SCHEDULED MAINTENANCE
Establish a regular maintenance schedule based on the actual chiller requirements such as chiller load, run hours, and water quality. The time intervals listed in this section are offered as guides to service only.
Service Ontime Ð The LID will display a SERVICE ONTIME value on the Status01 table. This value should be reset to zero by the service person or the operator each time major service work is completed so that time between serv- ice can be viewed.
Inspect the Control Center Ð Maintenance is lim- ited to general cleaning and tightening of connections. Vacuum the cabinet to eliminate dust build-up. In the event of chiller control malfunctions, refer to the Troubleshooting Guide sec- tion for control checks and adjustments.
Be sure power to the control center is off when cleaning and tightening connections inside the control center.
Check Safety and Operating Controls Monthly
ÐTo ensure chiller protection, the Control Test Automated Test should be done at least once per month. See Table 3 for safety control settings. See Table 7 for Control Test functions.
Changing Oil Filter Ð Change the oil ®lter on a yearly basis or when the chiller is opened for repairs. The 19XL has an isolatable oil ®lter so that the ®lter may be changed with the refrigerant remaining in the chiller. Use the follow- ing procedure:
1.Make sure that the compressor is off, and the disconnect for the compressor is open.
2.Disconnect the power to the oil pump.
3.Close the oil ®lter isolation valves (Fig. 4).
4.Connect an oil charging hose from the oil charging valve (Fig. 4), and place the other end in a clean container suitable for used oil. The oil drained from the ®lter hous- ing should be used as an oil sample to be sent to a labo- ratory for proper analysis. Do not contaminate this sample.
5.Slowly open the charging valve to drain the oil from the housing.
The oil ®lter housing is at a high pressure. Relieve this pressure slowly.
6.Once all oil has been drained, place some rags or ab- sorbent material under the oil ®lter housing to catch any drips once the ®lter is opened. Remove the 4 bolts from the end of the ®lter housing and remove the ®lter cover.
7.Remove the ®lter retainer by unscrewing the retainer nut. The ®lter may now be removed and disposed of properly.
8.Replace the old ®lter with a new ®lter. Install the ®lter retainer and tighten down the retainer nut. Install the ®l- ter cover and tighten the 4 bolts.
9.Evacuate the ®lter housing by placing a vacuum pump on the charging valve. Follow the normal evacuation pro- cedures. Shut the charging valve when done, and recon- nect the valve so that new oil can be pumped into the ®lter housing. Fill with the same amount that was removed, then close the charging valve.
10.Remove the hose from the charging valve, open the iso- lation valves to the ®lter housing, and turn on the power to the pump and the motor.
Oil Speci®cation Ð The 19XL compressor holds ap- proximately 11.7 gal. (44.3 L) of oil. If oil is added, it must meet the following Carrier speci®cations:
·Oil type for HCFC-22 Chillers only . . . . . . . . . . . Alkyl- benzene-based synthetic compressor oil speci®cally formatted for use in HCFC-22 gear-driven machines
ISO Viscosity Grade . . . . . . . . . . . . . . . . . . . . . . . . . . 86
·Oil Type for units using R-134a . . . . . . . . . . . . Inhibited polyolester-based synthetic compressor oil formatted for use with HFC, gear- driven, hermetic compressors.
ISO Viscosity Grade . . . . . . . . . . . . . . . . . . . . . . . . . . 68
The alkyl-benzene type oil (part number PP23BZ101) or the polyolester-based oil (part number PP23BZ103) may be ordered from your local Carrier representative.
Oil Changes Ð Carrier recommends changing the oil after the ®rst year of operation and every 3 years thereafter as a minimum in addition to a yearly oil analysis. However, if a continuous oil monitoring system is functioning and a yearly oil analysis is performed, time between oil changes can be extended.
TO CHANGE THE OIL
1.Transfer the refrigerant into the condenser (for isolatable vessels) or a storage tank.
2.Mark the existing oil level.
3.Open the control and oil heater circuit breaker.
4.When the chiller pressure is 5 psi (34 kPa) or less, drain the oil reservoir by opening the oil charging valve (Fig. 2A or Fig. 2B). Slowly open the valve against refrigerant pressure.
5.Change the oil ®lter at this time. See Changing Oil Filter section.
6.Change the refrigerant ®lter at this time; see the next sec- tion, Refrigerant Filter.
7.Charge the chiller with oil. Charge until the oil level is equal to the oil level marked in Step 2. Turn on the power to the oil heater and let the PIC warm it up to at least 140 F (60 C). Operate the oil pump manually, through the Control Test, for 2 minutes. The oil level should be full in the lower sight glass for shutdown conditions. If the oil level is above 1¤2 full in the upper sight glass, remove the excess oil. The oil level should now be equal to the amount shown in Step 2.
Refrigerant Filter Ð A refrigerant ®lter drier, located on the refrigerant cooling line to the motor (Fig. 2A or 2B), should be changed once a year, or more often if ®lter condition indicates a need for more frequent replacement. Change the ®lter with the chiller pressure at 0 psig (0 kPa) by transferring the refrigerant to the condenser vessel, (if iso- lation valves are present), or a storage tank. A moisture indicator sight glass is located beyond this ®lter to indicate the volume and moisture in the refrigerant. If the moisture indicator (dry-eye) indicates moisture, locate the source of water immediately by performing a thorough leak check.
Oil Reclaim Filters Ð The oil reclaim system has a strainer on the eductor suction line and a ®lter on the cooler scavaging line. Replace these ®lters once per year, or more often if ®lter condition indicates a need for more frequent replacement. Change these ®lters by transferring the refrig- erant charge to a storage vessel or the condenser.
