Carrier PIC 5+ Installation, Operation And Maintenance Instructions Download Page 14

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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)

Summary of Contents for PIC 5+

Page 1: ...ALLATION 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: ...tions 25 2 6 2 General 25 2 6 3 PIC 5 system components 25 2 6 4 Temperature sensors 29 2 6 5 Pressure transducers 30 3 INSTALLATION 30 3 1 Introduction 30 3 2 Step 1 Receive the machine 30 3 2 1 Inspect the product delivered 30 3 2 2 Identify machine 30 3 2 3 Installation requirements 33 3 2 4 Provide machine protection 34 3 2 5 Operating Environment 34 3 3 Step 2 Rig the machine 34 3 3 1 Rigging...

Page 3: ...iring 74 5 3 Ground Fault Troubleshooting 75 5 4 Check Purge Compressor Operation 75 5 5 Checking the Installation 76 5 6 Check Lubrication Circuit system 76 5 7 Charge unit with refrigerant 77 5 8 Software configuration 78 5 8 1 Input the Design Set Points 78 5 8 2 Input the local occupied schedule 79 5 8 3 Input service configurations 79 5 8 4 Field Set Up and Verification 86 5 9 Perform a contr...

Page 4: ... Be idle for a long time 95 8 PURGE OPERATION SEQUENCE 95 8 1 Purge Operating Modes 95 8 2 Non condensable Gas Pump Out 95 8 3 Carbon Tank and Regeneration Subsystem 95 9 MAINTENANCE 96 9 1 General maintenance 96 9 1 1 Soldering and welding 97 9 1 2 Refrigerant properties 97 9 1 3 Adding Refrigerant 97 9 1 4 Adjusting the Refrigerant Charge 97 9 1 5 Refrigerant Leak Testing 97 9 1 6 Leak Rate 97 9...

Page 5: ...Water treatment 106 9 3 15 Inspect remove the power cabinet equipment 106 9 3 16 Recalibrate Pressure Transducers 108 9 3 17 Recalibrate Temperature Thermistors 108 9 3 18 Corrosion control 108 9 3 19 Ordering Replacement Chiller Parts 108 10 TROUBLE SHOOTING GUIDE 108 10 1 overview 108 10 2 Checking Display Messages 108 10 3 Checking Temperature Sensors 108 10 4 Resistance Check 109 10 5 Voltage ...

Page 6: ...n and cause asphyxiation Provide adequate ventilation especially for enclosed and low overhead spaces Inhalation of high concentrations of vapour is harmful and may cause heart irregularities unconsciousness or death Misuse can be fatal Vapour is heavier than air and reduces the amount of oxygen available for breathing Product causes eye and skin irritation Decomposition products are hazardous Do ...

Page 7: ...ction manual it may cause interference to radio communications RISK OF INJURY OR DEATH by electrocution Voltage can be present on motor leads even though the motor is not running Open the power supply disconnect before touching motor leads or terminals 1 3 Operating checks relief valves Operating checks Important information regarding the refrigerant used Refrigerant type HFO R1233zd E Low pressur...

Page 8: ...as pressure loosen the collar and unscrew and discard the valve stem Do not incinerate VERIFY that refrigerant storage cylinders are clean with no residual moisture oil or refrigerant that can contaminate the refrigerant charge After refrigerant draining operations check the refrigerant type before adding refrigerant to the machine The introduction of the wrong refrigerant can cause damage or malf...

Page 9: ...e building Electrical cabinets are protected IP23 in accordance with standard IEC60529 1 The operating range of the selected unit must always be verified at full load and part load by the selection program for the chosen configuration The selection program values apply If they are outside the operating limits below the selection must be validated by the factory customer support team Indicative ope...

Page 10: ...uipment uses and can emit radio energy In the event of installation or use not in accordance with the instruction manual interference with radio communications may occur 2 4 1 CLASSIFICATION In accordance with the requirements of the Pressure Equipment Directive and the national regulations the safety accessories of the unit are classified as follows Safety component 1 Accessory for limiting damag...

Page 11: ...ains system temperature and pressure differences and moves the heat carrying refrigerant from the cooler to the condenser The 19DV utilizes a two stage back to back direct drive configuration 2 5 2 5 Purge unit A small independent condensing unit with compressor separator regenerative carbon filters heater and vacuum pump The purge extracts gas from condenser or from compressor if unit is not in o...

Page 12: ...w pressure V Variable Speed Drive 3 Evaporator frame size Length Pass arrangement tube count 4 Condenser frame size Length Pass arrangement tube count 5 Compressor frame size 4 1758 2813 kW 6 Compressor shroud code 3 4 5 6 7 Compressor Impeller Diameter Code 2 4 8 VFD code A high tier LF2 Rockwell 5 low tier VFD 0 Freestanding 9 Motor code B D F H 10 Motor voltage code 3 380 3 60 4 416 3 60 5 460 ...

Page 13: ... nozzles 8 Evaporator 9 PIC5 HMI touchscreen panel 10 Suction elbow 11 Evaporator sightglass 12 Evaporator charging valve 13 Evaporator pressure transducer 14 1 st stage Inlet Guide Vane IGV actuator 15 Compressor 16 Motor terminal box 17 Power cables from VFD to compressor motor 18 2 nd stage Inlet Guide Vane IGV actuator 19 Economizer pipe 20 Condenser relief valve assy 21 Evaporator relief valv...

