Carrier 19DV Series Installation, Operation And Maintenance Instructions
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Carrier 19DV Series Installation, Operation And Maintenance Instructions

Hermetic centrifugal liquid chillers dual stage
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INSTALLATION, OPERATION AND
MAINTENANCE INSTRUCTIONS
Hermetic Centrifugal Liquid Chillers
DUAL STAGE
19DV - PIC 5
Nominal cooling capacity 2100 – 2800 kW
ORIGINAL INSTRUCTIONS – CARRIER PROPERTY
IOM19DV_ENG_002 – 05/2019
1

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Summary of Contents for Carrier 19DV Series

  • Page 1 INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS Hermetic Centrifugal Liquid Chillers DUAL STAGE 19DV - PIC 5 Nominal cooling capacity 2100 – 2800 kW ORIGINAL INSTRUCTIONS – CARRIER PROPERTY IOM19DV_ENG_002 – 05/2019...

  • Page 2: Table Of Contents

    SAFETY CONSIDERATIONS ........................6 1.1 Installation safety considerations ......................6 1.2 Maintenance safety considerations ......................6 1.3 Operating checks, relief valves ........................ 7 1.4 Equipment and components under pressure ................... 7 1.5 - Repair safety considerations ........................8 INTRODUCTION AND CHILLER FAMILIARISATION ................9 2.1 Operating conditions range ........................
  • Page 3 3.6.2 CONNECT CONTROL OUTPUTS ....................49 3.6.3 High pressure safety accessory: SRMCR – Chiller equipped with VFD LF2 ........58 3.6.4 VFD wiring : ............................. 60 3.6.5 Carrier Comfort Network Interface (CCN) ..................61 4 START-UP/SHUT-DOWN/RECYCLE SEQUENCE ..................62 4.1 Local Start/Stop Control ......................... 62 4.2 Lubrication control ..........................
  • Page 4 6.6.6 Purge ............................... 89 6.6.7 Auxiliary equipment ......................... 89 6.6.8 Describe chiller cycles ........................89 6.6.9 Review maintenance ........................89 6.6.10 Safety devices and procedures ..................... 89 6.6.11 Check operator knowledge ......................89 6.7 Surge prevention trouble shooting guide:....................90 7.
  • Page 5 9.3.5 Changing Refrigerant Lubrication Filters ..................102 9.3.6 Purge Carbon Filter ........................102 9.3.7 Changing refrigerant pump ......................102 9.3.8 Inspect Refrigerant Float System ....................103 9.3.9 Inspect Safety Relief Devices and Piping ..................104 9.3.10 - Periodic check of the safety loop ....................104 9.3.11 –...

  • Page 6: Safety Considerations

    If for a specific installation water flow control and control of the cooling towers must be done by another means, a parallel Carrier control must be put in place. Any manipulation (opening or closing) of a shut-off valve must be carried out by a qualified and authorized engineer.

  • Page 7: Operating Checks, Relief Valves

    See Periodic check of the safety loop section for this safety device check procedure. For a detailed explanation of the high pressure switch test method contact Carrier Service. 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.

  • Page 8: Repair Safety Considerations

    The characteristics of this equipment/these components are given on the nameplate or in the required documentation, supplied with the products. 1.5 - Repair safety considerations All installation parts must be maintained by the personnel in charge, in order to avoid material deterioration and injuries to people.

  • Page 9: Introduction And Chiller Familiarisation

    When chiller is stopped, the maximum permissible circulation temperature in the exchangers is 65 ° C. Higher temperatures can result in a risk of valve tripping. 2.2 Abbreviations and explanations Frequently used abbreviations in this manual include: CCN — Carrier Comfort Network CCW — Counter Clock Wise CW — Clock Wise CHWR — Chilled Water Reclaim CHWS —...

  • Page 10: Chiller Technical Documentation (Wiring Diagram, Dimensional Drawings, Pid)

    RLA — Rated Load Amps SI — International System of Units SIOB — Starfire 2 Input Output Board (for Purge system control) VFD — Variable Frequency Drive The PIC5+ software version number of your 19DV unit will be located on the HMI module. Information on the unit control is not included in this manual.

  • Page 11: Chiller Familiarization 19Dv

    2.5 - Chiller familiarization 19DV 2.5.1 - Chiller information plate The chiller information plate is located in front of the electrical control box. 2.5.2. System components The main components include the cooler and condenser heat exchangers in separate vessels, motor- compressor, refrigerant, lubrication package, control panels, PIC5+ Touch Screen HMI, economizer, VFD, and purge system.

