Carrier 19XL specifications General Maintenance, Test After Service, Repair, or Major Leak Ð If

Page 61

TRANSFER ALL REFRIGERANT TO CHILLER COOLER/COMPRESSOR VESSEL

1. Push refrigerant into the chiller cooler vessel. a. Valve positions:

VALVE

1a

1b

2

3

4

5

8

11

12

13

14

CONDITION

 

 

C

 

 

C

C

 

C

C

C

 

 

 

 

 

 

 

 

 

 

 

 

b. Turn off chiller water pumps and pumpout condenser water.

c. Turn on pumpout compressor to push refrigerant out of the condenser.

d. When all liquid is out of the condenser, close cooler isolation valve 11.

e. Turn off the pumpout compressor.

2. Evacuate gas from the chiller condenser vessel.

a. Access the Control Test Pumpdown table on the LID display to turn on the chiller water pumps.

b. Close pumpout 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 pumpout condenser water.

d. Run the pumpout compressor until the chiller com- pressor reaches 18 in. Hg vac (40 kPa abs.). Monitor pressure at the LID and refrigerant gages.

e. Close valve 1b.

f. Turn off 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 pumpout condenser water.

i. Proceed to the Pumpdown test on the LID to turn off chiller water pumps and lockout chiller compressor.

RETURN REFRIGERANT TO NORMAL OPERATING CONDITIONS

1.

Be sure that the chiller vessel that was opened has been

 

evacuated.

 

 

 

 

 

 

 

 

 

 

 

 

2.

Access the Control Test Terminate Lockout table to view

 

vessel pressures and turn on chiller water pumps.

 

 

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.

Crack open valve 5, gradually increasing pressure in the

 

evacuated vessel to 68 psig (469 kPa) [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

 

between vessels.

 

 

 

 

 

 

 

 

 

 

 

8.

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

 

 

 

 

 

 

 

9.

Open isolation valves 11, 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 Terminate Pumpdown Lockout test to turn

 

off water pumps and enable the chiller compressor for

 

start-up.

 

 

 

 

 

 

 

 

 

 

 

 

GENERAL MAINTENANCE

Refrigerant Properties Ð HCFC-22 or HFC-134a is the standard refrigerant in the 19XL. At normal atmo- spheric pressure, HCFC-22 will boil at ±41 F (±40 C) and HFC-134a will boil at ±14 F (±25 C) and must, therefore, be kept in pressurized containers or storage tanks. The refrig- erants are practically odorless when mixed with air. Both refrigerants are non-combustible at atmospheric pressure. Read the Material Safety Data Sheet and the latest ASHRAE Safety Guide for Mechanical Refrigeration to learn more about safe handling of these refrigerants.

HCFC-22 and HFC-134a will dissolve oil and some non-metallic materials, dry the skin, and, in heavy con- centrations, may displace enough oxygen to cause asphyxiation. When handling this refrigerant, protect the hands and eyes and avoid breathing fumes.

Adding Refrigerant Ð Follow the procedures de- scribed in Trimming Refrigerant Charge section, page 54.

Always use the compressor Pumpdown function in the Control Test table to turn on the evaporator pump and lock out the compressor when transferring refrigerant. Liquid refrigerant may ¯ash into a gas and cause pos- sible freeze-up when the chiller pressure is below 65 psig (448 kPa) [30 psig (207 kPa)].

Removing Refrigerant Ð If the optional pumpout unit is used, the 19XL refrigerant charge may be transferred to a pumpout storage tank or to the chiller condenser or cooler vessels. Follow procedures in the Pumpout and Refrigerant Transfer Procedures section when removing refrigerant from the pumpout storage tank to the chiller vessel.

Adjusting the Refrigerant Charge Ð If the addi- tion or removal of refrigerant is required for improved chiller performance, follow the procedures given under the Trim Refrigerant Charge section, page 62.

Refrigerant Leak Testing Ð Because HCFC-22 and HFC-134a are above atmospheric pressure at room tempera- ture, leak testing can be performed with refrigerant in the chiller. Use an electronic, halide leak detector, soap bubble solution, or ultra-sonic leak detector. Be sure 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 Ð ASHRAE recommends that chillers should be immediately taken off line and repaired if the refrigerant leakage rate for the entire chiller is more than 10% of the operating refrigerant charge per year.

