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Carrier 19XRV Series Start-Up And Service Instructions

With pic iii/pic 6 controls eaton lcx9000 vfd option
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Start-Up and Service Instructions

SAFETY CONSIDERATIONS

Centrifugal liquid chillers are designed to provide safe and
reliable service when operated within design specifications.
When operating this equipment, use good judgment and
safety precautions to avoid damage to equipment and prop-
erty or injury to personnel.
Be sure you understand and follow the procedures and
safety precautions contained in the machine instructions, as
well as those listed in this guide.
Failure to follow these procedures will result in severe per-
sonal injury or death.
DO NOT VENT refrigerant relief devices within a building.
Outlet from rupture disc or relief valve must be vented out-
doors in accordance with the latest edition of ANSI/ASHRAE
15 (American National Standards Institute/American Society
of Heating, Refrigerating and Air-Conditioning Engineers)
(Safety Code for Mechanical Refrigeration). The accumula-
tion of refrigerant in an enclosed space can displace oxygen
and cause asphyxiation.
PROVIDE adequate ventilation in accordance with ANSI/
ASHRAE 15, especially for enclosed and low overhead
spaces. Inhalation of high concentrations of vapor is harmful
and may cause heart irregularities, unconsciousness, or death.
Intentional misuse can be fatal. Vapor is heavier than air and
reduces the amount of oxygen available for breathing. Product
causes eye and skin irritation. Decomposition products are
hazardous.
DO NOT USE OXYGEN to purge lines or to pressurize a
machine for any purpose. Oxygen gas reacts violently with oil,
grease, and other common substances.
DO NOT USE air to leak test. Use only refrigerant or dry
nitrogen.
NEVER EXCEED specified test pressures. VERIFY the
allowable test pressure by checking the instruction literature
and the design pressures on the equipment nameplate.
DO NOT VALVE OFF any safety device.
BE SURE that all pressure relief devices are properly installed
and functioning before operating any machine.
RISK OF INJURY OR DEATH by electrocution. High volt-
age is present on motor leads even though the motor is not run-
ning when a solid state or inside-delta mechanical starter is
used. Open the power supply disconnect before touching
motor leads or terminals.
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Catalog No. 04-53190062-01
DANGER
Printed in U.S.A.
with PIC III/PIC 6 Controls
Eaton LCX9000 VFD Option
Failure to follow these procedures may result in personal
injury or death.
DO NOT USE TORCH to remove any component. System
contains oil and refrigerant under pressure.
To remove a component, wear protective gloves and goggles
and proceed as follows:
a. Shut off electrical power to unit.
b. Recover refrigerant to relieve all pressure from system
using both high-pressure and low pressure ports.
c. Traces of vapor should be displaced with nitrogen and
the work area should be well ventilated. Refrigerant in
contact with an open flame produces toxic gases.
d. Cut component connection tubing with tubing cutter and
remove component from unit. Use a pan to catch any oil
that may come out of the lines and as a gage for how
much oil to add to the system.
e. Carefully unsweat remaining tubing stubs when neces-
sary. Oil can ignite when exposed to torch flame.
DO NOT USE eyebolts or eyebolt holes to rig machine sec-
tions or the entire assembly.
DO NOT work on high-voltage equipment unless you are a
qualified electrician.
DO NOT WORK ON electrical components, including con-
trol panels, switches, starters, or oil heater until you are sure
ALL POWER IS OFF and no residual voltage can leak from
capacitors or solid-state components.
LOCK OPEN AND TAG electrical circuits during servicing.
IF WORK IS INTERRUPTED, confirm that all circuits are
de-energized before resuming work.
AVOID SPILLING liquid refrigerant on skin or getting it into
the eyes. USE SAFETY GOGGLES. Wash any spills from the
skin with soap and water. If liquid refrigerant enters the eyes,
IMMEDIATELY FLUSH EYES with water and consult a
physician.
NEVER APPLY an open flame or live steam to a refrigerant
cylinder. Dangerous over pressure can result. When it is neces-
sary to heat refrigerant, use only warm (110°F [43°C]) water.
DO NOT REUSE disposable (nonreturnable) cylinders or
attempt to refill them. It is DANGEROUS AND ILLEGAL.
When cylinder is emptied, evacuate remaining gas pressure,
loosen the collar, and unscrew and discard the valve stem. DO
NOT INCINERATE.
CHECK THE REFRIGERANT TYPE before adding refriger-
ant to the machine. The introduction of the wrong refrigerant
can cause machine damage or malfunction.
(Warnings continued on next page.)
Form 19/23-9SS
Pg 1
19XRV, 23XRV
WARNING
6-19
Replaces: 19/23-5SS