  • Page 12: Product Identification

    • Control of purge compressor, vacuum pump, heater, and fan. 2.5.2.10. PIC 5+ Touch screen HMI This panel is the user interface for controlling the chiller and has the following functions: • Chiller operation • Chiller diagnostic • Chiller status display •...
  • Page 13 1. Interconnecting Compressor Piping (ICP) from 1 stage to 2 stage 2. VFD cooling piping 3. Condenser 4. Condenser waterbox nozzles 5. Economizer isolation valve (option) 6. Economizer 7. Evaporator waterbox nozzles 8. Evaporator 9. PIC5+ HMI touchscreen panel 10. Suction elbow 11.
  • Page 14 22. Control cabinet 23. Evaporator return end waterbox 24. Condenser return end waterbox 25. Envelop stability control valve (ECV) (option) 26. Purge system assy 27. Lubrication assy 28. VFD 29. Chiller serial plate label 30. Pressure switches assy Figure 2 – Typical 19DV chiller components (Chiller shown with LF2 2CC VFD model)

  • Page 15: Refrigeration Cycle

    1. Bearing support housing 2. Volute 3. Bearing housing 4. Spacer / sizer 5. Motor shaft laby 6. Motor housing 7. Roller element bearing assembly 8. Impeller labyrinth 9. Bearing flange 10. Impeller shim 11. Shroud 12. Eye laby 13. IGV 14.

  • Page 16: Refrigerant Lubrication Cycle

    2.5.5 Refrigerant lubrication cycle 2.5.5.1 Summary The 19DV Series chiller uses refrigerant to lubricate the bearings. The lubrication control is automatically controlled by the chiller controls. In normal RUN mode refrigerant is pumped by means of a refrigerant pump from the high side condenser float chamber to the bearings.
  • Page 17 Supply refrigerant is pulled through a filter drier by the refrigerant pump and is pumped to the bearings through two protective filters and then returned to the evaporator. There are two pressure sensors located across the refrigerant pump. During RUN mode a minimum of 82.7 kPa is required for the refrigerant pump delta difference.
  • Page 18 1. Strainer 2. From evaporator 3. To compressor motor bearings 4. Filter 5. From high side float chamber 6. Filter 7. Actuator, condenser valve 8. Pump discharge 9. Pump suction 10. Actuator and 3 way valve, cooler valve 11. Pump Figure 6 –...
  • Page 19 1.Compressor 2.Condenser 3.Motor cooling system 4.Moisture indicator 5.Cooler Figure 7 – Motor/VFD cooling system 2.5.5.4 VFD cooling The VFD enclosure is sealed from the atmosphere to protect electronics from outside contaminants. Refrigerant is routed through a coil in the VFD enclosure to regulate enclosure temperature while still maintaining a temperature high enough to prevent condensation.
  • Page 20 Fig 8 – VFD cabinet view (example of LF2 4AA) 1. Circuit breaker/main disconnect switch (QF101) for the following functions: - Short-circuit protection of the main circuit - Single connection point of the installation power cables - Isolation and shut-down of the machine, using the handle accessible on the outside of the control box - Emergency stop, initiated by the PIC control 2.
  • Page 21 Fig 9 – VFD cabinet lifting lugs 2.5.5.6 Purge system The purge system is located under the condenser. See Fig. 10. It has two gas inlets coming from condenser and compressor. When chiller is running, the condenser line is active/open and non-condensable gas will pulled out from condenser and when chiller is idle the compressor line is active and non-condensable are pulled out from compressor volute.
  • Page 22 1. Purge pumpout (SV01) 2. Extra filters with strap heaters (not shown) 3. Vacuum pump 4. Control panel 5. Compressor suction 6. Strainer 7. Purge drain (SV04) – connected to refrigerant pump inlet piping 8. Compressor 9. Condenser assembly 10. Venting (SV06), non-condensable exhaust 11.
  • Page 23 1. Compressor 2. Check valve (hidden) 3. Compressor valve (SV02) 4. Condenser valve (SV01) 5. Condenser 6. Purge drain (to lube assy) 7. Drain valve (SV04) 8. Level switches 9. Strainer 10. Suction temperature 11. Purge compressor 12. R134a circuit 13.
  • Page 24 2.5.5.7 Liquid bypass The liquid bypass (LBP) system will be an option for customer when the chiller operation envelope has lower profile like below: Fig 12 – liquid bypass envelop At very low Entering Condenser Water Temp, the pressure difference between condenser and evaporator is reduced.

  • Page 25: Controls

    The PIC5+ system provides open protocols to support the competitive BMS system and can be integrated into Carrier’s Lifecycle System Management for remote monitoring and data management.
  • Page 26 (VFD not shown) Fig 13 – Sensors, actuators location...
  • Page 27 1. Condenser water outlet temperature sensor (RT8) 2. Condenser water inlet temperature sensor (RT7) 3. Evaporator water outlet pressure transducer (BP12) 4. Evaporator water inlet pressure transducer (BP13) 5. High side level switch (HF_LS) 6. Condenser refrigerant pressure transducer (BP1) 7.
  • Page 28 19. Motor winding temperature sensor (RT31C) 20. Compressor discharge temperature sensor (RT21) 21. 1st stage bearing temperature sensor (RT39C) 22. 2 stage bearing temperature sensor (RT40C) 23. Bearing refrigerant supply temperature sensor (RT41) 24. Bearing inlet pressure transducer (BP70) 25. Bearing outlet pressure transducer (BP71) 26.