Page 14: ...4 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: ...cally 3 to 6 C The energy required for boiling is obtained from the water flowing through the evaporator tubes With heat energy removed the water becomes cold enough to use in an air conditioning circuit or process liquid cooling After taking heat from the water the refrigerant vapor is compressed by a back to back compression connected by means of interstage piping Compression adds heat energy an...

Page 16: ...ooler 6 Economizer Figure 4 Refrigeration cycle 19DV Two Stage Compressor CAUTION To avoid adverse effects on chiller operation considerations must be made to condenser water temperature control For steady state operation the minimum operating refrigerant pressure differential between cooler and condenser is approximately 7 psid 48 kPa with a maximum evaporator refrigerant temperature of 18 C Cons...

Page 17: ...roubleshooting Manual for details 1 Compressor 2 Condenser 3 High side float chamber 4 Low side float chamber 5 Cooler 6 Economizer 7 Purge system 8 Vent line 9 Refrigerant lubrication system 10 Eductor Purge Lube system Main refrigerant system Figure 5 Refrigerant lubrication Cycle 2 5 5 2 Bearings The 19DV motor compressor assembly include two sets of purely refrigerant lubricated bearings The m...

Page 18: ...ation After the refrigerant flows past an isolation valve an in line filter drier and a sight glass moisture indicator it is directed over the motor by spray nozzles The refrigerant collects in the bottom of the motor casing and is then drained back into the cooler through the motor refrigerant drain line The motor is protected by temperature thermistors embedded in the stator windings An increase...

Page 19: ...nted VFD 2 5 5 5 VFD All 19DV units are equipped with a VFD to operate the centrifugal hermetic compressor motor The VFD and control panel are the main field wiring interfaces for the installing contractor The VFD and control panel are most of time mounted on the chiller See Manufacturer VFD specific information and VFD schematics This VFD is used with low voltage motors between 380 and 460 vac It...

Page 20: ...oils for inlet filtering of the main circuit 9 Power module and associated control interface board GS for the following functions Compressor start up and shutdown by voltage frequency ramping to permit limiting of the couple and inrush current at start up Control of the voltage frequency applied to the compressor All electrical compressor protection devices All devices to protect against internal ...

Page 21: ...hiller compressor OFF or condenser saturated temperature when chiller compressor ON is greater than purge active temperature set point default 18 3 C If chiller compressor is running condenser solenoid valve should be opened to purge refrigerant from condenser If chiller compressor is not running open the compressor solenoid valve to purge refrigerant from compressor If Purge Comp Suction Temp is ...

Page 22: ...ressor 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 Connected to motor drain SV05 12 Connected to chiller condenser SV01 13 Connected to compressor volute SV02 14 Purge tank Fig 10 purge system ...

Page 23: ...er 10 Suction temperature 11 Purge compressor 12 R134a circuit 13 Purge condenser assy 14 Strainer 15 Throttle service 16 Sight glass 17 Pumpout valve SV03 18 Carbon filters 19 Vacuum pump 20 Vent valve SV06 21 Regeneration valve SV05 22 Check valve 23 Vent line field connection purge vent 3 8 NPT 24 Regenerated refrigerant to motor drain Fig 11 purge system diagram ...

Page 24: ...activated the chiller will operate as a single stage system The condenser float valve will still control the system flow rate according to the chamber liquid level When system lift decrease and evaporating saturated temperature goes to below evaporator freezing point default 0 56 C for a period of time or when the Leaving Condenser Water Temperature minus Leaving Evap Water Temperature is less tha...

Page 25: ...crease in guide vane opening decreases capacity The microprocessor based control center protects the chiller by monitoring the digital and analog inputs and executing capacity overrides or safety shutdowns if required The variable frequency drive VFD allows compressor start up and capacity control by modulating the motor frequency based on the operation condition 2 6 3 PIC 5 system components The ...

Page 26: ...26 VFD not shown Fig 13 Sensors actuators location ...

Page 27: ...4 8 Condenser water inlet pressure transducer BP15 9 Evaporator water outlet temperature sensor RT2 10 Evaporator water inlet temperature sensor RT1 11 Evaporator refrigerant liquid temperature sensor RT15 12 Evaporator refrigerant pressure transducer BP3 13 PIC5 HMI touchscreen panel 14 Refrigerant pump motor terminal 15 Refrigerant pump outlet pressure transducer BP81 16 Refrigerant pump inlet p...

Page 28: ...erant supply temperature sensor RT41 24 Bearing inlet pressure transducer BP70 25 Bearing outlet pressure transducer BP71 26 1 st Inlet Guide Vane actuator M67 27 2 nd Inlet Guilde Vane actuator M69 28 Pressure switch safety device SP1FB 29 Pressure switch safety device SP1FA 30 Pressure switch safety device spare SP2FB 31 Pressure switch safety device spare SP2FA Fig 13 Sensors actuators location...