Additionally, Carrier recommends that leaks totalling less than the above rate but more than a rate of 1 lb (0.5 kg) per year should be repaired during annual maintenance or whenever the refrigerant is pumped over for other service work.

Test After Service, Repair, or Major Leak Ð If

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

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Contents Safety Considerations Start-Up, Operation, and Maintenance InstructionsContents Contents Abbreviations and Explanations IntroductionRefrigeration Cycle Chiller FamiliarizationMOTOR/OIL Refrigeration Cooling Cycle 19XL Rear View Cooler In/Out Temperature Sensors Take-Apart Rabbet Fit ConnectorCondenser In/Out Temperature Sensors Cooler Pressure Schrader FittingRefrigerant Motor Cooling and Oil Cooling Cycles Lubrication CycleLubrication System Unit-Mounted Solid-State Starter Optional Starting EquipmentControls DenitionsMajor PIC Components Panel Locations PIC Component PanelPressure Transducer, Typical 19XL Controls and Sensor LocationsControl and OIL Heater Voltage Selector S1 Power Panel with OptionsGeneral LID Operation and Menus FigSelect Override Operations − Example of Point Status Screen Status01Example of Time Schedule Operation Screen 19XL Menu Structure 19XL Service Menu Structure 19XL Service Menu Structure Example of Set Point Screen SetpointLID Screens Description Range Units Reference Point Name Alarm HistoryExample 1 Ð STATUS01 Display Screen Menu Status SelectExample 3 Ð STATUS03 Display Screen Example 2 Ð STATUS02 Display ScreenExample 4 Ð Setpoint Display Screen MenuExample 6 Ð LEAD/LAG Configuration Display Screen Example 5 Ð Configuration Config Display ScreenECW Control Option ICE Build TerminationExample 7 Ð SERVICE1 Display Screen Spare Alert Enable Example 8 Ð SERVICE2 Display ScreenExample 9 Ð SERVICE3 Display Screen Menu ServiceExample 11 Ð Maintenance MAINT02 Display Screen Example 10 Ð Maintenance MAINT01 Display ScreenDischarge Temperature Bearing TemperatureExample 13 Ð Maintenance MAINT04 Display Screen Example 12 Ð Maintenance MAINT03 Display ScreenDescription RANGE/STATUS Units Reference Point Name PIC System Functions Page Protective Safety Limits and Control Settings Capacity Overrides Page Page ECW Lead/Lag ControlHgbp Hot Gas BypassPage Cent Capacity Ice Build ControlPage To LOG on Example of Attach to Network Device ScreenSequence Fig START-UP/SHUTDOWN/RECYCLERecycle Restart Delta T Before Initial START-UP Using the Optional Storage Tank and PumpoutJob Data Required Equipment Required19XL Leak Test Procedures Page Ð HCFC-22 Pressure Ð Temperature C Ð HCFC-22 Pressure Ð Temperature FÐ HFC-134a Pressure Ð Temperature C Ð HFC-134a Pressure Ð Temperature FTemperature Pressure Page Check Optional Pumpout Compressor Water Pip Inspect WiringMECHANICAL-TYPE Starters Check StarterBENSHAW, INC. SOLID-STATE Starter Benshaw, Inc. Solid-State Starter Power StackSet Up Chiller Control Conguration Power Up the Controls and Check the Oil HeaterLoad Surge Prevention Occurs TOO Soon Occurs TOO Late Volt Motor Code Amps Correction Factors For 19XL Motors19XL Chiller Equalization Without PUMP- OUT Unit Charge Refrigerant into ChillerControl Test Menu Functions Tests to be Devices Tested Performed19XL Total Refrigerant Charge Refrigerant ChargesCooler SizeDry Run to Test Start-Up Sequence Initial START-UPCheck Rotation Calibrate Motor Current Check Oil Pressure and Compressor StopOperating Instructions Operator DutiesTo Stop the Chiller Plant Operating the Optional Pumpout Compressor Pumpout and Refrigerant Transfer ProceduresTransfer Refrigerant from Storage Tank to Chiller TstatTransfer the Refrigerant from Chiller to Storage Tank Chillers with Isolation ValvesTest After Service, Repair, or Major Leak Ð If General MaintenanceReturn Refrigerant to Normal Operating Conditions Guide Vane Actuator Linkage Weekly MaintenanceCheck Safety and Operating Controls Monthly Scheduled MaintenanceTo Change the OIL Inspect the Heat Exchanger Tubes Compressor Bearing and Gear MaintenOptional Pumpout System Controls Troubleshooting Guide MAINT02 MAINT01MAINT03 MAINT04Timing OUT or Timed OUT Shutdown with ON/OFF/RESET-OFFNormal or AUTO.-RESTART Recycle ShutdownAutorestart in Progress LOW Chilled Water Compressor Jumpstart and Refrigerant Protection Normal RUN with RESET, TEMPERATURE, or DemandOUT-OF-RANGE Sensor Failures Normal RUN Overrides Active AlertsLimited Protective Limit Chiller Protect Limit FaultsSpare Sensor Alert Messages Chiller AlertsDESCRIPTION/MALFUNCTION Probable CAUSE/REMEDY Other PROBLEMS/MALFUNCTIONSTemperature Voltage Resistance Drop Ð Thermistor Temperature F vs Resistance/Voltage DropÐ Thermistor Temperature C vs Resistance/Voltage Drop Module Address Control ModulesInput Options Module Processor Module Psio Fig Starter Management Module SMM FigOptions Module Switch Options Setting Module InstallationTypical Benshaw, Inc. Solid-State Starter internal View Page Page Problem Probable Causes Area of Correction Benshaw, Inc. Solid-State Starter Troubleshooting GuideRV1 SCRAdditional Data for Marine Waterboxes Heat Exchanger DataCooler CondenserCoolers Waterbox Cover WeightsCondensers 1034 kPaCompressor Weights Compressor/Motor WeightsOptional Pumpout System Electrical Data Compressor Fits and Clearances Description Torque Compressor Assembly TorquesFt-lb ``ZCOM CLRComm EXTPage CLR Page Chiller Power Panel, Starter Assembly Motor Wiring Schematic Chiller Power Panel, Starter Assembly Motor Wiring Schematic POT PMRGFR HPSTypical Wye-Delta Unit Mounted Starter Wiring Schematic Index Index Copyright 1996 Carrier Corporation