  • Page 29: Temperature Sensors

    (VFD not shown) Fig 13 – Sensors, actuators location (end) 2.6.4 Temperature sensors: The system uses temperature sensors to measure and control the temperatures in the unit. There are three types of temperature sensors, 5K thermistor (standard), 10K thermistor and RTD (three wires) based on the IOB channel configurations.

  • Page 30: Pressure Transducers

    3. INSTALLATION 3.1 Introduction The 19DV machines are factory assembled, wired, leak tested and electrically tested. Installation (not by Carrier) consists primarily of establishing water and electrical services to the machine. The rigging, installation, field wiring, field piping, and insulation of waterbox covers are the responsibility of the contractor and/or customer.
  • Page 31 -- Medium used during the transport and quantity (kg) -- Medium used and group -- Medium charge -- Containment medium 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 setting -- Safety relief valve setting -- Unit leak test pressure...
  • Page 32 PS (see in the list above) -100 -100 TS (see in the list above) °C Pressure switch cut-out pressure Relief valve cut-out pressure Test pressure, unit leak test Check all items against shipping list. Immediately notify the nearest Carrier representative if any item is missing.

  • Page 33: Installation Requirements

    3.2.3 Installation requirements Prior to starting the chiller’s electrical installation, certain requirements should be checked. Input power wire sizes, branch circuit protection, and control wiring are all areas that need to be evaluated. Conduit Entry Size — It is important to determine the size of the conduit openings in the enclosure power entry plate so that the wire planned for a specific entry point will fit through the opening.

  • Page 34: Provide Machine Protection

    Each lifting cable or chain must be capable of supporting the entire weight of the machine. Contractors are not authorized to disassemble any part of the chiller without Carrier’s supervision. Any request otherwise must be approved in writing by the Carrier Technical Service Manager. Non-conformance to this requirement may result in loss of product warranty.
  • Page 35 Fig 16 – Machine Rigging Guide (comp frame size DV4) Notes : 1. Each chain must be capable of supporting the entire weight of the machine. See chart for maximum weight. (The maximum weights shown cover weights from steel and copper tubing, insulation, and refrigerant charge, excluding water weight.) 2.
  • Page 36 Overall max dimensions (mm) Weight max (kg) Unit model heat exch. frame Compr frame Motor frame Power VFD configuration Length Height Width Rigging Operating 19DV G2*G2* (12 feets) 02DV4 B, D,F, or H VFD LF2 2CC (608 A) 4760 3190 3055 16500 18800...
  • Page 37 Compressor components Weight (kg) Power Train Assembly(Include Motor Stator, Rotor Assembly and 2nd Stage Lube Support) 1000 2nd Stage lube support Rotor Assembly (Include Motor Rotor, 1st Stage Lube Support) 1st Stage Lube Support 1st Stage Suction Assembly(Include 1st Stage Blade Ring, 1st Stage Suction Housing) 1st Stage Blade Ring Assembly 1st Stage Suction Housing 2nd Stage Suction Assembly(Include 2nd Stage Blade Ring, 2nd Stage Suction Housing)
  • Page 38 Frame size Dry weight (kg) Water weight (kg) Frame size Dry weight (kg) Water weight (kg) 4858 4672 4936 4718 5013 4769 5091 4818 5194 1042 4892 1040 4858 4642 4914 4685 4992 4742 5075 4804 5165 1030 4862 1023 5174 4961 5264...
  • Page 39 Frame size Dry weight (kg) Water weight (kg) Frame size Dry weight (kg) Water weight (kg) 2620 2845 2708 2951 2788 3068 2594 2808 2670 2902 2752 3013 2807 3065 2909 3188 3002 3322 2777 3023 2865 3131 2961 3260 3446 3158 3589...

  • Page 40: Rigging The Machine Components

    NOTE: Wiring must also be disconnected. Label each wire before removal (see Carrier Certified Prints). In order to disconnect the VFD from the machine, remove wiring between the VFD from the machine, remove wiring between VFD and control panel, purge system and the main motor leads at the starter lugs.

