

These transducers can be calibrated if necessary. It is necessary to calibrate at initial start-up, particularly at high altitude locations, to ensure the proper refrigerant temperature/pressure relationship. Each transducer is supplied with 5 vdc power. If the power supply fails, a transducer voltage reference alarm occurs. If the transducer reading is suspected of being faulty, check the TRANSDUCER VOLTAGE REF supply voltage. It should be 5 vdc ± 0.5 v as displayed in Maintenance Menu



Maintenance Others, where all the transducer voltages are shown. If the TRANSDUCER VOLTAGE REF supply voltage is correct, the transducer should be recalibrated or replaced.

Also check that any external inputs have not been grounded and are not receiving anything other than a 4 to 20 mA signal.

TRANSDUCER REPLACEMENT

Since the transducers are mounted on Schrader-type fittings, there is no need to remove refrigerant from the vessel when replacing the transducers. Disconnect the transducer wiring. Do not pull on the transducer wires. Unscrew the transducer from the Schrader fitting. When installing a new transducer, do not use pipe sealer (which can plug the sensor). Put the plug connector back on the sensor and snap into place. Check for refrigerant leaks.

WARNING

Be sure to use a back-up wrench on the Schrader fitting whenever removing a transducer, since the Schrader fitting may back out with the transducer, causing a large leak and possible injury to personnel.

Fig. 44 — Motor Housing Temperature Sensors

Fig. 45 — First and Second Stage Bearing

Temperature Wiring and Motor Thermistor Wiring

EVAPORATOR, CONDENSER, REFRIGERANT PUMP SUCTION AND DISCHARGE, BEARING INLET AND OUTLET PRESSURE TRANSDUCER CALIBRATION

Calibration can be checked by comparing the pressure readings from the transducer to an accurate refrigeration gage reading. These readings can be viewed or calibrated from the HMI screen. The transducer can be checked and calibrated at 2 pressure points. These calibration points are 0 psig (0 kPa) and between 10 and 30 psig (69 and 207 kPa). Connect pressure transducer to Schrader connection. To calibrate these transducers:

1. Shut down the compressor, evaporator, and condenser pumps.

NOTE: There should be no flow through the heat exchangers.

2. Disconnect the transducer in question from its Schrader fitting for evaporator or condenser transducer calibration. For other pressure or flow device calibration, leave the transducer in place.

NOTE: If the evaporator or condenser vessels are at 0 psig (0 kPa) or are open to atmospheric pressure, the transducers can be calibrated for zero without removing the transducer from the vessel.

3. Access the PRESSURE or (if water side pressure) HYDRAULIC STATUS screen and view the particular transducer reading. To calibrate pressure or waterside flow device, view the particular reading. It should read 0 psig (0 kPa). If the reading is not 0 psig (0 kPa), but within ± 5 psig (35 kPa), the value may be set to zero from the Maintenance Menu while the appropriate transducer parameter is highlighted. The value will now go to zero.

Page 51

4. If the transducer value is not within the calibration range, the transducer returns to the original reading. If the pressure is within the allowed range (noted above), check the voltage ratio of the transducer. To obtain the voltage ratio, divide the voltage (dc) input from the transducer by the supply voltage signal or measure across the positive (+ red) and negative (– black) leads of the transducer. The input to reference voltage ratio must be between 0.80 and

0.11 for the software to allow calibration. Rotate the waterside flow pressure device from the inlet nozzle to the outlet nozzle and repeat this step. If rotating the waterside flow device does not allow calibration, pressurize the transducer until the ratio is within range. Then attempt calibration again.

5. Installation of pressure transducers into water nozzles using flushable dirt leg trap is suggested; see Fig. 46. Pressures can be calibrated between 100 and 250 psig (689.5 and

1723.7 kPa) by attaching a regulated 250 psig (1724 kPa) pressure (usually from a nitrogen cylinder). For calibration, access the Pressure Sensor Calibration Menu from the Maintenance Menu and calibrate the appropriate sensor.

The PIC6 control system does not allow calibration if the transducer is too far out of calibration. In this case, a new transducer must be installed and re-calibrated.

High Altitude Locations

Because the chiller is initially calibrated at sea level, it is necessary to recalibrate the pressure transducers if the chiller has been moved to a high altitude location. Note that Atmospheric

Pressure can be adjusted in the Service Parameters Menu (located in the Configuration Menu).

Quick Test

The Quick Test feature is located in the Main Menu. Use this feature to test chiller status, test the status of various actuators, view water temperature deltas, and test pump and relays, as well as control inlet guide vane, EC (Envelope Control) valve, alarms, condenser, and chilled water pumps. The tests can help to determine whether a switch is defective or a pump relay is not operating, as well as other useful troubleshooting issues. During pumpdown operations, the pumps are energized to prevent freeze-up and the vessel pressures and temperatures are displayed.

Quick Calibration

Use this menu to calibrate IGVs and the EC valve if it has feedback.

Pumpdown/Lockout

The Pumpdown/Lockout feature, available from the Maintenance Menu, prevents compressor start-up when there is no refrigerant in the chiller or if the vessels are isolated. The Terminate Lockout feature ends the Pumpdown/Lockout after the pumpdown procedure is reversed and refrigerant is added.

Physical Data

Tables 19-27 and Fig. 47-59 provide additional information on component weights, compressor fits and clearances, physical and electrical data, and wiring schematics for the operator’s convenience during troubleshooting.

WATERBOX NOZZLE

TWO (2) 2” PIPE NIPPLES

SCHRADER VALVE

/4 NPTF TEE, BRASS

BALL VALVE

/4 - 18 NPT

Fig. 46 — Suggested Installation of Pressure Transducers into Water Nozzles Using Flushable Dirt Leg Trap

Page 52

Table 19 — Component Weights

COMPONENT

SUCTION PIPE ASSEMBLY (INCLUDES FLANGES) 569 258

INTERSTAGE PIPING 346 156

DISCHARGE PIPING 53

HMI PANEL 24 11

CONTROL PANEL 190 86

HIGH SIDE FLOAT CHAMBER COVER 50 23

LOW SIDE FLOAT CHAMBER COVER 50 23

PURGE ASSEMBLY 263 119

ENVELOP CONTROL VALVE / HGBP (OPTION) 97 44

ECONOMIZER BYPASS VALVE (OPTION) 121 55

FREE COOLING VALVE (OPTION) 200 91

LIQUID BYPASS AND ISOLATION VALVE (OPTION) 300 136

VFD 32VSS0850 1450 658

VFD HARMONIC FILTER 800 363

VFD CABLE 200 91

VFD TRAY 124 57

DV4 COMPRESSOR

lb kg

Table 20 — 19DV Compressor and Motor Weights* — DV4 High-Efficiency Motors

MOTOR

CODE

Voltage: 380/460

* Total compressor weight is the sum of the compressor aerodynamic

† Compressor aerodynamic component weight only, motor weight not

COMPRESSOR

WEIGHT† (lb)

B 6195 1090 330 2810 494 150

D 6195 1150 340 2810 522 154

F 6195 1230 350 2810 558 359

H 6195 1316 364 2810 597 165

components (compressor weight column), stator, rotor, and end bell cover weights.

included. Applicable to standard compressors only.

