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

11
Fig. 8 — Purge System
Fig. 9 — Purge Tank
COMPRESSOR
VOLUTE (SV02)
CONDENSER
(SV01)
MOTOR
DRAIN
(SV05)
VENTING
(SV06)
PURGE TANK
PURGE PUMPOUT (SV03)
VACUUM PUMP
COMPRESSOR
SUCTION
CONTROL
PANEL
PURGE DRAIN (SV04)
(REFRIGERANT PUMP INLET)
COMPRESSOR
CONDENSER
ASSEMBLY
STRAINER
EXTRA FILTERS
WITH STRAP HEATERS
(NOT SHOWN)
CONDENSER
COMPRESSOR
SV01
SV02
COMPRESSOR VALVE
COMPRESSORSUCTION TEMP
STRAINER
134A CIRCUIT
LEVEL
SV04
PURGE DRAIN
CARBON FILTERS VACCUM PUMP SV06
SV05
STRAINER
SIGHT GLASS
CONDENSER ASSY
REGULATOR
SV03
PUMP OUT
VALVE
CHECK VALVE
(TO MOTOR DRAIN)
(TO LUBE ASSY)
FIELD CONNECTION / PURGE VENT
3/8 SAE FLARE
SWITCHES
VENT LINE
REGENERATED
REFRIGERANT
THROTTLE
DEVICE
CONDENSER VALVE

12
Non-condensables that come into contact with the cold coil in
the purge tank will not condense and will accumulate at the top
of the purge tank, raising the pressure and reducing the flow of
refrigerant vapor. When the controls sense that there is suffi-
cient non-condensable gas in the purge tank, the control will
open the pumpout valve, activate the purge evacuation pump,
and force the gas through the active carbon filters. To capture
any remaining refrigerant the gas is routed through two active
carbon filters that will absorb the refrigerant. As the carbon fil-
ters become saturated the system will regenerate the filters by
applying heat to the filters while under vacuum and then
disperse the regenerated refrigerant back to the evaporator
while releasing the non-condensables to atmosphere.
The 19DV purge control is automatic. Purge control should be
active when purge inlet temperature (evaporator refrigerant liq-
uid temp when chiller compressor OFF or condenser saturated
temperature when chiller compressor ON) is greater than purge
active temperature set point (65°F 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 sole-
noid valve to purge refrigerant from compressor. If Purge
Comp Suction Temp is less than purge compressor off temp
(default to 4°F [–15.5°C]) and the refrigerant level flag is ON,
close compressor solenoid valve and condenser solenoid valve,
and open pump out solenoid valve. Purge vent valve and purge
vacuum pump shall be kept ON for about 10s. After 10s dis-
charge, pump out solenoid valve, purge vent valve, and purge
vacuum pump shall be kept OFF. Condenser solenoid valve
shall be opened if chiller compressor is running or compressor
solenoid valve shall be opened if chiller compressor is not run-
ning. After 10s discharge, it will start 20s delay. Then, check
purge compressor suction temperature again; if it is less than
6°F (–14°C), it will continue cycle as before.
If refrigerant level in the purge tank is high (both PGLE_HI
and PGLE_LO are ON), or purge compressor suction tempera-
ture is less than 12°F (–11°C) and PGLE_LO is ON, then
drainage solenoid valve should be opened to drain refrigerant
from purge tank to evaporator (open CV1, SV04, SV01, SV02
when chiller is off, open SV04, SV01 when chiller is on). After
PGLE_LO is OFF, keep drain process for another 1s, then set
the refrigerant level flag to ON. If purge level in the purge tank
is low (both PGLE_HI and PGLE_LO are OFF), drainage sole-
noid valve should be closed.
If pump out solenoid valve is accumulated ON for 100 minutes,
purge system should do regeneration process for reg_tim minutes
(default = 120 minutes – 19DV Configuration Menu), regardless
whether purge is active. When regeneration process is active, the
Purge Regeneration Valve and Purge Heater should be on for
reg_tim minutes, purge vacuum pump should be on for 3 minutes
and then 10 minutes off, alternating during reg_tim minutes.
Upon regeneration completion, purge system will wait for an-
other 4 hours to let carbon filter cool down before it will oper-
ate normally.
CONTROLS
Definitions
ANALOG SIGNAL
An analog signal varies in proportion to the monitored source. It
quantifies values between operating limits. (Example: A tem-
perature sensor is an analog device because its resistance chang-
es in proportion to the temperature, generating many values.)