Page 29: ...ater temperature ECW RT1 IOB 1 AI1 J16 1 5 Leaving chilled water temperature LCW RT2 IOB 1 AI2 J16 2 6 Entering condenser water temperature ECDW RT7 IOB 1 AI3 J16 3 7 Leaving condenser water temperature LCDW RT8 IOB 1 AI4 J16 4 8 Evap refrigerant liquid temperature EVAP_T RT15 IOB 1 AI5 J15 6 12 Compressor Discharge temperature DGT RT21 IOB 1 AI6 J15 5 11 Motor winding temperature 1 MTRW1 RT31C IO...

Page 30: ...marily 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 3 2 Step 1 Receive the machine 3 2 1 Inspect the product delivered CAUTION Do not open any valves or loosen any connections The standard 19DV machine is shipped with a full refrigerant charg...

Page 31: ...lowable 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 Operating voltage Number of phases Maximum current drawn Maximum power input Unit net weight Cutout pressure setting of rupture disks if unit is equipped ...

Page 32: ... list above kPa 100 390 100 390 TS see in the list above C 15 60 15 60 Pressure switch cut out pressure kPa 262 Relief valve cut out pressure kPa 500 500 Test pressure unit leak test kPa 200 200 Check all items against shipping list Immediately notify the nearest Carrier representative if any item is missing ...

Page 33: ...ontrol and Signal Wire Sizes The recommended minimum size wire to connect I 0 signals to the control terminal blocks is 0 75 mm2 Recommended Airflow Clearances Be sure there is adequate clearance for air circulation around the enclosure 152 4 mm minimum clearance is required wherever vents are located in an enclosure Service Clearances Verify that there are adequate service clearances as identifie...

Page 34: ...om points other than those specified may result in serious damage to the unit and personal injury Rigging equipment and procedures must be adequate for machine weight See table 2 for the machine weights If the unit is disassembled for slinging the weight of each element of the machine must be known motor compressor heat exchangers with and without refrigerant charge electrical equipment special wa...

Page 35: ...equired Dimensions A and B define distance from machine center of gravity to tubesheet outermost surfaces Dim C defines distance from machine c o g to floor Dim D defines distance measured between the chain and lifting hooks 3 Rigging can be different and specific if unit is equipped of special components or devices which could have interference with chain way Please refer always to the official d...

Page 36: ...H VFD Danfoss E 19760 22780 19DV H4 H4 14 feets 02DV4 B D F or H Control cabinet only VFD not unit mounted 5195 3075 2790 17630 20650 COG position mm Rigging chain lengths mm Unit model heat exch frame Compr frame Motor frame Power VFD configuration A B C D E F 19DV G2 G2 12 feets 02DV4 B D F or H VFD LF2 2CC 608 A 1810 1135 1490 2500 2215 2670 19DV G2 G2 12 feets 02DV4 B D F or H VFD LF2 4AA 900 ...

Page 37: ... Suction Housing 351 2nd Stage Blade Ring Assembly 60 2nd Stage Suction Housing 274 1st Stage Volute 613 2nd Stage Volute 478 1st Stage Shroud 225 2st Stage Shroud 200 1st Stage IGV Shroud 54 2st Stage IGV Shroud 44 1st Stage Impeller 29 2st Stage Impeller 27 Miscellaneous 172 Total Weight Excludes Motor Stator and Motor Rotor 2810 Table 3 19DV Compressor weights COMPRESSOR FRAME MOTOR CODE STATOR...

Page 38: ...G4F 4927 917 G46 5240 958 G4G 4977 949 G47 5329 998 G4H 5043 991 G48 5426 1041 G4J 5115 1035 G49 5530 1089 G4K 5182 1080 H20 6316 962 H2A 6060 953 H21 6402 1001 H2B 6117 991 H22 6486 1039 H2C 6184 1035 H23 6599 1090 H2D 6257 1083 H24 6712 1142 H2E 6335 1135 H25 6287 950 H2F 6041 943 H26 6371 988 H2G 6098 981 H27 6471 1033 H2H 6162 1023 H28 6566 1077 H2J 6227 1067 H29 6679 1129 H2K 6305 1118 H40 68...

Page 39: ... 808 H22 3446 760 H2C 3158 820 H23 3589 818 H2D 3262 883 H24 3743 882 H2E 3376 951 H27 3390 738 H2H 3109 793 H28 3526 795 H2J 3203 851 H29 3671 855 H2K 3311 916 H42 3759 831 H4C 3430 899 H43 3923 897 H4D 3550 971 H44 4100 970 H4E 3681 1049 H47 3694 806 H4H 3374 869 H48 3852 870 H4J 3483 934 H49 4018 939 H4K 3608 1009 Table 7 19DV Condenser weights Frame size Steel weight kg DV4 1204 Table 8 19DV E...

Page 40: ...ect 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 Remove all transducer and sensor wires at the sensor Clip all wire ties necessary to pull heat exchangers apart To Separate Evaporator and Condenser 1 Place a support plate under each tube sheet leg to keep each vessel lev...

Page 41: ...tion Important Chiller housekeeping pad anchor bolts and attachment points that are designed by others must be in accordance with all applicable national and local codes 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 Chiller support ...

Page 42: ...arrier 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 Machine foot side view System base concrete Fig 18 Levelling accessory for 19DV units ...

