Carrier 19PV550, 19PV720, 19PV800 Installation, Operation And Maintenance Instructions

INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS

Original document

19PV

Nominal cooling capacity 550 - 1600 kW 50Hz

1 - INTRODUCTION ............................................................................................................................................................................ 4

1.1 - Installation safety considerations ................................................................................................................................................4

1.2 - Equipment and components under pressure ..............................................................................................................................5

1.3 - Maintenance safety considerations ............................................................................................................................................. 5

1.4 - Repair safety considerations ....................................................................................................................................................... 6

2 - PRELIMINARY CHECKS ...............................................................................................................................................................8

2.1 - Check equipment received .......................................................................................................................................................... 8

2.2 - Moving and siting the unit............................................................................................................................................................8

3 - DIMENSIONS, CLEARANCES ......................................................................................................................................................9

3.1 - 19PV550 to 800...........................................................................................................................................................................9

3.2 - 19PV900 to 1180 .......................................................................................................................................................................10

4 - PHYSICAL AND ELECTRICAL DATA ........................................................................................................................................12

4.1 - Physical data ............................................................................................................................................................................. 12

4.2 - Electrical data ............................................................................................................................................................................ 13

4.3 - Short-circuit stability current for all units....................................................................................................................................13

4.4 - Compressor usage per circuit (A, B) ......................................................................................................................................... 13

5 - ELECTRICAL CONNECTION .....................................................................................................................................................15

5.1 - Power supply ............................................................................................................................................................................. 15

5.2 - Voltage phase imbalance (%)....................................................................................................................................................15

5.3 - Power connection/disconnect switch.........................................................................................................................................15

5.4 - Recommended wire sections .................................................................................................................................................... 15

5.5 - Power cable entry......................................................................................................................................................................16

5.6 - Field control wiring ....................................................................................................................................................................16

5.7 - 24 and 230 V power reserve for the user .................................................................................................................................. 16

6 - APPLICATION DATA ................................................................................................................................................................... 17

6.1 -

Operating limits for 19PV units ...................................................................................................................................................... 17

6.2 - Minimum chilled water ow .......................................................................................................................................................17

6.3 - Maximum chilled water ow ......................................................................................................................................................17

6.4 - Condenser water ow rate .......................................................................................................................................................17

6.5 - Standard and optional number of water passes ........................................................................................................................ 18

6.6 - Min water volume and evaporator & condenser water ow rates..............................................................................................18

6.7 - Variable ow evaporator ............................................................................................................................................................18

6.8 - Evaporator pressure drop curves .............................................................................................................................................. 19

7 - WATER CONNECTIONS .............................................................................................................................................................20

7.1 - Operating precautions ............................................................................................................................................................... 20

7.2 - Water connections .....................................................................................................................................................................21

7.3 - Flow control ............................................................................................................................................................................... 21

7.4 - Evaporator and condenser water box bolt tightening ................................................................................................................ 21

7.5 - Operation of two units in master/slave mode ............................................................................................................................ 22

8 - UNIT WITH OPTION 322 ............................................................................................................................................................. 23

9 - UNIT OPERATION WITH OPTION 154 .......................................................................................................................................24

9.1 - Operating principle .................................................................................................................................................................... 24

9.2 - Communication to control the drycooler .................................................................................................................................... 24

9.3 - Conguration of the number of fan stages and the automatic changeover of the fan stages ................................................... 24

9.4 - Fan stage assignment ............................................................................................................................................................... 24

9.5 - Drycooler installation on units ...................................................................................................................................................24

10 - UNIT OPERATION WITH OPTION 313 .....................................................................................................................................25

10.1 - Operating principle .................................................................................................................................................................. 25

10.2 - Communication to control the drycooler .................................................................................................................................. 25

10.3 - Conguration of the fans control ............................................................................................................................................25

10.4 - Water valves ............................................................................................................................................................................25

10.5 - System installations recommandation ..................................................................................................................................... 25

11 - MAJOR SYSTEM COMPONENTS AND OPERATION DATA ...................................................................................................26

11.1 - MagLev centrifugal compressor ..............................................................................................................................................26

11.2 - Pressure vessels .....................................................................................................................................................................26

11.3 - Disconnect switches for power supply ....................................................................................................................................27

11.4 Electronic expansion valve (EXV) .......................................................................................................................................... 27

11.5 - Moisture indicator .................................................................................................................................................................... 27

11.6 - Filter drier ................................................................................................................................................................................27

11.7 - Sensors ...................................................................................................................................................................................27

CONTENT

The cover photograph is for illustrative purposes only and is not part of any offer for sale or contract.

This manual applies to the following all 19PV versions.

For the operation of the control please refer to the 19PV Touch'Pilot Control manual.

CONTENT

12 - OPTIONS ................................................................................................................................................................................... 28

13 - STANDARD MAINTENANCE ....................................................................................................................................................29

13.1 - Level 1 maintenance ............................................................................................................................................................... 29

13.2 - Level 2 maintenance ............................................................................................................................................................... 29

13.3 - Level 3 (or higher) maintenance..............................................................................................................................................29

13.4 - Tightening of the electrical connections ..................................................................................................................................29

13.5 - Tightening torques for the main bolts and screws ...................................................................................................................30

13.6 - Evaporator and condenser maintenance ................................................................................................................................30

14 - START-UP CHECKLIST FOR 19PV LIQUID CHILLERS (USE FOR JOB

FILE) .......................................................................31

1 - INTRODUCTION

The 19PV units are designed to cool water for the air conditioning of buildings and industrial processes.

Prior to the initial start-up of the 19PV units, the people involved in the on-site installation, start-up, operation, and maintenance of this unit should be thoroughly familiar with these instructions and

the specic project data for the installation site.

The 19PV liquid chillers are designed to provide a very high level of safety during installation, start-up, operation and maintenance. They will provide safe and reliable service when operated within their application range.

They are designed for an operating life of 15 years by assuming a 75% utilisation factor; that is approximately 100,000 operating hours.

This manual provides the necessary information to familiarize yourself with the control system before performing start-up procedures. The procedures in this manual are arranged in the sequence required for machine installation, start-up, operation and maintenance.

Always ensure that all required safety measures are followed, including those in this document, such as: wearing protective clothing (gloves, safety glasses and shoes) using appropriate tools, employing qualified and skilled technicians (electricians, refrigeration engineers) and following local regulations.

To nd out, if these products comply with European directives

(machine safety, low voltage, electromagnetic compatibility, equipment under pressure etc.) check the declarations of conformity for these products.

1.1 - Installation safety considerations

Access to the unit must be reserved to authorised personnel,

qualied and trained in monitoring and maintenance. The access

limitation device must be installed by the customer (e.g. cut-off, enclosure).

After the unit has been received, when it is ready to be installed or reinstalled, and before it is started up, it must be inspected for damage. Check that the refrigerant circuit(s) is (are) intact, especially that no components or pipes have shifted (e.g. following a shock). If in doubt, carry out a leak tightness check and verify with the manufacturer that the circuit integrity has not been

impaired. If damage is detected upon receipt, immediately le a

claim with the shipping company.

The manufacturer strongly recommends employing a specialised company to unload the machine.

It is compulsory to wear personal protection equipment.

Do not remove the skid or the packaging until the unit is in

its nal position. These units can be moved with a fork lift

truck, as long as the forks are positioned in the right place and direction on the unit.

The units can also be lifted with slings, using only the

designated lifting points marked on the unit.

Use slings or lifting beams with the correct capacity, and always follow the lifting instructions on the certied drawings supplied

with the unit. Do not tilt the unit more than 15°.

Safety is only guaranteed, if these instructions are carefully followed. If this is not the case, there is a risk of material deterioration and injuries to personnel.

Never cover any protection devices.

This applies to the relief valves (if used) in the refrigerant or heat transfer medium circuits, the fuse plugs and the pressure switches.

Ensure that the valves are correctly installed, before operating

the unit.

Classication and control

In accordance with the Pressure Equipment Directive and national usage monitoring regulations in the European Union

the protection devices for these machines are classied as

follows:

Safety

accessory

(1)

Damage limitation

accessory in case of an

external re

(2)

Refrigerant side

High-pressure switch x

External relief valve

(3)

Rupture disk x

Fuse plug x

Heat transfer uid side

External relief valve

(4) (4)

(1) Classied for protection in normal service situations. (2) Classied for protection in abnormal service situations. These accessories are

sized for res with a thermal ow of 10kW/m². No combustible matter should be

placed within 6.5m of the unit.

(3) The instantaneous over-pressure limited to 10% of the operating pressure does

not apply to this abnormal service situation. The control pressure can be higher than the service pressure. In this case either the design temperature or the high-pressure switch ensures that the service pressure is not exceeded in normal service situations.

(4) The selection of these discharge valves must be made by the personnel

responsible for completing the hydraulic installation.

If the relief valves are installed on a change-over valve, this is equipped with a relief valve on each of the two outlets. Only one of the two relief valves is in operation, the other one is isolated. Never leave the change-over valve in the intermediate

position, i.e. with both ways open bring the actuator in abutment, front or back according to the outlet to isolate. If

a relief valve is removed for checking or replacement please ensure that there is always an active relief valve on each of the change-over valves installed in the unit.

All factory-installed relief valves are lead-sealed to prevent any

calibration change.

The external relief valves and the fuses are designed and

installed to ensure damage limitation in case of a re.

In accordance with the regulations applied for the design, the European directive on equipment under pressure and in accordance with the national usage regulations:

• These relief valves and fuses are not safety accessories but damage limitation accessories in case of a re,

• The high pressure switches are the safety accessories.

The relief valve must only be removed if the re risk is fully controlled and after checking that this is allowed by local regulations and authorities. This is the responsibility of the

operator.

When the unit is subjected to re, safety devices prevent rupture due to over-pressure by releasing refrigerant. The uid may then be decomposed into toxic residues when subjected to the ame:

• Stay away from the unit

• Set up warnings and recommendations for personnel

in charge to stop the re.

Fire extinguishers appropriate to the system and the

refrigerant type must be easily accessible.

The external relief valves must in principle be connected to discharge pipes for units installed in a room. Refer to the installation regulations, for example those of European

standards EN 378 and EN 13136.

They include a sizing method and examples for configuration and calculation. Under certain conditions these standards

permit connection of several valves to the same discharge pipe. Note: Like all other standards these EN standards are available from national standards organisations.

1 - INTRODUCTION

These pipes must be installed in a way that ensures that

people and property are not exposed to refrigerant leaks.

These uids may be diffused in the air, but far away from any building air intake, or they must be discharged in a quantity that is appropriate for a suitably absorbing environment.

It is recommended to install an indicating device to show if part of the refrigerant has leaked from the valve.

The calibration of a valve that has leaked is generally lower than its original calibration. The new calibration may affect

the operating range. To avoid a nuisance tripping or leaks,

replace or re-calibrate the valve.

Periodic check of the relief valves: See paragraph 1.3 “Maintenance safety considerations”.

Provide a drain in the discharge circuit, close to each relief valve, to avoid an accumulation of condensate or rain water.

