Carrier 19XL Safety Shutdown , BEFORE INITIAL START-UP Job Data Required, Equipment Required, Using the Optional Storage Tankand Pumpout System , Remove Shipping Packaging , Open Oil Circuit Valves , Tighten All Gasketed Joints and Guide Vane Shaft Packing , Check Chiller Tightness , Refrigerant Tracer , Leak Test Chiller

Safety Shutdown — A safety shutdown is identical to

amanual shutdown with the exception that the LID will dis-

play the reason for the shutdown, the alarm light will blink

continuously, and the spare alarm contacts will be ener-

gized.A safety shutdown requires that the RESET softkey

be pressed in order to clear the alarm. If the alarm is still

present,the alarm light will continue to blink. Once the alarm

is cleared, the operator must press the CCN or

LOCAL softkeys to restart the chiller.

Do not reset starter loads or any other starter safety for

30 seconds after the compressor has stopped. Voltage

output to the compressor start signal is maintained for

10 seconds to determine starter fault.

BEFORE INITIAL START-UPJob Data Required

• list of applicable design temperatures and pressures (pro-

duct data submittal)

• chiller certiﬁed prints

• starting equipment details and wiring diagrams

• diagrams and instructions for special controls or options

• 19XL Installation Instructions

• pumpout unit instructions

Equipment Required

• mechanic’s tools (refrigeration)

• digital volt-ohmmeter (DVM)

• clamp-on ammeter

• electronic leak detector

• absolute pressure manometer or wet-bulb vacuum indica-

tor (Fig. 25)

• 500 v insulation tester (megohmmeter) for compressor

motors with nameplate voltage of 600 v or less, or a

5000-vinsulation tester for compressor motor rated above

600 v

Using the Optional Storage Tankand Pumpout

System — Refer to Pumpout and Refrigerant Transfer

Procedures section, page 59 for: pumpout system prepara-

tion, refrigerant transfer, and chiller evacuation.

Remove Shipping Packaging — Remove any

packagingmaterial from the control center, power panel, guide

vane actuator, motor cooling and oil reclaim solenoids,

motorand bearing temperature sensor covers, and the factory-

mounted starter.

Open Oil Circuit Valves — Check that the oil ﬁlter

isolationvalves (Fig. 4) are open by removing the valve cap

and checking the valve stem.

Tighten All Gasketed Joints and Guide Vane

Shaft Packing — Gaskets and packing normally relax

by the time the chiller arrives at the jobsite. Tighten all

gasketedjoints and guide vane shaft packing to ensure a leak-

tight chiller.

Check Chiller Tightness — Figure 26 outlines the

proper sequence and procedures for leak testing.

19XL chillers are shipped with the refrigerant contained

in the condenser shell and the oil charge shipped in the

compressor. The cooler will have a 15 psig (103 kPa)

refrigerantcharge. Units may be ordered with the refrigerant

shippedseparately, along with a 15 psig (103 kPa) nitrogen-

holding charge in each vessel.To determine if there are any

leaks, the chiller should be charged with refrigerant. Use an

electronicleak detector to check all ﬂanges and solder joints

after the chiller is pressurized. If any leaks are detected, fol-

low the leak test procedure.

Ifthe chiller is spring isolated, keep all springs blocked in

bothdirections in order to prevent possible piping stress and

damage during the transfer of refrigerant from vessel to

vesselduring the leak test process, or any time refrigerant is

transferred. Adjust the springs when the refrigerant is in

operating condition, and when the water circuits are full.

Refrigerant Tracer — Carrier recommends the use of

anenvironmentally acceptable refrigerant tracer for leak test-

ing with an electronic detector or halide torch.

Ultrasonic leak detectors also can be used if the chiller is

under pressure.

Do not use air or oxygen as a means of pressurizing the

chiller. Some mixtures of HCFC-22 or HFC-134a and

air can undergo combustion.

Leak Test Chiller — Due to regulations regarding

refrigerantemissions and the difficulties associated with sepa-

rating contaminants from refrigerant, Carrier recommends

thefollowing leak test procedures. See Fig. 26 for an outline

of the leak test procedures. Refer to Fig. 27 and 28 during

pumpout procedures and Tables5A, B, C, and D for refrig-

erant pressure/temperature values.

1. If the pressure readings are normal for chiller

condition:

a. Evacuatetheholding charge from the vessels, if present.

b. Raise the chiller pressure, if necessary, by adding re-

frigerantuntil pressure is at equivalent saturated pres-

surefor the surrounding temperature. Follow the pumpout

Fig. 25 — Typical Wet-BulbType

Vacuum Indicator