  • Page 41: Step 3 - Install Machine Supports

    3.4.2 Installation of levelling accessory (if necessary) Uneven floors or other considerations may dictate the use of accessory soleplates (supplied by Carrier for field installation) and leveling pads. Refer to Fig 18.
  • Page 42 3. Level foundation 4. Adjusting screws Note : Accessory (Carrier supplied, field-installed) soleplate package includes 4. Thickness of grout will vary depending on the amount necessary to level chiller.Use only pre-mixed non-shrinkink grout. Masterflow 648CP-Plus or Chemrex Embeco 636 Plus Grout 38 to 57 mm thick.
  • Page 43 1 : Condenser 2 : Cooler 19DV heat exchanger size Dimensions ( mm) COOLER CONDENSER 3951 2508 4472 2508 3951 2612 4472 2612 Fig 19 – 19DV footprint Note: X-X dimension refers to accessory soleplate. See fig 20. Those dimensions are standard. Please always refer to the certified dimensional drawings supplied with the unit.

  • Page 44: Installation Of Spring Isolation System

    3.4.3 Installation of spring isolation system Spring isolation may be purchased as an accessory from Carrier for field installation. It may also be field supplied and installed. Spring isolators may be placed directly under machine support plates or located under machine soleplates.

  • Page 45: Step 4 - Connection Of Water, Vent And Purge Piping

    Set chiller on all springs in one rig; jacking one end out of level will result in excess loading on springs and may cause damage. 2. The accessory spring isolators are supplied by Carrier for installation in the field if the accessory is purchased.

  • Page 46: Install Water Piping To Heat Exchanger

    Nozzle size (mm) (Nominal size) Heat exchanger Cooler Condenser frame size 1 pass 2 pass 3 pass 1 pass 2 pass pass (DN350) (DN300) (DN250) Table 12 – 19DV nozzle size Evaporator waterboxes Condenser waterboxes Pass In Out Arrangement code* In Out Arrangement code* * : Refer to certified drawings...
  • Page 47 Fig 23 – Typical nozzle piping (not supplied by Carrier) 6. Install waterbox vent and drain piping in accordance with individual job data. Consult certified drawings for connection size.

  • Page 48: Install Vent Piping To Relief Devices

    3.5.2 Install vent piping to relief devices If the relief valves are installed on a change-over manifold, 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.

  • Page 49: Connect Control Inputs

    Wiring may be specified for a spare safety switch, and a remote start/stop contact can be wired to the terminal strip. Additional spare sensors and control modules may be specified as well. Carrier Comfort Network® (CCN) communication is wired to the machine HMI panel.
  • Page 50 4-10 Bearing inlet pressure BRGI_P BP70 User option, 4-20 mA - customer Auto Demand limit input AUTO_DEM Auto demand limit terminals User option, 4-20 mA / not connected in Refrigerant leak sensor REF_LEAK AI10 Pump inlet Pressure PUMPI_P BP80 AI11 Guide Vane1 output GV1_OUT M67 3-4...
  • Page 51 Power Request Feedback POW_FDB Power Available Marine option Marine option, dry contact, NO, Customer Alert CUS_ALE ICCP 7-8 connected on terminals to ICCP Freecooling Start Switch FC_SS Marine option, dry contact Free Cooling Mode FC_MODE K120 Factory option Power Request 9-10 Power Request Output POW_REQ...
  • Page 52 Fig 24 - 19DV control box...
  • Page 53 1 : Power supply 24V AC 2 : LEN 3 : CCN 4 : Ethernet 5 : USB Fig 25 - 19DV HMI box rear view...
  • Page 54 Fig 26 - 19DV – IOB1 wiring Fig 27 - 19DV – IOB2 wiring...
  • Page 55 Fig 28 - 19DV – IOB3 wiring Fig 29 - 19DV – IOB4 wiring NOTE: 1. Field-supplied control connectors to be at least 0.75mm2 or larger. Supplied voltage of the wires in control panel should be low (limited to 50V). 2.
  • Page 56 power supply if total power consumes less than 40VA@20VAC. Others, power supply shall be provided by cus- tomer fused transformer. 3. The discrete input loop is powered by internal 24VAC power supply. Field optional contactor or switch must can withstand rated 24VAC voltage, maximal 60mA and rated 20 mA current. 4.

  • Page 58: High Pressure Safety Accessory: Srmcr - Chiller Equipped With Vfd Lf2

    SV01 — Condenser Solenoid Valve SV02 — Compressor Solenoid Valve SV03 — Pumpout Solenoid Valve SV04 — Drain Solenoid Valve SV05 — Regeneration Solenoid Valve SV06 — Vent Solenoid Valve TS01 — Purge Compressor Inlet Temperature Fig 30 – Purge system wiring 3TR —...
  • Page 59 - Mission duration 20 years. A periodic annual check is required. See annex maintenance test section. The K4 safety relay monitors the status of the HPS switches as well as the compressor power contactor. His security contacts are closed under the following conditions : •...