Ensure good ventilation, as accumulation of refrigerant in an enclosed space can displace oxygen and cause asphyxiation or explosions.

Inhalation of high concentrations of vapour is harmful and may cause heart irregularities, unconsciousness, or death. Vapour is heavier than air and reduces the amount of oxygen

available for breathing. These products cause eye and skin

irritation. Decomposition products are hazardous.

1.2 - Equipment and components under pressure

The units are intended to be stored and operate in an environment where the ambient temperature must not be less than the lowest allowable temperature indicated on the nameplate. See section “11.2 - Pressure vessels”.

1.3 - Maintenance safety considerations

The manufacturer recommends the following drafting for a logbook (the table below should not be considered as reference and does not involve manufacturer responsibility):

Intervention

Name of the

commissioning

engineer

Applicable

national

regulations

Verication

Organism

Date Nature

(1)

(1) Maintenance, repairs, regular verications (EN 378), leakage, etc.

Engineers working on the electric or refrigeration components

must be authorized, trained and fully qualied to do so.

All refrigerant circuit repairs must be carried out by a trained person,

fully qualied to work on these units. He must have been trained

and be familiar with the equipment and the installation. All welding

operations must be carried out by qualied specialists.

The insulation must be removed and heat generation must be limited by using a wet cloth.

Any manipulation (opening or closing) of a shut-off valve

must be carried out by a qualied and authorised engineer. These procedures must be carried out with the unit shut-

down.

NOTE: The unit must never be left shut down with the liquid line valve closed, as liquid refrigerant can be trapped between

this valve and the expansion device. (This valve is situated

on the liquid line before the lter drier box.)

Equip the engineers that work on the unit as follows:

Personal protection

equipment (PPE)

(1)

Operations

Handling

Maintenance,

service

Welding or

brazing

(2)

Protective gloves, eye protection, safety shoe, protective clothing.

X X X

Ear protection. X X

Filtering respirator. X

(1) We recommend to follow the instructions in EN 378-3.

(2) Performed in the presence of A1 refrigerant according to EN 378-1.

Never work on a unit that is still energized.

CAUTION:

The 19PV units are tted with electrical circuit not disconnected by the main disconnect switch(es).

Never work on any of the electrical components, until the

general power supply to the unit has been cut at field

installation or using the main supply and the excepted

disconnect switches in the control box.

CAUTION:

A motor mechanism module is integrated to insure the automatic main supply disconnect switch closure. If any maintenance operations are carried out on the unit, lock all the power supply circuit(s) in the open position.

If the work is interrupted, always ensure that all circuits are

still deenergized before resuming the work.

CAUTION:

Even if the unit has been stopped the power circuit remains

energized, unless the unit or circuit disconnect switch is open. Refer to the wiring diagram for further details. Attach

appropriate safety labels.

CAUTION:

The frequency variator drive integrated in the compressor(s)

used in 19PV units are equipped with capacitor batteries. A

delay of twenty (20) minutes after disconnecting the power,

corresponding to the discharge time, must be observed before to remove the compressor(s) input cover.

Operating checks:

Important information regarding the refrigerant used:

• This product contains uorinated greenhouse gas covered by the Kyoto protocol.

Fluid type: R-134A

Global Warming Potential (GWP): 1430

CAUTION:

1. Prevent the release of uorinated gas from the unit. Ensure that uorinated gas is never released to the atmosphere during installation, maintenance or disposal. If a leak of uorinated gas is detected, ensure the leak is stopped and repaired as quickly as possible.

2. Only a qualied service technician is allowed to access this product and to correct the fault.

3. Any handling of uorinated gas contained in this product (e.g. removing the charge or topping up the gas) must comply with the F-Gas Directive (EC) No. 517/2014 concerning certain uorinated greenhouse gases and any

other applicable local legislation.

4. The gas recovery for recycling, regeneration or destruction is at customer charge.

5. The deliberate gas release is strictly not allowed.

6. Contact your local dealer or installer if you have any questions.

• Carry out periodic leak tests. In the European Union, article 2 of regulation (EU) No.517/2014 makes these mandatory and sets their frequency. The table below shows this frequency, as originally published in the regulation. Check whether an inspection frequency is also set by other regulations or standards applicable to your system (e.g. EN 378, ISO 5149, etc.).

A logbook must be established for the systems

that require a tightness check. It should contain the quantity and the type of fluid present within the installation (added and recovered), the quantity of recycled fluid, the date and output of the leak test,

the designation of the operator and its belonging company, etc.

Leak test periodicity:

System WITHOUT leakage detection

No test

months

6 months 3 months

System WITH leakage detection

No test

months

6 months

Refrigerant charge per

circuit (equivalent CO2)

< 5 tons

5 ≤

charge <

50 tons

50 ≤

charge < 500 tons

Charge >

500

tonnes*

Refrigerant charge per

circuit (kg)

R134a

(PRP 1430)

Charge

< 3.5 kg

3.5 ≤

charge

< 34.9 kg

34.9 ≤

charge <

349.7 kg

charge >

349.7 kg

R407C

(PRP 1774)

Charge

< 2.8 kg

2.8 ≤

charge

< 28.2 kg

28.2 ≤

charge <

281.9 kg

charge >

281.9 kg

R410A

(PRP 2088)

Charge

< 2.4 kg

2.4 ≤

charge

< 23.9 kg

23.9 ≤

charge

< 239.5

charge >

239.5 kg

HFOs: R1234ze No requirement

* From 01/01/2017, units must be equipped with a leak detection system.

• During the life-time of the system, inspection and tests must be carried out in accordance with national regulations.

Protection device checks (EN 378):

The safety devices must be checked on site once a year for

safety devices (see chapter 11.3 - High-pressure safety switch), and every five years for external overpressure devices (external relief valves).

The company or organisation that conducts a pressure switch test

shall establish and implement a detailed procedure to x:

- Safety measures

- Measuring equipment calibration

- Validating operation of protective devices

- Test protocols

- Recommissioning of the equipment.

Consult the manufacturer Service for this type of test. The manufacturer mentions here only the principle of a test without removing the pressure switch:

- Verify and and record the set-points of pressure switches and relief devices (valves and possible rupture discs)

- Be ready to switch-off the main disconnect switch of the power supply if the pressure switch does not trigger (avoid overpressure or excess gas in case of valves on the high-pressure side with the recovery condensers)

- Connect a pressure gauge protected against pulsations (lled with oil with maximum pointer if mechanical), preferably calibrated (the values displayed on the user interface may be inaccurate in an instant reading because of the scanning delay applied in the control)

- Complete an HP Test

- Neutralize HP soft protection

- Cut condenser water ow

- Check the cut-off value

- Reactivate manually HP switch and reactivate HP soft value

- Repeat the procedure for each unit compressor.

CAUTION:

If the test leads to replacing the pressure switch, it is necessary to recover the refrigerant charge, these pressure switches are not installed on automatic valves (Schraeder type).

At least once a year thoroughly inspect the protection devices (valves). If the machine operates in a corrosive environment, inspect the protection devices more frequently.

Ensure regularly that the vibration levels remain acceptable

and close to those at the initial unit start-up.

Before opening a refrigerant circuit, purge and consult the pressure gauges.

Change the refrigerant when there are equipment failures,

following a procedure such as the one described in NF E29-

795 or carry out a refrigerant analysis in a specialist

laboratory.

If the refrigerant circuit remains open for longer than a day after an intervention (such as a component replacement), the

openings must be plugged and the circuit must be charged with nitrogen (inertia principle). The objective is to prevent

penetration of atmospheric humidity and the resulting corrosion on the internal walls and on non-protected steel surfaces.

1.4 - Repair safety considerations

It is compulsory to wear personal protection equipment.

The insulation must be removed and warming up must be limited by using a wet cloth.

Before opening the unit always ensure that the circuit has

been purged.

If work on the evaporator is required, ensure that the piping from the compressor is no longer pressurised (as the valve is not leaktight in the compressor direction).

All installation parts must be maintained by the personnel in charge,

in order to avoid material deterioration and injuries to people. Faults

and leaks must be repaired immediately. The authorized technician must have the responsibility to repair the fault immediately. Each time repairs have been carried out to the unit, the operation of the protection devices must be re-checked.

Comply with the regulations and recommendations in unit and HVAC installation safety standards, such as: EN 378, ISO 5149, etc.

If a leak occurs or if the refrigerant becomes contaminated (e.g. by a short circuit in a motor) remove the complete charge using a recovery unit and store the refrigerant in mobile containers.

Repair the leak detected and recharge the circuit with the total R-134a charge, as indicated on the unit name plate. Certain parts of the circuit can be isolated. Only charge liquid refrigerant R-134a at the liquid line.

Ensure that you are using the correct refrigerant type before

recharging the unit

The compressors operating are NOT lubricated. Charging any

oil type will impair machine operation and lead to a destruction of the compressor.

Charging any refrigerant other than the original charge type (R-134a) will impair machine operation and can even lead to a destruction of the compressors.

1 - INTRODUCTION

RISK OF EXPLOSION:

Do not use oxygen to purge lines or to pressurize a machine for any purpose. Oxygen gas reacts violently with oil, grease,

and other common substances.

Never exceed the specied maximum operating pressures. Verify the allowable maximum high- and low-side test pressures by checking the instructions in this manual and

the pressures given on the unit name plate.

Do not use air for leak testing. Use only refrigerant or dry nitrogen.

Do not unweld or flamecut the refrigerant lines or any refrigerant circuit component until all refrigerant (liquid and

vapour) has been removed from chiller. Traces of vapour should be displaced with dry air nitrogen. Refrigerant in contact with an open ame produces toxic gases.

The necessary protection equipment must be available, and

appropriate fire extinguishers for the system and the

refrigerant type used must be within easy reach.

Do not siphon refrigerant.

Avoid contact with liquid refrigerant on the skin or splashing it into the eyes. Use safety goggles. Wash any spills from the skin with soap and water. If liquid refrigerant enters the eyes,

immediately and abundantly ush the eyes with water and

consult a doctor.

The accidental releases of the refrigerant, due to small leaks

or signicant discharges following the rupture of a pipe or an unexpected release from a relief valve, can cause frostbites and burns to personnel exposed. Do not ignore such injuries.

Installers, owners and especially service engineers for these units must:

Seek medical attention before treating such injuries.

Have access to a rst-aid kit, especially for treating eye

injuries.

We recommend to apply standard EN 378-3 Annex 3.

Never apply an open ame or live steam to a refrigerant

container. Dangerous overpressure can result. If it is necessary to heat refrigerant, use only warm water.

During refrigerant removal and storage operations follow applicable regulations. These regulations, permitting conditioning and recovery of halogenated hydrocarbons under optimum quality conditions for the products and optimum safety conditions for people, property and the environment are described in standard NF E29-795.