HOUSING WEIGHT (lb)

ENGLISH SI

STATOR AND

ROTOR AND SHAFT

WEIGHT (lb)

COMPRESSOR

WEIGHT† (kg)

HOUSING WEIGHT (kg)

STATOR AND

ROTOR AND SHAFT

WEIGHT (kg)

Page 53

Table 21 — 19DV Two-Stage Compressor Frame Size DV4

Heat Exchanger Weights (English)

CODE†

G20 8611 — 700 — 1723 — G21 8772 — 700 — 1799 — G22 8942 6713 700 413 1879 1332 G23 9111 6956 700 405 1959 1430 G24 9330 7222 700 402 2063 1539 G25 8677 — 700 — 1695 — G26 8802 — 700 — 1754 — G27 8972 6669 700 413 1834 1245 G28 9147 6884 700 405 1917 1333 G29 9339 7140 700 402 2007 1437 G40 9260 — 840 — 1808 — G41 9446 — 840 — 1895 — G42 9641 7275 840 468 1986 1453 G43 9836 7555 840 458 2076 1566 G44 10088 7860 840 455 2195 1689 G45 9326 — 840 — 1780 — G46 9470 — 840 — 1847 — G47 9665 7220 840 468 1938 1363 G48 9867 7467 840 458 2032 1463 G49 10087 7760 840 455 2135 1581 G2A 8225 — 700 — 1740 — G2B 8324 — 700 — 1807 — G2C 8433 6198 700 413 1881 1424 G2D 8540 6402 700 405 1952 1544 G2E 8699 6585 700 397 2059 1653

G2F 8236 — 700 — 1675 — G2G 8331 — 700 — 1739 — G2H 8450 6180 700 413 1819 1340

G2J 8580 6359 700 405 1907 1446 G2K 8710 6504 700 397 1994 1532 G4A 8818 — 840 — 1827 — G4B 8933 — 840 — 1904 — G4C 9059 6688 840 468 1988 1558 G4D 9182 6922 840 458 2068 1696 G4E 9365 7133 840 448 2191 1819 G4F 8821 — 840 — 1757 — G4G 8931 — 840 — 1830 — G4H 9068 6663 840 468 1922 1471

G4J 9218 6869 840 458 2021 1591 G4K 9368 7036 840 448 2121 1690

H20 9572 — 741 — 2127 —

H21 9755 — 752 — 2213 —

H22 9936 7933 763 484 2298 1726

H23 10177 8253 778 495 2412 1856

H24 10420 8601 792 507 2527 1996

H25 9518 — 741 — 2101 —

H26 9697 — 752 — 2185 —

H27 9906 7815 763 484 2284 1678

H28 10115 8125 778 495 2383 1803

H29 10356 8450 792 507 2497 1936

H40 10315 — 841 — 2235 —

H41 10526 — 853 — 2334 —

H42 10734 8618 866 484 2430 1882

H43 11011 8985 883 495 2560 2029

H44 11291 9384 900 507 2690 2189

H45 10253 — 841 — 2205 —

H46 10459 — 853 — 2302 —

H47 10700 8482 866 563 2414 1827

H48 10940 8837 883 576 2527 1969

DRY RIGGING WEIGHT (LB)* REFRIGERANT WEIGHT (LB) WATER WEIGHT (LB)

EVAPORATOR

ONLY

CONDENSER

ONLY

EVAPORATOR

ONLY

CONDENSER

ONLY

EVAPORATOR

ONLY

CONDENSER

ONLY

Page 54

Table 21 — 19DV Two-Stage Compressor Frame Size DV4

Heat Exchanger Weights (English) (cont)

CODE†

H49 11218 9211 900 590 2657 2121 H2A 9025 — 700 — 2111 — H2B 9149 — 707 — 2195 — H2C 9294 7294 716 431 2293 1852 H2D 9453 7532 726 439 2400 1991

H2E 9623 7791 736 448 2514 2143

H2F 8990 — 700 — 2088 — H2G 9115 — 707 — 2172 — H2H 9253 7210 716 431 2266 1802

H2J 9402 7425 726 439 2363 1929 H2K 9568 7675 736 448 2477 2075 H4A 9692 — 795 — 2218 — H4B 9835 — 803 — 2313 — H4C 10002 7889 813 499 2424 2025 H4D 10185 8163 824 508 2546 2183

H4E 10381 8461 836 518 2676 2356

H4F 9652 — 795 — 2191 — H4G 9795 — 803 — 2286 — H4H 9956 7792 813 499 2393 1969

H4J 10126 8040 824 508 2504 2113 H4K 10318 8327 836 518 2634 2279

* Rigging weights are for standard Super B5LSL and Super C5 tubes

of standard wall thickness (0.025-in. [0.635 mm] wall) and do not include refrigerant weight.

† See Model Number Nomenclature on page 5.

NOTES:

1. Evaporator weight includes two-pass Victaulic dished heads.

2. Condenser weight includes the high side float chamber, discharge pipe, and two-pass Victaulic dished heads; does not include economizer weight.

DRY RIGGING WEIGHT (LB)* REFRIGERANT WEIGHT (LB) WATER WEIGHT (LB)

EVAPORATOR

ONLY

CONDENSER

ONLY

EVAPORATOR

ONLY

CONDENSER

ONLY

EVAPORATOR

ONLY

CONDENSER

ONLY

Page 55

Table 22 — 19DV Two-Stage Compressor Frame Size DV4

Heat Exchanger Weights (SI)

CODE†

G20 3906 — 318 —782— G21 3979 — 318 — 816 — G22 4056 3045 318 187 852 604 G23 4133 3155 318 184 889 649 G24 4232 3276 318 182 936 698 G25 3936 — 318 —769— G26 3993 — 318 —796— G27 4070 3025 318 187 832 565 G28 4149 3123 318 184 870 605 G29 4236 3239 318 182 910 652 G40 4200 — 381— 820 — G41 4285— 381— 860 — G42 4373 3300 381 212 901 659 G43 4462 3427 38 G44 4576 3565 381 206 996 766 G45 4230 — 381— 807 — G46 4296 — 381— 838 — G47 4384 3275 381 212 879 618 G48 4476 3387381208 922 664

G49 4575 3520 381 206 968 717 G2A 3731 — 318 —789— G2B 3776 — 318 — 820 — G2C 3825 2811 318 187 853 646 G2D 3874 2904 318 184 885 700 G2E 3946 2987318 180 934 750 G2F 3736 — 318 —760— G2G 3779 — 318 —789— G2H 3833 28

G2J 3892 2884318 184 865 656 G2K 3951 2950 318 180 904 695 G4A 4000 — 381— 829 — G4B 4052 — 381— 864 — G4C 4109 3034 381 212 902 707 G4D 4165 3140 381208 938 769 G4E 4248 3235 381 203 994 825 G4F 4001 — 381— 797— G4G 4051 — 381— 830 — G4H 4113 3022 381 212 872 667

G4J 4181 3116 381208 917 722 G4K 4249 3191 381 203 962 767

H20 — 4342 — 336 — 965

H21 4425 — 341 — 1004 —

H22 4507 3599 346 220 1042 783

H23 4616 3744 353 225 1094 842

H24 4726 3901 359 230 1146 905

H25

H26 4399 — 341 — 991 —

H27 4493 3545 346 220 1036 761

H28 4588 3685 353 225 1081 818

H29 4698 3833 359 230 1133 878

H40 4679 — 381 — 1014 —

H41 4774 — 387—1058 —

H42 4869 3909 393 220 1102 853

H43 4995 4075 401 225 1161 920

H44 5121 4256 408 230 1220 993

H45 4651 — 381 — 1000 —

H46 4744 — 387 — 1044 —

H47 4853 3847 393 255 1095 829

H48 4962 4008 401 261 1146 893

DRY RIGGING WEIGHT (kg)* REFRIGERANT WEIGHT (kg) WATER WEIGHT (kg)

EVAPORATOR

ONLY

4317 — 336 — 953 —

CONDENSER

ONLY

03 318 187 825 608

EVAPORATOR

ONLY

1208 942 710

CONDENSER

ONLY

EVAPORATOR

ONLY

CONDENSER

ONLY

Page 56

Table 22 — 19DV Two-Stage Compressor Frame Size DV4

Heat Exchanger Weights (SI) (cont)

