Carrier 19XL Fig. 47 Compressor Fits and Clearances (cont)

COMPRESSORASSEMBLY TORQUES

ITEM DESCRIPTION TORQUE

ft-lb N•m

1* Oil Heater Grommet Nut 10 14

2Impeller Retaining Bolt 44-46 60-62

3Bull Gear Retaining Bolt 80-85 108-115

4Motor Terminals(Low Voltage) 50 68

5Demister Bolts 15-19 20-26

6* Guide VaneShaft Seal Nut 25 34

7* Motor Terminals(High Voltage)

— Insulator 2-4 2.7-5.4

— Packing Nut 5 6.8

— Brass Jam Nut 10 13.6

LEGEND

N•m — Newton Meters

*Not shown.

*‘‘Z’’clearance is determined by a combination of impeller diameter and shroud size. The

tablelists ‘‘Z’’ clearances for each compressor code. Figure 1 shows the location (on the

chiller information plate) of the compressor code for each chiller.

COMPRESSOR

CODE ‘‘Z’’

(in.) ‘‘Z’’

(mm)

203-204 .025 0.635

223-274 .015 0.381

283-307 .025 0.635

321-377 .015 0.381

381-397 .025 0.635

410-469 .015 0.381

470-499 .025 0.635

Fig. 47 — Compressor Fits and Clearances (cont)

COMPRESSOR

CODE ‘‘Z’’

(in.) ‘‘Z’’

(mm)

516-517 .015 0.381

518-519 .025 0.635

526-527 .015 0.381

528-529 .025 0.635

536-537 .015 0.381

538-539 .025 0.635

COMPRESSOR

CODE ‘‘Z’’

(in.) ‘‘Z’’

(mm)