Any refrigerant transfer and recovery operations must be carried out using a transfer unit. A 3/8” SAE connector on the manual liquid line valve is supplied with all units for connection to the transfer station. The units must never be modified to add refrigerant, removal and purging devices. All these devices are

provided with the units. Please refer to the certied dimensional

drawings for the units.Do not re-use disposable (non-returnable)

cylinders or attempt to rell them. It is dangerous and illegal. When

cylinders are empty, evacuate the remaining gas pressure, and move the cylinders to a place designated for their recovery. Do not incinerate.

CAUTION:

Only use refrigerant R134a, in accordance with AHRI 700-2014 (Air conditioning, Heating and Refrigeration Institute). The use of any other refrigerant may expose users and operators to unexpected risks.

Do not attempt to remove refrigerant circuit components or

ttings, while the machine is under pressure or while it is running. Be sure pressure is at 0 kPa before removing

components or opening a circuit.

Do not attempt to repair or recondition any safety devices

when corrosion or build-up of foreign material (rust, dirt, scale, etc.) is found within the valve body or mechanism. If

necessary, replace the device. Do not install relief valves in

series or backwards.

CAUTION:

No part of the unit must be used as a walk-way, rack or

support. Periodically check and repair or if necessary replace any component or piping that shows signs of damage.

The refrigerant lines can break under the weight and release

refrigerant, causing personal injury.

Do not climb on a machine. Use a platform, or staging to work

at higher levels.

Use mechanical lifting equipment (crane, hoist, winch, etc.) to lift or move heavy components. For lighter components, use lifting equipment when there is a risk of slipping or losing

your balance.

Use only original replacement parts for any repair or component replacement. Consult the list of replacement parts that corresponds to the specification of the original equipment.

Do not drain water circuits containing industrial brines,

without informing the technical service department at the

installation site or a competent body rst.

Close the entering and leaving water shutoff valves and purge

the unit water circuit, before working on the components installed on the circuit (screen lter, pump, water ow switch,

etc.).

Do not loosen the water box bolts until the water boxes have been completely drained.

Periodically inspect all valves, fittings and pipes of the refrigerant and hydraulic circuits to ensure that they do not show any corrosion or any signs of leaks.

It is recommended to wear ear defenders, when working near the unit and the unit is in operation.

1 - INTRODUCTION

2.1 - Check equipment received

- Inspect the unit for damage or missing parts. If damage is

detected, or if shipment is incomplete, immediately le a claim

with the shipping company.

- Conrm that the unit received is the one ordered. Compare the name plate data with the order.

- The unit name plate must include the following information:

• Version number

• Model number

• CE marking

• Serial number

• Year of manufacture and test date

• Fluid being transported

• Refrigerant used and refrigerant class

• Refrigerant charge per circuit

• Containment uid to be used

• PS: Min./max. allowable pressure (high and low pressure

side)

• TS: Min./max. allowable temperature (high and low pressure

side)

• Pressure switch cut-out pressures

• Unit leak test pressure

• Voltage, frequency, number of phases

• Maximum current drawn

• Maximum power input

• Unit net weight

- Conrm that all accessories ordered for on-site installation have been delivered, and are complete and undamaged.

The unit must be checked periodically during its whole

operating life to ensure that no shocks (handling accessories, tools etc.) have damaged it. If necessary, the damaged parts

must be repaired or replaced. See also chapter 13 “Standard

maintenance”.

2.2 - Moving and siting the unit

2.2.1 - Moving

See chapter 1.1 “Installation safety considerations”.

CAUTION:

Only use slings at the designated lifting points which are marked on the unit.

2.2.2 - Siting the unit

Always refer to the chapter “Dimensions and clearances” to conrm

that there is adequate space for all connections and service operations. For the centre of gravity coordinates, the position of the unit mounting holes, and the weight distribution points, refer to the

certied dimensional drawing supplied with the unit.

Typical applications of these units are in refrigeration systems, and they do not require earthquake resistance. Earthquake

resistance has not been veried.

Before siting the unit check that:

- the permitted loading at the site is adequate or that appropriate strenghtening measures have been taken.

- the unit is installed level on an even surface (maximum tolerance is 5 mm in both axes).

- there is adequate space above the unit for air ow and to ensure access to the components.

- the number of support points is adequate and that they are in the right places.

- the location is not subject to ooding.

CAUTION:

Lift and set down the unit with great care. Tilting and jarring can damage the unit and impair unit operation.

2.2.3 - Checks before system start-up

Before the start-up of the refrigeration system, the complete

installation, including the refrigeration system must be veried

against the installation drawings, dimensional drawings, system piping and instrumentation diagrams and the wiring diagrams.

During the installation test national regulations must be followed. If no national regulation exists, standard EN 378 or ISO-5149 can be used as a guide.

External visual installation checks:

- Ensure that the machine is charged with refrigerant. Verify on

the unit nameplate that the ‘uid being transported’ is R-134a

and is not nitrogen.

- Compare the complete installation with the refrigeration syste m and power circuit diagrams.

- Check that all components comply with the design

specications.

- Check that all protection documents and equipment provided by the manufacturer (dimensional drawings, P&ID, declarations etc.) to comply with the regulations are present.

- Verify that the environmental safety and protection and devices and arrangements provided by the manufacturer to comply with the regulations are in place.

- Verify that all document for pressure containers, certicates, name plates, files, instruction manuals provided by the manufacturer to comply with the regulations are present.

- Verify the free passage of access and safety routes.

- Check that ventilation in the plant room is adequate.

- Check that refrigerant detectors are present.

- Verify the instructions and directives to prevent the deliberate removal of refrigerant gases that are harmful to the environment.

- Verify the installation of connections.

- Verify the supports and xing elements (materials, routing and connection).

- Verify the quality of welds and other joints.

- Check the protection against mechanical damage.

- Check the protection against heat.

- Check the protection of moving parts.

- Verify the accessibility for maintenance or repair and to check the piping.

- Verify the status of the valves.

- Verify the quality of the thermal insulation and of the vapour barriers.

2 - PRELIMINARY CHECKS

3.1 - 19PV550 to 800

COOLER

CONDENSER

NOTES:

Drawings are not contractually binding. Before designing an installation, consult the certied dimensional drawings supplied with the unit or available on request.

For the positioning of the xing points, weight distribution and centre of gravity coordinates please refer to the dimensional

drawings.

Dimension (mm)

A B C D

19PV

550 3045 1120 1745 2800

720 3070 1155 1846 2800

800 3270 1190 1925 3000

Legend:

All dimensions are given in mm.

Services clearances required

Space required to remove cooler tubes

Electrical box

Inlet water

Outlet water

Electrical supply entry

3 - DIMENSIONS, CLEARANCES

3.2 - 19PV900 to 1180

CONDENSER

COOLER

NOTES:

Drawings are not contractually binding. Before designing an installation, consult the certied dimensional drawings supplied with the unit or available on request.

For the positioning of the xing points, weight distribution and centre of gravity coordinates please refer to the dimensional

drawings.

Dimension (mm)

A B C D

19PV

900 4257 1290 1955 3950

1010 4257 1290 1955 3950

1180 4257 1290 1955 3950

Legend:

All dimensions are given in mm.

Services clearances required

Space required to remove cooler tubes

Electrical box

Inlet water

Outlet water

Electrical supply entry

3 - DIMENSIONS, CLEARANCES

3.3 - 19PV1300 to 1600

CONDENSER

COOLER

NOTES:

Drawings are not contractually binding. Before designing an installation, consult the certied dimensional drawings supplied with the unit or available on request.

For the positioning of the xing points, weight distribution and centre of gravity coordinates please refer to the dimensional

drawings.

Dimension (mm)

A B C D

19PV

1300 4705 1290 1955 4400

1450 4740 1290 2011 4400

1600 4740 1325 2065 4400

Legend:

All dimensions are given in mm.

Services clearances required

Space required to remove cooler tubes

Electrical box

Inlet water

Outlet water

Electrical supply entry

3 - DIMENSIONS, CLEARANCES

4 - PHYSICAL AND ELECTRICAL DATA

4.1 - Physical data

19PV 550 720 800 900 1010 1180 1300 1450 1600

Sound levels - standard unit

Standard unit

Sound power

(1)

dB(A) 89 92 94 92 94 95 94 95 97

Sound pressure at 10 m

(2)

dB(A) 57 60 62 60 62 63 62 63 65

Dimensions

Standard unit

Length mm 3140 3160 3360 4345 4345 4345 4800 4800 4800

Width mm 1270 1310 1335 1385 1385 1385 1385 1390 1410

Height mm 1780 1880 1965 2036 2036 2036 2000 2050 2100

Operating weight

(3)

Standard unit kg 2402 2930 3376 4831 4855 4904 5504 6164 6730

Compressors MagLev compressor TT300 / TT350

Circuit A 2 2 2 1 1 1 2 2 2

Circuit B - - - 2 2 2 2 2 2

Refrigerant

(3)

R134a

Circuit A

kg 95,0 120,0 140,0 100,0 100,0 100,0 125,0 135,0 150,0

teqCO2135,9 171,6 200,2 143,0 143,0 143,0 178,8 193,1 214,5

Circuit B

kg - - - 125,0 125,0 125,0 125,0 135,0 150,0

teqCO

- - - 178,8 178,8 178,8 178,8 193,1 214,5

Capacity control Touch'Pilot, electronic expansion valves (EXV)

Minimum capacity % 15 15 15 10 10 10 10 10 10

Evaporator Flooded multi-pipe type

Water volume l 115 165 180 285 285 285 330 330 365

Water connections (Victaulic) in 6 6 8 8 8 8 8 8 8

Drain and vent connections (NPT) in 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8

Max. water-side operating pressure kPa 1000 1000 1000 1000 1000 1000 1000 1000 1000

Condenser Flooded multi-pipe type

Water volume l 145 157 187 308 308 308 339 487 487

Water connections (Victaulic) in 6 6 8 8 8 8 8 8 8

Drain and vent connections (NPT) in 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8

Max. water-side operating pressure kPa 1000 1000 1000 1000 1000 1000 1000 1000 1000

(1) In dB ref=10

-12

W, 'A' weighted. Declared dual-number noise emission values in accordance with ISO 4871 with an associated uncertainty of +/-3dB(A). Measured in

accordance with ISO 9614-1 and certied by Eurovent.

(2) In dB ref 20μPa, 'A' weighted. Declared dual-number noise emission values in accordance with ISO 4871 with an associated uncertainty of +/-3dB(A). For information,

calculated from the sound power Lw(A).

(3) Values are guidelines only. Refer to the unit name plate.

