Carrier AquaEdge 19DV Installation Instructions Manual
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Carrier AquaEdge 19DV Installation Instructions Manual

Carrier AquaEdge 19DV Installation Instructions Manual

High-efficiency semi-hermetic centrifugal liquid chillers with greenspeed intelligence, pic6 controls, and hfo r-1233zd e 350 to 800 nominal tons 1231 to 2813 kw 50/60 hz
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CONTENTS
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . 1
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Job Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
CHILLER FAMILIARIZATION . . . . . . . . . . . . . . . . . . . 3
Chiller Information Nameplate . . . . . . . . . . . . . . . . . . 3
System Components . . . . . . . . . . . . . . . . . . . . . . . . . 3
Evaporator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Economizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
VFD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Purge System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
PIC6 Touch Screen Panel . . . . . . . . . . . . . . . . . . . . . . 3
Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Purge Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Lube Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Step 1 - Receive the Machine . . . . . . . . . . . . . . . . . 4
Step 2 - Rig the Machine . . . . . . . . . . . . . . . . . . . . . 8
Step 3 - Install Machine Supports . . . . . . . . . . . . . 21
• INSTALL TOP HAT (FOR 32VSH VFD - AHF OPTION
Step 4 - Connect Piping . . . . . . . . . . . . . . . . . . . . . 23
(For DV4 Units without AHF) . . . . . . . . . . . . . . . . 26
Step 7 - Install Field Insulation . . . . . . . . . . . . . . . 38
INSTALLATION START-UP CHECKLIST . . . . . . . CL-1
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Catalog No. 04-53190082-01
19DV High-Efficiency Semi-Hermetic Centrifugal
Liquid Chillers with Greenspeed
350 to 800 Nominal Tons (1231 to 2813 kW) 50/60 Hz
Installation Instructions
Page
Printed in U.S.A.
Form 19DV-CLT-5SI
PIC6 Controls, and HFO R-1233zd(E)

SAFETY CONSIDERATIONS

Centrifugal liquid chillers are designed to provide safe and reliable
service when operated within design specifications. When operat-
ing this equipment, use good judgment and safety precautions to
avoid damage to equipment and property or injury to personnel.
Be sure you understand and follow the procedures and safety pre-
cautions contained in the machine instructions, as well as those
listed in this guide.
Failure to follow these procedures will result in severe person-
al injury or death.
DO NOT VENT refrigerant relief devices within a building.
Outlet from rupture disc, relief valve, purge unit, or fusible
plugs must be vented outdoors 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 Refrig-
eration). The accumulation of refrigerant in an enclosed space
can displace oxygen and cause asphyxiation.
PROVIDE adequate ventilation in accordance with ANSI/
ASHRAE 15, especially for enclosed and low overhead spac-
es. Inhalation of high concentrations of vapor is harmful and
may cause heart irregularities, unconsciousness, or death. In-
tentional misuse can be fatal. Vapor is heavier than air and re-
duces 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 ma-
chine 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 ni-
trogen.
NEVER EXCEED specified test pressures. VERIFY the al-
lowable 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. Open the power supply disconnect before touching mo-
tor leads or terminals and wait for capacitors to fully discharge.
Pg 1
AquaEdge
Intelligence,
®
DANGER
5-21
Replaces: 19DV-CLT-4SI
®

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Summary of Contents for Carrier AquaEdge 19DV

  • Page 1: Table Of Contents

    • CONNECT CONTROL OUTPUTS • CONNECT VFD • CARRIER COMFORT NETWORK INTERFACE Step 7 — Install Field Insulation ....38 INSTALLATION START-UP CHECKLIST ..CL-1 Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
  • Page 2 PERIODICALLY INSPECT all valves, fittings, and piping for cited herein should comply with ANSI/ASHRAE 15 (latest corrosion, rust, leaks, or damage. edition). Contact Carrier for further information on use of this machine with other refrigerants. PROVIDE A DRAIN connection in the vent line near each...

  • Page 3: Introduction

    This component maintains system temperature and pressure dif- the contractor and/or customer. Carrier has no installation respon- ferences and moves the heat carrying refrigerant from the evapora- sibilities for the equipment. The refrigerant charge will be installed tor to the condenser.

