Carrier AquaEdge 19MV Installation Instructions Manual
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Carrier AquaEdge 19MV Installation Instructions Manual

Carrier AquaEdge 19MV Installation Instructions Manual

Two-stage high-efficiency semi-hermetic centrifugal liquid chillers with greenspeed intelligence, pic6 controls, and r-515b/r-513a/r-1234ze(e)
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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
PIC6 Touch Screen Panel . . . . . . . . . . . . . . . . . . . . . . 4
Power Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Economizer (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . 4
VFD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Magnetic Bearing System . . . . . . . . . . . . . . . . . . . . . 4
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Step 1 - Receive the Machine . . . . . . . . . . . . . . . . . 4
Step 2 - Rig the Machine . . . . . . . . . . . . . . . . . . . . . 5
Step 3 - Install Machine Supports . . . . . . . . . . . . . 19
Step 4 - Connect Piping . . . . . . . . . . . . . . . . . . . . . 21
Step 6 - Install Field Insulation . . . . . . . . . . . . . . . 39
APPENDIX A - A2L Refrigerant . . . . . . . . . . . . . . . . . 42
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. 04-53190107-01
Printed in U.S.A.
19MV Two-Stage High-Efficiency Semi-Hermetic Centrifugal
Liquid Chillers with Greenspeed
PIC6 Controls, and R-515B/R-513A/R-1234ze(E)
Installation Instructions
Page
Form No. 19MV-CLT-3SI
operating this equipment, use good judgment and safety precau-
tions to avoid damage to equipment and property or injury to per-
sonnel.
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.
DANGER
Failure to follow these procedures will result in severe
personal injury or death.
DO NOT VENT refrigerant relief devices within a building.
Outlet from relief valve 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
Refrigeration). 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
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
voltage is present on motor leads even though the motor is not
running. Open the power supply disconnect before touching
motor leads or terminals and wait for capacitors to fully
discharge.
Pg 1
AquaEdge
®
®
Intelligence,
8-24
Replaces: 19MV-CLT-2SI

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  • Page 1: Table Of Contents

    RISK OF INJURY OR DEATH by electrocution. High • CONNECT POWER voltage is present on motor leads even though the motor is not • CARRIER COMFORT NETWORK INTERFACE running. Open the power supply disconnect before touching motor leads or terminals and wait for capacitors to fully Step 6 —...
  • Page 2 Operation of this equipment with refrigerants other than those cited herein should comply with ANSI/ASHRAE 15 (latest CAUTION edition). Contact Carrier for further information on use of this machine with other refrigerants. Dispose of refrigerant per local codes and regulations.

  • Page 3: Introduction

    Carrier has no installation re- CONDENSER sponsibilities for the equipment. If unit is shipped without refrig- erant, the refrigerant charge will be installed by the Carrier Start- This heat exchanger operates at a higher refrigerant temperature/ up Technician during the start-up process.

  • Page 4: Pic6 Touch Screen Panel

    Sensor input and outputs (e.g., NEC [National Electric Code]/CEC regulations). General • Actuators control recommendations are included in the Carrier field wiring draw- • UPS power supply for the magnetic bearing controller (MBC) ings. Consult drawing for termination lug sizes.