4 - PHYSICAL AND ELECTRICAL DATA

4.2 - Electrical data

19PV 550 720 800 900 1010 1180 1300 1450 1600

Power circuit supply

Nominal voltage V-ph-Hz 400-3-50

Voltage range V 360-440

Control circuit supply 24 V via internal transformer

Maximum operating input power

(1)

- Standard unit

Circuit 1

(a)

kW 140 201 230 76 11 6 111 133 187 222

Circuit 2

(a)

kW - - - 152 152 222 204 187 222

Unit with option 81 kW - - - 229 269 333 337 375 445

Power factor at maximum power

(1)

0,92 0,92 0,92 0,92 0,92 0,92 0,92 0,92 0,92

Total harmonic distortion % <45 <45 <45 <45 <45 <45 <45 <45 <45

Nominal operating current draw

(2)

- Standard unit

Circuit 1

(a)

A 162 208 244 93 129 119 151 210 243

Circuit 2

(a)

A - - - 185 187 237 229 210 243

Unit with option 81 A - - - 278 315 356 380 420 486

Maximum operating current draw (Un)

(1)

- Standard unit

Circuit 1

(a)

A 220 315 361 119 183 174 209 294 349

Circuit 2

(a)

A - - - 239 239 349 319 294 349

Unit with option 81 A - - - 358 422 523 528 588 697

Maximum current (Un-10%)

(1)

- Standard unit

Circuit 1

(a)

A 237 340 390 129 197 188 225 318 377

Circuit 2

(a)

A - - - 258 258 377 345 318 377

Unit with option 81 A - - - 387 456 565 570 635 753

Maximum start-up current(Un) - Standard unit

(3)

Lower than max current

Dissipated power of electrical equipment

(1)

W 782 1249 1249 1144 1347 1814 1884 2351 2351

(1) Values obtained at unit continuous maximum operating conditions (data given on the unit nameplate) (2) Standardised EUROVENT conditions, water-cooled exchanger water inlet/outlet = 12°C/7°C, condenser entering/leaving water temperature = 30°C/35°C (3) Start-up current is limited by the soft-start controller included in the compressor. (a) When the machines are equipped with two power supplies, circuit 1 supplies the refrigerant circuit A and circuit 2 supplies the refrigerant circuit B

Note: Options 84 and 84R are not included in these values.

4.3 - Short-circuit stability current for all units

Short-circuit stability current for all units using the TN system (earthing system type): 50 kA (conditional system short-circuit current Icc/Icf at the unit connection point as rms value).

All units are equipped with circuit breakers located in the control box immediately downstream from the unit connection point.

4.4 - Compressor usage per circuit (A, B)

Compressor Circuit 550 720 800 900 1010 1180 1300 1450 1600

TT300

A 2 - - 1 - - 2 - -

B - - - 2 2 - - - -

TT350

A - 2 2 - 1 1 - 2 2

B - - - - - 2 2 2 2

4 - PHYSICAL AND ELECTRICAL DATA

Electrical data notes and operating conditions, 19PV units

• As standard: 19PV 550 to 19PV 800 units have a single power connection point located

immediately upstream of the main supply disconnect switche.

19PV 900 to19PV 1600 units have two connection points located immediately

upstream of the main supply disconnect switches.

• Control box includes the following standard features:

- Two disconnect switches per circuit: One main supply disconnect switch and one disconnect switch for the supply of the control part, the undervoltage protection circuit and the motor mechanism module,

- Filtering compressor currrent devices

- Anti-short cycle protection devices

- Control devices supply by internal transformers.

• Field connections: All connections to the system and the electrical installations must be in accordance

with all applicable codes.*

• 19PV units are designed and built to ensure conformance with these codes. The recommendations of European standard EN 60204-1 (corresponds to IEC 60204-

1) (machine safety - electrical machine components - part 1:general regulations)

are specically taken into account, when designing the electrical equipment.

• Generally the recommendations of IEC 60364 are accepted as compliance with the requirements of the installation regulation.

• Annex B of standard EN 60204-1 species the electrical features used for the

operation of the units. The features below complete the informations given in this document:

1. Physical environment:

The classication of environment is specied in standard EN 60364:

- Indoor installation**,

- Ambient temperature range: minimum temperature +5°C to +42°C, class AA4

- Altitude: AC1 of 2000 m or less,

- Presence of water: Class AD2 (possibility of water droplets)**

- Presence of hard solid: Class AE2 (no signicant dust present)**,

- Presence of corrosive and polluting substances, class AF1 (negligible),

- Competence of persons: BA4 (Persons wise),

- Overvoltage category: II (2,5KV).

2. Compatibility for low-frequency conducted disturbances according to class 2 levels per IEC61000-2-4 standard:

- Power supply frequency variation: +- 2Hz

- Phase imbalance : 2%

3. The neutral (N) line must not be connected directly to the unit (if necessary use a transformer).

4. Overcurrent protection of the power supply conductors is not provided with the unit.

5. The factory-installed disconnect switch(es)/circuit breaker(s) are of a type suitable for power interruption in accordance with EN 60947-3 (corresponds to IEC 60947-3).

6. The units are designed for connection to TN networks (IEC 60364). In IT networks,if

noise lters are integrated into the compressor(s) variable frequency drive(s),

this will render the units unsuitable for their intended purpose. In addition, the equipment characteristics in case of insulation failure are modified. For IT networks, the earth connection must not be at the network earth. Provide a local earth; consult competent local organisations to complete the electrical installation.

7. Electromagnetic environment: classication of the electromagnetic environment

is described in standard EN 61800-3 (corresponds to IEC 61800-3):

- Immunity to external interference dened by the second environment***

- Interference emission as dened in category C2

Warning: In a residential environment, this product may cause radio interference

in which case additional mitigation measures could be required.

The compressor variable frequency drive is a source of perturbations from the

harmonic currents. An investigation could be necessary to check that the perturbations don't exceed the compatibility limits with the other devices connected on the same power supply network. In an electrical installation, the levels of compatibility to be observed at the internal coupling point (IPC) to which other loads are connected are described in standard IEC 61000-2-4.

• Leakage currents: If protection by monitoring the leakage currents is necessary to ensure the safety of the installation, the presence of additional leakage currents introduced by the use of variable frequency drive(s) in the compressor must be considered.

In particular, the reinforced immunity protection types and a control value not

lower than 150 mA are recommended when selecting differential protective devices.

* Generally, the recommendations of the standard of International Electrotechnical

Commission (IEC60364) are identied to meet the requirements of the installation

guidelines.

** The required protection level for this class is IP21B or IPX1B (according to

reference document IEC 60529). All 19PV units are IP23 and full this protection

condition.

*** Example of second environnement installations: Industrial areas, technical facilities

supplied by a dedicated transformer

5 - ELECTRICAL CONNECTION

Please refer to the certied dimensional drawings, supplied with

the unit.

5.1 - Power supply

The power supply must conform to the specication on the unit nameplate. The supply voltage must be within the range specied

in the electrical data table. For connection details refer to the wiring diagrams.

CAUTION:

Operation of the unit with an improper supply voltage or

excessive phase imbalance constitutes abuse which will invalidate the manufacturer warranty. If the phase imbalance

exceeds 2% for voltage, or 10% for current, contact your local electricity supplier at once and ensure that the unit is not

switched on until corrective measures have been taken.

5.2 - Voltage phase imbalance (%)

100 x max. deviation from average voltage

Average voltage

Example:

On a 400 V - 3 ph - 50 Hz supply, the individual phase voltages were measured to be:

AB = 406 V; BC = 399 V; AC = 394 V

Average voltage = (406 + 399 + 394)/3 = 1199/3

= 399.7 say 400 V

Calculate the maximum deviation from the 400 V average:

(AB) = 406 - 400 = 6

(BC) = 400 - 399 = 1

(CA) = 400 - 394 = 6

The maximum deviation from the average is 6 V. The greatest percentage deviation is: 100 x 6/400 = 1.5 %. This is less than the

permissible 2% and is therefore acceptable.

5.3 - Power connection/disconnect switch

Units Connection points

19PV550 to 800 1 per unit

19PV900 to 1600

1 for circuit A 1 for circuit B

Option 81 1 per unit

5.4 - Recommended wire sections

Wire sizing is the responsibility of the installer, and depends on the characteristics and regulations applicable to each installation site. The following is only to be used as a guide-line, and does not make in any way liable. After wire sizing has been completed, using the certified dimensional drawing, the installer must ensure easy

connection and dene any modications necessary on site.

The connections provided as standard for the eld-supplied power

entry cables to the general disconnect/isolator switch are designed for the number and type of wires, listed in the second column of the table on the next page.

The calculations for favourable and unfavourable cases are based on the maximum current for each unit (see electrical data tables). The design uses the standardised installation methods in accordance with IEC 60364: multiconductor PVC (70°C) or XLPE (90°C) insulated cables with copper core; arrangement to comply with table 52c of the above standard. The maximum temperature is 40°C. The given maximum length is calculated to limit the voltage drop to 5%.

Motor

5 - ELECTRICAL CONNECTION

Minimum and maximum connectable wire sections for 19PV units

19PV

Max. connectable

wire section

(1)

Calculation of favourable case:

- Perforated horizontal conduit (standardised routing No. 13)

- 90°C insulated cable

- Copper conductor (Cu)

Calculation of unfavourable case:

- Closed conduit (standardised routing No. 41)

- 70°C insulated cable if possible

- Copper conductor (Cu)

Section

(2)

Max. length for a

voltage drop <5%

Cable type Section

(2)

Max. length for a

voltage drop <5%

Cable type

qty x mm²

(per phase)

qty x mm²

(per phase)

m -

qty x mm²

(per phase)

m -

Standard unit

550 2x300 1x95 191 90°C 1x185 360 70°C

720 2x300 1x150 217 90°C 2x150 383 70°C

800 2x300 1x185 227 90°C 2x185 388 70°C

900 2x300 / 2x300 1x50/1x120 177/208 90°C 1x95/2x150 348/382 70°C

1010 2x300 / 2x300 1x95/1x120 199/208 90°C 1x185/2x150 388/382 70°C

1180 2x300 / 2x300 1x70/2x95 186/196 90°C 1x185/2x240 388/366 70°C

1300 2x300 / 2x300 1x95/1x185 199/223 90°C 1x240/2x240 395/366 70°C

1450 2x300 / 2x300 1x185/1x185 223/223 90°C 2x185/2x185 374/374 70°C

1600 2x300 / 2x300 1x240/1x240 223/223 90°C 2x240/2x240 366/366 70°C

Unit + option 81

900 4x300 1x185 228 90°C 2x185 388 70°C

1010 4x300 1x240 236 90°C 2x240 396 70°C

1180 4x300 2x150 217 90°C 4x150 382 70°C

1300 4x300 2x150 217 90°C 4x150 382 70°C

1450 4x300 2x185 223 90°C 4x185 374 70°C

1600 4x300 2x240 224 90°C 4x240 366 70°C

(1) Connection capacities actually available for each machine. These are dened according to the connection terminal size, the electrical box access opening dimensions

and the available space inside the electrical box. (2) Selection simulation result considering the hypotheses indicated. (3) If the maximum calculated section is for an 90°C cable type, this means that a selection based on a 70°C cable type can exceed the connection capacity actually

available. Special attention must be given to selection. Note: Option 84 and 84R are not included in these values.

5.5 - Power cable entry

The power cables can enter the 19PV control box from above the unit. A removable aluminium plate on the upper part of the control

box face allows introduction of the cables. Refer to the certied

dimensional drawing for the unit.

