Carrier Comprehensive Guide to 19XR Manual, Oil Types, and Parts
Page 55

MECHANICAL STARTER

1.Check all field wiring connections for tightness, clear- ance from moving parts, and correct connection.

2.Check the contactor(s) to ensure they move freely. Check the mechanical interlock between contactors to ensure that 1S and 2M contactors cannot be closed at the same time. Check all other electro-mechanical devices, such as relays, for free movement. If the devices do not move freely, contact the starter manufacturer for replacement components.

3.Reapply starter control power (not main chiller power) to check the electrical functions.

Ensure the starter (with relay 1CR closed) goes through a complete and proper start cycle.

BENSHAW, INC. RediStart MICRO™ SOLID-STATE STARTER

This equipment is at line voltage when AC power is con- nected. Pressing the STOP button does not remove voltage.

1.Ensure all wiring connections are properly terminated to the starter.

2.Verify the ground wire to the starter is installed properly and is sufficient size.

3.Verify the motors are properly grounded to the starter.

4.Verify the proper ac input voltage is brought into the start- er according to the certified drawings.

5.Apply power to the starter

VFD STARTER

1.Turn off unit, tag and lock disconnects and wait 5 minutes.

2.Verify that the DC voltage is zero.

3.Ensure there is adequate clearance around the drive.

4.Verify that the wiring to the terminal strip and power ter- minals is correct.

5.Verify that wire size is within the terminal specification and the wires are secure.

6.Inspect the field supplied branch circuit protection is properly rated and installed.

7.Verify that the system is properly grounded.

8.Inspect all liquid cooling connections for leaks.

Oil Charge — The oil charge for the 19XR compressor de- pends on the compressor Frame size:

•Frame 2 compressor — 5 gal (18.9 L)

•Frame 3 compressor — 8 gal (30 L)

•Frame 4 compressor — 10 gal (37.8 L)

•Frame 5 compressor — 18 gal (67.8 L)

The chiller is shipped with oil in the compressor. When the sump is full, the oil level should be no higher than the middle of the upper sight glass, and minimum level is the bottom of the lower sight glass (Fig. 2). If oil is added, it must meet Carrier’s specification for centrifugal compressor use as de- scribed in the Oil Specification section. Charge the oil through the oil charging valve located near the bottom of the transmis- sion housing (Fig. 2). The oil must be pumped from the oil container through the charging valve due to higher refrigerant pressure. The pumping device must be able to lift from 0 to 200 psig (0 to 1380 kPa) or above unit pressure. Oil should only be charged or removed when the chiller is shut down.

Power Up the Controls and Check the Oil Heater — Ensure that an oil level is visible in the compres- sor before energizing the controls. A circuit breaker in the start- er energizes the oil heater and the control circuit. When first

powered, the CVC/ICVC should display the default screen within a short period of time.

The oil heater is energized by powering the control circuit. This should be done several hours before start-up to minimize oil-refrigerant migration. The oil heater is controlled by the PIC II and is powered through a contactor in the power panel. Starters contain a separate circuit breaker to power the heater and the control circuit. This arrangement allows the heater to energize when the main motor circuit breaker is off for service work or extended shutdowns. The oil heater relay status (OIL HEATER RELAY) can be viewed on the COMPRESS table on the CVC/ICVC. Oil sump temperature can be viewed on the CVC/ICVC default screen.

SOFTWARE VERSION — The software part number is la- beled on the backside of the CVC/ICVC module. The software version also appears on the CVC/ICVC configuration screen as the last two digits of the software part number.

Software Configuration

Do not operate the chiller before the control configurations have been checked and a Control Test has been satisfactorily completed. Protection by safety controls can- not be assumed until all control configurations have been confirmed.

As the 19XR unit is configured, all configuration settings should be written down. A log, such as the one shown on pages CL-1 to CL-16, provides a list for configuration values.

Input the Design Set Points — Access the CVC/ ICVC set point screen and view/modify the base demand limit set point, and either the LCW set point or the ECW set point. The PIC II can control a set point to either the leaving or enter- ing chilled water. This control method is set in the EQUIP- MENT SERVICE (TEMP_CTL) table.

Input the Local Occupied Schedule (OCCPC01S) —

Access the schedule OCCPC01S screen on the CVC/ICVC and set up the occupied time schedule according to the custom- er’s requirements. If no schedule is available, the default is fac- tory set for 24 hours occupied, 7 days per week including holidays.

For more information about how to set up a time schedule, see the Controls section, page 10.

The CCN Occupied Schedule (OCCPC03S) should be con- figured if a CCN system is being installed or if a secondary time schedule is needed.

NOTE: The default CCN Occupied Schedule OCCPC03S is configured to be unoccupied.

Input Service Configurations — The following con- figurations require the CVC/ICVC screen to be in the SER- VICE portion of the menu.