Page 43: ...102 559 406 38 13 G4 G4 4472 2508 102 559 406 38 13 H2 H2 3951 2612 102 559 406 38 13 H4 H4 4472 2612 102 559 406 38 13 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: ...ods to support and isolate pipes that are attached to spring isolated machines NOTE The springs are designed to support the weight of the chiller only Connected piping must be supported independently of the chiller NOTE It is recommended that any installation other than the ground floor should have spring isolation for the chiller and piping NOTE These isolators are not intended for seismic duty b...

Page 45: ... if the accessory is purchased Fig 21 Spring isolation installation 3 5 Step 4 Connection of water vent and purge piping For size and position of the heat exchanger water inlet and outlet connections refer to the certified dimensional drawings supplied with the unit See Fig 22 Standard waterboxes and nozzle arrangements The water pipes must not transmit any radial or axial force nor any vibration ...

Page 46: ... 6 D 1 3 S 3 7 6 E 10 3 T 4 9 F 1 12 U Refer to certified drawings Fig 22 Standard waterboxes and nozzle arrangements 3 5 1 Install water piping to heat exchanger Install piping using job data piping drawings and procedures outlined below A typical piping installation is shown in Fig 23 CAUTION Factory supplied insulation is not flammable but can be damaged by welding sparks and open flame Protect...

Page 47: ... Entering water is always the lower of the 2 nozzles Leaving water is always the upper nozzle for evaporator or condenser for two and three pass arrangements 1 Air vent 2 Pressure gages 3 Leaving chilled water 4 Entering chilled water 5 Isolation valves 6 Leaving condenser water 7 Entering condenser water Note It is also strongly recommended to install 1 inch diameter connection points with valves...

Page 48: ...or example NFE 35400 in France and EN 378 when applicable for the safety of chilling devices as well as any other applicable codes DANGER Refrigerant discharged into confined spaces can displace oxygen and cause asphyxiation If relief devices are manifolded the cross sectional area of the relief pipe must at least equal the sum of the areas required for individual relief pipes Provide a pipe plug ...

Page 49: ...rical wiring diagrams IOB1 BLOCK Terminal Point Description Point name Designation for wiring diagram Comments AI1 J16 1 5 Entering chilled water temperature ECW RT1 AI2 J16 2 6 Leaving chilled water temperature LCW RT2 AI3 J16 3 7 Entering condenser water temperature ECDW RT7 AI4 J16 4 8 Leaving condenser water temperature LCDW RT8 AI5 J15 6 12 Evap refrigerant liquid temperature EVAP_T RT15 AI6 ...

Page 50: ...n 4 20 mA connected on terminals AI9 J15 2 8 Common CHWR Temp CHWR_T Chiller CHWR Temp Used for lead lag option AI10 J15 1 7 AI11 J10 1 7 AO1 J14 1 4 Head Pressure Output HDPV_OUT Condenser sea water valve 4 20 mA connected on terminals AO2 J14 2 5 Head Pressure Output 2 HDPV_OU2 4 20 mA Not used yet but can be used AO3 J14 3 6 Guide Vane 2 Output GV2_OUT M69 3 4 DI1 J13 1 5 DI2 J13 2 6 DI3 J13 3 ...

Page 51: ...supply 1 2 Chiller Alarm relay Digital output 3 4 Chiller water pump Digital output 9 Condenser water pump Digital output 10 Tower fan high Digital output 11 Tower fan low Digital output 12 Feeback run Digital output 13 14 Evaporator flow switch Digital input 15 16 Condenser flow switch Digital input 17 18 Remote contact input Digital input 19 20 Emergency stop Digital input 21 22 Ice build contac...

Page 52: ...52 Fig 24 19DV control box ...

Page 53: ...53 1 Power supply 24V AC 2 LEN 3 CCN 4 Ethernet 5 USB Fig 25 19DV HMI box rear view ...

Page 54: ...54 Fig 26 19DV IOB1 wiring Fig 27 19DV IOB2 wiring ...

Page 55: ...st 0 75mm2 or larger Supplied voltage of the wires in control panel should be low limited to 50V 2 Each digital output loop shall be limited to a maximum of 1A AC RMS steady stat 24Vac high load relay is recommended and the coil voltage of relay is 24VAC Connect 5TB 1 to 3TB 1 and 5TB 2 to 3TB 2 for 24VAC ...

Page 56: ...kΩ 10kΩ NTC thermistor 0 4 20mA sensor and 5VDC sensor 5 Each analog output loop support 0 4 2OMA 0 2 10 VDC voltage output The analog output loop is powered by board Do not supply external power 6 For standard discrete input on 1 2 3 4 IOB only when the contactor switch is closed an alarm will be generated 7 SW2 configured by field if 4 20 mA signal sensor shall turn the switch to ON position 8 F...

Page 57: ...57 ...

Page 58: ... Relay SIOB Purge Input Output Board Fig 31 Purge system control box 3 6 3 High pressure safety accessory SRMCR Chiller equipped with VFD LF2 3 6 3 1 General description The unit is equipped with a safety loop also called measurement control and regulation devices playing a role in safety SRMCR for protection against overpressure that could be created by the compressor Made of 2 active pressure sw...

