Carrier AquaEdge 19DV series User guide

Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Catalog No. 04-53190056-01 Printed in U.S.A. Form 19DV-CLT-2SS Pg 1 6-19 Replaces: 19DV-CLT-1SS
Start-Up, Operation, and Maintenance
Instructions
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . 2
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ABBREVIATIONS AND EXPLANATIONS . . . . . . . . . . 4
CHILLER FAMILIARIZATION (FIG. 1 AND 2) . . . . . . . 4
Chiller Information Nameplate . . . . . . . . . . . . . . . . . . 4
System Components . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Evaporator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Economizer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Motor-Compressor. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Purge Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Variable Frequency Drive (VFD) . . . . . . . . . . . . . . . . . 4
Refrigerant Lubrication System . . . . . . . . . . . . . . . . . 4
Chiller Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Purge Control Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . 5
PIC6 Touch Screen HMI. . . . . . . . . . . . . . . . . . . . . . . . 5
REFRIGERATION CYCLE . . . . . . . . . . . . . . . . . . . . . . 7
REFRIGERANT LUBRICATION CYCLE . . . . . . . . . . . 8
Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Inhibitor Reclaim System . . . . . . . . . . . . . . . . . . . . . . 9
Motor Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . 9
VFD Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . 9
VFD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Purge System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Definitions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
PIC6 System Components . . . . . . . . . . . . . . . . . . . . 12
START-UP/SHUTDOWN/
RECYCLE SEQUENCE. . . . . . . . . . . . . . . . . . . . . . 13
Local Start/Stop Control . . . . . . . . . . . . . . . . . . . . . . 13
Lubrication Control . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
BEFORE INITIAL START-UP . . . . . . . . . . . . . . . . . . . 15
Job Data Required . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Equipment Required . . . . . . . . . . . . . . . . . . . . . . . . . 15
Remove Shipping Packaging . . . . . . . . . . . . . . . . . . 15
Tighten All Gasketed Joints . . . . . . . . . . . . . . . . . . . 15
Check Chiller Tightness . . . . . . . . . . . . . . . . . . . . . . 15
Refrigerant Tracer . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Leak Test Chiller . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Standing Vacuum Test . . . . . . . . . . . . . . . . . . . . . . . 18
Check the Installation . . . . . . . . . . . . . . . . . . . . . . . . 20
Inspect Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Chiller Dehydration . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Inspect Water Piping . . . . . . . . . . . . . . . . . . . . . . . . . 21
Check Safety Valves . . . . . . . . . . . . . . . . . . . . . . . . . .21
Check Purge Compressor Operation . . . . . . . . . . . .21
Ground Fault Troubleshooting . . . . . . . . . . . . . . . . .22
Carrier Comfort Network® Interface . . . . . . . . . . . . .22
Inhibitor Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Software Configuration . . . . . . . . . . . . . . . . . . . . . . .23
Charge Unit with Refrigerant . . . . . . . . . . . . . . . . . . .23
Field Set Up and Verification . . . . . . . . . . . . . . . . . . .31
Perform a Controls Test
(Quick Calibration/Quick Test) . . . . . . . . . . . . . . .32
INITIAL START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Check Motor Rotation. . . . . . . . . . . . . . . . . . . . . . . . .33
Check Refrigerant Lube . . . . . . . . . . . . . . . . . . . . . . .33
To Prevent Accidental Start-Up . . . . . . . . . . . . . . . . .33
Check Chiller Operating Condition . . . . . . . . . . . . . .33
Instruct the Customer Operator(s) . . . . . . . . . . . . . .34
OPERATING INSTRUCTIONS. . . . . . . . . . . . . . . . . . .36
Operator Duties. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Prepare the Chiller for Start-Up . . . . . . . . . . . . . . . . .36
To Start the Chiller . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Check the Running System . . . . . . . . . . . . . . . . . . . .36
To Stop the Chiller . . . . . . . . . . . . . . . . . . . . . . . . . . .36
After Limited Shutdown . . . . . . . . . . . . . . . . . . . . . . .36
After Extended Shutdown . . . . . . . . . . . . . . . . . . . . .36
