Carrier XRV Pumpout and Refrigerant Transfer Procedures, Operating the Optional Pumpout Unit

Page 67

Leave the oil charge in the chiller with the oil heater and controls energized to maintain the minimum oil reservoir temperature.

After Extended Shutdown — Ensure the water sys- tem drains are closed. It may be advisable to flush the water circuits to remove any soft rust which may have formed. This is a good time to brush the tubes and inspect the Schrader fit- tings on the waterside flow devices for fouling, if necessary.

Check the cooler pressure on the CVC/ICVC default screen and compare it to the original holding charge that was left in the chiller. If (after adjusting for ambient temperature changes) any loss in pressure is indicated, check for refrigerant leaks. See Check Chiller Tightness section, page 48.

Recharge the chiller by transferring refrigerant from the pumpout storage tank (if supplied). Follow the Pumpout and Refrigerant Transfer Procedures section, below. Observe freeze-up precautions.

Carefully make all regular preliminary and running system checks. Perform a Control Test before start-up. If the compres- sor oil level appears abnormally high, the oil may have absorbed refrigerant. Ensure that the oil temperature is above 140 F (60 C) or above the cooler refrigerant temperature plus 50° F (27° C).

Cold Weather Operation — When the entering con- denser water temperature drops very low, the operator should automatically cycle the cooling tower fans off to keep the tem- perature up. Piping may also be arranged to bypass the cooling tower. The PIC II controls have a low limit tower fan output that can be used to assist in this control (terminal 11 and 12 on ISM).

Manual Guide Vane Operation — It is possible to manually operate the guide vanes in order to check control operation or to control the guide vanes in an emergency. Manu- al operation is possible by overriding the target guide vane position. Access the COMPRESS screen on the CVC/ICVC and scroll down to highlight TARGET GUIDE VANE POS. To control the position, use the INCREASE or DECREASE softkey to adjust to the percentage of guide vane opening that is desired. Zero percent is fully closed; 100% is fully open. To release the guide vanes to automatic control, press the RELEASE softkey.

NOTE: Manual control overrides the configured pulldown rate during start-up and permits the guide vanes to open at a faster rate. Motor current above the electrical demand setting, capac- ity overrides, and chilled water temperature below the control point override the manual target and close the guide vanes. For descriptions of capacity overrides and set points, see the Con- trols section.

Refrigeration Log — A refrigeration log (as shown in Fig. 34), is a convenient checklist for routine inspection and maintenance and provides a continuous record of chiller per- formance. It is also an aid when scheduling routine mainte- nance and diagnosing chiller problems.

Keep a record of the chiller pressures, temperatures, and liquid levels on a sheet similar to the one in Fig. 34. Automatic recording of PIC II data is possible by using CCN devices such as the Data Collection module and a Building Supervisor. Contact a Carrier representative for more information.

PUMPOUT AND REFRIGERANT

TRANSFER PROCEDURES

Preparation — The 19XR may come equipped with an optional pumpout storage tank, pumpout system, or pumpout compressor. The refrigerant can be pumped for service work to either the chiller compressor vessel or chiller condenser vessel by using the optional pumpout system. If a pumpout storage

tank is supplied, the refrigerant can be isolated in the storage tank. The following procedures describe how to transfer refrig- erant from vessel to vessel and perform chiller evacuations.

Always run the chiller cooler and condenser water pumps and always charge or transfer refrigerant as a gas when the chiller pressure is less than 30 psig (207 kPa). Below these pressures, liquid refrigerant flashes into gas, resulting in extremely low temperatures in the cooler/condenser tubes and possibly causing tube freeze-up.

During transfer of refrigerant into and out of the optional storage tank, carefully monitor the storage tank level gage. Do not fill the tank more than 90% of capacity to allow for refrigerant expansion. Overfilling may result in damage to the tank or personal injury.

Do not mix refrigerants from chillers that use different compressor oils. Compressor damage can result.

Operating the Optional Pumpout Unit

1.Be sure that the suction and the discharge service valves on the optional pumpout compressor are open (back- seated) during operation. Rotate the valve stem fully counterclockwise to open. Front-seating the valve closes the refrigerant line and opens the gage port to compressor pressure.

2.Ensure that the compressor hold-down bolts have been loosened to allow free spring travel.

3.Open the refrigerant inlet valve on the pumpout compressor.

4.Oil should be visible in the pumpout unit compressor sight glass under all operating conditions and during shutdown. If oil is low, add oil as described under Optional Pumpout System Maintenance section, page 75. The pumpout unit control wiring schematic is detailed in Fig. 35.

TO READ REFRIGERANT PRESSURES during pumpout or leak testing:

1.The CVC/ICVC display on the chiller control panel is suitable for determining refrigerant-side pressures and low (soft) vacuum. To assure the desired range and accu- racy when measuring evacuation and dehydration, use a quality vacuum indicator or manometer. This can be placed on the Schrader connections on each vessel (Fig. 9) by removing the pressure transducer.

2.To determine pumpout storage tank pressure, a 30 in. -0-400 psi (-101-0-2769 kPa) gage is attached to the stor- age tank.

3.Refer to Fig. 29, 30, and 36 for valve locations and numbers.

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.

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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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