Carrier 19XR, XRV specifications VFD Cooling Cycle, Lubrication Cycle

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Flow to the motor cooling system passes through an orifice and into the motor. Once past the orifice, the refrigerant is directed over the motor by a spray nozzle. The refrigerant collects in the bottom of the motor casing and is then drained back into the cooler through the motor refrigerant drain line. An orifice (in the motor shell) maintains a higher pressure in the motor shell than in the cooler. The motor is protected by a temperature sensor imbedded in the stator windings. An increase in motor winding temperature past the motor override set point overrides the temperature capacity control to hold, and if the motor temperature rises 10° F (5.5° C) above this set point, closes the inlet guide vanes. If the temperature rises above the safety limit, the compressor shuts down.

Refrigerant that flows to the oil cooling system is regulated by thermostatic expansion valves (TXVs). The TXVs regulate flow into the oil/refrigerant plate and frame-type heat exchang- er (the oil cooler in Fig. 3). The expansion valve bulbs control oil temperature to the bearings. The refrigerant leaving the oil cooler heat exchanger returns to the chiller cooler.

VFD COOLING CYCLE

The unit-mounted variable frequency drive (VFD) is cooled in a manner similar to the motor and lubricating oil cooling cycle (Fig. 3).

If equipped with a unit-mounted VFD, the refrigerant line that feeds the motor cooling and oil cooler also feeds the heat exchanger on the unit-mounted VFD. Refrigerant is metered through a thermostatic expansion valve (TXV). To maintain proper operating temperature in the VFD, the TXV bulb is mounted to the heat exchanger to regulate the flow of refriger- ant. The refrigerant leaving the heat exchanger returns to the cooler.

LUBRICATION CYCLE

Summary — The oil pump, oil filter, and oil cooler make up a package located partially in the transmission casing of the compressor-motor assembly. The oil is pumped into a filter assembly to remove foreign particles and is then forced into an oil cooler heat exchanger where the oil is cooled to proper operational temperatures. After the oil cooler, part of the flow is directed to the gears and the high speed shaft bearings; the remaining flow is directed to the motor shaft bearings. Oil drains into the transmission oil sump to complete the cycle (Fig. 4).

Details — Oil is charged into the lubrication system through a hand valve. Two sight glasses in the oil reservoir permit oil level observation. Normal oil level is between the middle of the upper sight glass and the top of the lower sight glass when the compressor is shut down. The oil level should be visible in at least one of the 2 sight glasses during operation. Oil sump tem- perature is displayed on the CVC/ICVC (Chiller Visual Con- troller/International Chiller Visual Controller) default screen. During compressor operation, the oil sump temperature ranges between 125 to 150 F (52 to 66 C).

The oil pump suction is fed from the oil reservoir. An oil pressure relief valve maintains 18 to 25 psid (124 to172 kPad) differential pressure in the system at the pump discharge. This differential pressure can be read directly from the CVC/ICVC default screen. The oil pump discharges oil to the oil filter as- sembly. This filter can be closed to permit removal of the filter without draining the entire oil system (see Maintenance sec- tions, pages 71 to 75, for details). The oil is then piped to the oil

cooler heat exchanger. The oil cooler uses refrigerant from the condenser as the coolant. The refrigerant cools the oil to a tem- perature between 120 and 140 F (49 to 60 C).

As the oil leaves the oil cooler, it passes the oil pressure transducer and the thermal bulb for the refrigerant expansion valve on the oil cooler. The oil is then divided. Part of the oil flows to the thrust bearing, forward pinion bearing, and gear spray. The rest of the oil lubricates the motor shaft bearings and the rear pinion bearing. The oil temperature is measured in the bearing housing as it leaves the thrust and forward journal bearings. The oil then drains into the oil reservoir at the base of the compressor. The PIC II (Product Integrated Control II) measures the temperature of the oil in the sump and maintains the temperature during shutdown (see Oil Sump Temperature Control section, page 36). This temperature is read on the CVC/ICVC default screen.

During the chiller start-up, the PIC II energizes the oil pump and provides 45 seconds of pre-lubrication to the bearings after pressure is verified before starting the compressor. During shutdown, the oil pump will run for 60 seconds to post- lubricate after the compressor shuts down. The oil pump can also be energized for testing purposes during a Control Test.

Ramp loading can slow the rate of guide vane opening to minimize oil foaming at start-up. If the guide vanes open quickly, the sudden drop in suction pressure can cause any re- frigerant in the oil to flash. The resulting oil foam cannot be pumped efficiently; therefore, oil pressure falls off and lubrica- tion is poor. If oil pressure falls below 15 psid (103 kPad) dif- ferential, the PIC II will shut down the compressor.

If the controls are subject to a power failure that lasts more than 3 hours, the oil pump will be energized periodically when the power is restored. This helps to eliminate refrigerant that has migrated to the oil sump during the power failure. The con- trols energize the pump for 60 seconds every 30 minutes until the chiller is started.

Oil Reclaim System — The oil reclaim system returns oil lost from the compressor housing back to the oil reservoir by recovering the oil from 2 areas on the chiller. The guide vane housing is the primary area of recovery. Oil is also recov- ered by skimming it from the operating refrigerant level in the cooler vessel.

PRIMARY OIL RECOVERY MODE — Oil is normally re- covered through the guide vane housing on the chiller. This is possible because oil is normally entrained with refrigerant in the chiller. As the compressor pulls the refrigerant up from the cooler into the guide vane housing to be compressed, the oil normally drops out at this point and falls to the bottom of the guide vane housing where it accumulates. Using discharge gas pressure to power an eductor, the oil is drawn from the housing and is discharged into the oil reservoir.

SECONDARY OIL RECOVERY METHOD — The sec- ondary method of oil recovery is significant under light load conditions, when the refrigerant going up to the compressor suction does not have enough velocity to bring oil along. Under these conditions, oil collects in a greater concentration at the top level of the refrigerant in the cooler. This oil and refrigerant mixture is skimmed from the side of the cooler and is then drawn up to the guide vane housing. There is a filter in this line. Because the guide vane housing pressure is much lower than the cooler pressure, the refrigerant boils off, leaving the oil be- hind to be collected by the primary oil recovery method.

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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 OptionalDefinitions Unit-Mounted Wye-Delta Starter OptionalControls 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 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 ISM Starter Config Data Ismconf Description Status Units Point DefaultExample 15 Netopt Display Screen Example 16 Ismconf 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 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 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 Inspect Wiring Perform dehydration as followsWhite 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 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 Tests to be Devices Tested Performed Charge Refrigerant into ChillerControl Test Menu Functions Initial START-UP Refrigerant HFC-134a ChargeCheck Oil Pressure and Compressor Stop Dry Run to Test Start-Up SequenceCheck Motor Rotation 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 TransducersOccdefcm HeatexLlmaint 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 ModulesReplacing Defective Processor Modules Chiller Control Module CCM FigIntegrated Starter Module Fig 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 Motor Voltage Code Additional Miscellaneous WeightsOptional Pumpout System Electrical Data 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 toAmp 250 CL-8 65 to90 to 100 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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