Cold Weather Operation. . . . . . . . . . . . . . . . . . . . . . .37
Manual Guide Vane Operation. . . . . . . . . . . . . . . . . .37
Refrigeration and Service Log. . . . . . . . . . . . . . . . . .37
PUMPOUT AND REFRIGERANT
TRANSFER PROCEDURES . . . . . . . . . . . . . . . . . .39
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
GENERAL MAINTENANCE. . . . . . . . . . . . . . . . . . . . .42
Refrigerant Properties . . . . . . . . . . . . . . . . . . . . . . . .42
Adding Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . .42
Adjusting the Refrigerant Charge . . . . . . . . . . . . . . .42
Refrigerant Leak Testing . . . . . . . . . . . . . . . . . . . . . .42
Leak Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
Test After Service, Repair, or Major Leak. . . . . . . . .42
Repair Leaks, Retest, Standing Vacuum Test . . . . .42
Checking Guide Vanes. . . . . . . . . . . . . . . . . . . . . . . .42
Trim Refrigerant Charge. . . . . . . . . . . . . . . . . . . . . . .44
WEEKLY MAINTENANCE . . . . . . . . . . . . . . . . . . . . . .44
Check the Refrigerant Lubrication System . . . . . . .44
Check for Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
SCHEDULED MAINTENANCE . . . . . . . . . . . . . . . . . .44
Service Ontime . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
Inspect the Control Panel. . . . . . . . . . . . . . . . . . . . . .44
Inspect the Purge . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
AquaEdge® 19DV
Two-Stage Back-to-Back Centrifugal Liquid
Chillers with PIC6 Controls and HFO R-1233zd(E)
50/60 Hz

2
Changing Refrigerant Lubrication Filters . . . . . . . . 45
Inspect Refrigerant Float System . . . . . . . . . . . . . . . 45
Inspect Safety Relief Devices and Piping . . . . . . . . 45
Compressor Bearing Maintenance . . . . . . . . . . . . . . 46
Inspect the Heat Exchanger Tubes
and Flow Devices . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Water Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Water Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Inspect the VFD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Recalibrate Pressure Transducers . . . . . . . . . . . . . . 47
Recalibrate Temperature Thermistors . . . . . . . . . . . 47
Ordering Replacement Chiller Parts. . . . . . . . . . . . . 47
TROUBLESHOOTING GUIDE. . . . . . . . . . . . . . . . . . . 47
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Checking Display Messages . . . . . . . . . . . . . . . . . . . 47
Checking Temperature Sensors . . . . . . . . . . . . . . . . 47
Checking Pressure Transducers . . . . . . . . . . . . . . . 50
High Altitude Locations . . . . . . . . . . . . . . . . . . . . . . . 51
Quick Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Quick Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Pumpdown/Lockout . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Physical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
APPENDIX A — PIC6 SCREEN AND MENU
STRUCTURE . . . . . . . . . . . . . . . . . . . . . . . . 72
APPENDIX B — CCN COMMUNICATION WIRING
FOR MULTIPLE CHILLERS (TYPICAL) . . . . . . 75
APPENDIX C — MAINTENANCE SUMMARY AND
LOG SHEETS . . . . . . . . . . . . . . . . . . . . . . . . . . 76
APPENDIX D — REMOTE CONNECTIVITY
COMMISSIONING . . . . . . . . . . . . . . . . . . . . . . . . . . 77
INDEX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
INITIAL START-UP CHECKLIST . . . . . . . . . . . . . . CL-1
SAFETY CONSIDERATIONS
Centrifugal liquid chillers are designed to provide safe and reli-
able service when operated within design specifications. When
operating this equipment, use good judgment and safety pre-
cautions to avoid damage to equipment and property or injury
to personnel.
Be sure you understand and follow the procedures and safety
precautions contained in the chiller instructions as well as
those listed in this guide.
DANGER
Failure to follow these procedures will result in severe per-
sonal injury or death.
DO NOT VENT refrigerant relief valves within a building.
Outlet from rupture disc or relief valve must be vented out-
doors in accordance with the latest edition of ANSI/
ASHRAE 15 (American National Standards Institute/
American Society of Heating, Refrigerating, and Air-
Conditioning Engineers). 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 harm-
ful and may cause heart irregularities, unconsciousness, or
death. Misuse can be fatal. Vapor is heavier than air and re-
duces the amount of oxygen available for breathing. Prod-
uct causes eye and skin irritation. Decomposition products
are hazardous.
