Page 1: Table Of Contents
CONTENTS Ground Fault Troubleshooting ....21 Carrier Comfort Network Interface ....22 Page Charge Refrigerant into Chiller .
Page 2: Safety Considerations
APPENDIX D — REMOTE CONNECTIVITY SETUP NEVER EXCEED specified test pressures; VERIFY the (BY CARRIER SERVICE) ....59 allowable test pressure by checking the instruction literature INDEX .
Page 3 DO NOT STEP on refrigerant lines. Broken lines can whip cited herein should comply with ANSI/ASHRAE 15 (latest about and release refrigerant, causing personal injury. edition). Contact Carrier for further information on use of this DO NOT climb over a chiller. Use platform, catwalk, or chiller with other refrigerants.
Page 4: Introduction
— Building Management System BPHX — Braised Plate Heat Exchanger is intended to be used in combination with the 19MV Semi-Her- — Carrier Comfort Network ® metic Centrifugal Liquid Chillers Controls Operation and Trou- DCIB — Digital Control Interface Board bleshooting manual that describes the controls in detail.
Page 5 – – Description Special Code 19 — High Efficiency Semi-Hermetic – — Standard Centrifugal Liquid Chiller S — Special MV — Model Designation Voltage Code Bearing Option Code Volts-Phase-Hertz 3 — 380-3-60 – — Magnetic Bearing 4 — 416-3-60 5 — 460-3-60 Evaporator Frame Size 9 —...
Page 6 FIRST STAGE COMPRESSOR SECOND STAGE GUIDE VANE MOTOR GUIDE VANE TOPHAT ACTUATOR ACTUATOR EVAPORATOR INTEGRATED POWER PRESSURE AND CONTROL PANEL TRANSDUCER AND CHARGING VALVE RELIEF VALVES (NOT ALL SHOWN) ECONOMIZER (OPTION) CONDENSER WATERBOX RETURN END MBC CAVITY COVER EVAPORATOR EVAPORATOR WATERBOX RETURN END REFRIGERANT STORAGE...
Page 7: Motor-Compressor
ECONOMIZER VENT LINE BPHX ECONOMIZER COMPRESSOR ICP INLET SUPPORT BRACKET FILTER-DRYER ECONOMIZER EXV ISOLATION VALVE CONDENSER OUTLET ISOLATION VALVE MAIN EXV EXPANSION CONTROL SYSTEM VALVE (EXCSV) EVAPORATOR INLET Fig. 3 — Typical 19MV Economizer Assembly Detail Motor-Compressor Magnetic Bearing Controller (MBC) This component maintains system temperature and pressure dif- The 19MV compressor uses active magnetic bearings in place of ferences and moves the heat-carrying refrigerant from the evapo-...
Page 8: Refrigeration Cycle
CONDENSER LIQUID LEVEL SENSOR HOUSING ISOLATION VALVES Fig. 4 — Typical 19MV Liquid Level Assembly Detail the vapor condenses to liquid. The liquid drains from the bottom REFRIGERATION CYCLE of the condenser and, for units equipped with economizer option, The compressor continuously draws refrigerant vapor from the flows into the high pressure side of the BPHX.
Page 9 CONDENSER SUBCOOLER 1ST STAGE END ECONOMIZER Stg 1 2ND STAGE END Motor ECONOMIZER DUAL EXV EVAPORATOR EXPANSION CONTROL VALVE Fig. 5 — Refrigeration Cycle — 19MV Oil-free Compressor with Economizer CONDENSER SUBCOOLER 1ST STAGE END Stg 1 2ND STAGE END Motor DUAL EXV EXPANSION...
Page 10: Motor Cooling System
compressor operation. After exiting the condenser shell, the re- frigerant flows through a moisture indicating sight-glass and an CAUTION in-line filter drier. There is a ball valve positioned on each side of To avoid adverse effects on chiller operation, considerations above components for ease of service.
