Carrier 19DV User Manual

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.

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.)

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.

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

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

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)

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

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

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.

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

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

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.

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.

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

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-

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

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

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.

)

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 — —

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.

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.

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.

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.

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

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

/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

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.

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