DO NOT USE OXYGEN to purge lines or to pressurize a
chiller for any purpose. Oxygen gas reacts violently with
oil, grease, and other common substances.
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 USE air for leak testing. Use only refrigerant or
dry nitrogen.
DO NOT VALVE OFF any safety device.
BE SURE that all pressure relief devices are properly in-
stalled and functioning before operating any chiller.
RISK OF INJURY OR DEATH by electrocution. High
voltage can be present on motor leads even though the mo-
tor is not running. Open the power supply disconnect be-
fore touching motor leads or terminals.
WARNING
Failure to follow these procedures may result in personal
injury or death.
DO NOT USE TORCH to remove any component. System
contains refrigerant which may be under pressure.
To remove a component, wear protective gloves and gog-
gles and proceed as follows:
a. Shut off electrical power to unit.
b. Recover or isolate refrigerant from system using high-
pressure and low pressure ports as appropriate. Note that
R-1233zd(E) will be less than atmospheric pressure
until a temperature of about 65°F (18.5°C).
c. Traces of vapor should be displaced with nitrogen and
the work area should be well ventilated. Refrigerant in
contact with an open flame produces toxic gases.
d. Cut component connection tubing with tubing cutter
and remove component from unit.
e. Carefully unsweat remaining tubing stubs when necessary.
DO NOT USE eyebolts or eyebolt holes to rig chiller sec-
tions or the entire assembly.
DO NOT work on high-voltage equipment unless you are a
qualified electrician.
DO NOT WORK ON electrical components, including
control panels, switches, or starters, until you are sure ALL
POWER IS OFF and no residual voltage can leak from ca-
pacitors or solid-state components.
(Warnings continued on next page.)

3
INTRODUCTION
Prior to initial start-up of the 19DV unit, those involved in the
start-up, operation, and maintenance should be thoroughly fa-
miliar with these instructions and other necessary job data.
Procedures in this manual are arranged in the sequence re-
quired for proper chiller start-up and operation. This book also
outlines the control system for those involved in the start-up,
operation and maintenance of the unit before performing start-
up procedures. It is intended to be used in combination with the
19DV Semi-Hermetic Centrifugal Liquid Chillers Controls
Operation and Troubleshooting manual that describes the con-
trols in detail.
WARNING
LOCK OPEN AND TAG electrical circuits during servic-
ing. IF WORK IS INTERRUPTED, confirm that all cir-
cuits are de-energized before resuming work.
AVOID SPILLING liquid refrigerant on skin or getting it
into the eyes. USE SAFETY GOGGLES. Wash any spills
from the skin with soap and water. If liquid refrigerant en-
ters the eyes, IMMEDIATELY FLUSH EYES with water
and consult a physician.
NEVER APPLY an open flame or live steam to a refriger-
ant cylinder. Dangerous overpressure can result. When it is
necessary to heat refrigerant, use only warm (110°F [43°C])
water.
VERIFY that refrigerant storage cylinders are clean with no
residual moisture, oil, or refrigerant that can contaminate
the refrigerant charge.
DO NOT REUSE disposable (nonreturnable) cylinders or
attempt to refill them. It is DANGEROUS AND ILLE-
GAL. When cylinder is emptied, evacuate remaining gas
pressure, loosen the collar, and unscrew and discard the
valve stem. DO NOT INCINERATE.
CHECK THE REFRIGERANT TYPE before adding re-
frigerant to the chiller. The introduction of the wrong re-
frigerant can cause damage or malfunction to this chiller.
Operation of this equipment with refrigerants other than
those cited herein should comply with ANSI/ASHRAE 15
(latest edition). Contact Carrier for further information on
use of this chiller with other refrigerants.
DO NOT ATTEMPT TO REMOVE fittings, covers, etc.,
while chiller is refrigerant charged or at any time while
chiller is running. Be sure pressure is at 0 psig (0 kPa) be-
fore breaking any refrigerant connection. Note that chiller
will be in a vacuum condition when temperature is below
normal room temperature.
CAREFULLY INSPECT all rupture discs and other relief
devices AT LEAST ONCE A YEAR. If chiller operates in a
corrosive atmosphere, inspect the devices at more frequent
intervals.
DO NOT ATTEMPT TO REPAIR OR RECONDITION
any relief device when corrosion or build-up of foreign ma-
terial (rust, dirt, scale, etc.) is found within the valve body
or mechanism. Replace the device.
