Carrier 19XRV - Manual

Carrier 19XRV

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Table of Contents:

  • Page 3 – Fig. 2 — Opening Access Door; MULTIMETER; Fig. 3 — Check DC Bus Terminals; ss; Fig. 4 — Drive Assembly Catalog Number Nomenclature
  • Page 4 – Fig. 5 — Frame 6 Drive Components; NAME; Fig. 6 — Frame 7 Drive Components; NAME
  • Page 5 – never
  • Page 6 – Configure the VFD —; bold; bold; Commissioning the Unit —; — Machine Nameplate; Motor Nameplate RPM
  • Page 7 – Check Internal Jumpers —; Fig. 10 — PF755 Main Control Board; TB1 I/O Terminal Designations; TERMINAL
  • Page 8 – Fig. 11A — Jumper Wire Locations — Frame 6
  • Page 9 – Fig. 13 — Drive Module with Cover Removed
  • Page 10 – Fig. 15 — High Pressure Switch Wiring
  • Page 11 – Table 4 — ICVC Alert Codes; Excessive compressor starts
  • Page 12 – NORMAL RUN WITH OVERRIDES
  • Page 13 – CHILLER ALERTS
  • Page 15 – Table 5 — ICVC Alarm Codes; CHILLER PROTECTIVE LIMIT FAULTS
  • Page 21 – Table 6
  • Page 22 – Use the following procedure; Table 7; WARNING; Confirm that the DC bus has discharged before performing
  • Page 23 – Servicing the Drive; Table; Where; Fig. 16 — Open Access Door; FRAME; Fig. 17 — Check DC Bus Terminals
  • Page 24 – Fig. 19 — Enclosure Access for Removing Drive
  • Page 25 – Fig. 22 — Mount COMM Card Plate to Drive
  • Page 26 – Part Identification and Location —; for parts descriptions and locations.; Fig. 25 — Chill Plate and Internal Fans, Removal; CABLE; LEFT; Fig. 26 — Assembly Parts
  • Page 28 – ICVC; CCM
  • Page 30 – ROCKWELL POWERFLEX 755 WIRING SCHEMATIC (Typical)
  • Page 32 – APPENDIX B; — OPTIONAL BACNET COMMUNICATIONS WIRING; Optional BACnet; Fig. B — Address Rotary Switches
  • Page 33 – — OPTIONAL BACNET COMMUNICATIONS WIRING (cont); DS; Fig. C — DIP Switches
  • Page 35 – BACview Installation and User Guide; Device Connection
  • Page 36 – and; Error; LEDs Controller and Network Status Indication; ON; Run
  • Page 38 – APPENDIX B — OPTIONAL BACNET COMMUNICATIONS WIRING (cont)
Loading the manual

Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.

Catalog No. 04-53190012-01

Printed in U.S.A.

Form 19XRV-3SS

Pg 1

711 3-11

Replaces: New

Start-Up and Service Instructions

SAFETY CONSIDERATIONS

Centrifugal liquid chillers are designed to provide safe and
reliable service when operated within design specifica-
tions. When operating this equipment, use good judgment
and safety precautions to avoid damage to equipment and
property or injury to personnel.

Be sure you understand and follow the procedures and

safety precautions contained in the chiller instructions as
well as those listed in this guide

.

ONLY QUALIFIED Electrical Personnel familiar with the construction

and operation of this equipment and the hazards involved should install,

adjust, operate, or service this equipment.
READ AND UNDERSTAND this manual and other applicable manuals in

their entirety before proceeding. Failure to observe this precaution could

result in severe bodily injury or loss of life.
DO NOT install modification kits with power applied to the drive. Discon-

nect and lock out incoming power before attempting such installation or

removal. Failure to observe this precaution could result in severe bodily

injury or loss of life
UNUSED WIRES in conduit must be grounded at both ends to avoid a

possible shock hazard caused by induced voltages. Also, if a drive sharing

a conduit is being serviced or installed; all drives using this conduit should

be disabled to eliminate the possible shock hazard from cross-coupled

motor leads. Failure to observe these precautions could result in bodily

injury.
DO NOT VENT refrigerant relief valves within a building. Outlet from

rupture disc or relief valve must be vented outdoors in accordance with the

latest edition of ANSI/ASHRAE 15 (American National Standards Insti-

tute/American Society of Heating, Refrigerating, and Air Conditioning

Engineers). The accumulation of refrigerant in an enclosed space can dis-

place oxygen and cause asphyxiation.
PROVIDE adequate ventilation in accordance with ANSI/ASHRAE 15,

especially for enclosed and low overhead spaces. Inhalation of high con-

centrations of vapor is harmful and may cause heart irregularities, uncon-

sciousness, or death. Misuse can be fatal. Vapor is heavier than air and

reduces the amount of oxygen available for breathing. Product causes eye

and skin irritation. Decomposition products are hazardous.
DO NOT USE OXYGEN to purge lines or to pressurize a chiller for any

purpose. Oxygen gas reacts violently with oil, grease, and other common

substances.
NEVER EXCEED specified test pressures, VERIFY the allowable test

pressure by checking the instruction literature and the design pressures on

the equipment nameplate.
DO NOT 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 installed and func-

tioning before operating any chiller.
THERE IS A RISK OF INJURY OR DEATH by electrocution. High volt-

age may be present on the motor leads even though the motor is not run-

ning. Open the power supply disconnect before touching motor leads or

terminals.