Page 11: Vfd
The 19MV unit mounted starters are Danfoss FC102 VFDs fam- ily for standard tier and Rockwell PF755TL for high tier. The Approximate Weight VFDs are used to run Carrier’s Interior Permanent Magnet Drive (IPM), gear-less compressors family. The VFD, power panel, and control panel are mounted on the chiller.
Page 12: Controls
BMS system and can be inte- delayed or aborted. If the prestart tests are successful, the PIC6 grated into Carrier’s Lifecycle System Management for remote will perform MBC pre-start checks. After the MBC checks are monitoring and data management.
Page 13 vanes are more than 4% open, the start-up waits until the PIC6 advance the STARTS IN 12 HOURS counter. Any failure after control system closes the vanes. the 1CR/Start relay has energized results in a safety shutdown, advances the starts in 12 hours counter by one, and displays the Compressor ontime and service ontime timers start, and the com- applicable shutdown status on the display.
Page 14: Shutdown
• chiller certified prints Shutdown • wiring diagrams The unit can be stopped locally using the HMI by pressing the • diagrams and instructions for special controls or options green Start/Stop icon . The Unit Start/Stop screen is displayed. • 19MV Installation Instructions Press Confirm Stop (see Fig.
Page 15: Check Chiller Tightness
Table 3 — Bolt Torque Requirements, Foot Pounds SAE 2, A307 GR A HEX HEAD SAE 5, SOCKET HEAD OR HEX SAE 8, HEX HEAD NO MARKS WITH 3 RADIAL LINES, OR SA499 WITH 6 RADIAL LINES OR SA354 GR BD BOLT SIZE LOW CARBON STEEL MEDIUM CARBON STEEL...
Page 16 LEAK TEST OF 19MV 1. ATTACH COMPOUND GAGE TO EACH VESSEL 2. NOTE AMBIENT TEMPERATURE GAGE READINGS MACHINES WITH REFRIGERANT CHARGE MACHINES WITH NITROGEN HOLDING CHARGE PRESSURE ON CONDENSER VESSEL IS PRESSURE ON CONDENSER VESSEL IS AT REFRIGERANT SATURATED AT REFRIGERANT SATURATED CONDITIONS (SEE REFRIGERANT CONDITIONS (SEE REFRIGERANT PRESSURE READING IS LESS THAN 15...
Page 17: Perform Mbc Calibration And Clearance Checks
Perform MBC Calibration and Clearance Checks The initial calibration of the active magnetic bearings is per- formed before the chiller is shipped from the Carrier facility. If it becomes necessary to recalibrate, then select the Motor- Compressor icon on the home screen, then press the up arrow to navigate to the MBC status page.
Page 18: Refrigerant Tracer
If no leak is found during the initial start-up procedures, com- ant, Carrier recommends the following leak test procedure. Refer plete the transfer of refrigerant gas from the storage tank to to Tables 6 and 7 for refrigerant pressure/temperature values.
Page 19 Table 6 — Pressure — Temperature (F) Table 7 — Pressure — Temperature (C) TEMPERATURE HFC-134a PRESSURE R-513A PRESSURE TEMPERATURE HFC-134a PRESSURE R-513A PRESSURE (psig) (psig) (kPa) (kPa) 6.50 9.22 –17.8 44.8 63.6 7.52 10.32 –16.7 51.9 71.1 8.60 11.45 –15.6 59.3 79.0...
Page 20: Standing Vacuum Test
24 hours, re-pressurize the vessel and test for leaks. WARNING Repair the leak, retest, and proceed with dehydration. Do not apply power unless a qualified Carrier technician is Check the Installation present. Serious personal injury may result. Use the following instructions to verify the condition of the installation.
Page 21: Chiller Dehydration
(Fig. 18) may substantially reduce the time required to com- tube damage due to corrosion, scaling, or erosion. Carrier as- plete the dehydration and is recommended should the unit be ex- sumes no responsibility for chiller damage resulting from un- posed to liquid moisture.