DO NOT install relief devices in series or backwards.
USE CARE when working near or in line with a com-
pressed spring. Sudden release of the spring can cause it
and objects in its path to act as projectiles.
CAUTION
Failure to follow these procedures may result in personal
injury or damage to equipment.
DO NOT STEP on refrigerant lines. Broken lines can whip
about and release refrigerant, causing personal injury.
DO NOT climb over a chiller. Use platform, catwalk, or
staging. Follow safe practices when using ladders.
USE MECHANICAL EQUIPMENT (crane, hoist, etc.) to
lift or move inspection covers or other heavy components.
Even if components are light, use mechanical equipment
when there is a risk of slipping or losing your balance.
BE AWARE that certain automatic start arrangements CAN
ENGAGE THE STARTER, TOWER FAN, OR PUMPS.
Open the disconnect ahead of the starter, tower fans, or
pumps.
USE only repair or replacement parts that meet the code re-
quirements of the original equipment.
DO NOT VENT OR DRAIN waterboxes containing indus-
trial brines, liquid, gases, or semisolids without the permis-
sion of your process control group.
DO NOT LOOSEN waterbox cover bolts until the water-
box has been completely drained.
DO NOT LOOSEN a packing gland nut before checking
that the nut has a positive thread engagement.
PERIODICALLY INSPECT all valves, fittings, and piping
for corrosion, rust, leaks, or damage.
PROVIDE A DRAIN connection in the vent line near each
pressure relief device to prevent a build-up of condensate or
rain water.
DO NOT leave refrigerant system open to air any longer than
the actual time required to service the equipment. Seal circuits
being serviced and charge with dry nitrogen to prevent con-
tamination when timely repairs cannot be completed.
CAUTION
Do NOT punch holes or drill into the top surface of the con-
trol or VFD enclosure for field wiring. Knockouts are pro-
vided for field wiring connections. Drilling holes through
the top of the cabinet can result in a loss of warranty on the
starter assembly because of metal particulate falling on and
into electronic components.
CAUTION
PROVIDE MACHINE PROTECTION. Store machine and
starter indoors, protected from construction dirt and mois-
ture. Inspect under shipping tarps, bags, or crates to be sure
water has not collected during transit. Keep protective ship-
ping covers in place until machine is ready for installation.
Follow latest Water-Cooled Chillers Long Term Storage
document located in Chiller Builder Library.

4
ABBREVIATIONS AND EXPLANATIONS
Frequently used abbreviations in this manual include:
Factory-installed additional components are referred to as options
in this manual; factory-supplied but field-installed additional com-
ponents are referred to as accessories.
CHILLER FAMILIARIZATION (Fig. 1 and 2)
Chiller Information Nameplate
The information nameplate is located on the left side of the
chiller control panel.
System Components
The main components include the evaporator and condenser
heat exchangers in separate vessels, motor-compressor, refrig-
erant, lubrication package, control panels, PIC6 Touch Screen
HMI, economizer, VFD, and purge system.
Evaporator
This vessel is located underneath the compressor. The evapora-
tor is maintained at a lower temperature/pressure so evaporat-
ing refrigerant can remove heat from water flowing through its
internal tubes. Water flows through the internal tubes to pro-
vide comfort or process cooling.
Condenser
The condenser operates at a higher temperature/pressure than the
evaporator and has water flowing through its internal tubes in or-
der to remove heat from the refrigerant. It contains a metering de-
vice that regulates the flow of refrigerant into the economizer.
Economizer
This chamber reduces the refrigerant pressure to an intermediate
level between the evaporator and condenser vessels. In the econ-
omizer, vapor is separated from the liquid, the separated vapor
flows to the second stage of the compressor, and the liquid flows
into the evaporator. The energy removed from the vaporized re-
frigerant in the economizer allows the liquid refrigerant in the
evaporator to absorb more heat when it evaporates and benefits
the overall cooling efficiency cycle. It contains a float assembly
that regulates the flow of refrigerant into the evaporator.
Motor-Compressor
This component maintains system temperature and pressure
differences and moves the heat-carrying refrigerant from the
evaporator to the condenser. The 19DV utilizes a two-stage
back to back direct drive configuration.