  • Page 60: Vfd Wiring

    For Rockwell VFD, UPS can not be connected directly without VFD modification. NOTE: I General 1.0 Variable Frequency Drive (VFD) shall be designed and manufactured in accordance with Carrier engineering requirement. 1.1 All field-supplied conductors and devices must be compliant, and be installed in compliance with all applicable codes and job specifications.

  • Page 61: Carrier Comfort Network Interface (Ccn)

    3.6.5 Carrier Comfort Network Interface (CCN) The Carrier Comfort Network (CCN) communication bus wiring is supplied and installed by the electrical contractor. It consists of shielded, 3-conductor cable with drain wire. The system elements are connected to the communication bus in a daisy chain arrangement. The positive pin of each system element communication connector must be wired to the positive pins of the system element on either side of it.

  • Page 62: Start-Up/Shut-Down/Recycle Sequence

    Crimp one no. 8 size spring spade terminal on each conductor. Attach red to “+” terminal and white to “G” terminal and black to “–” terminal of CCN Network interface located in the PIC5+ touch screen panel. 1: drain wire 2 : ground drain wire 3 : PIC5+ touch screen panel 4 : CCN wiring...
  • Page 63 Fig 35 – Operating mode / Local On Note: Prior to start-up, the start-to-start timer and the stop-to-start timer must have elapsed and all alarms must be cleared. When start-up is initiated, the status screen displays the startup progress and the Start/Stop icon blinks green. Once local start-up begins, the PIC5+ control system performs a series of prestart tests to verify that all prestart alerts and safeties are within acceptable limits.
  • Page 64 1 : Machine safeties evaporator pump 2 : Condenser water pump 3 : Waterflow chilled water temp, guide vanes, refrigerant pump, and tower fan control 4 : Refrigerant pump 5 : Compressor, compressor on time, service on time 6 : 15-minute start-to-start 7 : 2 minute stop-to-start 8 : Elapsed time 9 : Compressor running...

  • Page 65: Lubrication Control

    ACTUAL LINE VOLTAGE >= OVERVOLTAGE THRESHOLD (Not applicable for Rockwell UM VFDs) Alarm Guide vane 1 has not been calibrated successfully Alarm Guide vane 2 has not been calibrated successfully Alarm * : If prestart Check condition is true, then resulting state is as indicated in the state number column. Table 15 –...

  • Page 66: Shutdown

    1: purge drain, 2: Cooler, 3: Pumpout drain, 4: High side float chamber, 5: sight glass, 6: strainer, 7: 3-way actuated valve, 8: strainer, 9: pump, 10: 2-way actuated valve, 11: refrigerant filter, 12: bearing filter, 13: pumpout drain. Fig 37 – Lube control assembly schematic 4.3 Shutdown The unit can be stopped locally using the HMI by pressing the green Start/Stop icon.

  • Page 67: Before Initial Start-Up

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

  • Page 68: Remove Shipping Packaging

    Fig 39 : Digital Vacuum gage 5.1.3 - Remove shipping packaging After receipt remove any packaging material from the unit, VFD, and control panels. 5.1.4 – Lubrication and purge circuit valves Check if the motorized valves on lubrication circuit are open and all solenoid valves and service valves are open on purging circuit.

  • Page 69: Check Chiller Tightness

    1382.1 1978.3 1423±34 2493.2 3563.7 2534±34 1653.1 2371.3 1721±68 2981 4268.3 3049±68 2262.9 3238.5 2331±68 4092.1 5840.1 4160±68 2953.9 4214.1 3022±68 5325.2 7601.6 5393±68 3970.2 5677.5 4038±68 7154.4 10230.3 7222±68 4268.3 6165.3 4336±68 7682.9 10975.5 7751±68 6165.3 8807.5 6233±68 11111 15867.1 11179±68 6775...
  • Page 70 Fig 40 – 19DV leak test procedure 5.1.6.2 Refrigerant Tracer Carrier recommends the use of an environmentally acceptable refrigerant tracer for leak testing with an electronic detector. Ultrasonic leak detectors can also be used if the chiller is under pressure.
  • Page 71 c. Leak test chiller as outlined in Steps 3 to 9. 2. If the pressure readings are abnormal for the chiller condition: Prepare to leak test chiller. For cooling machines, check for leaks by connecting a nitrogen bottle with added tracer to allow for electronic leak detection if possible;...

  • Page 72: Standing Vacuum Test

    29.4 50.5 151.9 32.2 65.6 81.9 183.3 37.8 99.3 200.7 40.6 118.1 219.5 43.3 138.1 239.5 46.1 159.6 48.9 182.4 283.8 51.7 206.8 308.2 54.4 232.7 334.1 57.2 260.3 361.7 289.6 Table 17 – R1233zd(E) Pressure / Temperature 5.1.7 Standing Vacuum Test When performing the standing vacuum test or chiller dehydration, use a manometer or a wet bulb indicator.