DISCRETE SIGNAL
Adiscrete signal is a 2-position representation of the value of a
monitored source. (Example: A switch produces a discrete sig-
nal indicating whether a value is above or below a set point or
boundary by generating an on/off, high/low, or open/closed
signal.)
General
The 19DV centrifugal liquid chiller contains a microprocessor-
based control center that monitors and controls all operations
of the chiller. The microprocessor control system matches the
cooling capacity of the chiller to the cooling load while provid-
ing state-of-the-art chiller protection. The system controls
cooling load within the set point plus the deadband by sensing
the leaving chilled water or brine temperature and regulating
the inlet guide vanes and compressor speed. The guide vane is
a variable flow pre-whirl assembly that controls the refrigera-
tion effect in the evaporator by regulating the amount of refrig-
erant vapor flow into the compressor. An increase in guide
vane opening increases capacity. A decrease 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 compres-
sor start-up and capacity control by modulating the motor fre-
quency based on the operating condition.
PIC6 System Components
The chiller control system is called the PIC6 (Product Integrated
Control 6). See Table 1. As with previous PIC versions, the PIC6
system controls the operation of the chiller by monitoring all op-
erating conditions. The PIC6 control system can diagnose a
problem and let the operator know what the problem is and what
to check. It positions the guide vanes and VFD speed to maintain
leaving chilled water temperature. It controls the refrigerant
pump providing compressor bearing lubrication and can inter-
face with auxiliary equipment such as pumps and cooling tower
fans to turn them on when required. It continually checks all
safeties to prevent any unsafe operating condition. It regulates
the envelope control valve for stabilized aerodynamic operation,
if installed. The PIC6 controls offer an operator trending func-
tion to help the operator monitor the chiller status more easily
and for critical compressor motor protection. The PIC6 system
provides open protocols to support the competitive BMS system
and can be integrated into Carrier’s Lifecycle System Manage-
ment for remote monitoring and data management.
Table 1 — Major Controls Components and
Panel Locations
NOTE: For detailed information about the PIC6 HMI (human ma-
chine interface), see the 19DV with PIC6 Controls Operation and
Troubleshooting manual.
WARNING
The main circuit breaker (if equipped) on the front of the
starter disconnects the main motor power only. Power may
be still energized for other circuits. Always check wiring
diagrams before initiating any work on the chiller and fol-
low applicable lock-out/tag-out procedures. Failure to dis-
connect power will result in personal injury.
PIC6 COMPONENT PANEL LOCATION
Variable Frequency Drive Top of condenser
Purge Panel Under condenser
Remote Monitoring Control Panel

13
START-UP/SHUTDOWN/
RECYCLE SEQUENCE
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. 10.
Fig. 10 — Chiller Start/Stop Icon
This initiates the PIC6 starting sequence by displaying the list of
operating modes. Press Local On to initiate start-up. See Fig. 11.
Fig. 11 — Local On
Prior to start-up the start-to-start timer and the stop-to-start
timer must have elapsed and all alarms must be cleared (see
Troubleshooting Guide section).
When start-up is initiated the status screen displays the start-up
progress and the Start/Stop icon blinks green.
Once local start-up begins, the PIC6 control system performs a
series of prestart tests to verify that all prestart alerts and safe-
ties are within acceptable limits. Table 2 shows appropriate
Prestart Alerts/Alarms conditions. If a test is not successful, the
start-up is delayed or aborted. If the tests are successful, the
start-up will be in progress and the COMPRESSOR RUN
STATUS will be “Startup.” The control will then energize the
chilled water/brine pump relay.
Five seconds later, the condenser pump relay energizes. Thirty
seconds later the PIC6 control system monitors the chilled water
and condenser water flow devices and waits until the WATER
FLOW VERIFY TIME (operator-configured, default 5 minutes)
expires to confirm flow. After flow is verified, the chilled water
temperature is compared to CONTROL POINT plus 1/2
CHILLED WATER DEADBAND. If the temperature is less than
or equal to this value, the PIC6 control system turns off the con-
denser pump relay and goes into a Recycle mode.
If the water/brine temperature is high enough, the start-up se-
quence continues and checks the guide vane position. If the
guide vanes are more than 4% open, the start-up waits until the
PIC6 control system closes the vanes. If the vanes are closed
and the refrigerant pump pressure difference is less than
2.5 psid (17.2 kPa), the refrigerant pump relay energizes. The
PIC6 control system then waits until the refrigerant pressure
(REF PRESS VERIFY TIME, operator-configured, default of
40 seconds) reaches 12 psid (82.7 kPa). After refrigerant pres-
sure is verified, if high side float chamber has adequate liquid
level, refrigerant pump will be kept ON for 20 seconds for pre-
lube; if not, refrigerant pump will be kept ON pumping refrig-
erant from evaporator to the high side float chamber until liq-
uid level is satisfied. Upon pre-lube satisfied the compressor
start relay is energized.