Purge Unit
This is a small independent condensing unit with compressor, sep-
arator, regenerative carbon filters, heater and vacuum pump. The
purge extracts gas from condenser (or from compressor if unit is
not in operation) and purifies it by removing non-condensable
gases and any water vapor that may be present.
Variable Frequency Drive (VFD)
The VFD variable frequency is a voltage source design that
converts line voltage into PWM (pulse width modulating) mo-
tor input for motor speed and torque control.
Refrigerant Lubrication System
This system provides lubrication to the compressor bearing by
means of a refrigerant pump.
Chiller Control Panel
This control panel includes the input and output boards (IOBs),
control transformer, relays, contactors, and circuit breakers. It pro-
vides the power distribution and protection to the electrical com-
ponents installed on chiller and has the following functions:
• Communication with PIC6 touch screen
• Communication with purge panel
• Communication with VFD
• Sensor input and outputs
• Actuators control
• Refrigerant pump control
CAUTION
WHEN FLUSHING THE WATER SYSTEMS isolate the
chiller from the water circuits to prevent damage to the heat
exchanger tubes.
CAUTION
This unit uses a microprocessor control system. Do not
short or jumper between terminations on circuit boards or
modules; control or board failure may result.
Be aware of electrostatic discharge (static electricity) when
handling or making contact with circuit boards or module
connections. Always touch a chassis (grounded) part to
dissipate body electrostatic charge before working inside
control center or use a grounding strap before handling
printed circuit boards.
Use extreme care when handling tools near boards and when
connecting or disconnecting terminal plugs. Circuit boards can
easily be damaged. Always hold boards by the edges and
avoid touching components and connections.
This equipment uses, and can radiate, radio frequency ener-
gy. If not installed and used in accordance with the instruc-
tion manual, it may cause interference to radio communica-
tions. The PIC6 control boards have been tested and found to
comply with the limits for a Class A computing device pur-
suant to International Standard in North America EN 61000-
2/3 which are designed to provide reasonable protection
against such interference when operated in a commercial en-
vironment. Operation of this equipment in a residential area
is likely to cause interference, in which case the user, at his
own expense, will be required to take whatever measures
may be required to correct the interference.
Always store and transport replacement or defective boards
in anti-static shipping bag.
AWG — American Wire Gage
BMS — Building Management System
CCN — Carrier Comfort Network®
DCIB — Digital Control Interface Board
DVM — Digital Volt-Ohmmeter
EC — Envelope Control
ECDW — Entering Condenser Water
ECW — Entering Chilled Water
EMS — Energy Management System
HMI — Human Machine Interface
HVIB — High Voltage Interface Board
I/O — Input/Output
IGBT — Insulated-Gate Bipolar Transistor
IGV — Inlet Guide Vane
IOB — Input Output Board
LCDW — Leaving Condenser Water
LCW — Leaving Chilled Water
LED — Light-Emitting Diode
MAWP — Maximum Allowable Working Pressure
NSTV — Network Service Tool V
OLTA — Overload Trip Amps
PIC — Product Integrated Controls
PPE — Protective Personal Equipment
PWM — Pulse Width Modulating
RLA — Rated Load Amps
RMS — Root Mean Square
SCCR — Short Circuit Current Rating
SCR — Silicon Controlled Rectifier
SIOB — Starfire 2 Input Output Board
TXV — Thermostatic Expansion Valve
VFD — Variable Frequency Drive
VPF — Variable Primary Flow

5
Purge Control Panel
The purge panel includes the input and output boards, control
transformer, relays, and fuse. It provides the power distribution
and protection to the electrical components which installed in
the purge system and has the following functions:
• Communication with PIC6 touch screen
• Sensor input and outputs
• Solenoid valve control
• Control of purge compressor, vacuum pump, heater, and fan.
