Carrier Comprehensive Guide on Guide Vane Calibration, Parts, and Maintenance for Chillers
Page 72

HFC-134a should not be mixed with air or oxygen and pressurized for leak testing. In general, this refrigerant should not be present with high concentrations of air or oxygen above atmospheric pressures, because the mixture can undergo combustion.

TESTING WITH REFRIGERANT TRACER — Use an en- vironmentally acceptable refrigerant as a tracer for leak test procedures. Use dry nitrogen to raise the machine pressure to leak testing levels.

TESTING WITHOUT REFRIGERANT TRACER — An- other method of leak testing is to pressurize with nitrogen only and to use a soap bubble solution or an ultrasonic leak detector to determine if leaks are present.

TO PRESSURIZE WITH DRY NITROGEN

NOTE: Pressurizing with dry nitrogen for leak testing should not be done if the full refrigerant charge is in the vessel because purging the nitrogen is very difficult.

1.Connect a copper tube from the pressure regulator on the cylinder to the refrigerant charging valve. Never apply full cylinder pressure to the pressurizing line. Follow the listed sequence.

2.Open the charging valve fully.

3.Slowly open the cylinder regulating valve.

4.Observe the pressure gage on the chiller and close the regulating valve when the pressure reaches test level. Do not exceed 140 psig (965 kPa).

5.Close the charging valve on the chiller. Remove the cop- per tube if it is no longer required.

Repair the Leak, Retest, and Apply Standing Vacuum Test — After pressurizing the chiller, test for leaks with an electronic halide leak detector, soap bubble solu- tion, or an ultrasonic leak detector. Bring the chiller back to at- mospheric pressure, repair any leaks found, and retest.

After retesting and finding no leaks, apply a standing vacu- um test. Then dehydrate the chiller. Refer to the Standing Vacu- um Test and Chiller Dehydration section (pages 50 and 53) in the Before Initial Start-Up section.

Checking Guide Vane Linkage — When the chiller is off, the guide vanes are closed and the actuator mechanism is in the position shown in Fig. 37. If slack develops in the drive chain, do the following to eliminate backlash:

1.With the chiller shut down and the actuator fully closed, remove the chain guard and loosen the actuator bracket hold-down bolts.

2.Loosen guide vane sprocket adjusting bolts.

3.Pry bracket upwards to remove slack, then retighten the bracket hold-down bolts.

4.Retighten the guide vane sprocket adjusting bolts. Ensure that the guide vane shaft is rotated fully in the clockwise direction in order close it fully.

Trim Refrigerant Charge — If, to obtain optimal chill- er performance, it becomes necessary to adjust the refrigerant charge, operate the chiller at design load and then add or re- move refrigerant slowly until the difference between the leav- ing chilled water temperature and the cooler refrigerant tem- perature reaches design conditions or becomes a minimum. Do not overcharge.

Refrigerant may be added either through the storage tank or directly into the chiller as described in the Charge Refrigerant into Chiller section.

Fig. 37 —Guide Vane Actuator Linkage

To remove any excess refrigerant, follow the procedure in Transfer Refrigerant from Chiller to Pumpout Storage Tank section, Steps 1a and b, page 70.

WEEKLY MAINTENANCE

Check the Lubrication System — Mark the oil lev- el on the reservoir sight glass, and observe the level each week while the chiller is shut down.

If the level goes below the lower sight glass, check the oil reclaim system for proper operation. If additional oil is re- quired, add it through the oil drain charging valve (Fig. 2). A pump is required when adding oil against refrigerant pressure. The oil charge for the 19XR compressor depends on the com- pressor 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 added oil must meet Carrier specifications for the 19XR. Refer to Changing Oil Filter and Oil Changes section on page 73. Any additional oil that is added should be logged by noting the amount and date. Any oil that is added due to oil loss that is not related to service will eventually return to the sump. It must be removed when the level is high.

An oil heater is controlled by the PIC II to maintain oil tem- perature (see the Controls section) when the compressor is off. The CVC/ICVC COMPRESS screen displays whether the heater is energized or not. The heater is energized if the OIL HEATER RELAY parameter reads ON. If the PIC II shows that the heater is energized and if the sump is still not heating up, the power to the oil heater may be off or the oil level may be too low. Check the oil level, the oil heater contactor voltage, and oil heater resistance.

The PIC II does not permit compressor start-up if the oil temperature is too low. The PIC II continues with start-up only after the temperature is within allowable limits.