CODE†

H49 5088 4178 408 268 1205 962 H2A 4094 — 318 —958 — H2B 4150 — 321 — 996 — H2C 4216 3308 325 195 1040 840 H2D 4288 3416 329 199 1089 903

H2E 4365 3534 334 203 1140 972

H2F 4078 —318 —947— H2G 4134 — 321 — 985— H2H 4197 3270 325 195 1028818

H2J 4265 3368 329 199 1072 875 H2K 4340 3481 334 203 1124 941 H4A 4396 — 361 — 1006 — H4B 4461 — 364 — 1049 — H4C 4537 3578 369 226 1100 919 H4D 4620 3703 374 230 1155 990

H4E 4709 3838 379 235 1214 1069

H4F 4378 — 361 — 994 — H4G 4443 — 364 — 1037 — H4H 4516 3535 369 226 1086 893

H4J 4593 3647 374 230 1136 958 H4K 4680 3777 379 235 1195 1034

* Rigging weights are for standard Super B5LSL and Super C5 tubes

of standard wall thickness (0.025-in. [0.635 mm] wall) and do not include refrigerant weight.

† See Model Number Nomenclature on page 5.

DRY RIGGING WEIGHT (kg)* REFRIGERANT WEIGHT (kg) WATER WEIGHT (kg)

EVAPORATOR

ONLY

CONDENSER

ONLY

EVAPORATOR

ONLY

NOTES:

CONDENSER

ONLY

1. Evaporator weight includes two-pass Victaulic dished heads.

2. Condenser weight includes the high side float chamber, discharge pipe, and two-pass Victaulic dished heads; does not include economizer weight.

EVAPORATOR

ONLY

CONDENSER

ONLY

Table 23 — 19DV Two-Stage Compressor Frame Size DV4

Economizer Weight

ECONOMIZER

SIZE 12 in. 1961 342 2303 889 155 1044 14 in. 2330 342 2672 1057 155 1212

* Includes standard economizer weight and all connecting piping to

compressor.

DRY WEIGHT

(lb)*

REFRIGERANT

WEIGHT (lb)

OPERATION

WEIGHT (lb)

DRY WEIGHT

(kg)*

REFRIGERANT

WEIGHT (kg)

Table 24 — Additional Weights for 19DV 150 psig (1034 kPa) Marine Waterboxes*

19DV4† — English (lb)

FRAME

* Add to evaporator and condenser weights for total weights. Evaporator

and condenser weights may be found in Tables 21 and 22. The first digit of the heat exchanger code (first column) is the heat exchanger frame size.

† Values are for Victaulic nozzles, two-pass dished head design.

NUMBER

PASSES

1 1221 1069 1174 612 498 1398 2 864 716 607 449 373 558 3 1533 1419 1001 848 778 1161 1 1517 1369 1131 815 703 1675 2 941 793 597 672 560 802 3 1659 1547 921 1080 1010 1395

RIGGING WGT

VICTAULIC FLANGE VICTAULIC FLANGE

EVAPORATOR CONDENSER

WATER WGT

RIGGING WGT

OPERATION WEIGHT (kg)

WATER WGT

Page 57

Table 25 — Additional Weights for 19DV 150 psig (1034 kPa)

19DV4† — SI (kg)

Marine Waterboxes*

FRAME

* Add to evaporator and condenser weights for total weights. Condenser

weights may be found in Tables 21 and 22. The first digit of the heat exchanger code (first column) is the heat exchanger frame size.

NUMBER

PASSES

1 554 485 533 278 226 634 2 392 325 275 204 169 253 3 695 644 454 385 353 527 1 688 621 513 370 319 760 2 427 360 271 305 254 364 3 753 702 418 490 458 633

RIGGING WGT

VICTAULIC FLANGE VICTAULIC FLANGE

EVAPORATOR CONDENSER

WATER WGT

† Values are for Victaulic nozzles, two-pass dished head design.

RIGGING WGT

WATER WGT

Table 26 — 19DV Waterbox Cover Weights, DV4 — English (lb)

WATERBOX

DESCRIPTION

NIH

DISHED COVER,

150 PSIG

MWB

FLAT COVER,

150 PSIG

LEGEND NOTE: Weights for dished head cover and MWB end cover 150 psig are

ASME — American Society of Mechanical Engineers MWB — Marine Waterbox

PASSES

1 494 417 515 437 232 172 249 187 2 682 528 714 560 308 235 390 273

2 return 404 424 154 168

3 557 499 588 529 247 210 268 232 1 2 172 214

2 return 404 422 154 168

3 668 759 172 215

FRAME G FRAME H FRAME G FRAME H

FLANGED VICTAULIC FLANGED VICTAULIC FLANGED VICTAULIC FLANGED VICTAULIC

EVAPORATOR CONDENSER

668 759

included in the heat exchanger weights shown in Table 21.

138 172

Table 27 — 19DV Waterbox Cover Weights, DV4 — SI (kg)

WATERBOX

DESCRIPTION

NIH

Dished Cover,

1034 kPa

MWB

FLAT COVER,

1034 kPa

LEGEND

ASME— American Society of Mechanical Engineers MWB — Marine Waterbox

NOTE: Weights for dished head cover and MWB end cover 1034 kPa are included in the heat exchanger weights shown in Table 22.

PASSES

1 224 189 234 198 105 78 113 85 2 309 239 324 254 140 107 177 124

2 return 183 192 70 76

3 253 226 267 240 112 95 122 105 1 2 78 97

2 return 183 191 70 76

3 303 344 78 98

FRAME G FRAME H FRAME G FRAME H

FLANGED VICTAULIC FLANGED VICTAULIC FLANGED VICTAULIC FLANGED VICTAULIC

EVAPORATOR CONDENSER

303 344

63 78

Page 58

BEARING SUPPORT HOUSING

VOLUTE

MOTOR HOUSING

NOSE PIECE

IGV

1ST STAGE

IMPELLER

EYE LABY

SHROUD

BEARING HOUSING

SPACER/ SIZER

MOTOR

2ND STAGE

SHAFT LABY

IMPELLER SHIM

BEARING/FLANGE IMPELLER

LABYRINTH

Fig. 47 — 19DV Compressor

Fig. 48 — HMI Panel

ROLLER ELEMENT BEARING ASSEMBLY

7TB IN HMI PANEL FOR CUSTOME R COMMUNICATION CCN CONNECTION A (+)

a19-2251

C (G) B (-)

Page 59

2TR

1CB

2CB

3CB

1TB

2TB

1TR

Fig. 49 — Control Panel

ETHERNET SWITCH FOR REMOTE CONNECTIVITY (IF EQUIPPED)

HFR

HPR

3TB-1

3TB-2

4TB

MODEM, FASTENED TO BACK OF DOOR (IF EQUIPPED)

5TB

Page 60

Fig. 50 — 19DV Control Wiring

Page 61

Fig. 51 — 19DV Input Output Board (IOB) Schematic

Page 62

Fig. 51 — 19DV Input Output Board (IOB) Schematic (cont)

Page 63

Fig. 51 — 19DV Input Output Board (IOB) Schematic (cont)

Page 64

Fig. 52 — 19DV Input Output Board (IOB) Schematic Abbreviations

Page 65

LEGEND

—

Refrigerant Pump Contactor

—

Liquid Bypass Valve Contactor (Option)

—

Economizer Vent Valve Contactor (Option)

—

Free Cooling Valve Contactor (Option)

1CB

—

Control Power Circuit Breaker

2CB

—

Control Power Circuit Breaker

1TB

—

L1, L2, L3 – Main 3-Phase Power

1TB

—

LL2, LL1 – 1-Phase Control Power

2TB

—

Control Power Wiring Terminal Block

3TB

—

24 VAC Control Power Wiring Terminal Block

4TB

—

VFD Communication and Interlock

5TB

—

Customer Field Connection Terminal Block

ETHERNET SWITCH

—

Remote Connectivity Ethernet Connection

HFR

—

High Float Level Switch Relay

HPR

—

High Pressure Switch Relay

Fig. 53 — Chiller Control Schematic

Page 66

Fig. 54 — Control Panel Schematic

NOTES FOR FIG. 51-54

19DV WITH 32VS VFD

I. General

1.0 Variable Frequency Drive (VFD) shall be designed and manufactured in accordance with Carrier engineering requirement.