  • Page 73: 9- Inspect Water Piping

    Before any start-up verify that the heat exchange fluid is compatible with the materials and the water circuit coating. In case additives or other fluids than those recommended by Carrier are used, ensure that the fluids are not considered as a gas, and that they belong to class 2, as defined in directive 97/23/EC.

  • Page 74: Check Relief Devices

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

  • Page 75: Ground Fault Troubleshooting

    If metal particulate has fallen into the rectifier or inverter assemblies contact Service Engineering or your Technical Service Manager for further instructions. WARNING: Do not apply power unless a qualified Carrier technician is present. Serious personal injury may result. 5.3 Ground Fault Troubleshooting Follow this procedure only if ground faults are declared by the chiller controls.

  • Page 76: Checking The Installation

    1 : Expansion valve 2 : Suction Schrader valve Note : Clockwise rotation of expansion valve adjustment screw increases the pressure setting and counterclockwise rotation decreases pressure setting. Fig 42 – purge system setting 5.5 Checking the Installation Use the following instructions to verify the condition of the installation: 1.

  • Page 77: Charge Unit With Refrigerant

    5.7 Charge unit with refrigerant Standard 19DV is shipped with refrigerant but it can also be shipped with holding nitrogen charge of 103 kPa. Chiller has to be loaded on job site with refrigerant. IMPORTANT: Turn on the chilled water and condenser water pumps to prevent freezing. CAUTION: Always operate the condenser and chilled water pumps whenever charging, transferring, or removing refrigerant from the chiller.

  • Page 78: Software Configuration

    5.8 Software configuration WARNING: Do not operate the chiller before the control configurations have been checked and a Calibration and Control Test has been satisfactorily completed. Protection by safety controls cannot be assumed until all control configurations have been confirmed. See the 19DV with PIC 5+ Controls Operation and Troubleshooting manual for instructions on using the PIC 5+ interface to configure the 19DV unit.

  • Page 79: Input The Local Occupied Schedule

    Fig 45: main menu – setpoint table icon The Setpoint screen is displayed (see Fig. 46). Set the base demand limit set point, and either the LCW set point or the ECW set point. To set a value, press the appropriate set point, enter the value, and press OK. For more information, see the PIC5+ Control User Manual.
  • Page 80 IMPORTANT: Be sure to remember the password. Retain a copy for future reference. Without the password, access to the SERVICE menu will not be possible unless accessed by a Carrier representative. LOGIN/LOGOUT — Press the lock icon on the home screen to enter the password.
  • Page 81 IOB 4 Option No/yes Guide Vane1 Type Digital=0, Analog=1 VFD Feedback Voltage Sel 0-5V=0, 0-10V=1 Marine option Disable/Enable Dsable Dsable Power Request option Disable/Enable Dsable Dsable Cont. Power Request Disable/Enable Dsable Dsable Purge System Option Disable/Enable Dsable Enable Liquid bypass Option Disable/Enable Dsable per selection...
  • Page 82 Cond Pre Override Dv 72 379.2 379.2 Cond Pre Cutout DV 72 406.8 406.8 Condenser freeze point Comp discharge Alert 93.3 93.3 Comp Motor Temp Override 93.3 93.3 Comp Bearing Temp Alert 79.4 79.4 Comp Bearing Temp trip Comp Bearing Alert R6/7 98.9 98.9 Comp Bearing Trip R6/7...
  • Page 83 DSH_Req param VFD 1st 0.9427 0.9427 DSH_Req param VFD Const -34.5 -34.5 DSH_Req param IGV F DSH_Req param IGV 2nd 0.0046 0.0046 DSH_Req param IGV 1st -0.562 -0.562 DSH_Req param IGV Const DSH_Req param Lift F DSH_Req param Lift 2nd 0.0006 0.0006 DSH_Req param Lift 1st...
  • Page 84 ECV On DT for Low Load 1,1 °C 1,1 °C (adjust as required) ECV Low Load DB 0,6 °C 0,6 °C (adjust as required) Head Pres Valve Option Dsable job site specific Head Pres Delta P 0% 172,4 kPa 172,4 kPa (adjust as required) Head Pres Delta P 100% 344,7 kPa 344,7 kPa (adjust as required)
  • Page 85 Enable Excessive Starts Oil Stir Cycle (19XR6/7) No Stir = 0, 30s/30m = 1, 1m/4h = 2, Comb. 0&1=3 Most Service Parameters do not require any change from default. Adjust as required. TABLE SETPOINT Access Menu Main Menu / Setpoint Setting Default value (SI units) Settings value (SI)

  • Page 86: Field Set Up And Verification

    • VFD Nameplate data - located on the VFD. MODIFY EQUIPMENT CONFIGURATION IF NECESSARY — The EQUIPMENT SERVICE table has screens to select, view, or modify parameters. Carrier’s certified drawings have the configuration values required for the jobsite. Modify these values only if requested.