Page 22: Carrier Comfort Network Interface
Carrier Comfort Network Interface CAUTION The Carrier Comfort Network (CCN) communication bus wiring ® is supplied and installed by the electrical contractor. It consists of Always operate the condenser and chilled water pumps shielded, 3-conductor cable with drain wire. during charging operations to prevent freeze-ups.
Page 23: Software Configuration
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 19MV with PIC6 Controls Operation and Troubleshoot- ing manual for instructions on using the PIC6 interface to con- figure the 19MV unit.
Page 24 Without the user password, access will not The Network Schedule should be configured if a CCN system is be possible unless accessed by a Carrier representative. Factory being installed. When control mode is NETWORK, the chiller can...
Page 25 MODIFY CONTROLLER IDENTIFICATION IF NECESSARY CONFIGURE TABLES The CCN address can be changed from the Configuration Menu. Access the related tables through MAIN MENU CONFIGURA- Change this address under CONTROL IDENTIFICATION for TION MENU (Fig. 25) to modify or view job site parameters each chiller if there is more than one chiller at the jobsite.
Page 26 Table 14 — Option Configuration Main Menu Configuration MenuOption [CONF_OPT] DESCRIPTION RANGE UNITS DEFAULT VALUE Frequent Restart Option Disable/Enable Enable job specific EXCSV Selection 0=Disable, 1=Surge,  job specific 2= Low Load, 3= Comb EXCSV Open IGV Position 0.5 to 10 job specific EXCSV Close IGV Position 1.5 to 20...
Page 27 Table 18 — UPS Main MenuConfiguration MenuUPS [Table CFG_UPS] DESCRIPTION RANGE UNITS DEFAULT VALUE UPS Option Disable/Enable Enable Battery Replacement Done No/Yes Battery Threshold 0 to 100 Battery Minimum Runtime 0 to 600 Battery Test Duration 0 to 600 Power Failure Max Number 0 to 100 Over Temp Duration 0 to 600...
Page 28: Field Set Up And Verification
The EQUIPMENT SERVICE table has screens to select, view, or sure Transducers, page 44, and High Altitude Locations, page 45. modify parameters. Carrier’s certified drawings have the configu- ration values required for the jobsite. Modify these values only if OPTIONAL EVAPORATOR AND CONDENSER PRES- requested.
Page 29 A high pressure point can be calibrated between 100 and 250 psig (689.5 and 1723.7 kPa) by attaching a regulated pressure source (usually from a nitrogen cylinder with high resolution pressure gage). The high pressure point can be calibrated by accessing the appropriate transducer parameter on the PRESSURES screen, highlighting the parameter, then increasing or decreasing the value to the exact pressure on the refrigerant gage.
Page 30: Initial Start-Up
batteries, remove power to unit, allow capacitors to discharge, INITIAL START-UP open high voltage power panel section, remove UPS cover, dis- Preparation connect wires to cables, remove screws to battery section, pull out batteries and replace. See Fig. 33 for detailed battery replace- Before starting the chiller, verify: ment steps.
Page 31: Check Motor Rotation
ECONOMIZER Check Motor Rotation Close the starter enclosure door. BPHX and economizer EXV. Pressure transducer and temperature Apply 3-phase power to drive. sensor location. The VFD checks for proper phase rotation as soon as power CONTROL SYSTEM is applied to the starter and the PIC6 controls power up. An alarm message will appear on the HMI screen if the NETWORK and LOCAL start, reset, menu, softkey functions, phase rotation is incorrect.
Page 32: To Stop The Chiller
It is also an aid when scheduling to circulate the water and avoid corrosion. Consult the water treat- routine maintenance and diagnosing chiller problems. ment company for details. Carrier is not responsible for waterside corrosion. Keep a record of the chiller pressures, temperatures, and liquid levels on a sheet similar to the one in Fig.
Page 33: Pumpout And Refrigerant Transfer Procedures
REFRIGERATION LOG CARRIER 19MV SEMI-HERMETIC CENTRIFUGAL REFRIGERATION MACHINE PLANT______________________ MACHINE MODEL NO.______________________ MACHINE SERIAL NO. _______________________ DATE DESCRIPTION PRESSURE SAT REFRIGERANT LIQUID TEMP EVAPORATOR FLOW WATER TEMP IN TEMP OUT PRESSURE REFRIGERANT TEMP SAT LEVEL CONDENSER FLOW WATER TEMP IN...