1.1 All field-supplied conductors and devices must be compliant, and be installed in compliance with all applicable codes and job specifications.

1.2 The routing of field-installed conduit and conductors and the location of field-installed devices must not interfere with equipment access or the reading, adjusting or servicing of any component.

1.3 Equipment installation and all starting and control devices must comply with details in equipment submittal drawings and literature.

1.4 Contacts and switches are shown in the position they would assume with the circuit deenergized and the chiller shutdown.

1.5 Warning — Do not use aluminum conductors.

1.6 Warning — Remove panel above VFD bus bar before drilling. Do not drill into any other VFD cabinet panels.

II. Power Wiring To VFD

2.0 Provide a means of disconnecting branch feeder power to VFD. Provide short circuit protection and interrupt capacity for branch feeder in compliance with all applicable codes.

2.1 Metal conduit must be used for the power wires, from VFD to branch feeder.

2.2 Line side power conductor rating must meet VFD nameplate voltage and chiller full load amps (minimum circuit ampacity).

2.3 Lug adapters may be required if installation conditions dictate that conductors be sized beyond the minimum ampacity required. Lugs will accommodate the quantity (#) and size cables (per phase) as follows. If larger lugs are required, they may be purchased from the manufacturer of the circuit breaker.

VFD MAX

INPUT AMPS

32VSS0850 4 4/0 - 500 kcmil 2/0

100KAIC LUG CAPACITY (PER PHASE)

NO. OF

CONDUCTORS

CONDUCTOR

RANGE

GROUND

CONNECTOR

2.4 Compressor motor and controls must be grounded by using equipment grounding lug provided inside unit-mounted VFD enclosure.

III. Control Wiring

3.0 Field-supplied control conductors to be at least 18 AWG (American Wire Gage) or larger.

3.1 Ice build start/terminate device contacts, remote start/stop device contacts and spare safety device contacts (devices not supplied by Carrier) must have 24 vac rating. Max current is 60 mA, nominal current is 10 mA. Switches with gold-plated bifurcated contacts are recommended.

3.2 Each integrated contact output can control loads (VA) for evaporator pump, condenser pump, tower fan low, tower fan high and alarm annunciator devices rated 5 amps at 115 vac and up to 3 amps at 250 vac.

WARNING

Control wiring required for Carrier to start pumps and tower fan motors, and established flows must be provided to assure machine protection. If primary pump, tower fan and flow control is by other means, also provide a parallel means for control by Carrier. Failure to do so could result in machine freeze-up or overpressure.

3.3 Do not use control transformers in the VFD enclosure or control panel as the power source for external or field-supplied contactor coils, actuator motors or any other loads.

3.4 Do not route control wiring carrying 30 v or less within a conduit which has wires carrying 50 v or higher or along side wires carrying 50 v or higher.

3.5 Spare 4 to 20 mA output signal is designed for controllers with a non-grounded 4 to 20 mA input signal and a maximum input impedance of 500 ohms.

Page 67

LEGEND

3TR —

Transformer

4TR —

Transformer

7TB 1,2 —

24VAC Low Voltage Wiring Terminal Block

7TB PP1, PP2 —

Main One Phase Power

7TB PE —

Ground

CC —

Purge Compressor/Fan Contactor

HC —

Purge Heater Contactor

HSR —

High Level Switch Relay

LSR —

Low Level Switch Relay

PR —

Purge Vacuum Pump Relay

SIOB —

Purge Input/Output Board

Fig. 55 — 19DV Purge Panel Layout

Page 68

LEGEND

SV01 —

Condenser Solenoid Valve

SV02 —

Compressor Solenoid Valve

SV03 —

Pumpout Solenoid Valve

SV04 —

Drain Solenoid Valve

SV05 —

Regeneration Solenoid Valve

SV06 —

Vent Solenoid Valve

TS01 —

Purge Compressor Inlet Temperature

Fig. 56 — Purge Schematic

Page 69

3456

—

FLEX BAR

—

DCIB

—

COIL ASSEMBLY

—

TRANSFORMER 4 kVA

—

DC REACTOR

—

CURRENT TRANSFORMERS

—

RECTIFIER

—

AC REACTOR

—

RECTIFIER FAN ASSEMBLY

—

INVERTER FAN ASSEMBLY

—

INVERTER

—

COIL ASSEMBLY

—

DCIB/HVIB (BACK) CONTROL ASSEMBLY

—

TRANSFORMER 4 kVA

—

DC REACTOR

—

CONTROL ASSEMBLY

—

CURRENT TRANSFORMERS

—

SERVICE COMMUNICATION PANEL

—

DC REACTOR

Fig. 57 — Exploded View of 32VS VFD

Page 70

DRIVE CONTROL INTERFACE BOARD

TRANSFER SWITCH FOR SINGLE PHASE SERVICE POWER (IF PROVIDED)

Fig. 58 — VFD Power Panel Assembly

Page 71

Fig. 59 — 32VS 850A VFD Control Schematic

Page 72

APPENDIX A — PIC6 SCREEN AND MENU STRUCTURE

HOME

MAIN MENU LOG IN/LOG OUT CONFIRM STOP CHOOSE OPERATING MODE ALARM MENU

Fig. A — Screen Structure, Basic Level (All) Access (No Password Required)

HOME

MAIN MENU LOG IN/LOG OUT CONFIRM

STOP CHOOSE OPERATING MODE ALARM MENU

Fig. B — Screen Structure, User Level Access (User Password Required)

Page 73

APPENDIX A — PIC6 SCREEN AND MENU STRUCTURE (CONT)

HOME

MAIN MENU LOG IN/LOG OUT CONFIRM STOP CHOOSE OPERATING MODE ALARM MENU

Fig. C — Screen Structure, Service (Advanced User) / Factory Level Access Password Required

Page 74

APPENDIX A — PIC6 SCREEN AND MENU STRUCTURE (CONT)

MAIN MENU DESCRIPTION

ICON DISPLAYED TEXT* ACCESS ASSOCIATED TABLE†

General Parameters Basic, User, Factory GENUINT

Temperatures Basic, User, Factory TEMP

Pressures Basic, User, Factory PRESSURE

Inputs Status Basic, User, Factory INPUTS

Outputs Status Basic, User, Factory OUTPUTS

Hydraulic Status Basic, User, Factory HYDRLIC

Run Times Basic, User, Factory RUNTIME

Modes Basic, User, Factory MODES

Set point User, Factory SETPOINT

Configuration Menu User, Factory CONFIG

Quick Test Factory QCK_TEST

Maintenance Menu Factory MAINTAIN

Trending Basic, User, Factory TRENDING

Quick Calibration Factory QCK_CALI

* Displayed text depends on the selected language (default is English). † See the 19DV with PIC6 Controls Operation and Troubleshooting

manual for table details.

Page 75

APPENDIX B — CCN COMMUNICATION WIRING FOR MULTIPLE CHILLERS (TYPICAL)

BLACK (G)

WHITE (-)

RED (+)

DRAIN WIRE

NOTE : Field-supplied terminal strip must be located in control panel.