PIC6 Touch Screen HMI
This panel is the user interface for controlling the chiller and
has the following functions:
• Chiller operation
• Chiller diagnostic
• Chiller status display
• Chiller parameter configuration
• Provide open protocol interface to outside BMS (Building Man-
agement System)
Fig. 1 — 19DV Chiller Model Number Identification
SERIAL NUMBER STRUCTURE
12 17 Q 26788
Week of Year
Ye ar of Manufacture
Unique Number
Place of Manufacture
a19-2271
Description
19 — High Efficiency Semi-Hermetic
Centrifugal Chiller
19 G 4
DV –
V — Variable Speed Drive
Evaporator Frame Size, Length,
Pass Arrangement, and Tube Count
44G44
Condenser Frame Size, Length,
Pass Arrangement, and Tube Count
44
Compressor Frame Size
Compressor Impeller Diameter Code
Motor Voltage Code
Code Volts-Phase-Hertz
3 — 380-3-60
4 — 416-3-60
5 — 460-3-60
9 — 400-3-50
Special Order Indicator
– — Standard
S — Special Order
VFD Code*
5 — 850 Amp Std Tier VFD
5H4
Compressor Shroud Code
3 —Smallest shroud
4— Small-Mid shroud
5— Mid-Large shroud
6— Largest shroud
Motor Code*
B —Smallest HP
D— Small-Mid HP
F — Mid-Large HP
H— Largest HP
2 —Small diameter
4— Large diameter
G20 - G4K — Frame G
H20 - H4K — Frame H
G22 - G4K — Frame G
H22 - H4K — Frame H
*Refer to 19DV NG E-Cat Builder
for motor and VFD size details.
4 — 500-800 nominal tons (1758-2813 kW)
D — Low Pressure

6
Fig. 2 — Typical 19DV 500-800 Ton Two-Stage Compressor Chiller Components
(DV4 Shown)
FRONT VIEW
8
9
7
6
5
4
10
11
12
13
14
15
16
17
18
19
12
3
1—Interconnecting Compressor Piping
2—VFD Drain (Field Drain Piping Required)
3—Condenser
4—Condenser Waterbox Return End
5—Economizer Isolation Valve (Option)
6—Economizer
7—Evaporator Waterbox Return End
8—Vacuum/Charging Valve (Hidden)
9—PIC6 HMI Touchscreen Panel
10 — Evaporator Bundle Sight Glasses
11 — Rupture Disc
12 — Suction Elbow
13 — Evaporator Charging Valve and
Evaporator Pressure Transducer
14 — First Stage Guided Vane Actuator
15 — Compressor Motor
16 — Moisture Indicator (Hidden)
17 — Evaporator
18 — Second Stage Guided Vane Actuator
19 — Evaporator Waterbox Nozzles
20 — Condenser Waterbox Nozzles
21 — Condenser Pressure Transducer
22 — Condenser Charging Valve
23 — Envelope Stability Control Pipe
24 — Purge Assembly
25 — Purge Vent (Hidden)
26 — Motor VFD Cooling Moisture Indicator
(Hidden)
27 — Control Panel
28 — Chiller Name Plate Label
29 — Lubrication Assembly
30 — Economizer Pipe
31 — VFD
32 — Discharge Pipe
REAR VIEW
31
30
28 27
26
24
23
22
21
20
25
29
32

7
REFRIGERATION CYCLE
The compressor continuously draws refrigerant vapor from the
evaporator at a rate set by the amount of first stage guide vane
opening and motor speed. As the compressor suction reduces
the pressure in the evaporator, the remaining refrigerant boils
at a fairly low temperature (typically 38 to 42°F [3 to 6°C]).
The energy required for boiling is obtained from the water
flowing through the evaporator tubes. With heat energy re-
moved, the water becomes cold enough to use in an air-condi-
tioning circuit or process liquid cooling.
After taking heat from the water, the refrigerant vapor is com-
pressed by a back-to-back compression connected by means of in-
terstage piping. Compression adds heat energy and the refrigerant
is quite warm (typically 98 to 102°F [37 to 40°C]) when it is dis-
charged from the compressor into the condenser.
Relatively cool (typically 65 to 90°F [18 to 32°C]) water flow-
ing into the condenser tubes removes heat from the refrigerant,
and the vapor condenses to liquid. The liquid drains into a high
side float valve chamber between the condenser and the econo-
mizer. The refrigerant is then metered into the economizer. In
the economizer, due to lower pressure, as liquid enters the
chamber, some liquid will flash into a vapor and cool the re-
maining liquid. The separated vapor flows to the second stage
of the compressor for greater cycle efficiency. The second
stage guide vane on the compressor acts as a pressure regulat-
ing device to stabilize operating conditions. At part load the
second stage guide vane will back up gas flow and thereby
raises the economizer pressure to allow appropriate refrigerant
flow from economizer to the compressor.