Page 59: ... supplied with the machine for detailed information 1 HPS spare Non active pressure switch 2 HPS active pressure switch 3 Reset button reset 4 K101 main power contactor 5 Logic 6 Safety relay K4 7 K2 control relay 8 To control status feedback 9 K101 10 Gate kill 11 Compressor Figure 32 SRMCR description The K4 safety relay monitors the status of the two active pressure switch HPS sensors the absen...

Page 60: ...ation of the Gate Kill function is self controlled by the drive 3 6 3 5 Detection of crossed short circuits The safety relay also has the function of detecting any short circuit that may occur between the inputs of the safety pressure switches HPS 3 6 3 6 Safety relay LED state The state of the relay can be visually verified with the status LEDs present on the component LED status Status Descripti...

Page 61: ...iring 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 The negative pins must be wired to the negative pin...

Page 62: ...5 touch screen panel 4 CCN wiring ______ factory wiring field wiring Fig 33 CCN network wiring 4 START UP SHUT DOWN RECYCLE SEQUENCE 4 1 Local Start Stop Control Local start up or manual start up is initiated by pressing the gray Start Stop icon on the HMI interface See fig 34 Fig 34 Chiller start stop icon This initiates the PIC5 starting sequence by displaying the list of operating modes Press L...

Page 63: ... guide vanes are more than 4 open the start up waits until the PIC5 control system closes the vanes If the vanes are closed and the refrigerant pump pressure difference is less than 34 5 kPa the refrigerant pump relay energizes The PIC5 control system then waits until the refrigerant pressure REF PRESS VERIFY TIME operator configured default of 40 seconds reaches a maximum of 82 7 kPa After refrig...

Page 64: ... and 2 minute inhibit timer starts G Ref pump and cooler pumps de energized 120 seconds after F Condenser pump and tower fan control may contin ue to operate if condenser pressure is high Cooler pump may continue if in RECYCLE mode O A Restart permitted both inhibit timers expired minimum of 15 minutes after E minimum of 2 minute after F Autorestart after power failure timing sequence will be fast...

Page 65: ...rt button the system will go into prestart check process When Refrigerant Pump request is on for pre lube and the bearing pressure difference is OK for start if cooler temperature minus leaving condenser water temperature is less than 5 6 C pump refrigerant from Cooler to Condenser until compressor is ON Else if cooler temperature plus leaving condenser water is equal or larger than 5 6 C pump ref...

Page 66: ... when in Network or Local Schedule control mode The chiller protective limit has been reached and chiller is in alarm The start stop status CHIL_S_S is overridden to stop from the network when in Network mode If the chiller is normally shut down from running soft stop shutdown will be performed The soft stop feature closes the guide vanes of the compressor automatically if a non alarm stop signal ...

Page 67: ...mental protection devices and arrangements are in place and comply with the applicable European standard Verify that all documents for pressure containers certificates name plates files instruction manuals required by the applicable European standard are present Verify the free passage of access and safety routes Check that ventilation in the plant room is adequate Check that refrigerant detectors...

Page 68: ...uction flanges at compressor and low side float chamber Compressor discharge flange Cooler inlet line spacer both sides Envelope control flange both sides of valve ICP piping flange High and low side float chamber covers See Tables 16 for bolt torque requirements BOLT SIZE CLASS 8 8 SAE 5 SA499 N m CLASS10 9 SAE 8 SA354 GR BD N m SOCKET HEAD OR HEX WITH 3 RADIAL LINES MEDIUM CARBON STEEL HEX HEAD ...

Page 69: ...gerant charge or with 1 bar dry nitrogen holding charge 5 1 6 1 Chiller shipped with 1 bar nitrogen holding charge without refrigerant Follow chart figure 40 19DV leak test procedure To check leaks in chiller in addition to the nitrogen gas the chiller should be charged with helium tracer gas Use an electronic leak detector to check all flanges and solder joints after the chiller is pressurized If...

Page 70: ...r recommends the following leak test procedure Refer to Table XX for refrigerant pressure temperature values 1 If the pressure readings are normal for the chiller condition a Evacuate the charge from the vessels if present b Raise the chiller pressure if necessary by adding refrigerant until pressure is at the equivalent saturated pressure for the surrounding temperature CAUTION Never charge liqui...

Page 71: ... leak rate as well as the full charge amount on the start up report 5 If no leak is found during the initial start up procedures complete the transfer of refrigerant gas from the storage tank to the chiller Recover any gas used for leak detection purposes as required per local jurisdiction 6 If no leak is found after a retest a Perform a standing vacuum test as outlined in the Standing Vacuum Test...

Page 72: ...ration is recommended if the chiller has been open for a considerable period of time if the chiller is known to contain moisture or if there has been a complete loss of chiller holding charge or refrigerant pressure CAUTION Do not start or megohm test the compressor motor or any other pump motor even for a rotation check if the chiller is under dehydration vacuum Insulation breakdown and severe da...

Page 73: ...eral attempts perform a leak test maximum 310 kPa pressure Locate and repair the leak and repeat dehydration 8 Once dehydration is complete the evacuation process can continue The final vacuum prior to charging the unit with refrigerant should in all cases be 0 3 kPa abs or less 5 1 9 Inspect water piping Refer to piping diagrams provided in the certified drawings Inspect the piping to the cooler ...