Page 76

APPENDIX C — MAINTENANCE SUMMARY AND LOG SHEETS

19DV MAINTENANCE INTERVAL REQUIREMENTS

WEEKLY

COMPRESSOR None CONTROLS Review PIC6 Alarm/Alert History.

EVAPORATOR None. VFD None.

CONDENSER None. OIL RECLAIM None.

MONTHLY

COMPRESSOR None. CONTROLS Review and record purge operating time.

ANNUALLY

COMPRESSOR

EVAPORATOR

CONDENSER

LUBRICATION

ASSEMBLY

COMPRESSOR None. CONTROLS None.

EVAPORATOR Perform eddy current test. VFD None.

CONDENSER

COMPRESSOR

EVAPORATOR None. VFD None.

CONDENSER None. PURGE

LUBRICATION

ASSEMBLY

COMPRESSOR None. CONTROLS Do not disconnect control power.

EVAPORATOR

CONDENSER

NOTE: Equipment failures caused by lack of adherence to the Maintenance Interval Requirements are not covered under warranty.

Change lubrication assembly refrigerant and bearing filters. Leak test. Vibration trending.

Inspect and clean evaporator tubes. Confirm there is no foreign debris in the tubes or waterboxes from the water system. Inspect all pressure relief devices. Leak test. Verify water pressure differential. Inspect water pumps. Send refrigerant sample out for analysis. Replace liquid strainer in inhibitor reclaim line (closes to evaporator inlet).

Inspect and clean condenser tubes. Leak test. Verify water pressure differential. Inspect water pumps and cooling tower.

Replace both refrigerant filter and bearing filter.

EVERY 3 TO 5 YEARS

Inspect float valves and strainers. Perform eddy current test.

EVERY 5 YEARS

Replace gas strainer prior to eductor (or when refrigerant is removed).

Replace lubrication assembly suction strainers (or when refrigerant is removed).

SEASONAL SHUTDOWN

Isolate and drain waterbox. Remove waterbox cover from one end. Use compressed air to clear tubes.

CONTROLS

VFD

PURGE

PURGE None.

CONTROLS None.

VFD None.

PURGE Purge operation is required to remove non-condensables.

Perform general cleaning. Tighten connections. Check pressure transducers. Confirm accuracy of thermistors.

Perform general cleaning. Tighten connections. Change refrigerant/motor filter feeding VFD devices. Perform visual inspection of the capacitors located on the DC bus and inductors. Check cooling fan operation. Check condensate drain for the VFD enclosure. Change VFD strainer.

Record total purge Pumpout Numbers and Pumpout Time. If excessive then leak test and correct. Inspect moisture sight glasses in line to bearings and VFD. Replace purge strainer in drain line.

Page 77

APPENDIX D — REMOTE CONNECTIVITY COMMISSIONING

ROUTER

MODEM (BACKSIDE OF RIGHT-HAND DOOR)

Introduction

Cellular Remote Connectivity is a system developed by Carrier to remotely monitor a chiller. It consists of a PIC6 controller, IP Switch, cellular modem, and an antenna.

This appendix describes typical commissioning steps required for a chiller supplied with the Remote Connectivity option.

First locate the cellular antenna which is located in the chiller control panel. See Fig. D. This component is not installed at the factory since optimum mounting location is needed to be identified at the site as part of Remote Connectivity commissioning.

Installation During Commissioning

1. Disconnect unit power. Use proper lockout-tagout procedures to ensure safety while installing this equipment since the control panel door will need to be open during installation. See Fig. E for 19DV modem and router installation locations.

2. In Table A, record serial number of Cellular Modem which is printed on two labels on either side of the modem. It begins with the manufacture year, such as “2017”. This will be required later during commissioning.

Control Box

Cellular

Antenna

PIC5 OR PIC6

Cellular

Modem

Fig. D — Remote Connectivity Option

24Vac

Controls

IP Switch

Fig. E — Modem and Router Installation Locations (19DV)

Page 78

APPENDIX D — REMOTE CONNECTIVITY COMMISSIONING (CONT)

Table A — Customer Gateway Data Submittal Information

Submittal Data: Fill out all white fields. Scan or photograph and submit per Customer Gateway instructions.

CHILLER INFORMATION

Parameter Write Values Below Description

PIC6 Software

1.1

Part Number

Chiller Model

1.2

Number Chiller Serial

1.3

Number

GATEWAY INFORMATION

Parameter Write Values Below

Modem information

2.1

____________________

Modem serial number e.g. “2017N089911”:

Modem S/N: ____________________

Shown at bottom of start-up screen, or in the menu under Configuration > Control Identification. E.g. SCG-SR-20M200400

E.g. 19DV-G4CG4C4425H4-

E.g. 5217Q28248

STATUS LED

2.2

CHILLER CONTROLLER INFORMATION

Parameter Value Description

BACnet

3.1

Identifier

IP Address

3.2

SITE INFORMATION

Parameter Value Description

Jobsite Name

4.1

Jobsite Address

4.2

Service Office

4.3

Service Office Contact _____________________

4.4

SIGNAL LED Color (per Table B) – (circle one): RED / YELLOW / GREEN

STATE (circle one): SOLID / FLASHING

_________________________

____.____.____.____

_____________________

Seven digits e.g. 1600001 (from Customer Gateway).

This is the IP address with which the PIC6 is configured (from Customer Gateway).

This is the name by which the jobsite is usually recognized. It will be used to distinguish the site in the monitoring system.

Full address of jobsite. Used to uniquely identify jobsites in case Jobsite Name is duplicated.

Name of service office that services this site.

Name and Telephone Number (or e-mail address).

Page 79

APPENDIX D — REMOTE CONNECTIVITY COMMISSIONING (CONT)

3. Verify that both power wiring and connection to router is intact. Verify that a SIM card is installed in the modem. See Fig. F for connections.

Fig. F — Modem Connections

4. Install the provided antenna and route through knockout in back of control panel. Be sure to observe the warning in Fig. G.

Fig. G — Arc Flash Warning

5. Apply appropriate protective personal equipment (PPE) and apply power to unit and verify that modem and router are powered by confirming power LEDs are on.

6. Wait approximately 5 minutes before proceeding to next step to allow communication to be fully initiated.

Signal Evaluation

Test the antenna at various positions where it can possibly be wall mounted. See Fig. H.

Fig. H — Antenna Mounting

At each position, wait at least 5 seconds, and then read the state of the SIGNAL LED on the modem. The states and conclusions are given in Table B. Signal strength is measured in DBm (decibel-milliwatts), and is always a negative number.

Table B — Signal Evaluation

COLOR STATE GSM SIGNAL ACTION

RED Flashing <–85 This location will not work

RED Solid –80 through –85

YELLOW Flashing –75 through –80

YELLOW Solid –70 through –75 This location should work

GREEN Flashing –65 through –70 This location should work well GREEN Solid >–65 This location is highly likely to work well

This location may work with a high-gain antenna, but other options should be explored first

This location may work, but there may be occasional delays in sending data, and it may not be robust over time

Even if a position is found with signal better than –75, several positions should be tested to find the best signal case. Also consideration should be given to the accessibility of each position for mounting. Consideration should also be given to the routed length of the antenna cable — total length 196 in. (5 m). For final mounting of the antenna secure the bracket to fixed object and ensure that the antenna body itself does not make contact with any objects.

Signal strength can also be evaluated with a smart phone if operating on AT&T network. Path to see the phone’s current dBm signal varies by phone make and model.