•password

•input time and date

•CVC/ICVC configuration

•service parameters

•equipment configuration

•automated control test

PASSWORD — When accessing the SERVICE tables, a pass- word must be entered. All CVC/ICVC are initially set for a password of 1-1-1-1.

INPUT TIME AND DATE — Access the TIME AND DATE table on the SERVICE menu. Input the present time of day, date, and day of the week. The HOLIDAY TODAY parameter should only be configured to YES if the present day is a holiday.

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Contents Safety Considerations Start-Up, Operation, and Maintenance InstructionsContents Contents Abbreviations and Explanations Introduction19XR Identification Chiller FamiliarizationTypical 19XR Components Motor and Lubricating OIL Cooling Cycle Refrigeration CycleLubrication Cycle VFD Cooling CycleUnit-Mounted Solid-State Starter Optional Starting EquipmentControls Unit-Mounted Wye-Delta Starter OptionalDefinitions Variable Frequency Drive VFD 19XR Controls and Sensor Locations PIC II Component Panel Location Major PIC II Components Panel LocationsControl Panel CVC/ICVC Operation and Menus Fig Example of Status Screen 19XR Chiller Display Menu Structure CVC/ICVC 19XR Service Menu Structure Time and Date Example of Time Schedule Operation Screen Example of Set Point Screen CVC/ICVC Display Data Example 1 Chiller Display Default ScreenStartup Description Status Units Point Example 2 Maintstat Display ScreenDescription Status Units Point Example 3 Startup Display ScreenExample 5 Heatex Display Screen Example 4 Compress Display ScreenExample 7 Ismstat Display Screen Example 6 Power Display ScreenExample 9 Setpoint Display Screen Menu Setpoint Select Description Status Units Point DefaultExample 8 CVC/ICVCPSWD Display Screen CVC Icvc Description Status Units PointControl Algorithm Status Override Description Units Point Example 11 Override Display ScreenExample 12 Llmaint Display Screen Example 14 Wsmdefme Display Screen Example 13 Ismhist Display ScreenControl Algorithm Status Wsmdefme Description Units Point Example 16 Ismconf Display Screen ISM Starter Config DataIsmconf Description Status Units Point Default Example 15 Netopt Display ScreenSpare ALERT/ALARM Enable Example 18 SETUP1 Display ScreenExample 17 Options Display Screen Example 20 Leadlag Display Screen Example 19 SETUP2 Display ScreenLAG=2, STANDBY=3 Example 22 Tempctl Display Screen Description Status Units Point DefaultReset Type Example 21 Rampdem Display ScreenPIC II System Functions Normal Control mode occurs when Active Delta TSurge Prevention Mode occurs when Active Delta T Mode IGV VFDPage Protective Safety Limits and Control Settings Page Capacity Overrides Evaporator Freeze Protection Icvc only a Page Head Pressure Reference Output Surge Protection Fixed Speed ChillerPage Page Point Example of Attach to Network Device Screen Example of Holiday Period Screen Local Start-Up Local start-up or a manual start-up is Default CVC/ICVC screen, press the MenuSTART-UP/SHUTDOWN Recycle Sequence FigEntering Condenser Water temperature plus 3 F -1.6C Job Data Required Before Initial START-UPEquipment Required 19XR Leak Test Procedures Page Page HFC-134a Pressure Temperature C HFC-134a Pressure Temperature FTemperature Pressure Perform dehydration as follows Inspect WiringManufacturer Cable no Check StarterWhite G Software Configuration Parameter Benshaw RediStart Micro Menu Items Verify VFD Configuration and Change Parameters if Necessary Description Setting VFD Title Setting ParameterDescription Settings Press Menu Press Status Press Compress Press Select Press Status Press Compress Press SelectLoad Surge Prevention Occurs TOO Soon Occurs TOO Late Estimated Minimum Load ConditionsCCM Temperature Thermistors Control Test Menu Functions Charge Refrigerant into ChillerTests to be Devices Tested Performed Refrigerant HFC-134a Charge Initial START-UPCheck Motor Rotation Dry Run to Test Start-Up SequenceCheck Oil Pressure and Compressor Stop To Stop the Chiller Operating InstructionsOperator Duties To Start the ChillerOperating the Optional Pumpout Unit Pumpout and Refrigerant Transfer ProceduresFLA Date Cooler Condenser CompressorTime BearingValve Condition Turn off pumpout condenser waterChillers with Isolation Valves Test After Service, Repair, or Major Leak If General MaintenanceGuide Vane Actuator Linkage Weekly MaintenanceCheck Safety and Operating Controls Monthly Scheduled MaintenanceInspect the Heat Exchanger Tubes and Flow Devices Compressor Bearing and Gear MaintenanceOptional Pumpout System Controls Ordering Replacement Chiller Parts WhenChecking Pressure Transducers Troubleshooting GuideLlmaint HeatexOccdefcm Ready to Start Terminate Pumpdown ModeShutdown in Progress ICE BuildRunning Temp Control PrestartAlert Autorestart in ProgressSensor FaultRUN Capacity LimitedStop ProtectiveFailure to StartFREEZE-UP LossCommunication PotentialPending Sensor AlertLOW OIL Pressure AutorestartDiffuser Pressure AlertRecycle Option SensorDrop Thermistor Temperature F vs. Resistance/Voltage DropTemperature PIC Resistance Thermistor Temperature C vs. Resistance/Voltage DropControl Modules Power is connected to Plug J1 on each moduleIntegrated Starter Module Fig Chiller Control Module CCM FigReplacing Defective Processor Modules Integratedstartermodule Checked Measure SCR Pairs Recorded Being BetweenNumber of Tubes English Code Heat Exchanger Data EnglishNumber of Tubes Code Heat Exchanger Data SI19XR Additional Data for Marine Waterboxes Compressor WeightsEnglish Motor 19XR Motor Weights Standard and High Efficiency Motors19XR Waterbox Cover Weights English lb 19XR Waterbox Cover Weights SI kg Optional Pumpout System Electrical Data Additional Miscellaneous WeightsMotor Voltage Code Description Torque Compressor Assembly TorquesCompressor Code View B High Speed Shaft 19XR Compressor ClearancesAllen-Bradley Wye-Delta Unit-Mounted Starter 100101 ISM 102Temp 103104 105 106 107 Power Panel Wiring Schematic108 Cutler-Hammer Wye Delta Unit Mounted Starter Sizes 3-5DP109 Cutler-Hammer Wye Delta Unit Mounted Starter Size 6DPSeparate Metering Option Ground Fault Phase Current Option111 AUX 112FU Fuse 113114 VFD 115116 Typical Variable Frequency Drive VFD Wiring Schematic117 118 119 120 121 122 Index Index JOB Data Required Remove and use for job fileCL-2 Inspect Wiring and Record Electrical Data Ratings15 to 40 to 10010 to 60.0CL-4 85 to 200 to460 105 to 115CL-6 30 to50 to 20 to Psi125 to 150 to90 to 12590 to 100 65 toAmp 250 CL-8 CL-9 25 toCL-10 50 to 145CL-11 0000 to0200 0000 to 0200000 100 to Selected line voltage 002 Power Module Dependent Selected motor 100% amps004 To H.022 Job Sheet 60 for 60 Hz and 50 for 50 Hz 028 10 to Job Sheet 60 for 60 Hz and 50 for 50 HzCL-13 CL-14 CCN Local ResetPage Incurring obligations
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19XR, XRV specifications