  • Page 4: Lube Assembly

    (e.g., NEC [National Electric Code]/CEC regulations). General The objective of the lube assembly is to provides lubricating liquid recommendations are included in the Carrier field wiring draw- refrigerant to the compressor bearings. ings. Consult drawing for termination lug sizes.
  • Page 5 Evaporator Length 2 — 12 Foot Length VFD Code 4 — 14 Foot Length 5 — Carrier VFD Evaporator Pass Arrangement and Tube Count 0 — 1 or 2 Pass, ¾" Tubes, Lowest Tube Count Compressor Impeller Diameter Code 1 — 1 or 2 Pass, ¾" Tubes, Lower-Medium Tube Count 2 —...
  • Page 6 FRONT VIEW — Interconnecting Compressor Piping — VFD Drain (Field Drain Piping Required) — Condenser — Condenser Waterbox Return End — Economizer Isolation Valve (Option) — Economizer — Evaporator Waterbox Return End — Vacuum/Charging Valve (Hidden) — PIC6 HMI Touchscreen Panel 10 —...
  • Page 7 VIEW SHOWING OPTIONAL ECONOMIZER LIQUID BYPASS LINE (CONTROL PANEL, PURGE, AND LUBE ASSEMBLY REMOVED) ECONOMIZER TO CONDENSER HIGH SIDE FLOAT CHAMBER TO EVAPORATOR ECONOMIZER BYPASS ACTIVE (WHEN VALVE OPEN) LOW SIDE FLOAT CHAMBER Fig. 4 — Typical 19DV Compressor Chiller Liquid Bypass...

  • Page 8: Step 2 - Rig The Machine

    IMPORTANT: Verify with company performing the rigging chiller in an area exposed to dust, dirt, corrosive fumes, or exces- that they have access to required spreader beam for 4 point lift. sive heat and humidity. Carrier is not responsible for rigging damage.
  • Page 9 Carrier’s supervision. Any request otherwise must specified may result in serious damage to the machine or per- be approved in writing by the Carrier Technical Service Manager. sonal injury. Rigging equipment and procedures must be ade- Non-conformance to this requirement may result in loss of prod- quate for maximum chiller weight.
  • Page 10 Air-Conditioning Engineers (ASHRAE) 15, latest edition, National 6. 19DV unit heights can vary depending on the configuration. Check 19DV cer- Fire Protection Association (NFPA) 70, local safety code, and Carrier drawings. tified drawings for height information. 2. Overhead clearance for service rigging compressor should be at minimum 3 ft 7.
  • Page 11 Table 4 — Component Weights DV3 COMPRESSOR DV4 COMPRESSOR COMPONENT SUCTION PIPE ASSEMBLY (INCLUDES FLANGES) 1000 INTERSTAGE PIPING (SECTION ONLY FROM FLANGE TO FLANGE) DISCHARGE PIPING HMI PANEL CONTROL PANEL HIGH SIDE FLOAT CHAMBER COVER LOW SIDE FLOAT CHAMBER COVER PURGE ASSEMBLY ENVELOP CONTROL VALVE ECONOMIZER BYPASS VALVE...
  • Page 12 Table 6 — 19DV Heat Exchanger Weights (English) DRY RIGGING WEIGHT (LB)* REFRIGERANT WEIGHT (LB) WATER WEIGHT (LB) CODE† EVAPORATOR ONLY CONDENSER ONLY EVAPORATOR ONLY** CONDENSER ONLY EVAPORATOR ONLY CONDENSER ONLY 7272 — — — 1311 — 7376 — — —...
  • Page 13 Table 6 — 19DV Heat Exchanger Weights (English) (cont) DRY RIGGING WEIGHT (LB)* REFRIGERANT WEIGHT (LB) WATER WEIGHT (LB) CODE† EVAPORATOR ONLY CONDENSER ONLY EVAPORATOR ONLY** CONDENSER ONLY EVAPORATOR ONLY CONDENSER ONLY 8580 6359 — 1907 1446 8710 6504 — 1994 1532 8818...
  • Page 14 Table 7 — 19DV Heat Exchanger Weights (SI) DRY RIGGING WEIGHT (KG)* REFRIGERANT WEIGHT (KG) WATER WEIGHT (KG) CODE† EVAPORATOR CONDENSER EVAPORATOR CONDENSER EVAPORATOR CONDENSER ONLY ONLY ONLY** ONLY ONLY ONLY 3299 — — — — 3346 — — — —...
  • Page 15 Table 7 — 19DV Heat Exchanger Weights (SI) (cont) DRY RIGGING WEIGHT (KG)* REFRIGERANT WEIGHT (KG) WATER WEIGHT (KG) CODE† EVAPORATOR CONDENSER EVAPORATOR CONDENSER EVAPORATOR CONDENSER ONLY ONLY ONLY** ONLY ONLY ONLY 3833 2803 — 3892 2884 — 3951 2950 —...
  • Page 16 Table 8 — 19DV Economizer Weight COMPRESSOR DRY WEIGHT REFRIGERANT OPERATION DRY WEIGHT REFRIGERANT OPERATION SIZE (lb)* WEIGHT (lb) WEIGHT (lb) (kg)* WEIGHT (kg) WEIGHT (kg) 1501 1728 1931 2273 1031 Includes standard economizer weight and all connecting piping to compressor. Table 9 —...
  • Page 17 Table 12 — 19DV Waterbox Cover Weights — SI (kg) EVAPORATOR CONDENSER WATERBOX PASSES FRAME F FRAME G FRAME H FRAME F FRAME G FRAME H DESCRIPTION Flanged Victaulic Flanged Victaulic Flanged Victaulic Flanged Victaulic Flanged Victaulic Flanged Victaulic Dished Cover, 2 return 1034 kPa Flat Cover,...
  • Page 18 RIG MACHINE COMPONENTS To Separate the Compressor from the Evaporator: Refer to instructions below, Fig. 7-9, and Carrier Certified Prints Unbolt motor drain flange. for machine component disassembly. Unbolt suction pipe flange. Unbolt discharge pipe flange. IMPORTANT: Only a qualified service technician should per- form this operation.
  • Page 19 DIMENSION C DIMENSION D DIMENSION E DIMENSION F DIMENSION G DIMENSION H ft-in. ft-in. ft-in. ft-in. ft-in. ft-in. 13-0 3969 12-3 3747 1873 3-11 1211 2283 14-8 4490 14-0 4267 2134 3-11 1211 2283 13-0 3969 12-3 3747 1873 1267 2483 14-8 4489...
  • Page 20 NOTE: Valves shut at factory to contain inhibitor in lubrication assembly. IMPORTANT: Open these prior to start-up. FUSIBLE PLUGS FUSIBLE PLUGS LUBRICATION ASSEMBLY FUSIBLE PLUG FUSIBLE PLUG PURGE ASSEMBLY Fig. 10 — Location of Fusible Plugs in Lubrication Assembly and Purge Assembly...

