Carrier Essential Maintenance and Control Functions for 19XR Chillers
Page 63

Check Optional Pumpout System Controls and Compressor — Controls include an on/off switch, a 3-amp fuse, the compressor overloads, an internal thermostat, a compressor contactor, and a refrigerant high pressure cutout. The high pressure cutout is factory set to open at 161 psig (1110 kPa) and reset at 130 psig (896 kPa). Ensure the water- cooled condenser has been connected. Loosen the compressor holddown bolts to allow free spring travel. Open the compres- sor suction and discharge the service valves. Ensure oil is visi- ble in the compressor sight glass. Add oil if necessary.

See the Pumpout and Refrigerant Transfer Procedures and Optional Pumpout System Maintenance sections, pages 67 and 75, for details on the transfer of refrigerant, oil specifications, etc.

Table 9 — Control Test Menu Functions

TESTS TO BE

DEVICES TESTED

PERFORMED

 

1. CCM Thermistors

Entering Chilled Water

 

Evaporator Refrigerant Tempera-

 

ture (ICVC only)

 

Leaving Chilled Water

 

Entering Condenser Water

 

Leaving Condenser Water

 

Remote Reset Sensor

 

Comp Discharge Temp

 

Oil Sump Temp

 

Comp Motor Winding Temp

 

Space Temperature 1

 

Space Temperature 2

2. CCM Pressure

Evaporator Pressure

Transducers

Condenser Pressure

 

Oil Pump Delta P

 

Condenser Water Delta P

 

Transducer Voltage Ref

3. Pumps

Chilled Water — Confirm pressure

 

Condenser Water — Confirm

 

Delta P

4. Discrete Outputs

Oil Heater Relay

 

Hot Gas Bypass Relay

 

Tower Fan Relay Low

 

Tower Fan Relay High

 

Alarm Relay

 

Shunt Trip Relay

5. Guide Vane Actuator

Open/Close

6. Diffuser Actuator

Open/Close

7.Pumpdown Lockout When using pumpdown/lockout, observe freeze up precautions when removing charge:

 

Instructs operator which valves to

 

close and when.

 

Starts chilled water and condenser

 

water pumps and confirms flows.

 

Monitors

 

Evaporator pressure

 

Condenser pressure

 

Evaporator temperature during

 

pumpout procedures

 

Turns pumps off after pumpdown.

 

Locks out compressor.

8 Terminate Lockout

Starts pumps and monitors flows.

 

Instructs operator which valves to

 

open and when.

 

Monitors

 

Evaporator pressure

 

Condenser pressure

 

Evaporator temperature during

 

charging process

 

Terminates compressor lockout.

High Altitude Locations — Because the chiller is ini- tially calibrated at sea level, it is necessary to recalibrate the pressure transducers if the chiller has been moved to a high alti- tude location. See the calibration procedure in the Trouble- shooting Guide section.

Charge Refrigerant into Chiller

The transfer, addition, or removal of refrigerant in spring isolated chillers may place severe stress on external piping if springs have not been blocked in both up and down directions.

Always operate the condenser and chilled water pumps during charging operations to prevent freeze-ups.

The standard 19XR chiller is shipped with the refrigerant already charged in the vessels. However, the 19XR may be or- dered with a nitrogen holding charge of 15 psig (103 kPa). Evacuate the nitrogen from the entire chiller, and charge the chiller from refrigerant cylinders.

CHILLER EQUALIZATION WITHOUT A PUMPOUT UNIT

When equalizing refrigerant pressure on the 19XR chiller after service work or during the initial chiller start-up, do not use the discharge isolation valve to equalize. Either the motor cooling isolation valve or the charging hose (con- nected between the pumpout valves on top of the cooler and condenser) should be used as the equalization valve.

To equalize the pressure differential on a refrigerant isolated 19XR chiller, use the terminate lockout function of the CON- TROL TEST on the SERVICE menu. This helps to turn on pumps and advises the operator on proper procedures.

The following steps describe how to equalize refrigerant pressure in an isolated 19XR chiller without a pumpout unit.

1.Access terminate lockout function on the CONTROL TEST screen.

2.IMPORTANT: Turn on the chilled water and con- denser water pumps to prevent freezing.

3.Slowly open the refrigerant cooling isolation valve. The chiller cooler and condenser pressures will gradually equalize. This process takes approximately 15 minutes.

4.Once the pressures have equalized, the cooler isolation valve, the condenser isolation valve, and the hot gas isola- tion valve may now be opened. Refer to Fig. 29 and 30, for the location of the valves.

Whenever turning the discharge isolation valve, be sure to reattach the valve locking device. This prevents the valve from opening or closing during service work or during chiller operation.

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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 EquipmentUnit-Mounted Wye-Delta Starter Optional ControlsDefinitions 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 PointExample 11 Override Display Screen Control Algorithm Status Override Description Units PointExample 12 Llmaint Display Screen Example 13 Ismhist Display Screen Example 14 Wsmdefme 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 ScreenExample 18 SETUP1 Display Screen Spare ALERT/ALARM EnableExample 17 Options Display Screen Example 19 SETUP2 Display Screen Example 20 Leadlag 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 Before Initial START-UP Job Data RequiredEquipment Required 19XR Leak Test Procedures Page Page HFC-134a Pressure Temperature F HFC-134a Pressure Temperature CTemperature Pressure Perform dehydration as follows Inspect WiringCheck Starter Manufacturer Cable noWhite G Software Configuration Parameter Benshaw RediStart Micro Menu Items Verify VFD Configuration and Change Parameters if Necessary VFD Title Setting Parameter Description SettingDescription 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 Charge Refrigerant into Chiller Control Test Menu FunctionsTests to be Devices Tested Performed Refrigerant HFC-134a Charge Initial START-UPDry Run to Test Start-Up Sequence Check Motor RotationCheck 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 GuideHeatex LlmaintOccdefcm 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 moduleChiller Control Module CCM Fig Integrated Starter Module 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 Additional Miscellaneous Weights Optional Pumpout System Electrical DataMotor 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 12565 to 90 to 100Amp 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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