546-547 .015 0.381

548-549 .025 0.635

556-557 .015 0.381

558-559 .025 0.635

566-567 .015 0.381

568-569 .025 0.635

89

Contents

Main Start-Up, Operation, and Maintenance Instructions SAFETY CONSIDERATIONS 19XL Hermetic Centrifugal Liquid Chillers 50/60 Hz With HCFC-22 and HFC-134a CONTENTS Page CONTENTS (cont) INTRODUCTION ABBREVIATIONSAND EXPLANATIONS CHILLER FAMILIARIZATION (Fig. 1, 2A, and 2B) Chiller Information Plate SystemComponents Cooler Condenser Motor-Compressor Fig. 2A Typical19XL Components Design I 19XL REAR VIEW 19XL FRONT VIEW Fig. 2B Typical 19XLComponents Design II 19XL REAR VIEW LUBRICATION CYCLE Summary Details Oil Reclaim System STARTING EQUIPMENT Unit-Mounted Solid-State Starter (Optional) Unit-MountedWye-Delta Starter (Optional) CONTROLS Denitions General PICSystem Components Page Page LID Operation and Menus (Fig. 13-19) Page Page Page Page Page Page Table 2 LID Screens Page Page Page Page Page Page PIC System Functions SafetyControls Default Screen Freeze Motor Cooling Control Table 3 Protective Safety Limits and Control Settings Ramp Loading Control Capacity Override (Table 4) High Discharge Temperature Control OilSump Temperature Control OilCooler RemoteStart/Stop Controls Spare Safety Inputs Tower Fan Relay Auto. Restart After Power Failure Water/Brine Reset Demand Limit Control, Option (Requires Optional 8-Input Module) Surge PreventionAlgorithm SurgeProtection Lead/Lag Control Page Ice Build Control Attachto Network Device Control Service Operation START-UP/SHUTDOWN/RECYCLE SEQUENCE (Fig. 24) Local Start-Up Shutdown Sequence AutomaticSoft Stop Amps Threshold (PSIO Soft- ware Version 09 and Higher) ChilledWater Recycle Mode Safety Shutdown BEFORE INITIAL START-UP Job Data Required Equipment Required Using the Optional Storage Tankand Pumpout System Remove Shipping Packaging Page StandingVacuum Test Table 5A HCFC-22 Pressure Temperature (F) Table 5B HCFC-22 Pressure Temperature(C) Table 5C HFC-134a Pressure Temperature(F) Table 5D HFC-134a Pressure Temperature(C) Page Chiller Dehydration InspectWater Piping CheckOptional Pumpout Compressor Water Pip- ing Check Relief Devices Inspect Wiring CarrierComfort Network Interface Check Starter Page Oil Charge PowerUp the Controls and Check the Oil Heater Set Up Chiller Control Conguration Input the Design Set Points Inputthe Local Occupied Schedule (OCCPC01S) Page CheckOptional Pumpout System Controls and Compressor HighAltitude Locations Charge Refrigerant into Chiller Page INITIAL START-UP Preparation ManualOperation of the Guide Vanes Dry Run to Test Start-Up Sequence Check Rotation Check Oil Pressure and Compressor Stop Calibrate Motor Current ToPrevent Accidental Start-Up Check Chiller Operating Condition Instructthe Customer Operator To Stop the Chiller After Limited Shutdown ExtendedShutdown After Extended Shutdown Cold Weather Operation REFRIGERATION LOG CARRIER 19XT HERMETIC CENTRIFUGALREFRIGERATION MACHINE Plant CHILLER MODEL NO. CHILLER SERIAL NO. REFRIGERANT TYPE Fig. 33 Refrigeration Log PUMPOUT AND REFRIGERANT TRANSFER PROCEDURES Preparation Operating the Optional Pumpout Compressor Chillers with Pumpout Storage Tanks Chillers with Isolation Valves GENERAL MAINTENANCE Refrigerant Properties Adding Refrigerant RemovingRefrigerant Adjusting the Refrigerant Charge Refrigerant Leak Testing Repair the Leak, Retest, and Apply Standing Vacuum Test CheckingGuide Vane Linkage TrimRefrigerant Charge WEEKLYMAINTENANCE Checkthe Lubrication System SCHEDULED MAINTENANCE Service Ontime Inspect the Control Center Check Safety and Operating Controls Monthly ChangingOil Filter Inspect Refrigerant Float System InspectRelief Valves and Piping Compressor Bearing and Gear Mainten- ance Inspect the Heat Exchanger Tubes WaterLeaks WaterTreatment Inspect the Starting Equipment Check Pressure Transducers Optional Pumpout System Maintenance Ordering Replacement Chiller Parts TROUBLESHOOTING GUIDE Overview Checking the Display Messages Checking Temperature Sensors Checking Pressure Transducers ControlAlgorithms Checkout Procedure Control Test with Troubleshooting Guides A. SHUTDOWN WITH ON/OFF/RESET-OFF B. TIMING OUT OR TIMED OUT LEGEND C. IN RECYCLE SHUTDOWN E. NORMAL OR AUTO.-RESTART F. START-UP FAILURES:This is an alarm condition. A manual reset is required to clear. G. COMPRESSOR JUMPSTART AND REFRIGERANT PROTECTION H. NORMAL RUN WITH RESET, TEMPERATURE, OR DEMAND I. NORMAL RUN OVERRIDES ACTIVE (ALERTS) J. OUT-OF-RANGE SENSOR FAILURES Page L. CHILLER ALERTS M. SPARE SENSOR ALERT MESSAGES N. OTHER PROBLEMS/MALFUNCTIONS Table 10A Thermistor Temperature (F) vs Resistance/Voltage Drop Table 10B Thermistor Temperature(C) vs Resistance/Voltage Drop Control Modules Notes on Module Operation Processor Module (PSIO) (Fig. 41) Starter Management Module (SMM) (Fig. 42) Options Modules (8-Input) ReplacingDefective Processor Modules Solid-StateStarters Page Page Table 11 Benshaw, Inc. Solid-State Starter Troubleshooting Guide Physical Data matics for operator convenience during troubleshooting. Table 12 Heat Exchanger Data COOLER CONDENSER Table 13 Additional Data for Marine Waterboxes* Table 14 WaterboxCover Weights* ENGLISH (lb) SI (kg) Table 15 Compressor/Motor Weights Table 16 Compressor Weights Table 17 Optional Pumpout System Electrical Data Page COMPRESSORASSEMBLY TORQUES Fig. 47 Compressor Fits and Clearances (cont) Page Page Fig. 49 Electronic PIC Controls Wiring Schematic (For 19XL with Halogen Backlight) Page Fig. 50 Chiller Power Panel, Starter Assembly, and Motor Wiring Schematic Page Fig. 51 Typical Wye-DeltaUnit Mounted Starter Wiring Schematic Fig. 51 Typical Wye-DeltaUnit Mounted Starter Wiring Schematic (cont) INDEX INDEX (cont)