Page 74: ... 2 Piping connections must allow for access to the valve mechanism for periodic inspection and leak testing The standard 19DV relief valves are set to relieve at 500 kPa pressure 5 2 Inspect wiring WARNING Do not check the voltage supply without proper equipment and precautions Serious injury may result Follow power company recommendations CAUTION Do not apply any kind of test voltage even for a r...

Page 75: ...and test between the group and ground 3 Divide the 60 second resistance reading by the 10 second reading The ratio or polarization index must be one or higher Both the 10 and 60 second readings must be at least 50 megohms If the readings are unsatisfactory repeat the test at the motor with the power leads disconnected Satisfactory readings in this second test indicate the fault is in the power lea...

Page 76: ...hat no external voltage potential are connected to any of the inputs 7 Verify that all of the VFD power module circuit board connectors are fully engaged and taped in place 8 Check that the wire size is within terminal specifications and that the wires are tightened properly and adequately supported 9 Check that specified branch circuit protection is installed and correctly rated 10 Check that the...

Page 77: ...output for certified values Prior to charging ensure the following a Standing vacuum test completed b Only initiate refrigerant charging into a deep vacuum c Adequate refrigerant supply is available as per unit nameplate With water pumps running connect charging hose from refrigerant cylinder to chiller cooler charging valve Start with charging gas until the pressure is greater than the above satu...

Page 78: ...tructions on using the PIC 5 interface to configure the 19DV unit As the unit is configured all configuration settings should be written down The welcome screen is the first screen shown after switching the unit on or after the re animation of the screen It displays the application name as well as current software version number Fig 43 Welcome screen 5 8 1 Input the Design Set Points To access the...

Page 79: ...hedule The Network Schedule should be configured if a CCN system is being installed When control mode is NETWORK the chiller can be started and stopped by the CHIL_S_S software point as written by other equipment through the network command and network schedule For more information about setting time schedules please refer to the PIC5 Control User Manual 5 8 3 Input service configurations For spec...

Page 80: ...il the time and date have been set NOTE The date format is MM DD YY for English units and DD MM YY for SI units MODIFY CONTROLLER IDENTIFICATION IF NECESSARY The CCN address can be changed from the Configuration Menu Change this address under CONTROL IDENTIFICATION for each chiller if there is more than one chiller at the jobsite Write the new address on the PIC5 Touch Screen module for future ref...

Page 81: ...ion 100 93 6 Surge Line Offset 0 8 0 8 Surge Line Lower DB 0 6 0 6 Surge Line Upper DB 0 6 0 6 Surge Line Shape Factor 0 01 selection output Sound Line Shape Factor 0 01 selection output Surge Line speed factor 2 selection output Surge delay time 15 sec 15 sec Surge Time Period 8 min 8 min Surge Delta Amps 20 20 Rampdown Factor 0 1 0 1 GV1 Close Step Surge 2 2 VFD Speed Step Surge 1 50 1 50 EC val...

Page 82: ...demand 0 4 20mA 1 0 0 Pulldown rampe type Temp 0 Load 1 1 1 Demand limit source Amps 0 kW 1 0 0 TABLE CFGEVFD General VFD Config Access Menu Configuration Menu General VFD Config Setting Default value SI units Settings value SI Comments VFD gain 0 75 0 75 VFD Max Speed Per 100 100 VFD Min Speed Per 70 55 VFD Start Speed Per 100 100 VFD Current limit 250 A 872 Max current output for UM VFD VFD Load...

Page 83: ...y 1 102 Hz 102 Hz UM Rockwell LF2 Skip Frequency 2 102 Hz 102 Hz UM Rockwell LF2 Skip Frequency 3 102 Hz 102 Hz UM Rockwell LF2 Skip Frequency Band 0 Hz 0 Hz Increase Ramp Time 30 sec 30 sec Decrease Ramp Time 30 sec 30 sec Line Voltage Imbalance 0 1 10 Line Volt Imbalance Time 10 sec 10 sec Line Current Imbalance 0 4 40 Line Current Imbal Time 10 sec 10 sec Motor Current Imbalance 0 4 40 Motor Cu...

Page 84: ...l sec adjust as required Evap Flow Rate Baseline 0 l sec adjust as required Evap Pres Drop Baseline 0 kPa adjust as required Cond Flow Rate Baseline 0 l sec adjust as required Cond Pres Drop Baseline 0 kPa adjust as required Water Pres Drop 20mA 68 95 kPa adjust as required Max Oil Pressure Diff 344 7 kPa N A Oil Pump VFD Max Step 7 N A Vapor Source SV Delay 5 min N A Vapor Source SV Option Dsable...

Page 85: ...O 1 Type 1 1 Chiller status output mA IOB2 AI 1 Type 4 4 Motor winding temperature 1 IOB2 AI 2 Type 4 0 IOB2 AI 3 Type 4 2 EC option IOB2 AI 4 Type 0 0 IOB2 AI 8 Type 0 2 Auto Demand limit input IOB2 AI 9 Type 0 0 No Refrigerant leak sensor IOB2 AI 10 Type 5 1 IOB2 AO 1 Type 1 1 Guide Vane1 output IOB2 AO 2 Type 1 0 not used IOB3 AI 1 Type 4 4 1st stage bearing temp IOB3 AI 2 Type 4 4 2nd stage be...

