Carrier XRV, 19XR specifications General Maintenance, Test After Service, Repair, or Major Leak If

Page 71

2. Evacuate the refrigerant gas from the chiller condenser vessel.

a. Access the PUMPDOWN LOCKOUT function accessed from the CVC/ICVC CONTROL TEST table to turn on the chiller water pumps. Turn the chiller water pumps on manually if they are not controlled by the PIC II.

b.

Close pumpout unit valves 3 and 4; open valves 2

 

and 5.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

VALVE

1a

1b

2

3

4

5

 

8

11

12

13

14

 

 

CONDITION

 

 

 

C

C

 

 

C

C

C

C

C

c.

Turn on the pumpout condenser water.

 

 

 

d.

Run the pumpout compressor until the chiller

 

condenser pressure reaches 18 in. Hg vac (40 kPa

 

abs.). Monitor pressure at the CVC/ICVC and at

 

refrigerant gages.

 

 

 

 

 

 

 

 

 

 

e.

Close valve 1b.

 

 

 

 

 

 

 

 

 

 

 

f.

Turn off the pumpout compressor.

 

 

 

 

 

g.

Close valves 1a, 2, and 5.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

VALVE

1a

1b

2

3

4

5

 

8

11

12

13

14

 

 

CONDITION

C

C

C

C

C

C

 

C

C

C

C

C

h.

Turn off the pumpout condenser water.

 

 

 

i.

Proceed to the PUMPDOWN LOCKOUT test

 

from the CVC/ICVC CONTROL TEST table to

 

turn off the chiller water pumps and lock out the

chiller compressor. Turn off the chiller water pumps manually if they are not controlled by the

PIC II.

RETURN CHILLER TO NORMAL OPERATING CONDITIONS

1.

Ensure vessel that was opened has been evacuated.

 

2.

Access the TERMINATE LOCKOUT function CVC/

 

ICVC from the CONTROL TEST table to view vessel

 

pressures and turn on chiller water pumps. If the chiller

 

water pumps are not controlled by the PIC II, turn them

 

on manually.

 

 

 

 

 

 

 

 

 

 

 

 

 

3.

Open valves 1a, 1b, and 3.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

VALVE

 

1a

1b

2

 

3

 

4

5

8

11

12

13

14

 

 

CONDITION

 

 

 

C

 

 

 

C

C

C

C

C

C

C

4.

Slowly open valve 5, gradually increasing pressure in the

 

evacuated vessel to 35 psig (141 kPa). Feed refrigerant

 

slowly to prevent tube freeze up.

 

 

 

 

 

 

 

5.

Leak test to ensure vessel integrity.

 

 

 

 

 

 

6.

Open valve 5 fully.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

VALVE

 

1a

1b

2

 

3

 

4

5

8

11

12

13

14

 

 

CONDITION

 

 

 

C

 

 

 

C

 

C

C

C

C

C

7.

Open valve 11 to equalize the liquid refrigerant level be-

 

tween the vessels.

 

 

 

 

 

 

 

 

 

 

 

 

 

8.

Close valves 1a, 1b, 3, and 5.

 

 

 

 

 

 

 

 

 

9.

Open isolation valves 12, 13, and 14 (if present).

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

VALVE

 

1a

1b

2

 

3

 

4

5

8

11

12

13

14

 

 

CONDITION

C

C

C

C

C

C

C

 

 

 

 

10.

Proceed to the TERMINATE LOCKOUT screen (access-

 

ed from the CONTROL TEST table) to turn off the water

 

pumps and enable the chiller compressor for start-up. If

the chiller water pumps are not controlled by the PIC II, turn them off manually.

GENERAL MAINTENANCE

Refrigerant Properties — The standard refrigerant for the 19XR chiller is HFC-134a. At normal atmospheric pres- sure, HFC-134a will boil at –14 F (–25 C) and must, therefore, be kept in pressurized containers or storage tanks. The refriger- ant is practically odorless when mixed with air and is noncom- bustible at atmospheric pressure. Read the Material Safety Data Sheet and the latest ASHRAE Safety Guide for Mechani- cal Refrigeration to learn more about safe handling of this refrigerant.