  • Page 5: Step 2 - Rig The Machine

    Carrier’s supervision. Any request otherwise must sive heat and humidity. The mechanical room should have four be approved in writing by the Carrier Technical Service Manager. walls and a ceiling. Non-conformance to this requirement may result in loss of prod- NOTE: NEMA Type 1 power panels are constructed for indoor uct warranty.
  • Page 6 LEGEND — Suction Elbow First Stage — Refrigerant Economizer — Integrated Power and Control Panel — Condenser Waterbox Return End — Bolt Together Plate — Evaporator Waterbox Return End — HMI Adjustment Arm — 10.4 in. Color Touchscreen Display — Refrigerant Charging Valve —...
  • Page 7 LEGEND 1 — Suction Elbow First Stage 2 — Evaporator 3 — Integrated Power and Control Panel 4 — Condenser Waterbox Return End 5 — Evaporator Waterbox Return End 6 — HMI Adjustment Arm 7 — 10.4 in. Color Touchscreen Display 8 —...
  • Page 8 LEGEND — Suction Elbow First Stage — Refrigerant Economizer — Integrated Power and Control Panel — Condenser Waterbox Return End — Bolt Together Plate — Evaporator Waterbox Return End — HMI Adjustment Arm — 10.4 in. Color Touchscreen Display — Refrigerant Charging Valve —...
  • Page 9 LEGEND 1 — Suction Elbow First Stage 2 — Refrigerant Economizer 3 — Integrated Power and Control Panel 4 — Condenser Waterbox Return End 5 — Bolt Together Plate 6 — Evaporator Waterbox Return End 7 — HMI Adjustment Arm 8 —...
  • Page 10 For actual unit dimensions, contact your Carrier sales professional for certified drawings. Pressure relief device sizing is based on the assumption that there are no combustible materials within 20 ft (7.7 m) of the pressure vessels.
  • Page 11 [1600 mm]. The overhead rigging space will allow the tube pull area to be utilized for service area. For actual unit dimensions, contact your Carrier sales professional for certified drawings. If the service clearances are not met, extraordinary actions to perform equipment repairs will not be covered by warranty.
  • Page 12 CHAIN LENGTH MAX. VESSEL COMPRESSOR EVAPORATOR DIM. “A” DIM. “B” DIM. “C” DIM. “D” WEIGHT LENGTH “E” “F” FRAME CODE lb (kg) 31E-31N, 31R-31Z 19,100 (8662) 33E-33N, 33R-33Z 19,600 (8909) 41E-41N, 41R-41Z 21,700 (9855) 19MV3 43E-43N, 43R-43Z 23,200 (10503) 51E-51N, 51R-51Z 23,600 (10723) 53E-53N, 53R-53Z 25,300 (11478)
  • Page 13 Service access should be provided per American Society of Heating, Refrigerating, and Air-Conditioning Engineers (ASHRAE) 15, latest edition, National Fire Protection Association (NFPA) 70, local safety code, and Carrier drawings. b. Overhead clearance for service rigging compressor should be at minimum 5 ft (1524 mm) with floor space identified adjacent to unit as per service clearance illustration to allow for compressor service.
  • Page 14 Service access should be provided per American Society of Heating, Refrigerating, and Air-Conditioning Engineers (ASHRAE) 15, latest edition, National Fire Protection Association (NFPA) 70, local safety code, and Carrier drawings. b. Overhead clearance for service rigging compressor should be at minimum 5 ft (1524 mm) with floor space identified adjacent to unit as per service clearance illustration to allow for compressor service.
  • Page 15 Table 5 — VFD and Power Panel Weights POWER PANEL WEIGHT TOTAL WEIGHT VFD CODE FRAME VFD NAME lb [kg] lb [kg] With Oil Without Oil Weight, lb [kg] D1h (110-160kw) DD212,DD260,DD315 136.7 [62] 253.1 [241] 668.0 [303.0] 478.4 [217] 755.3 [342.6] D2h (200-315kw) DD395,DD480,DD588...

  • Page 16: Rig Machine Components

    RIG MACHINE COMPONENTS NOTE: Wiring must also be disconnected. Label each wire before removal (see Carrier Certified Prints). In order to disconnect the Refer to instructions below, Fig. 11-12, and Carrier Certified VFD from the machine, remove wiring and flex cables between Prints for machine component disassembly.
  • Page 17 To Separate the Compressor from the Evaporator: Review compressor handling procedure due to permanent magnet rotor. Unbolt motor drain flange. All fasteners should be torqued to the rated value of the Unbolt suction pipe flange. fastener. Remove discharge pipe from compressor by attaching a lifting eye and rigging chain/strap to check valve;...
  • Page 18 WIDTH OF FOOT PLATE 19MV HEAT EXCHANGER SIZE DIMENSION C DIMENSION D DIMENSION E DIMENSION F DIMENSION G FRAME ft-in. ft-in. ft-in. ft-in. ft-in. 11' - 9-1/4" 3588 11' - 2" 3404 1' - 6-3/4" 3' - 1-3/8" 13' - 9-1/4" 4198 13' - 2"...

  • Page 19: Step 3 - Install Machine Supports

    NOTE: If transmission of vibrations from mechanical equip- leveling pads. Refer to Fig. 13. ment is of concern, Carrier suggests that a structural engineer Chiller support plates must be level within 1/4 in. (6 mm) from be consulted. Sound transmission from the equipment to the one end to the other.