The Carrier 19XR and 19XRV chillers are sophisticated cooling solutions that represent the forefront of HVAC technology. Designed for large commercial and industrial applications, these chillers provide exceptional performance, energy efficiency, and reliability, making them ideal for a variety of environments ranging from hospitals to manufacturing facilities.

One of the most significant features of the Carrier 19XR and 19XRV chillers is their advanced scroll compressor technology. These units employ a tandem scroll design that enhances efficiency while minimizing operational noise. This makes them ideal for urban environments where noise restrictions may be in place. Moreover, the compressors are equipped with variable speed drive options in the 19XRV model, which allows for greater energy savings by adjusting cooling output based on real-time demand.

In addition to their advanced compressors, the 19XR and 19XRV units incorporate the Carrier GreenChoice refrigerant, which has a lower global warming potential compared to traditional refrigerants. This innovative choice not only meets regulatory requirements but also contributes to sustainability goals, making these chillers a responsible choice for environmentally conscious organizations.

The units are engineered with a robust heat exchanger design, which enhances heat transfer efficiency and overall system performance. This ensures optimal operation even in extreme conditions. They feature a microprocessor-based control system that allows for precise monitoring and control of the chiller’s performance, enabling operators to make real-time adjustments to maximize energy efficiency.

The Carrier 19XR and 19XRV chillers also prioritize serviceability. The design incorporates easy access to key components, simplifying maintenance procedures and reducing downtime. This focus on maintainability extends the lifespan of the equipment, leading to lower lifecycle costs.

In terms of connectivity, these chillers are equipped with advanced Building Management System (BMS) integration capabilities. This allows for seamless monitoring and control of the chillers using a centralized platform, facilitating energy management and operational optimization.

Overall, the Carrier 19XR and 19XRV chillers stand out in the market for their blend of cutting-edge technology, energy efficiency, and user-friendly features. They are engineered to meet the demanding needs of modern commercial and industrial applications, making them a preferred choice for facility managers seeking reliable cooling solutions.
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