Page 86: ...nu Quick Test and verify operation on desired components Note that this is a very useful feature for troubleshooting The QUICK TEST screens can only be accessed when the chiller is in STOP mode On the QUICK TEST table screen select a test to be performed The Quick Test checks all outputs and inputs for proper functionality In order to successfully proceed with the controls test the compressor must...

Page 87: ... X Table 20 PIC 5 QUICK TEST LIST 5 9 1 Cooler and condenser pressure transducer and waterside flow device calibration Waterside Device Optional with IOB Inputs Available Calibration can be checked by comparing the pressure readings from the transducer to an accurate refrigeration gage reading The transducer can be checked and calibrated at 2 pressure points These calibration points are 0 psig 0 k...

Page 88: ... automatic ensure water is circulating properly 6 2 Check Motor Rotation 1 Close the VFD enclosure door 2 Apply 3 phase power to drive 3 The VFD checks for proper phase rotation as soon as power is applied to the starter and the PIC5 controls power up 4 An alarm message will appear on the HMI screen if the phase rotation is incorrect If this occurs reverse any 2 of the 3 incoming power leads to th...

Page 89: ...us chiller parts and explain their function as part of the complete system 6 6 1 Cooler Condenser High side float chamber relief devices refrigerant charging valve temperature sensor locations pressure transducer locations Schrader fittings waterboxes and tubes and vents and drains 6 6 2 Motor compressor assembly Guide vane actuator transmission motor cooling system temperature and pressure sensor...

Page 90: ...ne shape factor can be adjusted at the same time 2 If chiller no surge but efficiency cannot meet the target the surge prevention line should be increased a If the problem only occurs at full load region Delta Tsmax should be increased by 0 28 C for each step until chiller enters real surge See Fig 48 for the effect of delta Tsmax on surge prevention line b If the problem only occurs at low load r...

Page 91: ...91 Fig 49 Effect of surge delta TSmin on Surge prevention Fig 50 Effect of surge line shape factor on Surge prevention ...

Page 92: ... timers have expired the start sequence will start Follow the procedure described in the Start Up Shutdown Recycle Sequence section 7 3 Check the running system After the compressor starts the operator should monitor the display and observe the parameters for normal operating conditions 1 The normal bearing temperature should be about 35 C Alert will initiate at 40 C and Alarm will be initiated at...

Page 93: ... an alarm condition do not restart the chiller until the problem is diagnosed and corrected 7 5 After Limited Shutdown No special preparations should be necessary Follow the regular preliminary checks and starting procedures 7 6 Preparation for Extended Shutdown If freezing temperatures are likely to occur in the chiller area drain the chilled water condenser water and the pumpout condenser water ...

Page 94: ...ction and maintenance and provides a continuous record of chiller performance It is also an aid when scheduling routine maintenance and diagnosing chiller problems Keep a record of the chiller pressures temperatures and liquid levels 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 in...

Page 95: ...53 For the Purge Operation Diagram 8 1 Purge Operating Modes Purge system has two operation modes Auto and Manual You can choose it in Configuration Menu Lab Test Forced Purge Forced Select 0 means Auto mode Select 1 or 2 means Manual mode where 1 means purge will be active regardless the purge active condition 2 means you can control purge related valves manually 8 2 Non condensable Gas Pump Out ...

Page 96: ...applicable national regulations If there are no similar criteria in local regulations the information on checks during operation in annex C of standard EN 378 2 can be used External visual checks Annex A and B of standard EN 378 Corrosion checks Annex D of standard EN 378 2 These controls must be carried out After an intervention that is likely to affect the resistance or a change in use or change...

Page 97: ...1 5 Refrigerant Leak Testing Since parts of the refrigerant system operates in vacuum non condensables will enter the cooling systems The PIC5 HMI will issue an alert indicating excessive purge operation Leaks which cause frequent purge cycles should be repaired without delay Non condensable gas in the machine causes higher than normal condenser pressure compressor surge at start up and frequent p...

Page 98: ...sphere to reduce the potential for corrosion After retesting and finding no leaks apply a standing vacuum test Then dehydrate the chiller Refer to the Standing Vacuum Test and Chiller Dehydration sections in the Before Initial Start Up section 9 1 9 Checking Guide Vanes During normal shutdown when the chiller is off the guide vanes are closed Complete the following steps to adjust position if requ...

Page 99: ...tor details 9 1 10 Trim Refrigerant Charge If to obtain optimal chiller performance it becomes necessary to adjust the refrigerant charge operate the chiller at design load and then add or remove refrigerant slowly until the difference between the leaving chilled water temperature and the cooler refrigerant temperature reaches design conditions or becomes a minimum Do not overcharge Use cooler sig...