The cooled liquid left in the economizer flows through a low
side float valve and then into the evaporator. The float valve
forms a liquid seal to keep vapor from entering the evaporator.
The refrigerant is now at a temperature and pressure at which the
cycle began. Figure 3 summarizes the refrigeration cycle.
The 19DV unit utilizes R-1233zd(E) refrigerant. At atmospher-
ic pressure its boiling point is 65.5°F (18.6°C). The result is
that at normal operating conditions the evaporator typically
will be in a vacuum condition and the condenser will operate at
a pressure above atmospheric pressure. Unit near room tem-
perature will be close to atmospheric pressure.
Fig. 3 — Refrigeration Cycle — 19DV Two-Stage Compressor
HIGH SIDE FLOAT
CHAMBER
COOLER
ECONOMIZER
LOW SIDE
FLOAT CHAMBER
CONDENSER
COMPRESSOR

8
REFRIGERANT LUBRICATION CYCLE
Summary
The 19DV Series chiller uses refrigerant to lubricate the bearings.
The lubrication control is automatically controlled by the chiller
controls. In normal RUN mode refrigerant is pumped by means of
a refrigerant pump from the high side condenser float chamber to
the bearings. Prior to start-up, liquid level in the high side con-
denser float chamber is maintained by pumping refrigerant liquid
from the evaporator to the high side float chamber until level sen-
sor is satisfied. If liquid high side float level is not satisfied, the
pump will move refrigerant from the evaporator to the condenser.
During pre-lube and post-lube cycles, refrigerant is drawn from
the evaporator for bearing lubrication.
Figures 4 and 5 identify the refrigerant lubrication assembly. Sup-
ply refrigerant is pulled through a filter drier by the refrigerant
pump and is pumped to the bearings through two protective filters
and then returned to the evaporator.
There are two pressure sensors located across the refrigerant
pump. During RUN mode a minimum of 12 psid is required for
the refrigerant pump delta difference. An alert will trigger if
this value is less than 13 psid while the machine is in normal
operating mode. Consult the 19DV with PIC6 Controls Opera-
tion and Troubleshooting manual for details.
Bearings
The 19DV motor-compressor assembly includes two matched
sets of refrigerant-lubricated bearings. The motor shaft is sup-
ported by a combination set of journal bearing and roller ele-
ment bearings on each end of compressor. The refrigerant lu-
brication pressure difference is defined as the bearing input
pressure minus the bearing output pressure plus the Refrigerant
Delta P Offset.
Fig. 4 — Refrigerant Lubrication Cycle
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 evaporator and condenser is ap-
proximately 7 psid (48 kPa) with a maximum evaporator re-
frigerant temperature of 65°F (18°C). Consult Chiller Build-
er for required steady state operational limits and low lift op-
tions. Inverted start conditions are acceptable for short
durations of time, but for periods exceeding 5 minutes, a spe-
cial control solution strategy should be used to allow the
chiller to establish a minimum refrigerant pressure differen-
tial (and thereby adequate equipment cooling).
PURGE SYSTEM
CONDENSER
HIGH SIDE FLOAT
CHAMBER
REFRIGERANT
LUBRICATION
SYSTEM
VENT LINE
COOLER
ECONOMIZER
LOW SIDE
FLOAT CHAMBER
COMPRESSOR
EDUCTOR
= PURGE
= LUBE SYSTEM
= MAIN REFRIGERANT SYSTEM
LEGEND

9
Fig. 5 — Refrigerant Lubrication Assembly
Inhibitor Reclaim System
The inhibitor reclaim system moves inhibitor from the evaporator
and returns it to the first stage suction inlet which allows it to be
mixed in the system since it has a tendency to have higher concen-
tration in the evaporator compared with the rest of the system. The
reclaim is powered by an eductor driven by the gas pressure differ-
ence between first stage suction and discharge of second stage.