19XL specifications

The Carrier 19XL is a highly regarded commercial heating and cooling solution, designed to provide optimum performance and energy efficiency in various applications. This rooftop unit is engineered to meet the diverse needs of businesses, making it an ideal choice for those requiring reliable climate control in their facilities.

One of the standout features of the Carrier 19XL is its advanced cooling and heating capabilities. The unit utilizes a high-efficiency scroll compressor that ensures a quieter operation and improved reliability. The system can operate across a wide range of temperatures, making it versatile for various climates. Additionally, it offers both cooling and heating options, allowing for year-round comfort.

Energy efficiency is a focal point of the 19XL design. With an impressive Seasonal Energy Efficiency Ratio (SEER) and Heating Seasonal Performance Factor (HSPF), this unit not only helps reduce energy costs but also supports environmental sustainability initiatives. The unit is equipped with environmentally friendly refrigerants, further contributing to lower greenhouse gas emissions.

The Carrier 19XL features a user-friendly control system, allowing for easy monitoring and management of the unit's performance. This control system is designed to maximize energy savings, offering features such as demand control ventilation and integrated economizers that facilitate the use of outdoor air for cooling, reducing reliance on mechanical systems when conditions allow.

Construction-wise, the Carrier 19XL is built to withstand tough environmental conditions. Its robust cabinet is made from galvanized steel, providing durability and protection against the elements. The design also includes insulation to minimize noise levels, creating a more comfortable indoor environment.

Maintenance is a key consideration in the design of the 19XL. The unit features accessible service ports and a simplified access panel, allowing technicians to perform routine maintenance with ease. This proactive design helps ensure the longevity of the system and minimizes downtime, keeping operations running smoothly.

In summary, the Carrier 19XL is an exceptional choice for commercial heating and cooling needs. With its energy-efficient features, advanced technology, and durable construction, it stands out as a reliable solution for businesses looking for sustainable climate control options.
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