Page 34 The display on the chiller control panel is suitable for d. Turn off the chiller water pumps. determining refrigerant-side pressures and low (soft) vac- e. Close valves 3 and 4. uum. To assure the desired range and accuracy when mea- f.
Page 35 until the chiller pressure is reduced to 18 in. Hg vacuum b. Make sure that liquid line service valves 3 and 4 are (41 kPa absolute). closed and valves 2 and 5 are open. This operation can be done in Automatic or On mode. In VALVE Automatic mode, the compressor will stop automatically CONDITION...
Page 36: General Maintenance
Open valve 2. 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 re- paired during annual maintenance or whenever the refrigerant is VALVE transferred for other service work.
Page 37 2ND STAGE IGV ACTUATOR 2ND STAGE IGV ACTUATOR 1ST STAGE IGV ACTUATOR Fig. 36 — Integrated Guide Vane Actuator NOTE: For first stage, rotate coupling clockwise to close guide vanes; rotate coupling counterclockwise to open guide vanes. For second stage, rotate coupling counter- clockwise to close guide vanes;...
Page 38: Trim Refrigerant Charge
When the drop counter is within 2000 revolu- WARNING tions of its limit contact Carrier service engineering to schedule Ensure power to the starter is isolated when cleaning and tight- maintenance to avoid unexpected down time. Ensure to revise the ening connections inside the starter enclosure.
Page 39: Inspect Heat Exchanger Tubes And Flow Devices
DESICCANT PACK MOUNTING BRACE DESICCANT PACK O-RING Fig. 39 — MBC Cavity Details against the leaving condenser water temperature. If this reading is Inspect Heat Exchanger Tubes and Flow Devices more than what the design difference is supposed to be, the con- EVAPORATOR AND OPTIONAL FLOW DEVICES denser tubes may be dirty, water flow may be incorrect, or non- condensables have contaminated the refrigerant circuit.
Page 40: Water Treatment
If the unit is going electrical cleaner for electrical parts as required. Perform visual in- to be stored for an extended period of time, Carrier has specific spection of the capacitors located on the DC bus and inductors.
Page 41: Troubleshooting Guide
RESISTANCE CHECK TROUBLESHOOTING GUIDE Turn off the control power and, from the module, disconnect the Overview terminal plug of the sensor in question. With a digital ohmmeter, The PIC6 control system has many features to help the operator measure sensor resistance between receptacles as designated by and technician troubleshoot a 19MV chiller.
Page 42 Table 20 — Thermistor Temperature (F) vs. Resistance/Voltage Drop TEMPERATURE RESISTANCE TEMPERATURE RESISTANCE TEMPERATURE RESISTANCE VOLTAGE VOLTAGE VOLTAGE (OHMS) (OHMS) (OHMS) DROP (V) DROP (V) DROP (V) –25 4.700 97,706 2.565 6,568 0.630 –24 4.690 94,549 2.533 6,405 0.619 –23 4.680 91,474 2.503...
Page 43 Table 21 — Thermistor Temperature (C) vs. Resistance/Voltage Drop TEMPERATURE RESISTANCE TEMPERATURE RESISTANCE VOLTAGE VOLTAGE (OHMS) (OHMS) DROP (V) DROP (V) –33 4.722 105 616 1.338 2 272 –32 4.706 99 640 1.300 2 184 –31 4.688 93 928 1.263 2 101 –30 4.670...
Page 44: Checking Pressure Transducers
EVAPORATOR AND CONDENSER PRESSURE TRANS- DUCER CALIBRATION Calibration can be checked by comparing the pressure readings from the transducer to an accurate refrigeration gage read- ing.These readings can be viewed or calibrated from the HMI screen. The transducer can be checked and calibrated at 2 pres- sure points.