  • Page 20: Install Spring Isolation

    NOTE: These isolators are not intended for seismic duty, but are intended to reduce the vibration and noise levels transmitted Spring isolation may be purchased as an accessory from Carrier from the chiller to the surrounding environment. For installa- for field installation. It may also be field supplied and installed.

  • Page 21: Step 4 - Connect Piping

    Reuse Cover Plate From Power Panel Top Hat High Voltage Section Access Panel Low Voltage Section Reuse Hardware From Door Power Panel Cover Shunt Trip E-stop Power Light Indicator High Voltage Top Hat Detail Section Door Fig. 15 — Tophat Installation (19MV3 Only) Step 4 —...

  • Page 22: Install Vent Piping To Relief Devices

    Isolation valves are recommended on the evaporator and con- Provide a removable fitting near outlet side of each relief denser piping to each chiller for service. device for leak testing. Provide pipe fittings that allow vent piping to be disconnected periodically for inspection of valve Apply appropriate torque on the retaining bolts in a crisscross mechanism.
  • Page 23 19MV2 NOZZLE-IN-HEAD (NIH) WATERBOXES 2nd Stage End 1st Stage End NOZZLE ARRANGEMENT CODES FOR NOZZLE-IN-HEAD WATERBOXES EVAPORATOR WATERBOXES CONDENSER WATERBOXES PASS Arrangement Code PASS Arrangement Code Fig. 18 — Nozzle Arrangement Codes for 19MV2 Nozzle-in-Head Waterboxes MARINE WATERBOXES (MWB) CONDENSER CONDENSER EVAPORATOR EVAPORATOR...
  • Page 24 19MV2 MARINE WATERBOXES (MWB) 2nd Stage End 1st Stage End NOZZLE ARRANGEMENT CODES FOR MARINE WATERBOXES EVAPORATOR WATERBOXES CONDENSER WATERBOXES PASS Arrangement Code PASS Arrangement Code NOTE(S): a. Vents and drains are 3/4 in., FPT, located on waterbox head. b. Refer to certified drawings. c.

  • Page 25: Step 5 - Make Electrical Connections

    CONNECT POWER The 19MV chiller has a unit-mounted, factory-installed VFD starter. See Fig. 31-33. The VFD is fully wired to the Carrier control panel and HMI. To apply power, attach power leads by routing them through the tophat to the line side of the chiller main circuit breaker.
  • Page 26 Fig. 22 — CCN Communication Wiring for Multiple Chillers (Typical)
  • Page 27 IOB2 and Optional IOB3 and IOB4 (See Individual IOB Figures) Breaker Lugs Modem Ground Lug SIOB MCB Breaker L1, L2, L3 Bus Bars To VFD Power Converter Ethernet Switch T2 - 120v:24v CB1 and CB2 Controls T1 - 120v:24v PS4 - MBC Transformer Circuit Breakers Power Supply...
  • Page 28 3CT 240V:120V (1500 VA) EMI Filter MCB - Main Breaker 1CT - Step-down Transformer (4 KVA) NOTE: Field Wiring Connections Are All on Terminal Blocks TB3 and TB4 (Located on Floor of Low Voltage Section) Fig. 25 — Control Panel - Top View...
  • Page 29 Fig. 26 — Customer Power Supply and Danfoss Standard Tier VFD Wiring...
  • Page 30 Fig. 27 — Customer Power Supply and Rockwell High Tier VFD Wiring...
  • Page 31 Fig. 28 — Rockwell High Tier VFD Field Wiring...
  • Page 32 For details, see Fig. 30-33. Fig. 29 — Field Wiring...
  • Page 33 Fig. 30 — Danfoss Standard Tier VFD Field Wiring...
  • Page 34 LEGEND FOR FIG. 22-30 Symbols Abbreviations 1-5TB — Terminal Block 1-5 Terminal Block Connection 2-4IOB — Carrier Input Output Board 2-4 — Chiller Alarm Relay AUTO_DEM — Auto Demand Limit Input Female Connector AUTO_RES — Auto Water Temp Reset — Circuit Breaker CDWP —...
  • Page 35 (devices not supplied in compliance with all applicable codes and job 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.
  • Page 36 8 — Strainers • Optional Remote Sensors 9 — Chilled Water Pump 4. IMPORTANT: Carrier suggests that a structural engineer be consulted if transmission of vibrations from mechanical equipment is of concern. 10 — Condenser Water Pump 5. Isolation valves are recommended on the evaporator and condenser water piping to each 11 —...
  • Page 37 8 — Chilled Water Pump e. Optional Remote Sensors 9 — Condenser Water Pump 4. IMPORTANT: Carrier suggests that a structural engineer be consulted if transmission of 10 — Pressure Gages vibrations from mechanical equipment is of concern. 11 — Local Disconnect 5.
  • Page 38 Optional Remote Sensors • 10 — Condenser Water Pump 4. IMPORTANT: Carrier suggests that a structural engineer be consulted if transmission of 11 — Pressure Gages vibrations from mechanical equipment is of concern. 12 — Local Disconnect (hidden - in power panel) 5.