  • Page 21: Step 3 - Install Machine Supports

    For adequate and long lasting machine support, proper grout se- Figure 9 shows the position of support plates and shear flex lection and placement is essential. Carrier recommends that only pads, which together form the standard machine support system. pre-mixed, epoxy type, non-shrinking grout be used for machine installation.

  • Page 22: Install Spring Isolation

    NOTE: It is recommended that any installation other than the ground floor should have spring isolation for the chiller and piping Spring isolation may be purchased as an accessory from Carrier vibration isolation. for field installation. It may also be field supplied and installed.

  • Page 23: Step 4 - Connect Piping

    Fig. 13 — Top Hat Installation Provide openings in water piping for required pressure gages Step 4 — Connect Piping and thermometers. For thorough mixing and temperature sta- INSTALL WATER PIPING TO HEAT EXCHANGERS bilization, wells in the leaving water pipe should extend Install piping using job data, piping drawings, and procedures out- inside pipe at least 2 in.

  • Page 24: Install Vent Piping To Relief Devices

    storage and the water box cover requires retightening of the If the vent tubing from the purge unit is connected to the rup- bolts during installation. ture disk vent piping, the piping should be sloped away from the rupture disk to prevent liquid refrigerant from condensing INSTALL VENT PIPING TO RELIEF DEVICES and accumulating on the atmospheric side of the rupture disk The 19DV chiller is factory equipped with a rupture disc on the...
  • Page 25 MARINE WATERBOXES (MWB) NOZZLE ARRANGEMENT CODES EVAPORATOR MARINE WATERBOXES CONDENSER MARINE WATERBOXES Arrangement Arrangement PASS PASS Code* Code* *Refer to certified drawings. Fig. 16 — Nozzle Arrangement Codes for 19DV Marine Waterboxes Table 13 — Relief Device Locations FRAME PRESSURE RELIEF DEVICE LOCATION SIZE OUTLET SIZE...