  • Page 87: Cooler And Condenser Pressure Transducer And Waterside Flow Device Calibration

    Q_GV1CL Quick Test GV1 Close Q_GVSRD DISABLE/ENABLE GV1/SRD Joint Test Q_SRD 0.0~100.0 Quick Test Diffuser Pos Q_GV1ACT Guide Vane 1 Actual Pos Q_DIFTGT Diffuser Target Pos Q_HGBPOP Quick Test ECV Open Q_HGBPCL Quick Test ECV Close Q_HGBP_T 0.0~100.0 EC Valve Tested Pos Q_DMPOP Quick Test Damper Open Q_DMPCL...

  • Page 88: Initial Start-Up

    step. If rotating the waterside flow device does not allow calibration then pressurize the transducer until the ratio is within range. Then attempt calibration again. 4. A high pressure point can be calibrated between 10-30 psig (68.9 -206.8 kPa) by attaching a regulated pressure source (usually from a nitrogen cylinder with high resolution pressure gage).

  • Page 89: Check Refrigerant Lube

    6.3 Check Refrigerant Lube 1. In Quick Test the refrigerant lube pressure can be checked. First open cooler valve and condenser drain valve, then run the refrigerant pump. Usually the pressure drop across bearing is above 55 kPa. If the bearing pressure drop is negative, please check pump rotation.

  • Page 90: Surge Prevention Trouble Shooting Guide

    6.7 Surge prevention trouble shooting guide: If chiller surges very frequently, the surge prevention line should be decreased a. If chiller surges only at full load region, Delta Tsmax should be decreased by 0.28°C for each step until there is no abnormal surge occurs. See Fig. 48 for the effect of delta Tsmax on surge prevention line. b.
  • Page 91 Fig 49 – Effect of surge delta TSmin on Surge prevention Fig 50 – Effect of surge line shape factor on Surge prevention...

  • Page 92: Operating Instructions

    Fig 51 – Effect of surge line speed factor on Surge prevention 7. OPERATING INSTRUCTIONS 7.1 operator duties 1. Become familiar with the chiller and related equipment before operating the chiller. 2. Prepare the system for start-up, start and stop the chiller, and place the system in a shutdown condition. 3.

  • Page 93: To Stop The Chiller

    start-up. There will be an alarm if compressor is ON and the bearing pressure drop is less than 68.9 kPa diff for 10 seconds. 5. The moisture indicator sight glass on the refrigerant motor cooling line should indicate single phase refrigerant flow and a dry condition.

  • Page 94: Manual Guide Vane Operation

    Automatic recording of data is possible by using CCN devices such as the Data Collection module and a Building Supervisor. Contact a Carrier representative for more information. SERVICE AND OPERATION LOG CARRIER 19DV SEMI-HERMETIC CENTRIFUGAL REFRIGERATION MACHINE MACHINE MACHINE JOB SITE : MODEL NO.

  • Page 95: Chiller Idle Requirement

    7.11 Chiller Idle Requirement 7.11.1 Be idle for a short time: There is no special requirement, follow the conventional procedure to check and start-up. 7.11.2 Be idle for a long time: 1. Chiller leak prevention a. If chiller is idle for one month, suggest running purge every week. b.

  • Page 96: Maintenance

    1 : Venting line 2 : Discharge valve 3 : Vacuum pump 4 : Pump out valve 5 : Condenser 6 : Compressor 7 : Suction temperature 8 : High level sensor 9 : Expansion valve 10 : Low level sensor 11 : Purge cooler 12 : Drain filter 13 : Chiller cooler...

  • Page 97: Soldering And Welding

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

  • Page 98: Repair The Leak, Retest, And Apply Standing Vacuum Test

    1. Connect a copper tube from the pressure regulator on the cylinder to the refrigerant charging valve. Never apply full cylinder pressure to the pressurizing line. Follow the listed sequence. 2. Open the charging valve fully. 3. Slowly open the cylinder regulating valve. 4.

  • Page 99: Trim Refrigerant Charge

    NOTE: For first stage, rotate coupling clockwise to close guide vanes; rotate coupling counterclockwise to open guide vanes. For second stage, rotate coupling counterclockwise to close guide vanes; rotate coupling clockwise to open guide vanes. 1 : actuator 2 : Connector 3 : Set screw 4 : Bracket 5 : Coupling...

  • Page 100: Weekly Maintenance

    tubes should be covered with liquid refrigerant at all times. There is no benefit to have a refrigerant level higher than the tubes and capacity will be lost if the tubes are not covered with liquid. Refrigerant may be added either through a storage tank or directly into the chiller as described in the Charging Refrigerant section.