Motor Cooling System
The motor is cooled by liquid refrigerant taken from the bot-
tom of the high side condenser float chamber. Refrigerant flow
is maintained by the pressure differential that exists due to
compressor operation. After the refrigerant flows past an isola-
tion valve, an in-line filter drier, and a sight glass/moisture in-
dicator, it is directed over the motor by spray nozzles. The re-
frigerant collects in the bottom of the motor casing and is then
drained back into the evaporator through the motor refrigerant
drain line. The motor is protected by temperature thermistors
embedded in the stator windings. An increase in motor wind-
ing temperature past the motor override set point overrides the
temperature capacity control to hold, and if the motor tempera-
ture exceeds 10°F (5.5°C) above this set point, the controls
close the inlet guide vanes. If the temperature rises above
122°F (50°C), the compressor shuts down. See Fig. 6.
VFD Cooling System
The VFD enclosure is sealed from the atmosphere to protect elec-
tronics from outside contaminants. Refrigerant is routed through a
coil in the VFD enclosure to regulate enclosure temperature while
still maintaining a temperature high enough to prevent condensa-
tion. The VFD cooling line is branched off the motor cooling sup-
ply. The refrigerant is then drained back into the evaporator
through the motor/VFD drain line. Rectifier and inverter sections
are air-cooled and protected by temperature sensors embedded in
the inverter. An increase in inverter temperature past the override
set point overrides the temperature capacity control to hold, and if
the temperature exceeds 10°F (5.5°C) above this set point, the
controls close the inlet guide vanes. If the IGBT temperature rises
above 144°F (80°C), the compressor shuts down. See Fig. 6.
VFD
All 19DV units are equipped with a VFD to operate the centrifu-
gal semi-hermetic compressor motor. The VFD and control pan-
el are the main field wiring interfaces for the installing contrac-
tor. The VFD and control panel are mounted on the chiller. See
Manufacturer VFD specific information and VFD schematics.
VFD model 32VS is designed to operate in an ambient range of
up to 104°F (40°C). The drive has two control circuit boards.
The Digital Control Interface Board (DCIB) controls the fans for
cooling operation, controls insulated-gage bipolar transistors
(IGBTs), measures three phase line current, controls temperature
input and cooling solenoid, controls outputs for pilot relays, and
controls communication with HMI controller.
The High Voltage Interface Board (HVIB) steps down incom-
ing voltage to 24 VAC and sends this to the DCIB for monitor-
ing. The HVIB measures DC Bus voltage, controls the pre-
charge circuit, and controls SCR gating. It contains watchdog
LED to confirm DC Bus potential is depleted.
If the drive needs to be removed, use the 4 lifting lugs. See Fig. 7.
A 32VS 850A weighs approximately 1500 lbs. The drive is com-
patible with the Network Service Tool V (NSTV) for diagnostics.
Purge System
The purge system is located under the condenser. See Fig. 8. It has
two gas inlets coming from condenser and compressor. When
chiller is running, the condenser line is active/open and non-con-
densable gas is pulled out from condenser; when chiller is idle the
compressor line is active and non-condensables are pulled out
from compressor volute. This is implemented due to non-condens-
able gas density being less than refrigerant and therefore it will ac-
cumulate at the highest point when chiller is not running.
In the purge tank the purge gas is cooled by a separate integral
R-134a cooling system. The cooling system consists of an
compressor, an air cooled condenser coil, an expansion valve,
and a cooling coil in purge tank. Cooling the purge gas results
in condensation of R-1233zd(E) vapor as it touches the coil, re-
sulting in a vacuum with the result that more refrigerant is
pushed to the coil. As the purge tank fills up with refrigerant it
will be drained through the purge drain to the refrigerant pump
assembly. See Fig. 9.
STRAINER
FROM EVAPORATOR
TO COMPRESSOR/
MOTOR BEARINGS
ACTUATOR
FROM
HIGH SIDE
FLOAT
CHAMBER
REFRIGERANT
PUMP
PUMP
DISCHARGE
PUMP
SUCTION
FILTER
NOTE: VALVESSHUT AT FACTORY TO CONTAIN
INHIBITOR IN LUBRICATION ASSEMBLY.
IMPORTANT: OPEN THESE VALVES
PRIOR TO STARTUP.

10
Fig. 6 — Motor/VFD Cooling System
Fig. 7 — 32VS 850A
MOISTURE
INDICATOR
VFD
P
P
MOTOR COOLING
SYSTEM
CONDENSER
COOLER
MOISTURE
INDICATOR
SOLENOID VALVE
COMPRESSOR
LIFTING LUGS
LIFTING LUGS