5.6 - Field control wiring

IMPORTANT: Field connection of interface circuits may lead

to safety risks: any control box modication must maintain

equipment conformity with local regulations. Precautions

must be taken to prevent accidental electrical contact between circuits supplied by different sources:

• The routing selection and/or conductor insulation characteristics must ensure dual electric insulation.

• In case of accidental disconnection, conductor xing between different conductors and/or in the control box prevents any contact between the conductor ends and

an active energised part.

Refer to the 19PV Touch'Pilot Control manual and the certied wiring diagram supplied with the unit for the eld control wiring of

the following features:

- Remote on/off switch

- Demand limit external switch

- Remote dual set point

- Heating/Cooling switch mode

- Alarm and operation report

- Evaporator ow control by 0-10V signal

- Heat condenser pump control

- Various interlocks on the Energy Management Module (EMM) board

- Condenser water inlet valve (option 152)

- Set-point adjustement by 4-20 mA signal

5.7 - 24 and 230 V power reserve for the user

Control circuit reserve:

After all required options have been connected, the TC transformer

includes a power reserve that can be used for the eld control wiring:

- Unit without option 84/84R 2 A (24 V a.c.) or 48 VA

- Unit with option 84/84R 1.3 A (24 V a.c.) or 30 VA

At this TC transformer the 230 V, 50 Hz circuit allows the supply of a battery charger for a laptop at 0.8 A maximum at 230 V. The connection is via an EEC 7/16 type socket (2 poles without earth) located under the control box and accessible from outside. Only devices with class II double insulation can be connected at this socket.

6 - APPLICATION DATA

6.1 -

Operating limits for 19PV units

19PV Minimum Maximum

Evaporator

Entering temperature at start-up °C - 35

Leaving temperature during operation °C 3,3 20

Entering/leaving water temperature difference

K 3 11,1

Condenser

Entering temperature at start-up °C 13

(1)

Leaving temperature during operation °C 14

(1)

Entering/leaving water temperature difference

K 3 11,1

(1) For lower condenser temperatures a water ow control valve must be used at

the condenser (two or three-way valve). Please refer to Control for option 152 to ensure the correct condensing temperature.

Note: Ambient temperatures: These units are dedicated for indoor environment. The

external temperature at chiller start up should be at least 5°C. For such low ambient, option 152 is recommended. During storage and transport of the 19PV units (including by container) the minimum and maximum permissible temperatures are -20°C and 66 °C.

Evaporator leaving water temperature, °C

Condenser leaving water

temperature, °C

0510 15 20

6.2 - Minimum chilled water ow

The minimum chilled water ow is shown in the table in chapter 6.7.

If the system ow is less than the minimum unit ow rate, the evaporator ow can be recirculated, as shown in the diagram.

For minimum chilled water ow rate

Legend

1. Evaporator

2. Recirculation

6.3 - Maximum chilled water ow

The maximum chilled water ow is limited by the permitted pressure

drop in the evaporator. It is provided in the table in chapter 6.6

- Select the option 100C that will allow a higher maximum water

ow rate (see the option 100C in the table in chapter 6.5).

- Bypass the evaporator as shown in the diagram to obtain a

lower evaporator ow rate.

For maximum chilled water flow rate

Legend

1. Evaporator

2. Bypass

6.4 - Condenser water ow rate

The minimum and maximum condenser water ow rates are shown

in the table in chapter 6.6

If the system ow is higher than the maximum unit ow rate, select the option 102C that will allow a higher maximum water ow rate.

Please refer to option 102C in the table in chapter 6.5.

6 - APPLICATION DATA

6.5 - Standard and optional number of water passes

19PV 550 720 800 900 1010 1180 1300 1450 1600

Evaporator

Standard 2 2 2 2 2 2 2 2 2

Evaporator with option 100C 1 1 1 1 1 1 1 1 1

Condenser

Standard 2 2 2 2 2 2 2 2 2

Condenser with option 102C 1 1 1 1 1 1 1 1 1

6.6 - Min water volume and evaporator & condenser water ow rates

These below values are given for standard units. For Evaporator and condenser with option 100C/102C, please refer to the unit selection program.

19PV 550 720 800 900 1010 1180 1300 1450 1600

Minimum installation volume (l)

Air conditioning application 1770 2310 2570 2890 3240 3790 4170 4640 5130

Industrial process application 3530 4620 5140 5780 6480 7570 8330 9290 10250

Evaporator water ow rate, (m3/h)

Minimum

(1)

34 34 34 34 61 61 61 61 61

Maximum

(3)

179 235 257 281 289 286 295 295 329

Condenser water ow rate, (m

/h)

Minimum

(2)

21 21 36 36 36 36 36 36 36

Maximum

(3)

245 299 346 486 457 454 428 594 526

(1) Minimum evaporator ow rate based on a water velocity of 0,5 m/s. (2) Minimum condenser ow rate based on a water velocity of 0,3 m/s. (3) Maximum ow rate based on a pressure drop of 120 kPa (units with two evaporator passes and two condenser passes).

This volume is necessary for stable operation.

It is often necessary to add a buffer water tank to the circuit in order to achieve the required volume. The tank must itself be internally

bafed in order to ensure proper mixing of the liquid (water or

brine). Refer to the examples below.

Connection to a buffer tank

Bad

Good

6.7 - Variable ow evaporator

Variable evaporator ow can be used. The controlled ow rate must be higher than the minimum ow given in the table of permissible ow rates and must not vary by more than 10% per

minute.

If the ow rate changes more rapidly, the system should contain

a minimum of 6.5 litres of water per kW instead of 3.25 l/kW.

6 - APPLICATION DATA

6.8 - Evaporator pressure drop curves

Units with two evaporator passes (standard)

CDEF G

H I

Pressure drop, kPa

Water ow rate, l/s

Legend

1 19PV550 6 19PV1180

2 19PV720 7 19PV1300

3 19PV800 8 19PV1450

4 19PV900 9 19PV1600

5 19PV1010

Units with one evaporator pass (option 100C)

Pressure drop, kPa

Water ow rate, l/s

B C D

Legend

1 19PV550 6 19PV1180

2 19PV720 7 19PV1300

3 19PV800 8 19PV1450

4 19PV900 9 19PV1600

5 19PV1010

6.9 - Condensor pressure drop curves

Units with two condenser passes (standard)

Pressure drop, kPa

Water ow rate, l/s

B C D EF

Legend

1 19PV550 6 19PV1180

2 19PV720 7 19PV1300

3 19PV800 8 19PV1450

4 19PV900 9 19PV1600

5 19PV1010

Units with one condenser pass (Option 102C)

B C D

F G

Pressure drop, kPa

Water ow rate, l/s

Legend

1 19PV550 6 19PV1180

2 19PV720 7 19PV1300

3 19PV800 8 19PV1450

4 19PV900 9 19PV1600

5 19PV1010

7 - WATER CONNECTIONS

ATTENTION: Before carrying out any water connections

install the water box purge plugs (one plug per water box in the lower section - supplied in the control box).

For size and position of the heat exchanger water inlet and outlet

connections refer to the certied dimensional drawings supplied with

the unit.

The water pipes must not transmit any radial or axial force to the heat exchangers nor any vibration.

The water supply must be analysed and appropriate ltering,

treatment, control devices, isolation and bleed valves and circuits built in, to prevent corrosion, fouling and deterioration of the pump

ttings. Consult either a water treatment specialist or appropriate literature on the subject.

7.1 - Operating precautions

The water circuit should be designed to have the least number of elbows and horizontal pipe runs at different levels. Below the main points to be checked for the connection:

- Comply with the water inlet and outlet connections shown on the unit.

- Install manual or automatic air purge valves at all high points in the circuit(s).

- Use a pressure reducer to maintain pressure in the circuit(s) and install a relief valve as well as an expansion tank.

- Install thermometers in both the entering and leaving water connections.

- Install drain connections at all low points to allow the whole circuit to be drained.

- Install stop valves, close to the entering and leaving water connections.

- Use flexible connections to reduce the transmission of vibrations.

- Insulate all pipework, after testing for leaks, both to reduce heat gains and to prevent condensation.

- Cover the insulation with a vapour barrier.

- Where there are particles in the uid that could foul the heat

exchanger, a screen lter should be installed ahead of the

pump, or directly at the exchanger inlet in case the pump is

more than 20m away. The mesh size of the lter must be 1.2

mm.

- Before the system start-up verify that the water circuits are connected to the appropriate heat exchangers (e.g. no reversal between evaporator and condenser).

- Do not introduce any signicant static or dynamic pressure into the heat exchange circuit (with regard to the design operating pressures).

- Before any start-up verify that the heat exchange uid is compatible with the materials and the water circuit coating.

- The use of different metals on hydraulic piping could generate eletrolytic pairs and consequently corrosion. Verify then, the

need to install sacricial anodes.

In case additives or other uids than those recommended by the manufacturer are used, ensure that the uids are not considered as a gas, and that they belong to class 2, as dened in directive

2014/68/UE.

The manufacturer recommendations on heat exchange uids:

- No NH4+ ammonium ions in the water, they are very detrimental for copper. This is one of the most important factors for the operating life of copper piping. A content of several tenths of mg/l will badly corrode the copper over time.

- Cl- Chloride ions are detrimental for copper with a risk of perforations by corrosion by puncture. If possible keep below 125 mg/l.

- SO

sulphate ions can cause perforating corrosion, if their

content is above 30 mg/l.

- No uoride ions (<0.1 mg/l).

- No Fe2+ and Fe3+ ions with non negligible levels of dissolved oxygen must be present. Dissolved iron < 5 mg/l with dissolved oxygen < 5 mg/l.

- Dissolved silicon: silicon is an acid element of water and can also lead to corrosion risks. Content < 1 mg/l.

- Water hardness: > 0.5 mmol/l. Values between 1 and 2.5 can be recommended. This will facilitate scale deposit that can limit corrosion of copper. Values that are too high can cause piping blockage over time. A total alkalimetric titre (TAC) below 100 mg/l is desirable.

- Dissolved oxygen: Any sudden change in water oxygenation conditions must be avoided. It is as detrimental to deoxygenate the water by mixing it with inert gas as it is to over-oxygenate it by mixing it with pure oxygen. The disturbance of the oxygenation conditions encourages destabilisation of copper hydroxides and enlargement of particles.

- Electric conductivity 10-600µS/cm.

- pH: Ideal case pH neutral at 20-25°C

7 < pH < 8

If the water circuit must be emptied for longer than one month, the complete circuit must be placed under nitrogen charge to avoid any risk of corrosion by differential aeration.

Charging and removing heat exchange uids should be done with

devices that must be included on the water circuit by the installer.

Never use the unit heat exchangers to add heat exchange uid.

7.2 - Water connections

The water connections are Victaulic type connections. The inlet and outlet connection diameters are identical.