Compressor ontime and service ontime timers start, and the
compressor STARTS IN 12 HOURS counter and the number of
starts over a 12-hour period counter advance by one.
Failure to verify any of the requirements up to this point will
result in the PIC6 control system aborting the start and display-
ing the applicable prestart alert alarm state number near the
bottom of the home screen on the HMI panel. A prestart failure
does not advance the STARTS IN 12 HOURS counter. Any fail-
ure after the 1CR relay has energized results in a safety shut-
down, advances the starts in 12 hours counter by one, and dis-
plays the applicable shutdown status on the display.
The minimum time to complete the entire prestart sequence is
approximately 185 seconds. See Fig. 12 for normal start-up
timing sequence. See Table 2 for a list of prestart checks.
Lubrication Control
For the 19DV system, refrigerant is used to lubricate and cool
the compressor bearings. The refrigerant lubrication system in-
cludes refrigerant pump pressure transducers, control valves,
filters, liquid level switch and inhibitor reclaim system. See
Fig. 13 for the lube assembly schematic.
When the chiller is powered on, the controller will maintain the
liquid level in the condenser float chamber. If liquid level is
low, refrigerant will be pumped from evaporator to the con-
denser high side float chamber until the liquid level switch is
ON. Once the operator pushes the start 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 evaporator temperature plus
leaving condenser water temperature is less than 10°F (–12.2°C),
pump refrigerant from evaporator to condenser until compressor is
ON. Else, if evaporator temperature plus leaving condenser water
is equal or larger than 10°F (–12.2°C), pump refrigerant from con-
denser to bearing and drain to condenser until compressor is ON.
During pre-lubrication, if the bearing pressure difference is less
than 8 psid (55.2 kPa) for 8 seconds continuously, the chiller will
shut down. To proceed to start-up, the bearing pressure difference
needs to exceed 12 psid (82.7 kPa) during the pressure verification
time. The compressor will run after the pre-lubrication process.
Refrigerant from the high side condenser float chamber will be
pumped to bearings and will drain to evaporator. When chiller
shuts down, the condenser control valve will be opened and the re-
frigerant evaporator control valve will open (3-way valve will
connect evaporator to pump suction). This position allows refrig-
erant to be pumped from evaporator to condenser high side float
chamber. When the chiller is OFF, always open evaporator control
valve. While running, if compressor is ON and the bearing pres-
sure difference is less than 10 psid (68.9 kPa) for 10 seconds con-
tinuously, the chiller will shut down.

14
Table 2 — Prestart Checks
* If Prestart Check Condition is True, then resulting State is as indi-
cated in the State Number column.
† See the Controls Operation and Troubleshooting guide for alarm
and alert codes.
** Evap trip point = 33°F (0.6°C) (water) or EVAP REFRIG TRIP-
POINT (brine).
†† Condition ignored for Eaton/Rockwell VFDs.
Fig. 12 — Control Timing Sequence for Normal Start-Up
Fig. 13 — Lube Assembly Schematic
PRESTART CHECK CONDITION* STATE NUMBER†
STARTS IN 12 HOURS 8(not counting recycle restarts or auto restarts after power failure) Alert – 100
COND PRESSURE COND PRESS OVERRIDE – 20 psi Alert – 102
#RECYCLE RESTARTS LAST 4 HOURS > 5 Alert – 103
COMP BEARING TEMP >= COMP BEARING ALERT– 10°F (5.6°C) Alarm – 230
COMP MOTOR WINDING TEMP COMP MOTOR WINDING– 10°F (5.6°C) Alarm – 231
COMP DISCHARGE TEMPERATURE COMP DISCHARGE ALERT– 10°F (5.6°C) Alarm – 232
EVAP_SAT <Evap trip point** + EVAP OVERRIDE DELTA T Alarm – 233
EVAP REFRIG LIQUID TEMP <Evap trip point** + EVAP OVERRIDE DELTA T Alarm – 233
AVERAGE LINE VOLTAGE UNDERVOLTAGE THRESHOLD†† Alarm – 234
AVERAGE LINE VOLTAGE OVERVOLTAGE THRESHOLD†† Alarm – 235
CHECK FOR GUIDE VANE 1 CALIBRATION Alarm – 236
CHECK FOR GUIDE VANE 2 CALIBRATION Alarm – 238
ASTART INITIATED: prestart checks are made; evaporator
pump started.*
B Condenser water pump started (5 seconds after A).