Note that the network signal strength is outside of Carrier’s control. If no suitable positions are identified with the standard antenna cable, there are some alternate approaches that can be considered such as trying a high gain antenna (expect +3-5dBm but this option also has a longer cable), using an AT&T signal boost device, or installing a Remote Connectivity Accessory box (a separately powered box that can be installed up to 100m [330 ft] from chiller).

The standard offering during the start-up of the chiller is with the 5 meter cable equipment supplied with the chiller. Any additional requirements to get the remote connectivity fully functional will be part of the chiller installation cost, is not part of the standard chiller start-up, and is not covered under warranty.

Commissioning the Modem

As the Remote Connectivity feature involves communication over the cellular network into a server, commissioning requires support from support personnel at the Customer Gateway.

Fill out Table A, sections 1, 2, and 4, and then call the Customer Gateway at 877-963-1995 and advise that you are commissioning Cellular Remote Connectivity. They will assign a case number and inform the support personnel. The assigned support engineer will call back within a short time.

Receive Data for Configuring the PIC6 and Enter in PIC6 HMI

REQUIRED DATA

There are two pieces of data that have to be provided by the Customer Gateway support engineer and configured into the PIC6 by the commissioning engineer.

• BACnet Identifier

• IP Address

These parameters should be recorded and kept for future use.

PIC6 CONFIGURATION

For PIC6 the network configuration is entered from Main Menu → System Configuration [Service level password required].

PIC5 CONFIGURATION

For PIC5, hold fingers on the left side of the Home Screen. The Setup menu will appear after about 10 seconds; see Fig. I.

Page 80

APPENDIX D — REMOTE CONNECTIVITY COMMISSIONING (CONT)

Fig. I — PIC5 Home Screen and Setup Menu

From the Setup Menu, select “Network”. The PIC5 Network Setup menu will display; see Fig. J.

In Network Configuration do the following:

• “Enable” BACnet/IP

• Verify that BACnet Metric Units is set to the default “No”

• Type in the provided BACnet Identifier from the Customer Gateway

After making these changes, save the changes and the PIC5 panel will cycle power automatically. For PIC6 BACnet IP is configured from Main Menu → Protocol ConfigurationT.

INADEQUATE SIGNAL STRENGTH

Sites with inadequate signal strength should work with Carrier Service for the best on-site solution to activate the remote connectivity. Current alternatives to the standard antenna are a higher gain antenna, AT&T signal boost device or installing a Remote Connectivity Accessory box which is a separately powered box that can be installed up to 100 m (330 ft) from chiller.

Fig. J — PIC5 Network Setup

Verify that “Enable DHCP” is unchecked and Subnet mask is set to 255.255.255.0.

Enter the supplied IP Address. Save the changes. Enter current Factory Password into PIC5, then go to Configu-

ration → Network Configuration and navigate to page 3 (see Fig. K) using the bottom right arrow.

Fig. K — PIC5 Network Configuration Menu

(page 3 of 5)

Page 81

Abbreviations and explanations, 4 Bearing and gear maintenance, 46 Bearings, 8 Bolt torque requirements, 16 Chiller Components, 6 Dehydration, 20 Familiarization, 4 Identification, 5 Information nameplate, 4 Leak test, 18 Limited shutdown, operation after, 36 Operating condition, checking, 33 Preparing for start-up, 36 Replacement parts, ordering, 47 Starting, 36 Stopping, 36 Tightness, checking, 15 Cold weather operation, 37 Compressor Bearing and gear maintenance, 46 Description, 4 Condenser

Description, 4

Control Panel Inspecting, 44 Controller identification, modifying, 27 Controls Description, 12 PIC6 system components, 12 Display messages, checking, 47 Economizer Description, 4 Equipment required, 15 Evaporator Description, 4 Extended shutdown Preparing for, 36 Operation after, 36 Field set up and verification, 31 Filter, changing, 45 Gasketed joints, tightening, 15 Guide vanes Checking, 42 Operation, manual, 37 Heat exchanger tubes and flow devices, maintenance, 46 High altitude locations, 51 Initial start-up, 33 Initial start-up checklist, CL-1 Inspecting equipment, 46 Instructing customer operator, 34 Job data required, 15 Leak test procedures (chart), 17 Limited shutdown, operation after, 36 Local start/stop control, 13 Lubrication control, 13 Lubrication cycle, 8 Lubrication system, checking, 44 Machine identification, 31 Maintenance General, 42 Scheduled, 44 Summary and log sheets, 76 Weekly, 44 Motor rotation, checking, 33 Operating instructions, 36 Operator duties, 36 Physical data, 51 PIC6 Screen and menu reference, 72 System components, 12 Piping Inspecting before start-up, 21 Maintenance, 45 Pressure transducers Calibration, 50 Checking, 50

INDEX

Recalibrating, 47 Pumpdown/lockout, 51 Pumpout and refrigerant transfer, 39 Quick test Perform, 32 Use in troubleshooting, 51 Refrigerant

Adding, 42

Adjusting charge, 42 Charge, 24,25 Float system, inspecting, 45 Leak rate, 42 Leak testing, 42 Properties, 42 Testing after service, repair, or major leak, 42 Tracer, 18 Trimming charge, 44 Refrigeration cycle, 7 Refrigeration log, 37,38 Replacement parts, ordering, 47 Running system, checking, 36 Safety considerations, 2 Safety valves Checking before start-up, 21 Maintenance, 45 Schedule, inputting local occupied, 27 Sensor accuracy, checking, 50 Service configurations, inputting, 27 Service ontime, 44 Service tables, configuring, 28 Shipping packaging, removing, 15 Shutdown After extended, 36 After limited, 36 Local (with HMI), 15 Preparation for extended, 36 Software configuration, 23 Standing vacuum test, 18 Start-Up Accidental, preventing, 33 Before initial, 15 Chiller dehydration, 20 Control test (quick test), 32 Equipment required, 15 Field set up and verification, 31 Gasketed joints, tightening, 15 Initial, 33 Inspecting water piping, 21 Job data required, 15 Leak test, 18 Safety valves, checking, 21 Schedule, inputting local occupied, 27 Service configurations, inputting, 27 Shipping packaging, removing, 15 Software configuration, 23 Standing vacuum test, 18 Timing sequence, 14 Tracer, 18 Start-up/shutdown/recycle sequence, 13 Surge prevention, 34 System components, 4 Temperature sensors, checking, 47 Thermistor temperature vs. resistance/voltage drop (C) 49 Thermistor temperature vs. resistance/voltage drop (F) 48 Time and date, inputting, 27 Troubleshooting guide, 47 Wa te r Leaks, 46 Treatment, 46 Wiring Bearing temperature sensors, 50 CCN for multiple chillers, 75 Control panel IOB layer, 59 HMI panel, 58

Page 82

Catalog No. 04-53190056-01 Printed in U.S.A. Form 19DV-CLT-2SS Pg 82 6-19 Replaces: 19DV-CLT-1SS

Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.

Page 83

INITIAL START-UP CHECKLIST

FOR 19DV SEMI-HERMETIC TWO-STAGE CENTRIFUGAL LIQUID CHILLER

(Remove and use for job file.)

NOTE: To avoid injury to personnel and damage to equipment or property when completing the procedures listed in this start-up checklist, use good judgment, follow safe practices, and adhere to the safety considerations/information as outlined in preceding sections of this Start-Up, Operation, and Maintenance Instructions document.

MACHINE INFORMATION:

NAME SALES ORDER NO.