Inlet/outlet diameters

19PV 550 720 800 900 1010 1180 1300 1450 1600

Evaporator

Units without evaporator with one pass less (option 100C)

Nominal diameter in 6 6 8 8 8 8 8 8 8

Actual outside diameter mm 168,3 168,3 219,1 219,1 219,1 219,1 219,1 219,1 219,1

Units with evaporator with one pass less (option 100C)

Nominal diameter in 6 6 8 8 8 8 8 8 8

Actual outside diameter mm 168,3 168,3 219,1 219,1 219,1 219,1 219,1 219,1 219,1

Condenser

Units without condenser with one pass less (option 102C)

Nominal diameter in 6 8 8 8 8 8 8 8 8

Actual outside diameter mm 168,3 219,1 219,1 219,1 219,1 219,1 219,1 219,1 219,1

Units with condenser with one pass less (option 102C)

Nominal diameter in 6 8 8 8 8 8 8 8 8

Actual outside diameter mm 168,3 219,1 219,1 219,1 219,1 219,1 219,1 219,1 219,1

7.3 - Flow control

Evaporator ow switch and chilled water pump interlock

IMPORTANT: On 19PV units, the unit water ow switch must be energised. Failure to follow this instruction will void the

manufacturer guarantee.

The water ow switch is installed on the evaporator water inlet and adjusted by the control, based on unit size and application. If adjustment is necessary, it must be carried out by qualied

personnel trained by manufacturer Service.

7.4 - Evaporator and condenser water box bolt

tightening

The evaporator (and condenser) are of the shell and tube type with removable water boxes to facilitate cleaning. Re-tightening or tightening must be done in accordance with the illustration in the example below.

Water box tightening sequence

Legend

1 Sequence 1: 1 2 3 4 Sequence 2: 5 6 7 8 Sequence 3: 9 10 11 12 Sequence 4: 13 14 15 16

2 Tightening torque Bolt size M16 - 171 - 210 Nm

NOTE: Before this operation we recommend draining the

circuit and disconnecting the pipes to be sure that the bolts

are correctly and uniformly tightened.

7 - WATER CONNECTIONS

7.5 - Operation of two units in master/slave mode

The control of a master/slave assembly is in the entering water and does not require any additional sensors (standard conguration).

It can also be located in the leaving water. In this case two additional sensors must be added on the common piping.

All parameters, required for the master/slave function must be congured using the MST_SLV menu.

All remote controls of the master/slave assembly (start/stop, set point, load shedding etc.) are controlled by the unit congured as

master and must only be applied to the master unit.

Each unit controls its own water pump. If there is only one common pump, in cases with variable ow, isolation valves must be installed

on each unit. They will be activated at the opening and closing by the control of each unit (in this case the valves are controlled using the dedicated water pump outputs). See the 19PV Touch'Pilot Control manual for a more detailed explanation.

19PV with conguration: leaving water control

Legend

Master unit

Slave unit

Control boxes of the master and slave units

Water inlet

Water outlet

Water pumps for each unit (included as standard for units with hydraulic module)

Additional sensors for leaving water control, to be connected to channel 1 of the slave boards of each master and slave unit

IP communication bus

Connection of two additional sensors

7 - WATER CONNECTIONS

8 - UNIT WITH HEAT PUMP APPLICATION (OPTION 322)

The physical data, electrical data, dimensions & clearances are the same as standard 19PV units.

Unlike in the cooling mode, the unit uses the heating setpoint in this conguration. The evaporator leaving water control (lowest setpoint

taken into consideration) is still maintained to prevent operation at very low temperatures.

9 - UNIT OPERATION WITH OPTION 154

9.1 - Operating principle

The units have been designed to optimise the operation of

systems, using drycoolers as heat rejection system.

With a variable-speed condenser water pump integrated into the unit the complexity of traditional systems, using a three-way valve has been reduced.

The installation of an operational system is limited on the condensing water loop side to connect the drycooler entering and leaving water piping to the unit.

The Touch'Pilot control of the unit includes algorithms to permit constant automatic optimisation of:

- drycooler fan stage operation

- water ow rate variation in the loop between the condenser and the drycooler.

Parallel control of the fan stages (up to 8 stages maximum) and

of the variable water ow rate of the loop permit year-round system

operation down to -10 °C outside temperature without any additional control.

9.2 - Communication to control the drycooler

The electronic board specically integrated in the control box of the

drycooler, by an option selection on the manufacturer drycooler, and a communication LEN bus connected to the microprocessor board of the unit is used for the overall system control.

Pay attention that Dry cooler and Chiller have to be both equipped with the option 154.

The option is supplied in the manufacturer ’s drycooler control box.

Connect the unit to board AUX1 in the drycooler, using a communication cable. the communication cable should be connect to the plug with 3 points Wago type (5 mm spacing or equivalent). the communication cable should be a shielded type.

The Touch'Pilot control optimises system operation to obtain the

best efciency with variation of the water ow rate and the number

of fans required for any thermal load and outside temperature conditions.

The electronic board (AUX1) integrated in the control box of the drycooler has analogue inputs for outside air temperature and drycooler leaving water temperature sensors, as well as eight digital outputs permitting control of up to eight fan stages.

9.3 - Conguration of the number of fan stages and the automatic changeover of the fan stages

Please refer to the instructions in the Touch'Pilot IOM for the

conguration of the number of fan stages to be controlled. It is

enough to enter the number of fan stages of the drycooler in the Touch'Pilot service menu. The number of digital outputs controlling the fans are activated by the control.

Touch'Pilot controls the automatic switching of all fan stages, based on operating time and number of start-ups of

the different stages. This function prevents fan motors from only running a little or not at all and the shafts seizing up, especially during periods with a low cooling demand, when the outside temperature is low. Switching is

often specied by the drycooler manufacturers to ensure a long

operating life of fan motors that are only used a little or not at all in these particular operating conditions.

9.4 - Fan stage assignment

The minimum conguration of the number of fan stages is 2 for

correct operation.

Depending on the drycooler capacity the number of fans can be between 2 and 8. They can be controlled by one fan or by linked pairs, if necessary.

A drycooler with 4 or 6 fans installed in series for example along the

length of the unit will result in a conguration of 4 or 6 fan stages.

Reciprocally a drycooler with 8 or 12 fans arranged in pairs along

the length of the unit will also result in a conguration of 4 or 6 fan

stages.

Conguration with 4 and 6 stages (min. 2 - max. 8)

1 2 3 4 5 6

Fans linked in pairs - 4 and 6-stage conguration

(min. 2 - max. 8)

1 2 3 4 5 6

Legend

A Entering and leaving water manifold side 1 to 6 Fans

9.5 - Drycooler installation on units

For the drycooler installation follow professional guidelines.

- Water pipe sizing.

- Maximum piping and shut-off valve pressure drops based on the available pressure of the unit pumps.

- Maximum drycooler elevation in relation to the unit (relief valve at 4 bar on the unit water circuit).

- Fan stage control (see “Fan stage control”).

- Good positioning of the outside air temperature and drycooler leaving water temperature sensors.

10 - UNIT OPERATION WITH OPTION 313

10.1 - Operating principle

The units have been designed to optimize the operation of systems, using drycoolers as free cooling system (method using low outdoor air temperature to chill the water of the air conditioning system).

This system allows substantial energy and cost savings, which is the most effective when the outdoor air temperature is low.

The Touch'Pilot control of the unit includes algorithms to permit constant automatic optimization of:

- drycooler fans operation

- water ow rate variation in the loop

- cooling capacity (drycooler and chiller can operate independently or simultaneously)

- valves positions depending on operating mode.

The control denes the optimal conguration considering water

set point value, outdoor air temperature and water loop temperature (the control will give priority to the drycooler).

Parallel control of the fans and of the variable water ow rate of

the loop permit system operation down to -20 °C outside temperature without any additional control.

Pay attention that drycooler and chiller have to be both

equipped with the option 313

Chiller

DC free cooling

LEN communication

OAT

V2V control

For an optimal free cooling operation, the chiller has to be

congurated:

- on entering water temperature control

- on delta temperature control in case of variable speed pump

10.2 - Communication to control the drycooler

When the option is selected, a specific electronic board is integrated in the control box of the drycooler. A communication LEN bus connected between the drycooler (board AUX1) and the chiller is needed for the overall system control.

This cable should be a 3 points Wago type (5 mm spacing or equivalent) and should be shielded.

The board integrated in the control box of the drycooler has analog inputs for outside air temperature (mark 1), return water loop temperature (mark 3) and drycooler leaving water temperature sensors (mark 2), as well as digital outputs permitting the control of the fans.

The option works as a system split in two parts:

The chiller (with option 313)

- Dedicated control algorithms with LEN connector to communicate and control the drycooler

The drycooler (with option 313) :

- AUX board with the I/O

- OAT sensor to be place in outdoor zone.

- Dry Cooler Leaving Water Temperature (factory mounted)

- Water loop Temperature (to be mounted on the common pipe before valve)

- Control & 230V power supply for 2 two ways valve or one three ways valve

The temperature difference between dry-cooler OAT and water

loop sensor denes if free cooling mode can be activated.

10.3 - Conguration of the fans control

To set the conguration corresponding the drycooler installed (number of fans, control type – xed or variable speed), please refer to the

instructions in the

Touch'Pilot

control IOM. Following these

parameters, the

Touch'Pilot

will activate the adequate number of

digital outputs to control the fans.

Touch'Pilot controls the automatic switching of all fans, based on operating time and number of start-up, to ensure a long operating life of fan motors.

Compatible fans conguration:

- 1 to 20 fans

- xed speed or variable speed

- fans in one l or 2 lines

Refer to the drycooler electrical diagram to see the fan stages arrangement.

10.4 - Water valves

The free cooling system requires 2 two-way valves (one Normally Opened, one Normally Closed) or a three-way valve, not supplied with the unit or the dry cooler.

A two-way valves kit is available in the list of drycooler accessories.

The drycooler electrical box includes 230V power supply for 2 two-way valves.

Recommended motor valve (per default): 230V 3 points

Refer to drycooler electrical diagram for valves wiring on customer connections.

10.5 - System installations recommandation

For physical characteristics, dimensions, performances: refer to the drycooler documentation.

For electrical connections information, refer to the electrical wiring delivered with the drycooler.

For software configuration information, refer to the control documentation of the chiller.

For a proper drycooler installation, follow the professional guidelines for the following topics:

- Water pipe sizing

- Pressure drops (verify that the available pressure of the unit

pump is sufcient compared to the piping and valves pressure

drops - check for all running modes)

- Maximum drycooler elevation (in relation to the unit safety valve)

- Good positioning for temperature sensors: outside air temperature and water loop temperature .

11 - MAJOR SYSTEM COMPONENTS AND OPERATION DATA

11.1 - MagLev centrifugal compressor

- 19PV units use TT (Twin-Turbine) MagLev centrifugal compressors equipped with an inlet guide valve and controlled by a speed variator.

- Compressor capacity control is ensured by successive use of speed variation (using a frequency variator) and swept volume variation at the turbine (using the Inlet Guide Valve).

- The combination of these two control modes permits ne control of the unit capacity between 15% and 100%.