C
Water flows verified (30 seconds to 5 minutes maximum
after B). Chilled water temperatures checked against control
point. Guide vanes checked for closure. Refrigerant pump
started; tower fan control enabled.
DRef pressure verified (15 seconds minimum, 300 seconds
maximum after C).
E
Compressor motor starts; compressor on-time and service
on-time start, 15-minute inhibit timer starts (10 seconds after
D), total compressor starts advances by one, and the num-
ber of starts over a 12-hour period advances by one.
F
SHUTDOWN INITIATED; Compressor motor stops; com-
pressor on-time and service on-time stop, and 2-minute
inhibit timer starts.
G
Refrigerant pump and evaporator pumps de-energized
(120 seconds after F).Condenser pump and tower fan con-
trol may continue to operate if condenser pressure is high.
Evaporator pump may continue if in RECYCLE mode.
O/A Restart permitted (both inhibit timers expired: minimum of
15 minutes after E; minimum of 2 minutes after F).
* Auto Restart After Power Failure Timing sequence will be faster.
MACHINE SAFETIES
EVAPORATOR PUMP
CONDENSER
WATER PUMP
WATER FLOW, CHILLED WATER
TEMP, GUIDE VANES, REF PUMP,
TOWER FAN CONTROL
REF PUMP
COMPRESSOR,
COMPRESSOR ONTIME,
SERVICE ONTIME
15-MINUTE
START-TO-STAR T
2-MINUTE
STOP-TO-STA R T
PUMP REFRIGERANT FILTER
PURGE DRAIN
COOLER
SIGHT GLASSSTRAINER
STRAINER
PUMPOUT
DRAIN
BEARING FILTER
BEARING
SUPPLY
HSFLOAT CHAMBER
2-WAY
ACTUATED VALVE
3-WAY
ACTUATED
VALVE

15
Shutdown
The unit can be stopped locally using the HMI by pressing the
green Start/Stop icon . The Unit Start/Stop screen is dis-
played. Press Confirm Stop (see Fig. 14).
Fig. 14 — Confirm Stop
Chiller shutdown begins if any of the following occurs:
• Local OFF button is pressed
• A recycle condition is present
• The time schedule has gone into unoccupied mode 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 shut-
down will be performed. The soft stop feature closes the guide
vanes of the compressor automatically if a non-alarm stop signal
occurs before the compressor motor is de-energized.
Any time the compressor is directed to stop (except in the cases
of a fault shutdown), the guide vanes are directed to close and
VFD is directed to minimum speed for variable speed com-
pressor, and the compressor shuts off when any of the follow-
ing is true:
• PERCENT LOAD CURRENT (%) drops below the SOFT
STOP AMPS THRESHOLD
• ACTUAL GUIDE VANE OPENING drops below 4%
• 4 minutes have elapsed after initializing stop.
When any one of the above conditions is true, the shutdown se-
quence stops the compressor by deactivating the compressor
start relay. Then the guide vane shall be closed and stay at the
fully closed position, the refrigerant pump relay will be turned
off after 120 seconds post lube, and the chilled water/brine
pump and condenser water pump will be shut down.
BEFORE INITIAL START-UP
Job Data Required
• list of applicable design temperatures and pressures (prod-
uct data submittal)
• chiller certified prints
• VFD details and wiring diagrams
• diagrams and instructions for special controls or options
• 19DV Installation Instructions
Equipment Required
• mechanic’s tools (refrigeration)
• digital volt-ohmmeter (DVM)
• true RMS (root mean square) digital multimeter with
clamp-on current probe or true RMS digital clamp-on am-
meter rated for at least 480 vac
• electronic refrigerant leak detector
• absolute pressure manometer or electronic micron gage
(see Fig. 15)
• drum charging valve (unless refrigerant bottles already
have charging valves)
• charging hose
Fig. 15 — Digital Vacuum Gage
Remove Shipping Packaging
Remove any packaging material from the unit, VFD, and control
panels. Inspect the unit for damage that occurred during shipping
or installation. Document any damage that was identified.