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  Summary of Contents for Carrier 19XRV Series

  • Page 1: Safety Considerations

    19XRV, 23XRV with PIC III/PIC 6 Controls Eaton LCX9000 VFD Option Start-Up and Service Instructions SAFETY CONSIDERATIONS WARNING Centrifugal liquid chillers are designed to provide safe and reliable service when operated within design specifications. Failure to follow these procedures may result in personal When operating this equipment, use good judgment and injury or death.
  • Page 2: Table Of Contents

    INTRODUCTION ........2 edition). Contact Carrier for further information on use of this ABBREVIATIONS AND EXPLANATIONS.
  • Page 3: Identifying Drive Components

    The DC bus terminals for all modules are connected to each other (+) to (+) and (–) to (–). Fig. 3 — Check DC Bus Terminals Table 1 — VFD Frame Size and Application (19XRV, 380-480V) CARRIER CARRIER MAXIMUM EATON PART NO.
  • Page 4: Start-Up

    Initial start-up of the VFD should be completed by a trained Coming into contact with this voltage is extremely danger- technician certified by Eaton and Carrier as a commissioner for ous and will result in severe personal injury or death.
  • Page 5: Verify Installation

    Table 4 is from the PIC III VFD_CONF screen. Parameters in italics are to be entered or confirmed at start-up. Parameters in bold are to be changed only after consulting with Carrier ser- vice engineering.
  • Page 6: Commissioning The Unit

    Table 4 — VFD Configurations (PIC3/VFD_CONF) Commissioning the Unit The commission procedure is as follows: DEFAULT PARAMETER VALUE 1. If the chiller has been stored outdoors, allow at least 24 hours MOTOR NAMEPLATE VOLTAGE room temperature stabilization prior to commissioning. En- COMPRESSOR 100% SPEED sure any condensation that occurs as a result of the ambient LINE FREQ=60 HZ? (NO=50)
  • Page 7: Service

    ensure it does not lead to a fault condition. The alert code will automatically be cleared from the HMI when the condition causing the alert no longer exists. CHILLER ALARM CODES — An alarm condition is indicated by a message on the HMI screen. If an alarm occurs, the drive coasts to stop and the RUN LED on the keypad will turn off.
  • Page 8: Checking Power Modules And Motor Input

    Checking Power Modules and Motor Input with Input Power Off WARNING Use the following procedure to check the drive’s power mod- DC bus capacitors retain hazardous voltages after input power ule circuitry with power off: has been disconnected. After disconnecting input power, wait 1.
  • Page 9 9. Lift the drive chassis with the hoist until the chassis is free from the Z bracket. Remove the 2 or 4 top bolts. BOLT (4 PLACES) 10. Pull the drive forward of the Z bracket and lift the drive chas- sis from the cabinet.
  • Page 10 Table 6 — Eaton LCX9000 Fault Code Descriptions and Corrective Actions (PIC III Controls) ICVC FAULT PIC 6 FAULT FAULT CODE ON FAULT DESCRIPTION SOLUTION CORRECTIVE ACTION STATE TYPE VFD HIST STATE (PIC III) SCREEN Check VFD configurations. Alarm Drive has detected too high a occurs if phase current exceeds 106% current in the motor cable: of configured motor amps.
  • Page 11 Table 6 — Eaton LCX9000 Fault Code Descriptions and Corrective Actions (PIC III Controls) (cont) ICVC FAULT PIC 6 FAULT FAULT CODE ON FAULT DESCRIPTION SOLUTION CORRECTIVE ACTION STATE TYPE VFD HIST STATE (PIC III) SCREEN Decrease the motor load. Decrease the motor load.
  • Page 12: Parts Identification And Location