Page 100: ... directly into the chiller as described in the Charging Refrigerant section 9 2 Weekly maintenance 9 2 1 Check the Refrigerant Lubrication System 1 Enter INPUT menu and verify that Liquid Level Switch is closed if compressor is on 2 Check moisture indicating sight glass on bearing supply line Fig 56 as well as on the motor VFD liquid cooling line located between vessels feeding of the high side fl...

Page 101: ...the purge run time for the past 24 hours as well as the past 7 days can be obtained from RUNTIME menu 9 3 Scheduled maintenance Establish a regular maintenance schedule based on your actual chiller requirements such as chiller load run hours and water quality The time intervals listed in this section are offered as guides to service only 9 3 1 Service On time The HMI will display a resettable Afte...

Page 102: ...hanged with refrigerant remaining in the chiller Strainers such as 2x refrigerant pump suction strainers and inductor are to be replaced every 5 years or as required when the machine is open for service These filters do not contain desiccant for moisture removal so changing the filter will not change the moisture indicator status Change strainers filters by closing isolation valves and slowly open...

Page 103: ...ressure and increase in condenser pressure This will be accompanied by a loss of EER The liquid line downstream of the float valve feels warm and float valve seems stuck based on a visual inspection through the end cover sight glass This indicates condenser gas flowing past the float 1 Transfer the refrigerant into a pumpout storage tank 2 Remove the float access cover 3 Clean the chamber and valv...

Page 104: ... functioning of the following elements Opening and setting of safety switches HPS pressure switches The good opening of the contactor K101 and its return of state The proper operation of the GateKill stop function 9 3 10 1 Checking the adjustment of safety switches Invert the direction of the three way valve so that the two standby switches start the operation Remove the first pressure switches an...

Page 105: ...ll not depressed 9 Reconnect the NC contact Na 10 Reset the safety relay by pressing the reset button Na 11 Check that the PWR IN and OUT LED of the safety relay K4 is on Check that the contactor tap K101 is depressed Table 21 Safety chain check 9 3 11 Compressor bearing maintenance The key to good bearing maintenance is proper lubrication Inspect the lubrication system regularly and thoroughly An...

Page 106: ...mal condenser pressures check the purge pump out as follow 1 Check purge out frequency on HMI touch screen purge menu If average pump out time per day is above 15 min Please check the leak and repair it Using purge to pump out remaining non condensable inside chiller 2 If however purge pump out time per day is below 15 min the high condenser pressure is caused by dirty tubes or by abnormal conditi...

Page 107: ...urged and this can cause injuries or damage to the machine Ensure that the power supply has been disconnected and that all safety measures are in place before removing the VFD box This procedure minimizes the number of sensors and cables that need to be disconnected WARNING Do not disconnect the evaporator and condenser before VFD has been disconnected and removed VFD box has a high level centre o...

Page 108: ... be viewed while the unit is running The PIC 5 TOUCH SCREEN default screen indicates when an alarm occurs Once all alarms have been cleared by correcting the problems the PIC 5 TOUCH SCREEN default screen indicates normal operation For information about displaying and resetting alarms and a list of alert codes please refer to separated PIC5 Control User Manual The Configuration menu screens displa...

Page 109: ...9 93 0 316 418 26 4 586 69 332 14 2 844 8 232 54 0 999 1 550 94 0 308 405 25 4 562 65 205 15 2 788 7 855 55 0 969 1 493 95 0 299 393 24 4 538 61 343 16 2 73 7 499 56 0 941 1 439 96 0 291 382 23 4 512 57 745 17 2 672 7 160 57 0 913 1 387 97 0 283 371 22 4 486 54 411 18 2 615 6 839 58 0 887 1 337 98 0 275 360 21 4 458 51 341 19 2 559 6 535 59 0 861 1 290 99 0 267 349 20 4 429 48 536 20 2 503 6 246 6...

Page 110: ...not exceed 1 2 C The sensors are immersed directly in the refrigerant or water circuits When installing a new sensor apply a pipe sealant or thread sealant to the sensor threads An additional thermistor factory installed in the bottom of the cooler barrel is displayed as Evap Refrig Liquid Temp on the TEMPERATURES display screen This thermistor provides additional protection against a loss of wate...

Page 111: ...ly voltage It should be 5 vdc 0 5 v as displayed in MAINTENANCE MENU MAINTENANCE OTHERS where all the transducer voltages are shown If the TRANSDUCER VOLTAGE REF supply voltage is correct the transducer should be recalibrated or replaced Also check that any external inputs have not been grounded and are not receiving anything other than a 4 to 20 mA signal TRANSDUCER REPLACEMENT Since the transduc...

Page 112: ...s control inlet guide vane envelop control valve alarms condenser and chilled water pumps The tests can help to determine whether a switch is defective or a relay is not operating as well as other useful troubleshooting issues During pumpdown operations the pumps are energized to prevent freeze up and the vessel pressures and temperatures are displayed 10 10 Quick Calibration Use this menu to cali...

Page 113: ...113 APPENDIX A SmartView SCREEN AND MENU STRUCTURE ...

Page 114: ...114 Detailed menu description ...

Page 115: ...PPENDIX 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: ...116 APPENDIX B MAINTENANCE SUMMARY AND LOGSHEETS Cont 19DV monthly Maintenance Log ...

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Carrier PIC 5+, Installation, Operation And Maintenance Instructions

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