Tighten All Gasketed Joints
Gaskets normally relax by the time the chiller arrives at the
jobsite. Tighten all gasketed joints to ensure a leak-tight chiller
(does not apply to refrigerant joints covered by factory insula-
tion). Gasketed joints (excluding O-rings) may include joints at
some or all of the following:
• Waterbox covers
• Compressor first suction elbow flanges (at compressor and
at the evaporator)
• Compressor secondary suction flanges (at compressor and
low side float chamber)
• Compressor discharge flange
• Evaporator inlet line spacer (both sides)
• Envelope control flange (both sides of valve)
• ICP piping flange
• High and low side float chamber covers
See Tables 3 and 4 for bolt torque requirements.
Check Chiller Tightness
Figure 16 outlines the proper sequence and procedures for leak
testing.
The 19DV chillers are shipped without the refrigerant charge.
The chiller is shipped with a 15 psig (103 kPa) dry nitrogen-
holding charge.
If the 15 psig factory nitrogen charge is present, then release pres-
sure and proceed to pull a deep vacuum on the unit. Vacuum
should be pulled through 11/2-in. female NPT located under bot-
tom of first stage side of the evaporator. Upon completion of pull-
ing the required vacuum the chiller can be charged with refriger-
ant. The 1/2-in. charging valve on top of the evaporator shell should
Unit Start/Stop

16
be used for charging by lifting charge cylinder and gravity feed
into the evaporator. The chiller should be charged with refrigerant.
If the holding charge is not present, the chiller must be examined
for leaks. To test for leaks add a small refrigerant holding charge to
unit and pressurize with nitrogen up to 20 psig to determine and
correct the origin of the leak. Use an electronic leak detector to
check all flanges and solder joints after the chiller is pressurized. If
the 15 psig factory nitrogen charge is present, then release pres-
sure and proceed to pull a vacuum on the unit. The chiller should
be charged with refrigerant. Follow the leak test chiller procedure
(page 18).
If the chiller is spring isolated, keep all springs blocked in both
directions to prevent possible piping stress and damage during
the transfer of refrigerant from vessel to vessel during the leak
test process, or any time refrigerant is being transferred. Adjust
the springs when the refrigerant is in operating condition and
the water circuits are full. Any piping weights are to be sepa-
rately supported.
Table 3 — Bolt Torque Requirements, Foot Pounds
Table 4 — Bolt Torque Requirements, Foot Pounds (Metric Bolts)
BOLT SIZE
(in.)
SAE 2, A307 GR A
HEX HEAD
NO MARKS
LOW CARBON STEEL
SAE 5
SOCKET HEAD OR HEX
WITH 3 RADIAL LINES, OR SA499
MEDIUM CARBON STEEL
SAE 8
HEX HEAD
WITH 6 RADIAL LINES OR
SA354 GR BD
MEDIUM CARBON STEEL
MINIMUM MAXIMUM MINIMUM MAXIMUM MINIMUM MAXIMUM
1/446 69913
5/16 811 13 1820 28
3/813 19 22 31 32 46
7/16 21 30 35 50 53 75
1/232 45 53 75 80115
9/16 46 65 75 110 115 165
5/865 95 105 150 160 225
3/4105 150 175 250 260 370
7/8140 200 265 380 415 590
1210 300 410 580 625 893
11/8330 475 545 7809851,410
11/4460 660 770 1,100 1,3801,960
13/8620 885 1,020 1,460 1,840 2,630
11/2740 1060 1,220 1,750 2,200 3,150
15/81010 1450 1,670 2,390 3,020 4,310
13/41320 1890 2,180 3,110 3,930 5,610
17/81630 2340 2,930 4,190 5,2807,550
21900 2720 3,150 4,500 5,670 8,100
21/42180 3120 4,550 6,500 8,200 11,710
21/23070 4380 5,000 7,140 11,350 16,210
23/45120 7320 8,460 12,090 15,710 22,440
36620 9460 11,040 15,770 19,900 28,440
BOLT SIZE
(METRIC)
CLASS 8.8 CLASS 10.9
MINIMUM MAXIMUM MINIMUM MAXIMUM
M4 1.75 2.5 2.5 3.5
M6 69812
M8 14 20 20 30
M10 2840 40 57
M12 4870 70 100
M16 118170 170 240
M20 230 330 330 470
M24 400 570 570 810
M27 580830 820 1175

17
Fig. 16 — 19DV Leak Test Procedures
19DV Field Procedure for new unitswith
less than 15 psig holding charge or units
suspected of leaking.