DO NOT WELD OR FLAMECUT any refrigerant line or vessel until all

refrigerant (

liquid and vapor

) has been removed from chiller. Traces of

vapor should be displaced with dry air or nitrogen and the work area

should be well ventilated.

Refrigerant in contact with an open flame pro-

duces toxic gases

.

DO NOT work on high-voltage equipment unless you are a qualified elec-

trician.
DO NOT WORK ON electrical components, including control panels,

switches, VFD, or oil heater until you are sure ALL POWER IS OFF and

no residual voltage can leak from capacitors or solid-state components.

LOCK OPEN AND TAG electrical circuits during servicing. IF WORK IS

INTERRUPTED, confirm that all circuits are deenergized 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 enters the eyes, IMMEDIATELY FLUSH EYES

with water and consult a physician.
DO NOT ATTEMPT TO REMOVE fittings, covers, etc., while chiller is

under pressure or while chiller is running. Be sure pressure is at 0 psig (0

kPa) before breaking any refrigerant connection.

TO AVOID an electric shock hazard, verify that the voltage on the bus

capacitors has discharged completely before servicing. Check the DC bus

voltage at the Power Terminal Block by measuring between the +DC and -

DC terminals, between the +DC terminal and the chassis, and between the

-DC terminal and the chassis. The voltage must be zero for all three mea-

surements.
THE USER is responsible to conform with all applicable local, national,

and international codes. Failure to observe this precaution could result in

damage to, or destruction of, the equipment.
THIS DRIVE contains ESD (Electrostatic Discharge) sensitive parts and

assemblies. Static control precautions are required when installing, testing,

servicing or repairing this assembly. Component damage may result if

ESD control procedures are not followed. For static control procedures,

reference Rockwell publication Guarding Against Electrostatic Damage, or

any other applicable ESD protection handbook.
DO NOT alter the setting of any jumper. Failure to observe this precaution

could result in damage to, or destruction of, the equipment.
USE OF power correction capacitors on the output of the drive can result

in erratic operation of the motor, nuisance tripping, and/or permanent dam-

age to the drive. Remove power correction capacitors before proceeding.

Failure to observe this precaution could result in damage to, or destruction

of, the equipment.
MOST CODES require that upstream branch circuit protection be pro-

vided to protect input power wiring. If fuses are chosen as the protection

method, refer to the PowerFlex 750 user manual. Failure to observe this

precaution could result in damage to, or destruction of, the equipment.
DO NOT route signal and control wiring with power wiring in the same

conduit. This can cause interference with drive operation. Failure to

observe this precaution could result in damage to, or destruction of, the

equipment.
DISTRIBUTION SYSTEM short circuit capacity shall not exceed the rat-

ing of the drive. Failure to observe this precaution could result in damage

to, or destruction of, the 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 VFD, TOWER FAN, OR PUMPS. Open the disconnect

ahead

of the

VFD, tower fans, or pumps.
USE only repair or replacement parts that meet the code requirements of

the original equipment.
PERIODICALLY INSPECT all valves, fittings, and piping for corrosion,

rust, leaks, or damage.

DANGER

WARNING

CAUTION

19XRV

with PIC III Controls

Rockwell PowerFlex 755 VFD Option

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Summary

Page 3 - Fig. 2 — Opening Access Door; MULTIMETER; Fig. 3 — Check DC Bus Terminals; ss; Fig. 4 — Drive Assembly Catalog Number Nomenclature

3 Opening the VFD Access Door 1. Using recommended screwdriver = 6.4 mm (0.25 in.) flat or T20 star, open access door. See Fig. 2. 2. Check to be sure that the voltage between DC+ and DC- and from each DC terminal to the chassis is zero before proceeding. See Fig. 3. Drive Assembly Catalog Number — ...

Page 4 - Fig. 5 — Frame 6 Drive Components; NAME; Fig. 6 — Frame 7 Drive Components; NAME

4 LEGEND Fig. 5 — Frame 6 Drive Components NO. NAME DESCRIPTION 1 Power Terminals R/L1, S/L2, T/L3, U/T1, V/T2, W/T3 2 PE Grounding Studs Terminating point to chassis ground for incoming motor shield 3 DC Bus and Brake Terminals +DC, -DC, BR1, BR2 4 PE-A and PE-B MOV and CMC Jumper Wires 5 DC+ and D...

Page 5 - never

5 START-UP Alternate Wire Lugs — In the case where the incoming power wire size does not fit the standard lug, alternate lugs may be used. See Table 1. Note that lugs rated for a higher current than the circuit breaker may be used. Table 1 — Wire Lugs Verify Installation — Record the following job i...

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