Page 45: Condenser Level
The EXV motor winding resistance can be checked by removal High Altitude Locations of the EXV plug. The resistance across coil I should be Because the chiller is initially calibrated at sea level, it is neces- 52 Ohm (10%) and the resistance across coil II should be sary to recalibrate the pressure transducers if the chiller has been 52 Ohm (...
Page 46 Table 24 — MV Evaporator and Condenser Weights* EVAPORATOR DRY RIGGING WEIGHT DRY RIGGING WEIGHT CONDENSER FRAME FRAME AND BUNDLE SIZE AND BUNDLE SIZE 31E - 31N 4331 1965 31C - 31N 5518 2503 33E - 33N 4662 2115 31R - 31Z 4592 2083 33C - 33N...
Page 47 LEGEND 1 — First Stage Volute 2 — Permanent Magnet Motor Rotor 3 — Motor Stator 4 — Second Stage Volute 5 — Second Stage Inlet Guide Vane 6 — Second Stage Impeller 7 — Magnetic Bearing System 8 — First Stage Impeller 9 —...
Page 48 SCB - SERVICE CIRCUIT BREAKER RELAYS FOR FIELD OUTPUTS, E.G. #1 CHWP - CHILLED WATER PUMP (4CR) #2 CDWP - CONDENSER WATER PUMP (5CR) #6 TFR_HIGH - TOWER FAN HIGH (9CR) #7 TRF_LOW - TOWER FAN LOW (10CR) TB1/TB2 LOCATED TB3/4 LOCATED IN HIGH VOLTAGE IN LOW VOLTAGE...
Page 49 Fig. 46 — SIOB...
Page 50 Fig. 47 — IOB2...
Page 51 Fig. 48 — 19MV Auxiliary Controls Wiring...
Page 52 Fig. 49 — Motor Bearing Control Board Wiring...
Page 53 LEGEND FOR FIG. 46-49 Abbreviations Symbols 1-5TB — Terminal Block 1-5 2-4IOB — Carrier Input Output Board 2-4 Terminal Block Connection — Chiller Alarm Relay AUTO_DEM — Auto Demand Limit Input AUTO_RES — Auto Water Temp Reset Female Connector — Circuit Breaker CDWP —...
Page 54: Structure
APPENDIX A — PIC6 SCREEN AND MENU STRUCTURE Fig. A — Screen Structure, Basic Level (All) Access (No Password Required) Fig. B — Screen Structure, User Level Access (User Password Required)
Page 55: Appendix A - Pic6 Screen And Menu
APPENDIX A — PIC6 SCREEN AND MENU STRUCTURE (CONT) Fig. C — Screen Structure, Service / Factory Level Access Password Required...
Page 56 APPENDIX A — PIC6 SCREEN AND MENU STRUCTURE (CONT) Main Menu Description ICON DISPLAYED TEXT* ACCESS ASSOCIATED TABLE† General Parameters Basic, User, Factory GENUINT Temperatures Basic, User, Factory TEMP Pressures Basic, User, Factory PRESSURE Inputs Status Basic, User, Factory INPUTS Outputs Status Basic, User, Factory OUTPUTS...
Page 57: Appendix B - Ccn Communication Wiring For Multiple Chillers (Typical)
APPENDIX B — CCN COMMUNICATION WIRING FOR MULTIPLE CHILLERS (TYPICAL) DRAIN WIRE BLACK (G) WHITE (-) RED (+) NOTE : Field-supplied terminal strip must be located in control panel.
Page 58: Appendix C - Maintenance Summary And Log Sheets
APPENDIX C — MAINTENANCE SUMMARY AND LOG SHEETS 19MV Maintenance Interval Requirements WEEKLY COMPRESSOR None. CONTROLS Review PIC6 Alarm/Alert History. EVAPORATOR None. None. PIC6 automatically performs UPS Discharge Level test of the battery. Alert 117 will be active should the test fail. Should Alert 117 become active the battery will need to be replaced within 2 weeks.