1. Attach compound gage to vessel
2. Note ambient temperature
Raise pressure to 20 psig (138 kPa)
using Nitrogen with added tracer gas for
electronic leak detection
Leak check
Pass
Evacuate vessel and
perform standing
vacuum test
Locate and mark all
leak sources
Dehydrate
Pass
Charge unit
NOTE: Be sure to add refrigerant
as gas until chiller pressure exceeds
15 in Hg (vac) / 380 mmHg (vac)
to avoid possible tube freezing.
Repair all leaks
No Yes
YesNo

18
Refrigerant Tracer
Carrier recommends the use of an environmentally acceptable
refrigerant tracer for leak testing with an electronic refrigerant
detector.
Ultrasonic leak detectors can also be used if the chiller is under
pressure.
Leak Test Chiller
Due to regulations regarding refrigerant emissions and the diffi-
culties associated with separating contaminants from the refrig-
erant, Carrier recommends the following leak test procedure.
Refer to Table 5 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.
c. Leak test chiller as outlined in Steps 3 to 7.
2. If the pressure readings are abnormal for the chiller condition:
a. Prepare to leak test chiller.
b. For cooling machines, check for leaks by connecting a
nitrogen bottle with added tracer to allow for elec-
tronic leak detection if possible; otherwise, soap bub-
ble solution is to be used. Raise the pressure to
20 psig (138 kPa). If electronic leak detector is avail-
able, ensure small amount of tracer material is added.
c. Plainly mark any leaks that are found.
d. Release the pressure in the system.
e. Repair all leaks.
f. Retest the joints that were repaired.
NOTE: Suggested test pressure is 20 psig (138 kPa); maximum al-
lowable test pressure 45 psig (310 kPa).
3. Check the chiller carefully with an electronic leak detector
or soap bubble solution.
4. Leak Determination — If an electronic leak detector indi-
cates a leak, use a soap bubble solution, if possible, to con-
firm. Total all leak rates for the entire chiller. Leakage at
rates greater than 0.1% of the total charge per year should
be repaired. Local regulation governs the requirements for
when repair of leaks become mandatory. Note the total
chiller 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 section, below.
b. If the chiller fails the standing vacuum test, repeat
leak test and repair.
c. If the chiller passes the standing vacuum test, dehy-
drate the chiller. Follow the procedure in the Chiller
Dehydration section, page 20. Charge the chiller with
refrigerant.
7. If the chiller is opened to the atmosphere for an extended
period, evacuate it before repeating the leak test. A nitro-
gen purge should be maintained to reduce the potential for
corrosion when open to the atmosphere.
NOTE: Alternate optional leak testing method is to isolate the wa-
ter circuits and use a portable water heater to raise the temperature
of the evaporator and condenser water circuits to approximately
100°F (38°C) which corresponds to a pressure of approximately
14.40 psig (99.3 kPag).
Standing Vacuum Test
When performing the standing vacuum test or chiller dehydra-
tion, use a manometer or a wet bulb indicator. Dial gages can-
not indicate the small amount of acceptable leakage during a
short period of time.
1. Attach an absolute pressure manometer or wet bulb indica-
tor to the chiller.
2. Evacuate the vessel to at least 18 in. Hg vac (41 kPa [abs]),
using a vacuum pump or a pumpout unit.
3. Valve off the pump to hold the vacuum and record the
manometer or indicator reading.
a. If the leakage rate is less than 0.05 in. Hg (0.17 kPa)
in 24 hours, the chiller is sufficiently tight.
b. If the leakage rate exceeds 0.05 in. Hg (0.17 kPa) in
24 hours, re-pressurize the vessel and test for leaks.
4. Repair the leak, retest, and proceed with dehydration.
WARNING
Do not use air or oxygen as a means of pressurizing the
chiller. Mixtures of HFO R-1233zd(E) and air at elevated
pressure can undergo combustion, resulting in equipment
damage and possible personal injury.
CAUTION
Never charge liquid refrigerant into the chiller if the pres-
sure in the chiller is less than 15 in. Hg (vac) / 380 mm Hg
(vac) for HFO R-1233zd(E). Charge as a gas only, with the
evaporator and condenser pumps running, until this pres-
sure is reached, using PUMPDOWN/LOCKOUT (located
in the Maintenance menu) and END LOCKOUT mode on
the PIC6 control interface. Flashing of liquid refrigerant at
low pressures can cause tube freeze-up and considerable
damage.