    Table 6 — Eaton LCX9000 Fault Code Descriptions and Corrective Actions (PIC III Controls) (cont) ICVC FAULT PIC 6 FAULT FAULT CODE ON FAULT DESCRIPTION SOLUTION CORRECTIVE ACTION STATE TYPE VFD HIST STATE (PIC III) SCREEN • option board or device Device added Reset.
  • Page 13 460V TRANSFORMER 3KVA 120V Cutler-Hammer ready fault START bypass STOP enter LEGEND — Inverter (198 lb; 485, 550, 605, or 680 amp) a19-1933 — Shunt Trip — Breaker Lug Kit (Load Side) — Breaker Lug Kit (Line Side) — Breaker Rating Plug —...
  • Page 14 SUB-PANEL DETAIL 12 13 a19-2091 LEGEND — Inverter (198 lb; 416 or 502 amp) — Line Choke, 3% nominal impedance (414 amp reactor, 98 lb; 515 amp reactor, 175 lb) — Main Breaker Kit — Control Transformer (53 lb) — Oil Heater Circuit Breaker, CB2 (15 amp) —...
  • Page 15 460V TRANSFORMER 3KVA 120V Cutler-Hammer ready fault START bypass STOP enter LEGEND — Inverter (264 lb; 765, 855, 960, or 1070 amp) — Line Choke (400 amp, 118 lb; 500 amp, 118 lb; 600 amp, 175 lb) — Shunt Trip —...
  • Page 16 a19-1953...
  • Page 17 a19-2093...
  • Page 18: Appendix A - Wiring Schematics

    APPENDIX A — WIRING SCHEMATICS (cont) 19XRV CHILLER CONTROL SCHEMATIC (PIC III) Continued on next page (SHIELD) (RED) AUTO DEMAND LIMIT 4-20mA (OPTIONAL) (BLK) (1-5vdc) (CLR) AUTO CHILLED WATER 4-20mA RESET (OPTIONAL) (CLR) (1-5vdc) (BLK) (SHIELD) 4-20mAkw OUTPUT (RED) EVAP ENT WATER TEMP (BLK) SWITCH POSITION...
  • Page 19 APPENDIX A — WIRING SCHEMATICS (cont) 19XRV CHILLER CONTROL SCHEMATIC (PIC III) (cont) (GRN) TO TB-G ** COMP'R OIL HEATER OPEN 230V CLOSE (BLK) (BLK) (BLK) (WHT) 115V (BLK) (BLK) HGBP ACTUATOR (WHT) (RED) (WHT) (WHT) (WHT) (BLK) (WHT) (WHT) 230V WIRING MODIFICATION COMP'R OIL HEATER (BLU)
  • Page 20 APPENDIX A — WIRING SCHEMATICS (cont) 19XRV CHILLER CONTROL SCHEMATIC (PIC 6) Continued on next page...
  • Page 21 APPENDIX A — WIRING SCHEMATICS (cont) 19XRV CHILLER CONTROL SCHEMATIC (PIC 6) (cont) Continued from previous page...
  • Page 22 APPENDIX A — WIRING SCHEMATICS (cont) 23XRV CHILLER CONTROL SCHEMATIC OPTA9 4-20mA PRESS REF -/+ SPARE SAFETY OPTA9 ICE BUILD REMOTE START HIGH PRESSURE SW. OPTA2 Continued on next page...
  • Page 23 LEGEND CB-XX — Circuit Breaker (Example: CB-1B) Denotes Control Panel Terminal — Chiller Control Module — Carrier Comfort Network Denotes Oil Pump Terminal HGBP — Hot Gas Bypass Denotes Power Panel Terminal ICVC — International Chiller Visual Controller OPT** —...
  • Page 24 © Carrier Corporation 2019 Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. Catalog No. 04-53190062-01 Printed in U.S.A. Form 19/23-9SS Pg 24 6-19 Replaces: 19/23-5SS...