- The MagLev centrifugal compressor models used are: TT300, TT350

- The MagLev centrifugal compressors are NOT lubricated

- The compressor drive and the compressor motor are cooled by a liquid line. The cooling system is controlled by two valves located in the compressor drive.

11.1.1 - Refrigerant

The 19PV is a liquid chiller operating only with refrigerant R-134a.

11.1.2 - Capacity control system

19PV units are equipped with a frequency variator that permits

compressor capacity adjustment by varying the motor speed. The

frequency range depends on the refrigerant pressure ratio. At the minimum speed, the compressor reduces the capacity by closing the inlet guide valve.

The compressor drive uses power supply waveform generation with variable frequency and voltage, generated by pulse width modulation (PWM).

Compressor start-up and stopping and the frequency setting for the operating range is only by RS485 communication in the MODBUS protocol via the controller.

11.1.3 - Suction valve (Option 92)

An isolating valve can be added to ease maintenance on compressor. This valve can be moved ONLY without pressure differential upstream and downstream of this valve.

The following markers indicate the fully opened position and the fully closed position of the valve.

Opened position Closed position

11.1.4 - Line reactor

A line reactor is a special form of inductor that is typically used between the line and the load to smooth current inrush, reduce harmonics and noise, and buffer the systems connected to it.

Specically it is an inductor that adds inductive impedance to a

circuit

One Line reactor by compressor is mandatory and they are located in the electrical box.

11.1.5 - EMC Filter

The EMC filter reduces electrical noise on the power lines (conducted emissions), it is located close to the compressor to reduce broadcasting of the noise (radiated emissions) from the power lines themselves.

11.1.6 - Fast acting fuses

All compressors are tted with class T fast acting fuses to protect

the solid state inverter.

The fuses are included in the TT300 compressor under the main cover. With the TT350 compressor, the fast acting fuses are located in the electrical box.

11.2 - Pressure vessels

General

Monitoring during operation, re-qualication, re-testing and re-

testing dispensation:

- Follow the regulations on monitoring pressurised equipment.

- It is normally required that the user or operator sets up and

maintains a monitoring and maintenance le.

- If no regulations exist or to complement regulations, follow the control programmes of EN 378.

- If they exist follow local professional recommendations.

- Regularly inspect the condition of the coating (paint) to detect blistering resulting from corrosion. To do this, check a noninsulated section of the container or the rust formation at the

insulation joints.

- Regularly check for possible presence of impurities (e.g.

silicon grains) in the heat exchange uids. These impurities

maybe the cause of the wear or corrosion by puncture.

- Filter the heat exchange uid check and carry out internal inspections as described in EN 378.

- In case of re-testing please refer to the maximum operating pressure given on the unit nameplate.

- The reports of periodical checks by the user or operator must

be included in the supervision and maintenance le.

Repair

Any repair or modication, including the replacement of moving

parts:

- must follow local regulations and be made by qualified operators and in accordance with qualified procedures, including changing the heat exchanger tubes.

- must be made in accordance with the instructions of the original manufacturer. Repair and modification that necessitate permanent assembly (soldering, welding, expanding etc.) must be made using the correct procedures and by qualified operators.

- An indication of any modification or repair must be shown in

the monitoring and maintenance file.

Recycling

The unit is wholly or partly recyclable. After use it contains refrigerant vapours. It is coated by paint.

Operating life

The evaporator is designed for:

- prolonged storage of 15 years under nitrogen charge with a temperature difference of 20 K per day.

- 452000 cycles (start-ups) with a maximum difference of 6 K between two neighbouring points in the vessel, based on 6 start-ups per hour over 15 years at a usage rate of 57%.

11 - MAJOR SYSTEM COMPONENTS AND OPERATION DATA

Corrosion allowances:

Gas side: 0 mm

Heat exchange uid side: 1 mm for tubular plates in lightly alloyed

steels, 0 mm for stainless steel plates or plates with copper-nickel or stainless steel protection.

11.2.1 - Evaporator

19PV chillers use a ooded multi-tube evaporator. The water circulates in the tubes and the refrigerant is on the outside in the shell. One vessel is used to serve both refrigerant circuits. There is a centre tube sheet which separates the two refrigerant circuits. The tubes are 3/4” diameter copper with an enhanced surface inside

and out. There is just one water circuit with two water passes (one

pass with Evaporator with option 100C, please refer to chapter 6.5).

The evaporator shell has a polyurethane foam thermal insulation and a water drain and purge.

It has been tested and stamped in accordance with the applicable pressure codes. The maximum standard relative operating pressure is 1850kPa for the refrigerant-side and 1000 kPa for the water-side. These pressures can be different depending on the code applied. The water connection of the heat exchanger is a Victaulic connection.

The products that may be added for thermal insulation of the containers during the water piping connection procedure must be chemically neutral in relation to the materials and coatings to which they are applied. This is also the case for the products originally supplied by the manufacturer.

11.2.2 - Condenser

The 19PV chiller uses a ooded multi-tube condenser. It is mounted below the evaporator. The water circulates in the tubes and the refrigerant is on the outside in the shell. One vessel is used to serve both refrigerant circuits. There is a center tube sheet which separates the two refrigerant circuits. The tubes are 3/4” or 1”

diameter internally and externally nned copper tubes.

There is just one water circuit with two water passes (one pass

with Condenser with option 102C, please refer to chapter 6.5). For the Heat Machine units the condenser shell can have a polyurethane foam thermal insulation (Option 86 or 322) and a water drain and purge.

It has been tested and stamped in accordance with applicable pressure codes. The maximum standard relative operating pressure is 1850kPa for the refrigerant-side and 1000 kPa for the water-side. These pressures can be different depending on the code applied. The water connection of the heat exchanger is a Victaulic connection.

11.3 - Disconnect switches for power supply

Each circuit includes two disconnect switches: One main supply disconnect switch for the compressor(s) supply and one disconnect switch associated with a handle for the supply of the control part, the under-voltage protection circuit and the motor mechanism module.

The motor mechanism module and an under-voltage protection circuit are mounted on the main supply disconnect switch

Note: The following procedure must be done to lock the main

supply disconnect switch:

- Set the motor mechanism in “Manual” position. The circuit breaker must be to the O (OFF) position before this operation.

- Pull up the locking tab.

- Lock the circuit breaker using the keylock (leaving the tab out).

After removing the lock, the motor mechanism must be switch in “Auto” position before to supply the unit.

The command of the main supply disconnect switch closure is ensured by the software using the motor mechanism module when the unit is turned on (with the handle) or when the voltage is back after the loss of the power supply.

The under-voltage protection circuit ensures the main supply disconnect switch opening in case of a turn off (using the handle from the front panel), a high-pressure safety switch opening or when the doors is open.

The downstream circuit of the disconnect switch with the handle

is consider as an excepted circuit and is identied with orange

conductors.

11.3.1 - Safety chain of the automatic reset

11.3.1.a - High-pressure switch HP

19PV units are equipped with high-pressure safety switches.

In accordance with the applicable code , the unit is equipped with high pressure switches with manual reset, called PZH (former DBK).

These pressure switches are located at the discharge line of each compressor.

11.3.1.b - Safety door contacts

The purpose of the door contact is to inhibite the possibility of an automatic closure order of the main supply disconnect switch from the software while the door is opened

11.4 Electronic expansion valve (EXV)

The 19PV unit is equipped with two EXV :

- The main EXV located in the liquid line. The main EXV

regulates refrigerant ow into the evaporator.

- The staging EXV located in the discharge line. The staging

EXV regulates by-pass ow during compressor stat-up.

The EXV is equipped with a stepper motor 480 steps that is controlled via the EXV board.

The EXV is also equipped with a sightglass that permits verication

of the mechanism movement and the presence of the liquid gasket (Relevant only for main EXV).

11.5 - Moisture indicator

Located on the EXV and on the compressor cooling line, permits control of the unit charge and indicates moisture in the circuit. The

presence of bubbles in the sight-glass indicates an insufcient

charge or non-condensables in the system. The presence of moisture changes the colour of the indicator paper in the sightglass.

11.6 - Filter drier

The role of the lter drier is to keep the circuit clean and moisture-

free. The moisture indicator shows, when it is necessary to change

the element. A difference in temperature between the lter inlet

and outlet shows that the element is dirty.

11.7 - Sensors

The units use thermistors to measure the temperature, and pressure transducers to control and regulate system operation (see 19PV Touch'Pilot Control manual for a more detailed explanation).

12 - OPTIONS

Option No. Description Advantage Use 19PV

Low noise level 15 Discharge piping acoustic insulation Up to 3 dB(A) quieter than standard unit 0550-1600

Master/slave operation 58A

Unit equipped with supplementary water outlet

temperature sensor kit (to be eld installed)

allowing master/slave operation of two units connected in parallel over Ethernet network (IP)

Optimised operation of two units connected in parrallel operation with operating time equalisation

0550-1600

Single power connection point 81

Unit power connection via one main supply connection

Quick and easy installation 0900-1600

Evap. single pump power/control circuit

Unit equipped with an electrical power and control circuit for one pump evaporator side

Quick and easy installation: the control of

xed speed pumps is embedded in the unit

control

0550-1180

Cond. single pump power/control circuit

84R

Unit equipped with an electrical power and control circuit for one pump condenser side

Quick and easy installation: the control of xed

speed pumps is embedded in the unit control

0550-1180

Condenser insulation 86 Thermal condenser insulation

Minimizes thermal dispersions condenser side (key option for heat pump or heat recovery applications)

0550-1600

Service valve set 92

Liquid line valve (evaporator inlet) and compressor suction line valve

Allow isolation of various refrigerant circuit components for simplified service and maintenance

0550-1600

Evaporator with one pass less 100C

Evaporator with one pass on the water side. Evaporator inlet and outlet on opposite sides.

Easy to install, depending on site. Reduced pressure drops

0550-1600

Condenser with one pass less 102C

Condenser with one pass on the water side. Condenser inlet and outlet on opposite sides.