  • Page 101: Check For Leaks / Purge Operation

    A : Moisture indicating sightglass cooler side B : Moisture indicating sightglass condenser side Fig 56 - Moisture indicating sightglass for inspection 3. Check that pressure Ref Pump Delta P (PRESSURE Menu) is above 89.6 kPa. Check the sight glass on bearing inlet line.

  • Page 102: Inspect The Control Panel

    9.3.2 Inspect the Control Panel Maintenance consists of general cleaning and tightening of connections. Vacuum the control cabinets to eliminate dust build-up. If the chiller control malfunctions, refer to the Troubleshooting Guide section for control checks and adjustments. 9.3.3 Inspect Purge A purge protects the machine against non-condensable gases.

  • Page 103: Inspect Refrigerant Float System

    Fig 57 – Refrigerant pump assembly 9.3.8 Inspect Refrigerant Float System For 19DV unit, the condenser has a high side ball type float system, and the economizer has a low side ball type float system. This applies for both the high side float (first float downstream of condenser) and the low side float (second float downstream of condenser).

  • Page 104: Inspect Safety Relief Devices And Piping

    A : Float ball B : refrigerant exit Fig 58 – Float ball valve details 9.3.9 Inspect Safety Relief Devices and Piping Refer to chapter 1 “Safety considerations”. The relief valves on this chiller protect the system against the potentially dangerous effects of overpressure. These devices must be kept in peak operating condition. As a minimum, the following maintenance is required: •...

  • Page 105: Compressor Bearing Maintenance

    4- Reconnect the pressure switch. Switch off the power supply by acting on the QF1 circuit breaker. Wait at least 5 seconds Put the power supply back on the circuit breaker QF1. Reset the safety relay by pressing the reset button. 5- Check that the PWR, IN and OUT LED of the safety relay K4 is on.

  • Page 106: Inspect The Heat Exchanger Tubes And Flow Devices

    CAUTION: Water must be within design flow limits, clean, and treated to ensure proper chiller performance and reduce the potential of tube damage due to corrosion, scaling, erosion, and algae. Carrier assumes no responsibility for chiller damage resulting from untreated or improperly treated water.
  • Page 107 For commissioning, installation and operation instructions for units with VFD LF2 and PIC5+ control, refer to chapter 8 of the Carrier 19XR / 19XRV manual. CAUTION : The motor leads must be disconnected from the VFD before an insulation test is performed. The voltage generated from the tester can damage the drive components.

  • Page 108: Recalibrate Pressure Transducers

    (paint) condition. 9.3.19 Ordering Replacement Chiller Parts When ordering Carrier specified parts, the following information must accompany an order: • chiller model number and serial number • name, quantity, and part number of the part required •...

  • Page 109: Resistance Check

    temperature by measuring voltage drop; if the controls are powered off, determine sensor temperature by measuring resistance. Compare the readings to the values listed in Table 22. 10.4 Resistance Check Turn off the control power from the module, disconnect the terminal plug of the sensor in question. With a digital ohmmeter, measure sensor resistance between receptacles as designated by the wiring diagram.

  • Page 110: Check Sensor Accuracy

    10.6 Check Sensor Accuracy Place the sensor in a medium of known temperature and compare that temperature to the measured reading. The thermometer used to determine the temperature of the medium should be of laboratory quality with 0.25 °C graduations. The sensor in question should be accurate to within 1.2 °C. Note that the PIC5+ control module, MAINTENANCE menu, offers a temperature sensor calibration feature where the sensor temperature can be offset.

  • Page 111: Checking Pressure Transducers

    1 : 2 stage bearing temperature sensor (RT40C) 2 : 1 stage bearing temp. sensor (RT39C) 3 : Motor winding temp sensor (RT31C) Fig 61 – Motor housing temperature sensors 10.7 Checking Pressure Transducers There are 6 factory-installed pressure transducers measuring refrigerant pressure: condenser pressure, evaporator pressure, refrigerant pump suction, discharge pressure, bearing inlet pressure, and bearing outlet pressure.

  • Page 112: High Altitude Locations

    10.8 High Altitude Locations Because the chiller is initially calibrated at sea level, it is necessary to recalibrate the pressure transducers if the chiller has been moved to a high altitude location. Note that Atmospheric Pressure can be adjusted in the Service Parameters Menu (located in the Configuration Menu).
  • Page 113 APPENDIX A — SmartView SCREEN AND MENU STRUCTURE...
  • Page 114 Detailed menu description...
  • Page 115 APPENDIX B — MAINTENANCE SUMMARY AND LOGSHEETS 19DV Maintenance Interval Requirements Note : Equipment failures caused by lack of adherence to the Maintenance Interval Requirements are not covered under warranty.
  • Page 116 APPENDIX B — MAINTENANCE SUMMARY AND LOGSHEETS (Cont.) 19DV monthly Maintenance Log...

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