HFC-134a will dissolve oil and some nonmetallic materi- als, dry the skin, and, in heavy concentrations, may dis- place enough oxygen to cause asphyxiation. When handling this refrigerant, protect the hands and eyes and avoid breathing fumes.

Adding Refrigerant — Follow the procedures de- scribed in Trim Refrigerant Charge section, page 72.

Always use the compressor pumpdown function in the Control Test table to turn on the cooler pump and lock out the compressor when transferring refrigerant. Liquid refrig- erant may flash into a gas and cause possible freeze-up when the chiller pressure is below 30 psig (207 kPa) for HFC-134a.

Removing Refrigerant — If the optional pumpout sys- tem is used, the 19XR refrigerant charge may be transferred to a pumpout storage tank or to the chiller condenser or cooler vessels. Follow the procedures in the Pumpout and Refrigerant Transfer Procedures section when transferring refrigerant from one vessel to another.

Adjusting the Refrigerant Charge — If the addi- tion or removal of refrigerant is required to improve chiller per- formance, follow the procedures given under the Trim Refrig- erant Charge section, page 72.

Refrigerant Leak Testing — Because HFC-134a is above atmospheric pressure at room temperature, leak testing can be performed with refrigerant in the chiller. Use an elec- tronic halide leak detector, soap bubble solution, or ultrasonic leak detector. Ensure that the room is well ventilated and free from concentration of refrigerant to keep false readings to a minimum. Before making any necessary repairs to a leak, transfer all refrigerant from the leaking vessel.

Leak Rate — It is recommended by ASHRAE that chillers be taken off line immediately and repaired if the refrigerant leak rate for the entire chiller is more than 10% of the operating refrigerant charge per year.

In addition, Carrier recommends that leaks totalling less than the above rate but more than a rate of 0.1% of the total charge per year should be repaired during annual maintenance or whenever the refrigerant is transferred for other service work.

Test After Service, Repair, or Major Leak — If

all the refrigerant has been lost or if the chiller has been opened for service, the chiller or the affected vessels must be pressure tested and leak tested. Refer to the Leak Test Chiller section to perform a leak test.

71

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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 EquipmentDefinitions Unit-Mounted Wye-Delta Starter OptionalControls 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 12 Llmaint Display Screen Example 11 Override Display ScreenControl Algorithm Status Override Description Units Point Control Algorithm Status Wsmdefme Description Units Point Example 13 Ismhist Display ScreenExample 14 Wsmdefme Display Screen Example 16 Ismconf Display Screen ISM Starter Config DataIsmconf Description Status Units Point Default Example 15 Netopt Display ScreenExample 17 Options Display Screen Example 18 SETUP1 Display ScreenSpare ALERT/ALARM Enable LAG=2, STANDBY=3 Example 19 SETUP2 Display ScreenExample 20 Leadlag Display Screen 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 Equipment Required Before Initial START-UPJob Data Required 19XR Leak Test Procedures Page Page Temperature Pressure HFC-134a Pressure Temperature FHFC-134a Pressure Temperature C Perform dehydration as follows Inspect WiringWhite G Check StarterManufacturer Cable no Software Configuration Parameter Benshaw RediStart Micro Menu Items Verify VFD Configuration and Change Parameters if Necessary Description Settings VFD Title Setting ParameterDescription Setting 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 Tests to be Devices Tested Performed Charge Refrigerant into ChillerControl Test Menu Functions Refrigerant HFC-134a Charge Initial START-UPCheck Oil Pressure and Compressor Stop Dry Run to Test Start-Up SequenceCheck Motor Rotation 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 GuideOccdefcm HeatexLlmaint 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 moduleReplacing Defective Processor Modules Chiller Control Module CCM FigIntegrated Starter Module Fig 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 Motor Voltage Code Additional Miscellaneous WeightsOptional Pumpout System Electrical Data 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 125Amp 250 CL-8 65 to90 to 100 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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