19
Table 5 — HFO R-1233zd(E) Pressure and Temperature
TEMP. PRESSURE
F C PSIA PSIG IN HG KPAG KPA ABS MMHG (VAC) % VACUUM
20.0 –6.7 5.16 –9.54 –19.4 –65.835.6 493.5 65
22.0 –5.6 5.43 –9.27 –18.9 –63.9 37.4 479.4 63
24.0 –4.4 5.72 –8.98–18.3 –61.9 39.4 464.6 61
26.0 –3.3 6.01 –8.69 –17.7 –59.9 41.5 449.3 59
28.0 –2.2 6.32 –8.38–17.1 –57.843.6 433.3 57
30.0 –1.1 6.64 –8.06 –16.4 –55.6 45.8416.7 55
32.0 0.0 6.98–7.72 –15.7 –53.2 48.1 399.3 53
34.0 1.1 7.33 –7.37 –15.0 –50.850.5 381.3 50
36.0 2.2 7.69 –7.01 –14.3 –48.3 53.0 362.6 48
38.0 3.3 8.06 –6.64 –13.5 –45.855.6 343.2 45
40.0 4.4 8.45 –6.25 –12.7 –43.1 58.3 323.0 42
42.0 5.6 8.86–5.84–11.9 –40.3 61.1 302.0 40
44.0 6.7 9.28–5.42 –11.0 –37.4 64.0 280.2 37
46.0 7.89.72 –4.98–10.1 –34.3 67.0 257.6 34
48.0 8.9 10.17 –4.53 –9.2 –31.2 70.1 234.2 31
50.0 10.0 10.64 –4.06 –8.3 –28.0 73.4 209.9 28
52.0 11.1 11.13 –3.57 –7.3 –24.6 76.7 184.824
54.0 12.2 11.63 –3.07 –6.2 –21.2 80.2 158.7 21
56.0 13.3 12.15 –2.55 –5.2 –17.6 83.8131.7 17
58.0 14.4 12.69 –2.01 –4.1 –13.887.5 103.814
60.0 15.6 13.25 –1.45 –2.9 –10.0 91.4 74.9 10
62.0 16.7 13.83–0.87–1.8–6.0 95.4 45.0 6
64.0 17.814.43 –0.27 –0.6 –1.9 99.5 14.0 2
66.0 18.9 15.05 0.35 0.7 2.4 103.7 — —
68.0 20.0 15.69 0.99 2.0 6.8108.1 — —
70.0 21.1 16.34 1.64 3.3 11.3 112.7 — —
72.0 22.2 17.03 2.33 4.7 16.0 117.4 — —
74.0 23.3 17.73 3.03 6.2 20.9 122.2 — —
76.0 24.4 18.46 3.76 7.6 25.9 127.2 — —
78.0 25.6 19.20 4.50 9.2 31.1 132.4 — —
80.0 26.7 19.985.2810.7 36.4 137.7 — —
82.0 27.820.77 6.07 12.4 41.9 143.2 — —
84.0 28.9 21.59 6.8914.0 47.5 148.9 — —
86.0 30.0 22.44 7.74 15.853.4 154.7 — —
88.0 31.1 23.31 8.61 17.5 59.4 160.7 — —
90.0 32.2 24.21 9.51 19.4 65.6 166.9 — —
92.0 33.3 25.13 10.43 21.2 71.9 173.3 — —
94.0 34.4 26.0811.3823.2 78.5 179.8——
96.0 35.6 27.06 12.36 25.2 85.2 186.6 — —
98.0 36.7 28.07 13.37 27.2 92.2 193.5 — —
100.0 37.829.10 14.40 29.3 99.3 200.7 — —
102.0 38.9 30.17 15.47 31.5 106.7 208.0 — —
104.0 40.0 31.26 16.56 33.7 114.2 215.5 — —
106.0 41.1 32.39 17.69 36.0 122.0 223.3 — —
108.0 42.2 33.54 18.8438.4 129.9 231.3 — —
110.0 43.3 34.73 20.03 40.8138.1 239.5 — —
112.0 44.4 35.95 21.25 43.3 146.5 247.9 — —
114.0 45.6 37.20 22.50 45.8155.1 256.5 — —
116.0 46.7 38.4823.7848.4 164.0 265.3 — —
118.0 47.839.8025.10 51.1 173.1 274.4 — —
120.0 48.9 41.16 26.46 53.9 182.4 283.8——
122.0 50.0 42.54 27.8456.7 192.0 293.3 — —
124.0 51.1 43.97 29.27 59.6 201.8303.1 — —
126.0 52.2 45.42 30.72 62.6 211.8313.2 — —
128.0 53.3 46.92 32.22 65.6 222.1 323.5 — —
130.0 54.4 48.45 33.75 68.7 232.7 334.1 — —

20
Check the Installation
Use the following instructions to verify the condition of the
installation. Note that the contractor should not apply power
to the chiller before the Carrier Start-up Technician arrives at
the job site.