Page 59: Appendix D - Remote Connectivity Setup
Introduction 169.254.1.2. Set the interface for the PIC6 ethernet port Cellular Remote Connectivity is a system developed by Carrier which is going to be used to 169.254.101 for the first chiller to remotely monitor a chiller. It consists of a PIC6 controller, and if multiple chillers increase last digit by one for each ethernet switch, cellular modem, and an antenna.
Page 60: Index
Schedule, inputting local occupied, 24 Initial start-up checklist, CL-1 Sensor accuracy, checking, 41 © 2022 Carrier Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. Catalog No. 04-53190079-01 Printed in U.S.A.
Page 61: Initial Start-Up Checklist
OLTA REFRIGERANT: Type: Charge Yes  No  CARRIER OBLIGATIONS: Disassembled at Job Site ..Yes  No  Assemble....
Page 62 B: Take at least two sets of operational log readings and record. C: Give operating instructions to owner’s operating personnel. Given at: Hours D: Call your Carrier factory representative to report chiller start-up. E: Return a copy of this checklist to the local Carrier Service office. SIGNATURES: CARRIER CUSTOMER...
Page 63 19MV PIC6 SET POINT TABLE CONFIGURATION SHEET DESCRIPTION RANGE UNITS DEFAULT VALUE Cooling LCW Set point 10 to 120 °F Base Demand Limit 10.0 to 100.0 100.0 PIC6 TOUCH SCREEN Software Version Number: PIC6 TOUCH SCREEN Controller Identification: BUS: ADDRESS: 19MV PIC6 TIME SCHEDULE CONFIGURATION SHEET PERIOD 1 DAY FLAG OCCUPIED...
Page 64 19MV PIC6 FACTORY TABLE CONFIGURATION SHEET DESCRIPTION RANGE UNITS DEFAULT VALUE Chiller Type 19XR6/7=0,19XR2~E/D/V=1, 0 to 4 19DV=2, 19XRF=3, 19MV=4 Lubrication Type Mag Bearing=2 VFD/Starter Option Danfoss VFD=7 Unit Type Cooler Only=0 Ref Type R-134a=0, R-513A=1 Chilled Medium Type Water/Brine Water Cond Shell Side MAWP...
Page 65 19MV PIC6 CFGSURGE_SURGE CORRECTION CONFIG TABLE CONFIGURATION SHEET DESCRIPTION RANGE UNITS DEFAULT VALUE Surge Line Configuration 0 to 2 PR=0, Delta T=1, PR Table=2 Surge Line PR Offset% 1.5 to 7 Surge Line PR Lower DB% 0 to 4.5 Surge Line PR Upper DB% 0.2 to 4 Surge Delay Time 0 to 120...
Page 66 19MV PIC6 CFGUMVFDUM VFD CONFIGURATION TABLE CONFIGURATION SHEET DESCRIPTION RANGE UNITS DEFAULT VALUE Compressor Speed 100% 47 to 450 Rated Line Voltage 200 to 13800 Volts Motor Nameplate Current 10 to 2000 AMPS Motor Rated Load Current 10 to 2000 AMPS Motor Nameplate RPM 0 to 15000...
Page 67 19MV PIC6 CFGMETER - Config Metering TABLE CONFIGURATION SHEET DESCRIPTION RANGE UNITS DEFAULT VALUE Eco EXV Option Disable/Enable Enable Cond Liquid Level Determination 0 to 1 0=Capacity Percent, 1=Setpoint Liquid level SP-Cap 0% Liquid level SP-Cap 25% Liquid level SP-Cap 50% Liquid level SP- Cap 75% Liquid level SP- Cap 100% Low SST Set Point...
Page 68: Form 19Mv-Clt-1Ss Pg
© 2022 Carrier Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. Catalog No. 04-53190079-01 Printed in U.S.A. Form 19MV-CLT-1SS Pg CL-8 4-22 Replaces: NEW...

Carrier AquaEdge 19MV Start-Up, Operation And Maintenance Instructions Manual

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