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Contents Start-Up, Operation, and Maintenance Instructions Safety ConsiderationsContents Contents Introduction Abbreviations and ExplanationsChiller Familiarization 19XR IdentificationTypical 19XR Components Refrigeration Cycle Motor and Lubricating OIL Cooling CycleVFD Cooling Cycle Lubrication CycleStarting Equipment Unit-Mounted Solid-State Starter OptionalUnit-Mounted Wye-Delta Starter Optional ControlsDefinitions Variable Frequency Drive VFD 19XR Controls and Sensor Locations Major PIC II Components Panel Locations PIC II Component Panel LocationControl 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 Example 1 Chiller Display Default Screen CVC/ICVC Display DataExample 2 Maintstat Display Screen Description Status Units PointExample 3 Startup Display Screen Startup Description Status Units PointExample 4 Compress Display Screen Example 5 Heatex Display ScreenExample 6 Power Display Screen Example 7 Ismstat Display ScreenMenu Setpoint Select Description Status Units Point Default Example 8 CVC/ICVCPSWD Display ScreenCVC Icvc Description Status Units Point Example 9 Setpoint Display ScreenExample 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 ISM Starter Config Data Ismconf Description Status Units Point DefaultExample 15 Netopt Display Screen Example 16 Ismconf 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 Description Status Units Point Default Reset TypeExample 21 Rampdem Display Screen Example 22 Tempctl Display ScreenNormal Control mode occurs when Active Delta T Surge Prevention Mode occurs when Active Delta TMode IGV VFD PIC II System FunctionsPage Protective Safety Limits and Control Settings Page Capacity Overrides Evaporator Freeze Protection Icvc only a Page Surge Protection Fixed Speed Chiller Head Pressure Reference OutputPage Page Point Example of Attach to Network Device Screen Example of Holiday Period Screen Default CVC/ICVC screen, press the Menu START-UP/SHUTDOWNRecycle Sequence Fig Local Start-Up Local start-up or a manual start-up isEntering 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 Inspect Wiring Perform dehydration as followsCheck 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 Status Press Compress Press Select Press Menu Press Status Press Compress Press SelectEstimated Minimum Load Conditions Load Surge Prevention Occurs TOO Soon Occurs TOO LateCCM Temperature Thermistors Charge Refrigerant into Chiller Control Test Menu FunctionsTests to be Devices Tested Performed Initial START-UP Refrigerant HFC-134a ChargeDry Run to Test Start-Up Sequence Check Motor RotationCheck Oil Pressure and Compressor Stop Operating Instructions Operator DutiesTo Start the Chiller To Stop the ChillerPumpout and Refrigerant Transfer Procedures Operating the Optional Pumpout UnitDate Cooler Condenser Compressor TimeBearing FLATurn off pumpout condenser water Valve ConditionChillers with Isolation Valves General Maintenance Test After Service, Repair, or Major Leak IfWeekly Maintenance Guide Vane Actuator LinkageScheduled Maintenance Check Safety and Operating Controls MonthlyCompressor Bearing and Gear Maintenance Inspect the Heat Exchanger Tubes and Flow DevicesOrdering Replacement Chiller Parts When Optional Pumpout System ControlsTroubleshooting Guide Checking Pressure TransducersHeatex LlmaintOccdefcm Terminate Pumpdown Mode Shutdown in ProgressICE Build Ready to StartPrestart AlertAutorestart in Progress Running Temp ControlFault RUN CapacityLimited SensorProtective Failure toStart StopLoss CommunicationPotential FREEZE-UPSensor Alert LOW OIL PressureAutorestart PendingPressure Alert RecycleOption Sensor DiffuserThermistor Temperature F vs. Resistance/Voltage Drop DropThermistor Temperature C vs. Resistance/Voltage Drop Temperature PIC ResistancePower is connected to Plug J1 on each module Control ModulesChiller Control Module CCM Fig Integrated Starter Module FigReplacing Defective Processor Modules Integratedstartermodule Measure SCR Pairs Recorded Being Between CheckedHeat Exchanger Data English Number of Tubes English CodeHeat Exchanger Data SI Number of Tubes CodeCompressor Weights 19XR Additional Data for Marine Waterboxes19XR Motor Weights Standard and High Efficiency Motors English Motor19XR Waterbox Cover Weights English lb 19XR Waterbox Cover Weights SI kg Additional Miscellaneous Weights Optional Pumpout System Electrical DataMotor Voltage Code Compressor Assembly Torques Description TorqueView B High Speed Shaft 19XR Compressor Clearances Compressor Code100 Allen-Bradley Wye-Delta Unit-Mounted Starter101 102 ISM103 Temp104 105 106 Power Panel Wiring Schematic 107Cutler-Hammer Wye Delta Unit Mounted Starter Sizes 3-5DP 108Cutler-Hammer Wye Delta Unit Mounted Starter Size 6DP 109Ground Fault Phase Current Option Separate Metering Option111 112 AUX113 FU Fuse114 115 VFDTypical Variable Frequency Drive VFD Wiring Schematic 116117 118 119 120 121 122 Index Index Remove and use for job file JOB Data RequiredInspect Wiring and Record Electrical Data Ratings CL-240 to 100 10 to60.0 15 toCL-4 200 to 460105 to 115 85 to30 to 50 to20 to Psi CL-6150 to 90 to125 125 to65 to 90 to 100Amp 250 CL-8 25 to CL-950 to 145 CL-100000 to 02000000 to 0200 CL-11002 Power Module Dependent Selected motor 100% amps 004 To H.022 Job Sheet 60 for 60 Hz and 50 for 50 Hz028 10 to Job Sheet 60 for 60 Hz and 50 for 50 Hz 000 100 to Selected line voltageCL-13 CCN Local Reset CL-14Page 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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