1. Inspect the water piping to the chiller to confirm it is cor-
rect. Confirm it is adequately supported from the chiller
and there are isolation valves installed.
2. Turn off, lock out, and tag the input power to the drive.
3. Wait a minimum of 5 minutes for the DC bus to discharge.
4. All wiring should be installed in conformance with the
applicable local, national, and international codes (e.g.,
NEC/CSA).
5. Remove any debris, such as metal shavings, from the
enclosure.
6. Check that there is adequate clearance around the
machine.
7. Verify that the wiring to the terminal strip and the power
terminals is correct and that no external voltage potential
is connected to any of the inputs.
8. Verify that all of the VFD power module circuit board con-
nectors are fully engaged and taped in place.
9. Check that the field-installed wire size is within terminal
specifications and that the wires are tightened properly and
adequately supported.
10. Check that specified branch circuit protection is installed
and correctly rated.
11. Check that the incoming power is within ±10% of chiller
nameplate voltage.
12. Verify that a properly sized ground wire is installed and a
suitable earth ground is used. Check for and eliminate any
grounds between the power leads. Verify that all ground
leads are unbroken to the power supply. Only a wye sec-
ondary power supply transformer with solidly grounded
neutral is acceptable as a power supply to this chiller. If a
ground wire is not present or the transformer secondary is
any other type than a wye with solidly grounded delta,
please contact the Technical Service Manager or Service
Engineering.
Inspect Wiring
1. Examine the wiring for conformance to the job wiring dia-
grams and all applicable electrical codes.
2. Ensure that the VFD is protected by fused disconnects or
circuit breakers as per electrical code.
3. Compare the ampere rating on the VFD nameplate to rat-
ing on the compressor nameplate.
4. Check that there is adequate service clearance around the
machine.
5. Check that specified branch circuit protection is installed
and correctly rated.
6. Ensure there is capability to turn off, lock out, and tag the
input power to the drive.
7. If power is applied to the drive then wait a minimum of
5 minutes for the DC bus to discharge and check DC bus
voltage prior to starting any work.
8. Inspect the control panels and VFD enclosure to ensure
that the contractor has used the knockouts or provided top
hat to feed the wires into the enclosures. Generally, wiring
into the top of the enclosures can allow debris to fall into
the enclosures. Clean and inspect the interior of the power
panel and VFD enclosure if this has occurred. If metal par-
ticulate has fallen into the rectifier or inverter assemblies
contact Service Engineering or your Technical Service
Manager for further instructions.
9. Check that the incoming power is within ±10% of chiller
nameplate voltage.
10. Check that the room environmental conditions match the
chiller enclosure type.
11. Ensure the customer’s contractor has verified proper oper-
ation of the pumps, cooling tower fans, and associated
auxiliary equipment. This includes ensuring motors are
properly lubricated and have proper electrical supply and
proper rotation. Carrier must maintain pump control for
freeze protection algorithm.
12. Verify that the incoming source does not exceed the SCCR
(short circuit current rating) of the equipment marking.
13. Ensure all electrical equipment and controls are properly
grounded in accordance with the job drawings, certified
drawings, and all applicable electrical codes.
Test #1: For 3-lead motor, tie terminals 1, 2, and 3 together and
test between the group and ground.
1. With the tester connected to the motor leads, take 10-second
and 60-second megohm readings.
2. 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 on a field-installed
starter 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 leads.
Test #2: Only perform this test if the unit has been disassem-
bled at the job site, if the starter has been removed, or during
annual maintenance.
Perform a megohm test from each terminal to ground. The
megohm value should be greater than 20 megohm. Note that if
a megohm test is performed between the terminals it will show
a direct short and is not a valid test because of the 3 terminal
motor internal delta configuration.
Chiller Dehydration
Dehydration 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.
WARNING
Do not check the voltage supply without proper equipment
and precautions. Serious personal injury may result. Follow
power company recommendations.
CAUTION
Do not apply any kind of test voltage, even for a rotation
check, if the chiller is under a dehydration vacuum. Insula-
tion breakdown and serious damage may result.
WARNING
Do not apply power unless a qualified Carrier technician is
present. Serious personal injury may result.
CAUTION
Disconnect leads to VFD prior to megohm test. The voltage
generated from the tester can damage VFD components.