ADDRESS MODEL

CITY STATE ZIP S/N

DESIGN CONDITIONS:

TONS

(kW)

EVAPORATOR ******

CONDENSER ******

BRINE

FLOW

RATE

TEMPERATUREINTEMPERATURE

OUT

PRESSURE

DROP

PASS

SUCTION

TEMPERATURE

CONDENSER

TEMPERATURE

CHILLER LINE SIDE: Volts FLA OLTA

REFRIGERANT: Type:

CARRIER OBLIGATIONS: Disassembled at Job Site . . . . . . . . Yes  No 

Charge

Assemble... . . . . . . . . . . . . . . . . Yes  No 

Leak Test . . . . . . . . . . . . . . . . . . . Yes  No 

Dehydrate . . . . . . . . . . . . . . . . . . Yes  No 

Charging . . . . . . . . . . . . . . . . . . . Yes  No 

Operating Instructions

Hrs.

START-UP TO BE PERFORMED IN ACCORDANCE WITH APPROPRIATE MACHINE START-UP INSTRUCTIONS JOB DATA REQUIRED:

1. Machine Installation Instructions Yes No 

2. Machine Assembly, Wiring and Piping Diagrams Yes No 

3. Starting Equipment Details and Wiring Diagrams Yes No 

4. Applicable Design Data (see above) Yes No 

5. Diagrams and Instructions for Special Controls Yes No 

INITIAL MACHINE PRESSURE:

YES NO

Was Machine Tight?

If Not, Were Leaks Corrected?

Was Machine Dehydrated After Repairs?

RECORD ACTUAL PRESSURE DROPS Evaporator Condenser

CHARGE REFRIGERANT: Initial Charge Final Charge After Trim

Catalog No. 04-53190056-01 Printed in U.S.A. Form 19DV-CLT-2SS Pg CL-1 6-19 Replaces: 19DV-CLT-1SS

Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.

Page 84

INSPECT WIRING AND RECORD ELECTRICAL DATA:

RATINGS: Motor Voltage

Motor RLA Chiller LRA Rating Actual Line Voltages: VFD Refrigerant (1TB L1/L2/L3) Pump Controls (1TB LL1/LL2) Verify 6-in. clearance surrounding all VFD enclosure louvers. Yes  No 

Record:

L1 to ground L2 to ground L3 to ground L1 to L2 L1 to L3

L2 to L3 NOTE: The % of voltage imbalance should be the same for the two different measurements Visually inspect the top of the starter cabinet for penetrations and internally for metal particulate: Yes  No  VFD Manufacturer ___________________________ VFD Serial Number __________________________ Mfd in _____________________________________

CONTROLS: SAFETY, OPERATING, ETC.

Perform Quick Calibration (Yes/No)

COMPRESSOR MOTOR AND CONTROL PANEL MUST BE PROPERLY AND INDIVIDUALLY CONNECTED BACK TO THE EARTH GROUND IN THE VFD (IN ACCORDANCE WITH CERTIFIED DRAWINGS). THE TRANSFORMER SUPPLYING POWER TO THE UNIT SHOULD BE A WYE SECONDARY WITH SOLIDLY GROUNDED NEUTRAL.

VFD Nameplate I.D. Number ___________________ VFD Nameplate Input Rating ___________________ on ________________________________________

Yes

WATER/BRINE PUMP CONTROL: Can the Carrier controls independently start the pumps?

Condenser Water Pump Yes  No  Chilled Water Pump Yes  No 

RUN MACHINE: Do these safeties shut down machine?

Condenser Water Flow Yes  No  Chilled Water Flow Yes  No  Pump Interlocks (optional) Yes  No 

INITIAL START: Line up all valves in accordance with instruction manual: Start water pumps and establish water flow: Check refrigerant pump rotation-pressure: Check compressor motor rotation (first stage suction housing sight glass) and record: Clockwise Restart compressor, bring up to speed (operating for at least 2 minutes), and shut down.

Any abnormal coastdown noise? If yes, determine cause: Yes  No 

START MACHINE AND OPERATE. COMPLETE THE FOLLOWING: A: Trim charge and record under Charge Refrigerant section on page CL-1. B: Take at least two sets of operational log readings and record. C: Give operating instructions to owner’s operating personnel. Given at:

Hours D: Call your Carrier factory representative to report chiller start-up. E: Return a copy of this checklist to the local Carrier Service office.

SIGNATURES: CARRIER

TECHNICIAN

CUSTOMER REPRESENTATIVE

CUT ALONG DOTTED LINE CUT ALONG DOTTED LINE

DATE

CL-2

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -- - - - - - - - - - - - - - - - - - - -

Page 85

19DV PIC6 SET POINT TABLE CONFIGURATION SHEET

DESCRIPTION RANGE UNITS DEFAULT VALUE

Cooling ECW Set point –9.4 to 48.9 °C 15.6

EWT Control Option DISABLE/ENABLE — DSABLE

Ice Build Set point –9.4 to 15.6 °C 4.4

Cooling LCW Set point –12.2 to 48.9 °C 7.2

Base Demand Limit 10.0 to 100.0 % 100.0

PIC6 TOUCH SCREEN Software Version Number:

PIC6 TOUCH SCREEN Controller Identification: BUS: ADDRESS:

19DV PIC6 TIME SCHEDULE CONFIGURATION SHEET PERIOD 1

Period 1:

Period 2:

Period 3:

Period 4:

Period 5:

Period 6:

Period 7:

Period 8:

Period 1:

Period 2:

Period 3:

Period 4:

Period 5:

Period 6:

Period 7:

Period 8:

DAY FLAG

MTWT FS SH

OCCUPIED

TIME

19DV PIC6 TIME SCHEDULE CONFIGURATION SHEET PERIOD 2

DAY FLAG

MTWT FS SH

OCCUPIED

TIME

UNOCCUPIED

TIME

UNOCCUPIED

TIME

Period 1:

Period 2:

Period 3:

Period 4:

Period 5:

Period 6:

Period 7:

Period 8:

19DV PIC6 TIME SCHEDULE CONFIGURATION SHEET PERIOD 3

DAY FLAG

MTWT FS SH

OCCUPIED

TIME

CL-3

UNOCCUPIED

TIME

Page 86

19DV PIC6 FACTORY TABLE CONFIGURATION SHEET

DESCRIPTION RANGE UNITS DEFAULT VALUE

Chiller Type 19XR6/7=0,19XR2~E/D/V=1, 19DV=2

Unit Type Cool Only=0,Heat Mach=1

Comp(Single=0,Dual=1) 0 to 1 0 Chilled Medium Type

Water =0, Brine =1 19DV Comp Design Press

44PSI=0 72PSI=1 Free Cooling Option 0 to 1 0 VFD Option

No=0,FS VFD=1,Carrier=2 Rockwell LF2=3, Eaton=4 Rockwell STD=5

IOB4 Option 0 to 1 0 Guide Vane1 Type

Digital=0 Analog=1 Marine Option 0 to 1 0 Power Request Option 0 to 1 0 Cont. Power Request 0 to 1 0 Purge System Option 0 to 1 0 Liquid Bypass Option 0 to 1 0

0 to 2 0

0 to 1 0

0 to 5 0

0 to 1 0

19DV PIC6 CFG_19DV CONFIGURATION TABLE CONFIGURATION SHEET

DESCRIPTION RANGE UNITS DEFAULT VALUE

Motor Pole Pair Single=1 Double=2

IGV2 Travel Limit 30 to 100 % 96.0 IGV2 Minimum Degree 0 to 20 Deg. 2.0 IGV2 Fully Open Degree 10 to 100 Deg. 90.0 IGV2 Actuator Max 90 to 120 Deg. 94.0 IGV2 Position @IGV1 20° 10 to 30 Deg. 28.1 IGV2 Position @IGV1 30° 10 to 50 Deg. 37.2 IGV2 Position @IGV1 50° 10 to 80 Deg. 71.6 VFD Rate Speed Hz 10 to 200 Hz 80.5 Purge Regen Lasting Time 0 to 65535 min 120 Daily PG Pumpout Limit 20 to 200 min 50