  • Page 39: Carrier Comfort Network Interface

    CARRIER COMFORT NETWORK INTERFACE If a cable with a different color scheme is selected, a similar color code should be adopted for the entire network. The Carrier Comfort Network (CCN) communication bus wiring ® At each system element, the shields of its communication bus is supplied and installed by the electrical contractor.
  • Page 40 Top View 2nd Stage End 1st Stage End Front View 2nd Stage End 1st Stage End Fig. 34 — 19MV3 Standard Insulation Area...
  • Page 41 Fig. 35 — 19MV2 Standard Insulation Area...

  • Page 42: Appendix A - A2L Refrigerant

    WARNING may apply. Follow all safety codes. Wear safety glasses and work gloves. Use This manual is intended for use by owner or Carrier quenching cloth for unbrazing operations. Have fire extinguisher authorized service personnel. available for all brazing operations.

  • Page 43: Safety Instructions

    APPENDIX A — A2L Refrigerant Installation Supplement (cont) SAFETY INSTRUCTIONS Presence of Fire Extinguisher If any hot work is to be conducted on the refrigerating equip- ment or any associated parts, appropriate fire extinguishing WARNING equipment should be available to hand. Have a dry powder or fire extinguisher adjacent to the charging area.
  • Page 44 APPENDIX A — A2L Refrigerant Installation Supplement (cont) refrigerant employed, and the appropriate percentage of gas (25% maximum) is confirmed. WARNING In the case for R-1234ze(E) below, the detection should be if it exceeds the lower value of: Do not use means to accelerate the defrosting process or to clean, other than those recommended by the manufacturer.
  • Page 45 APPENDIX A — A2L Refrigerant Installation Supplement (cont) IMPORTANT: Servicing should be performed only as WARNING recommended by the manufacturer When a remote located refrigerant sensor is specified by the manufacturer, the instructions should state when it is Ventilation Volumetric Air Flow Rates required and how to install and connect the sensor.
  • Page 46 APPENDIX A — A2L Refrigerant Installation Supplement (cont) • Access to the refrigerating machinery room should be re- Natural Ventilation for Unventilated Machine stricted to authorized personnel. Doors should be clearly Room marked, or permanent signs should be posted at each en- Connected spaces should be provided with permanent natural trance to indicate this restriction.
  • Page 47 APPENDIX A — A2L Refrigerant Installation Supplement (cont) • Supply and return ducts. Freeze Protection of Water Piping • Transfer air ductwork. • Two or more spaces connected by a mechanical ventilation WARNING system. • Closures in the air distribution system. An automatic air/refrigerant separator and pressure relief valve must be installed as close as possible to the heat Where different stories and floor levels connect through an...
  • Page 48 APPENDIX A — A2L Refrigerant Installation Supplement (cont) COMMISSIONING CAUTION Do not mix refrigerants in recovery units and especially not in CAUTION cylinders. Ensure that the floor area is sufficient for the refrigerant charge or that the ventilation duct is assembled in a correct manner. CAUTION Before using the recovery machine, check that it is in CAUTION...
  • Page 50 © 2024 Carrier Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. Catalog No. 04-53190107-01 Printed in U.S.A. Form No. 19MV-CLT-3SI Pg 50 8-24 Replaces: 19MV-CLT-2SI...
  • Page 51 The machine’s wiring is complete. The wiring is installed per installation instructions and  certified prints. Power wiring to Carrier Power Panel (line side) completed with Carrier supplied tophat installed. (If chiller was disassembled during installation, motor leads must not be taped until the Carrier technician megger-tests the motor.)
  • Page 52 ____________________________________________________________________________________________ ____________________________________________________________________________________________ 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. Your contact at the jobsite will be _________________________________________________________________...

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