  • Page 26: Step 5 - Install Disconnect Switch Handle

    VFD mounting assembly through the Carrier controller. It also will support three types of under the pullbox. Install by ensuring clamp is tightly secured to...
  • Page 27 Fig. 19 — CCN Communication Wiring for Multiple Chillers (Typical) 7TB IN HMI PANEL FOR CUSTOMER COMMUNICATION CCN CONNECTION A (+) a19-2251 C (G) B (-) Fig. 20 — HMI Panel...
  • Page 28 REFRIG PUMP POWER CTL POWER ECONOMIZER VENT POWER GUIDE VANE 1 PURGE POWER GUIDE VANE 2 COMMUNICATION - FREE COOLING VFD/CONTROL PANEL ENVELOPE CONTROL (HGBP) REFRIGERANT PUMP POWER INTERLOCK - VFD/CONTROL PANEL ECONOMIZER BYPASS HMI POWER HMI COMMUNICATION HMI GROUND Fig.
  • Page 29 ETHERNET SWITCH FOR REMOTE CONNECTIVITY (IF EQUIPPED) 3TB-1 3TB-2 MODEM, FASTENED TO BACK OF DOOR (IF EQUIPPED) REFRIGERANT PUMP POWER (3-PHASE) VFD COMMUNICATION CONTROL PANEL POWER ADDITIONAL ETHERNET REFRIGERANT PUMP CONNECTIONS (OPTION INTERLOCK FOR REMOTE CONNECTIVITY) CONTROL PANEL POWER HPR INTERLOCK CONTROL POWER CIRCUIT BREAKER PURGE CIRCUIT...
  • Page 30 Fig. 23 — IOB1...
  • Page 31 Fig. 24 — IOB2 and IOB3...
  • Page 32 Fig. 25 — IOB 4...
  • Page 33 LEGEND FOR Fig. 21-25 Control Abbreviations Instrument Code (Within Control Panel) — Refrigerant Pump Contactor — Chiller Alarm AUTO_DEM — Demand Limit Input — Liquid Bypass Valve Relay AUTO_RES — Auto Water Temp Reset — Economizer Vent Valve Relay BRGI_P —...
  • Page 34 Fig. 26 — Optional Field Wiring...
  • Page 35 Fig. 27 — Typical 19DV VFD - Factory Unit Mounted...
  • Page 36 (devices not supplied specifications. by Carrier) must have 24 vac rating. Max current is 60 mA, nomi- 1.2 The routing of field-installed conduit and conductors and the loca- nal current is 10 mA. Switches with gold-plated bifurcated contacts tion of field-installed devices must not interfere with equipment are recommended.
  • Page 37 • 4 to 20 mA Resets 6 — HMI (hidden) • Optional Remote Sensors 4. IMPORTANT: Carrier suggests that a structural engineer be consulted if trans- 7 — Unit-Mounted VFD mission of vibrations from mechanical equipment is of concern. 8 — Control Panel 5.

  • Page 38: Carrier Comfort Network Interface

    CARRIER COMFORT NETWORK INTERFACE At each system element, the shields of its communication bus cables must be tied together. If the communication bus is entirely The Carrier Comfort Network (CCN) communication bus wiring ® within one building, the resulting continuous shield must be con- is supplied and installed by the electrical contractor.
  • Page 39 Fig. 29 — 19DV Standard Insulation Area...
  • Page 40 Fig. 30 — 19DV Free-Cooling Insulation Area...
  • Page 42 © 2021 Carrier Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. Catalog No. 04-53190082-01 Printed in U.S.A. Form 19DV-CLT-5SI Pg 42 5-21 Replaces: 19DV-CLT-4SI...
  • Page 43 The transformer feeding the VFD is confirmed to have a Wye secondary with a solidly grounded Neutral. Immediately contact Carrier Service if this is not the case. b. Line side voltage is within ±10% of chiller nameplate voltage c. Other 8.
  • Page 44 Concerns about the installation/request for additional assistance: I am aware that the start-up time for a Carrier chiller can take between 2 and 6 days depending on the model of the machine and the options and accessories used with it.

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