Easy to install, depending on site. Reduced pressure drops

0550-1600

Reversed evaporator water connections

107 Evaporator with reversed water inlet/outlet

Easy installation on sites with specific requirements

0550-1600

Reversed condenser water connections

107A Condenser with reversed water inlet/outlet

Easy installation on sites with specific requirements

0550-1600

Bacnet over IP 149

Bi-directional high-speed communication using BACnet protocol over Ethernet network (IP)

Easy and high-speed connection by ethernet line to a building management system. Allows access to multiple unit parameters

0550-1600

Control for low cond. temperature 152

Output signal (0-10 V) to control the condenser water inlet valve

Simple installation: for applications with cold water at condenser inlet (ex. ground-source,

groundwater-source, supercial water-source

applications) the signal permits to control a 2 or 3-way valve to maintain condenser water temperature (and so conden

0550-1600

Dry-cooler control 154

Remote control of 09PE or 09VE dry-cooler based on a 0-10V signal. The 09PE or 09VE dry-cooler shall be selected with control cabinet option

Easy system management, extended control capabilities of a remote dry-cooler

0550-1600

Input contact for Refrigerant leak detection

159

0-10 V signal to report any refrigerant leakage in the unit directly on the controlller (the leak detector itself must be supplied by the customer)

Immediate customer notication of refrigerant

losses to the atmosphere, allowing timely corrective actions

0550-1600

Compliance with Swiss regulations

197

Additional tests on the water heat exchangers: supply (additional of PED documents)

supplementary certicates and test certications

Conformance with Swiss regulations 0550-1600

Compliance with Russian regulations

199 EAC certication Conformance with Russian regulations 0550-1600

Welded evaporator connection kit 266 Victaulic piping connections with welded joints Easy installation 0550-1600

Welded condenser water connection kit

267 Victaulic piping connections with welded joints Easy installation 0550-1600

Flanged evaporator water connection kit

268 Victaulic piping connections with anged joints Easy installation 0550-1600

Flanged condenser water connection kit

269 Victaulic piping connections with anged joints Easy installation 0550-1600

230V electrical plug 284

230V AC power supply source provided with plug socket and transformer (180 VA, 0,8 Amps)

Permits connection of a laptop or an electrical device during unit commissioning or servicing

0550-1600

Free-cooling dry-cooler control 313

Remote control of 09PE or 09VE dry-cooler based on a 0-10V signal. The 09PE or 09VE dry-cooler shall be selected with control cabinet option

Easy system management, extended control capabilities of a remote dry-cooler used in free-cooling mode

0550-1600

Heat Pump application 322

Unit congurated for Heat Pump application,

includes thermal condenser insulation

Optimisation on heating mode & minimize thermal dispersions condenser side

0550-1600

13 - STANDARD MAINTENANCE

Air conditioning equipment must be maintained by professional technicians, whilst routine checks can be carried out locally by

specialised technicians. See the standard EN 378-4.

Simple preventive maintenance will allow you to get the best performance from your HVAC unit:

- improved cooling performance

- reduced power consumption

- prevention of accidental component failure

- prevention of major time-consuming and costly interventions

- protection of the environment

There are ve maintenance levels for HVAC units, as dened by

the AFNOR X60-010 standard.

13.1 - Level 1 maintenance

See note below.

Simple procedure can be carried out by the user:

- Air heat exchanger (condenser) cleaning - see chapter “Condenser coil - level 1”

- Check for removed protection devices, and badly closed doors/covers

- Check the unit alarm report when the unit does not work (see report in the 19PV Touch'Pilot Control instruction manual ).

General visual inspection for any signs of deterioration.

13.2 - Level 2 maintenance

See note below.

This level requires specic know-how in the electrical, hydraulic and mechanical elds. It is possible that these skills are available

locally: existence of a maintenance service, industrial site, specialised subcontractor.

In these cases, the following maintenance operations are recommended.

Carry out all level 1 operations, then:

- At least once a year tighten the power circuit electrical connections (see tightening torques table).

- Check and re-tighten all control/command connections, if required (see tightening torques table).

- Check the differential switches for correct operation every 6 months.

- Remove the dust and clean the interior of the control boxes,

if required. Check the lter condition.

- Check the presence and the condition of the electrical protection devices.

- Replace the fuses every 3 years or every 15000 hours (age- hardening).

- Replace the control box cooling fans (if used) every ve years.

- Check the water connections.

- Purge the water circuit (see chapter 7 “Water connections”).

- Clean the water lter (see chapter 7 “Water connections”).

- Check the unit operating parameters and compare them with previous values.

- Replace compressor capacitors every 10 years (if energized) or 5 years (if de-energized).

- Replace compressor soft start fan every 5 years.

- Keep and maintain a maintenance sheet, attached to each HVAC unit.

All these operations require strict observation of adequate safety measures: individual protection garments, compliance with all industry regulations, compliance with applicable local regulations

and using common sense.

13.3 - Level 3 (or higher) maintenance

See note below.

The maintenance at this level requires specic skills/approval/

tools and know-how and only the manufacturer, his representative or authorised agent are permitted to carry out these operations. These maintenance operations concern for example:

- A major component replacement (compressor, evaporator)

- Any intervention on the refrigerant circuit (handling refrigerant)

- Changing of parameters set at the factory (application change)

- Removal or dismantling of the HVAC unit

- Any intervention due to a missed established maintenance operation

- Any intervention covered by the warranty

NOTE: Any deviation or non-observation of these maintenance

criteria will render the guarantee conditions for the HVAC unit

nul and void, and the manufacturer, will no longer be held responsible.

13.4 - Tightening of the electrical connections

13.4.1 - Tightening torques for the main electrical

connections

Component

Designation

in the unit

value

(N·m)

Screw on bus bar and PE, customer connection

M6 L1/L2/L3 9,6

M8 L1/L2/L3 24

M10 L1/L2/L3 49

M12 L1/L2/L3 79,4

Screw on Main supply disconnect switch

QS10* 28

Screw on Control supply disconnect switch

QS10*A 1,7

Screw on Line reactor

Line reactor for TT300 - M8 Z* 24

Line reactor for TT350 - M10 Z* 49

Screw on EMC Filter

PE ZC* 16 (+/- 1)

Phases ZC* 15

Screw on Fast acting fuse connection

FU* 38

Screw on TT300 bar connection

L1/L2/L3 25

Screw on PE panels

M8 PE 24

Screw on Compressor connection

TT300 - Cap L1/L2/L3 31

TT300 - M8 PE 21,7

TT350 - M10 L1/L2/L3 21,7

TT350 - M8 PE 21,7

Control disconnect switch connection

Upstream and downstream screws at terminals

QF10* &

QM10**

Power supply 24VDC unit

Upstream and downstream screws at terminals VC* 0,5

13 - STANDARD MAINTENANCE

13.5 - Tightening torques for the main bolts and screws

Screw type Used for Torque Value (N.m)

M20 nut Chassis 190

M20 nut Heat exchanger side-side connection 240

M16 nut Heat exchanger connection 190

M10 nut Compressor xing 30

H M16 screw Heat exchanger water boxes, structure 190

Thx M16x65 screw Compressor suction anges 75

Thx M10x30 screw Compressor discharge anges 22

Brass tting TT300 Motor cooling brass tting 40

Brass tting TT350 Motor cooling brass tting 50

Phillips head screw Compressor cover plate 13

H M8 Screw Drier cover 35

H M10 Screw Check valve cover 41

Taptite screw M10 Plate xing, control box, terminal box 30

H nut condenser Motor coolinh brass tting 50

13.6 - Evaporator and condenser maintenance

Check that:

- the insulating foam is intact and securely in place,

- the sensors and ow switch are correctly operating and correctly positioned in their support,

- the water-side connections are clean and show no sign of leakage.

14 - START-UP CHECKLIST FOR 19PV LIQUID CHILLERS (USE FOR JOB

FILE)

Preliminary information

Job name: ................................................................................................................................................................................................

Location: ..................................................................................................................................................................................................

Installing contractor: ................................................................................................................................................................................

Distributor: ...............................................................................................................................................................................................

Unit

Model: ..............................................................................................

Compressors

Circuit A Circuit B

Model number.................................................................................. Model number ..............................................................................

Serial number .................................................................................. Serial number ..............................................................................

Motor number .................................................................................. Motor number ...............................................................................

Evaporator

Model number..................................................................................

Serial number ..................................................................................

Condenser section

Model number..................................................................................

Serial number ..................................................................................

Additional optional units and accessories................................................................................................................................................

.................................................................................................................................................................................................................

Preliminary equipment check

Is there any shipping damage? ....................................................... If so, where? ................................................................................

Will this damage prevent unit start-up? ...................................................................................................................................................

Unit is level in its installation Power supply agrees with the unit nameplate Electrical circuit wiring has been sized and installed properly Unit ground wire has been connected Electrical circuit protection has been sized and installed properly All terminals are tight All chilled water valves are open All chilled water piping is connected properly All air has been vented from the chilled water circuit The unit is switched off again, after the pump test has been completed Chilled water pump (CWP) is operating with the correct rotation. Check the phase sequence of the electrical connection.

Circulate chilled water in the water circuit for at least two hours, then remove, clean and replace the screen lter. The unit is switched

off again, after the pump test has been completed.

Inlet piping to cooler includes a 20 mesh strainer with a mesh size of 1.2 mm.

14 - START-UP CHECKLIST FOR 19PV LIQUID CHILLERS (USE FOR JOB FILE)

Unit start-up

All discharge and liquid line valves are open Locate, repair and mark all refrigerant leaks All suction valves are open, if used

Checks have been carried out for any possible leaks. Unit has been leak checked (including ttings)

- on the whole unit

- at all connections

Locate, repair, and report any refrigerant leaks .............................................................................................................................

......................................................................................................................................................................................................

Check voltage imbalance: AB ................ AC .................. BC ..................

Average voltage = ................................. V

Maximum deviation = ............................ V

Voltage imbalance = ............................. %

Voltage imbalance is less than 2%

CAUTION:

Operation of the chiller with an improper supply voltage or excessive phase imbalance constitutes abuse which will invalidate the manufacturer warranty. If the phase imbalance exceeds 2% for voltage, or 10% for current, contact your local electricity supplier at once and ensure that the chiller is not switched on until corrective measures have been taken.

Check cooler water loop

Water loop volume = ............................. litres

Calculated volume = ............................. litres

3.25 litres/nominal kW capacity for air conditioning

6.5 litres/nominal kW capacity for process cooling

Proper loop volume established

Proper loop corrosion inhibitor included .................. litres of ...........................

Proper loop freeze protection included (if required) ............................litres of ..............................

Piping includes electric heater tape, if exposed to temperatures below 0°C

Inlet piping to cooler includes a 20 mesh strainer with a mesh size of 1.2 mm

Check pressure drop across the cooler

Entering cooler = ................................... kPa

Leaving cooler = .................................... kPa

Leaving - entering = .............................. kPa

CAUTION:

Plot cooler pressure drop on performance data table (in product data literature) to determine total litres per second (l/s) and nd unit’s minimum ow rate.

Total = .................................................... l/s

Nominal kW = ........................................ l/s

Total l/s is greater than unit’s minimum ow rate

Total l/s meets job specied requirement of ................................................l/s

CAUTION:

Once power is supplied to the unit, check for any alarms (refer to the 19PV Touch'Pilot instruction manual for the alarm menu).

Note all alarms:.......................................................................................................................................................................................

NOTE:

The pouch supplied with the unit contains the label indicating the refrigerant used and describing the procedure required

under the Kyoto Protocol F-Gas Regulation:

• Attach this label to the machine.

• Follow and observe the procedure described.

Notes: .....................................................................................................................................................................................................

Order No.: 10266, 03.2018. Supersedes order No.: New. Manufactured by: Carrier SCS, Montluel, France.

Manufacturer reserves the right to change any product specications without notice. Printed in the European Union.

CARRIER participates in the ECP programme for LCP/HP Check ongoing validity of certicate: www.eurovent-certication.com

Carrier 19PV550, 19PV720, 19PV800 Installation, Operation And Maintenance Instructions

Specifications and Main Features

Frequently Asked Questions

User Manual