1 to 2 1

19DV PIC6 CFGSURGE_SURGE CORRECTION CONFIG TABLE CONFIGURATION SHEET

DESCRIPTION RANGE UNITS DEFAULT VALUE

Surge Line Configuration PR = 0, Delta T = 1

IGV1 POS Configuration Degree =0, Percentage =1

Surge Delta Tsmax 0 to 150 °F 70 Surge Delta Tsmin 0 to 150 °F 45 IGV1 Full Load Open Deg. 80.0 to 120.0 Deg. 88.0 IGV1 Minimum Open Deg. 0.0 to 10.0 Deg. 2.0 IGV1 Actuator Max Deg. 90.0 to 120.0 Deg. 109.0 IGV1 Minimum Position 0.0 to 100.0 % 5.0 IGV1 Full Load Position 0.0 to 100.0 % 100.0 Envelope Line Offset 0.1 to 3.0 °F 2.0 Envelope Speed Factor 0.00 to 3.00 2.0 Surge Line Shape Factor –1.000 to 0.000 –0.01

0 to 1 0

19DV PIC6 CFGGEVFD_GENERAL VFD CONFIG TABLE CONFIGURATION SHEET

DESCRIPTION RANGE UNITS DEFAULT VALUE VFD Max Speed Per 90 to110 % 100 VFD Min Speed Per 65 to VFD Start Speed Per 45 to 100 % 100 VFD Current Limit 0 to 99999 AMPS 250

89% 70

CUT ALONG DOTTED LINE CUT ALONG DOTTED LINE

CL-4

Page 87

19DV PIC6 CFGUMVFDUM VFD CONFIGURATION TABLE CONFIGURATION SHEET

DESCRIPTION RANGE UNITS DEFAULT VALUE Compressor Speed 100% 47 to 200 Hz 50 Motor Rated Line Voltage 200 to 13800 Volts 460 Motor Nameplate Current 10 to 2000 AMPS 200 Motor Rated Load Current 10 to 2000 AMPS 200 Motor Nameplate Voltage 200 to 13800 Volts 460 Motor Nameplate RPM 1500 to 5000 rpm 3000 Motor Nameplate KW 0 to 5600 KW 1500 Skip Frequency 1 0.0 to 102 Hz 30 Skip Frequency 2 0.0 to 102 Hz 30 Skip Frequency 3 0.0 to 102 Hz 30

19DV PIC6 SERVICE PARAMETERS TABLE CONFIGURATION SHEET

DESCRIPTION RANGE UNITS DEFAULT VALUE Atmospheric Pressure 8.000 to 15.000 PSI 14.5 GV1 Travel Limit 30 to 100 % 80.7 GV1 Closure at Startup 0 to 40 % 4 Controlled Fluid DB 0.5 to 2 ^F 1 Demand Limit At 20 mA 10 to 100 % 40 Demand Limit Prop Band 3 to 15 % 10 Amps or KW Ramp per Min 5 to 20 % 5 Temp Ramp per Min 1 to 10 ^F 3 Recycle Shutdown Delta T 0.5 to 4 ^F 1 Recycle Restart Delta T 2 to 10 ^F 5 Soft Stop Amps Threshold 40 to 100 % 70 Water Flow Verify Time 0.5 to 5 min 5 Power Calibration Factor 0.5 to 2 — 1 Enable Excessive Starts 0 to 1 — 0 Purge Active Temp SP 30 to 90 — 65

19DV PIC6 OPTION CONFIGURATION TABLE (CONF_OPT) CONFIGURATION SHEET

DESCRIPTION RANGE UNITS DEFAULT VALUE Auto Restart Option 0 to 1 0 Common Sensor Option 0 to 1 0 EC Valve Option

No=0, Cont.=1 ON/OFF=2, mA=3

EC Selection Disable=0, Surge=1 Low Load=2, Comb=3

Ice Build Option 0 to 1 0 Water Flow Determination 0 to 1 0 Liquid Bypass Selection 0 to 1 0 Purge On Idle Option 0 to 1 0

0 to 3 0

19DV PIC6 GENERAL PARAMETERS TABLE (GENUNIT) CONFIGURATION SHEET

DESCRIPTION RANGE UNITS DEFAULT VALUE Cooling/Heating Select 0 to 1

19DV PIC6 SETPOINT TABLE CONFIGURATION SHEET

DESCRIPTION RANGE UNITS DEFAULT VALUE Cooling ECW Setpoint 15 to 120 °F 60 Cooling LCW Setpoint –12.2 to 48.9 °F 45 ICE Build Setpoint –9.4 to 15.6 °F 104 Heating ECDW Setpoint 17.2 to 65.6 °F 113 Heating LCDW Setpoint 20 to 65.6 °F 40 Base Demand Limit 10.0 to 100.0 % 100.0

ALARM SHUTDOWN STATE RECORD SHEET

PRIMARY MESSAGE DATE TIME CHW IN CHW OUT EVAP REF CDW IN CDW OUT COND REF AMPS%

CL-5

Page 88

Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.

Catalog No. 04-53190056-01 Printed in U.S.A. Form 19DV-CLT-2SS Pg CL-6 6-19 Replaces: 19DV-CLT-1SS

CUT ALONG DOTTED LINE CUT ALONG DOTTED LINE

Carrier 19DV User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

SAFETY CONSIDERATIONS

INTRODUCTION

ABBREVIATIONS AND EXPLANATIONS

CHILLER FAMILIARIZATION (Fig. 1 and 2)

Chiller Information Nameplate

System Components

Evaporator

Condenser

Economizer

Motor-Compressor

Purge Unit

Variable Frequency Drive (VFD)

Refrigerant Lubrication System

Chiller Control Panel

Purge Control Panel

PIC6 Touch Screen HMI

REFRIGERATION CYCLE

REFRIGERANT LUBRICATION CYCLE

Summary

Bearings

Inhibitor Reclaim System

Motor Cooling System

VFD Cooling System

Purge System

CONTROLS

Definitions

ANALOG SIGNAL

DISCRETE SIGNAL

General

PIC6 System Components

Local Start/Stop Control

Lubrication Control

Shutdown

BEFORE INITIAL START-UP

Job Data Required

Equipment Required

Remove Shipping Packaging

Tighten All Gasketed Joints

Check Chiller Tightness

Refrigerant Tracer

Leak Test Chiller

Standing Vacuum Test

Check the Installation

Inspect Wiring

Chiller Dehydration

Inspect Water Piping

Check Safety Valves

Check Purge Compressor Operation

Ground Fault Troubleshooting

Carrier Comfort Network® Interface

Inhibitor Charge

Software Configuration

Charge Unit with Refrigerant

HOME SCREEN

CHANGE THE SET POINTS

PA SS WO R D

INPUT THE LOCAL OCCUPIED SCHEDULE

INPUT SERVICE CONFIGURATIONS

INPUT TIME AND DATE

MODIFY CONTROLLER IDENTIFICATION IF NECESSARY

CONFIGURE TABLES

Field Set Up and Verification

LABEL LOCATIONS

MODIFY EQUIPMENT CONFIGURATION IF NECESSARY

Perform a Controls Test (Quick Calibration/Quick Test)

OPTIONAL THERMAL DISPERSION FLOW SWITCH CALIBRATION

HYDRAULIC STATUS

INITIAL START-UP

Preparation

Check Motor Rotation

Check Refrigerant Lube

To Prevent Accidental Start-Up

Check Chiller Operating Condition

Instruct the Customer Operator(s)

EVAPORATOR-CONDENSER

MOTOR COMPRESSOR ASSEMBLY