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Carrier 19XR, XRV specifications INDEX cont

Models: 19XR XRV

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	INDEX (cont)
Start-Up/Shutdown/Recycle Sequence, 46	Troubleshooting Guide, 76
Start the Chiller, 66	Unit-Mounted Solid-State Starter, 9
Stop the Chiller, 66	Unit-Mounted VFD, 10
Storage Vessel, 7	Unit-Mounted Wye-Delta Starter, 10
Summary (Lubrication Cycle), 8	Using the Optional Storage Tank and Pumpout
Surge Prevention Algorithm (Fixed Speed Chiller), 39	System, 48
Surge Prevention Algorithm with VFD, 40	VFD Cooling Cycle, 8
Surge Protection (Fixed Speed Chillers), 40	Water/Brine Reset, 38
Surge Protection VFD Units, 40	Water Leaks, 74
System Components, 5	Water Piping (Inspect), 53
Temperature Sensors (Check), 76	Water Treatment, 75
Test After Service, Repair, or Major Leak, 71	Weekly Maintenance, 72
Tighten All Gasketed Joints and Guide Vane Packing, 48	Wiring (Inspect), 53
Tower Fan Relay Low and High, 38
Trim Refrigerant Charge, 72

Copyright 2001 Carrier Corporation

Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.

Book	2	PC 211	Catalog No. 531-982	Printed in U.S.A.	Form 19XR-5SS	Pg 124	6-01	Replaces: 19XR-4SS
Tab	5a

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Carrier 19XR, XRV specifications INDEX cont

Contents

Start-Up, Operation, and Maintenance Instructions SAFETY CONSIDERATIONSopen flame produces toxic gases CONTENTS High Discharge Temperature ControlUsing the Optional Storage Tank ABBREVIATIONS AND EXPLANATIONS . . . . . . . . 4,5CONTENTS cont Power Up the Controls andPUMPOUT AND REFRIGERANT TRANSFER PROCEDURES Check Safety and Operating ControlsOptional Pumpout System Maintenance Ordering Replacement Chiller PartsControl Algorithms Checkout Procedure INITIAL START-UP CHECKLIST FOR 19XR, XRV HERMETIC CENTRIFUGALCHILLER FAMILIARIZATION Fig. 1 and Fig. 1 - 19XR IdentificationFRONT VIEW Fig. 2 - Typical 19XR ComponentsREAR VIEW MOTOR AND LUBRICATING OIL COOLING CYCLE REFRIGERATION CYCLEFig. 3 - Refrigerant Motor Cooling and Oil Cooling Cycles VFD COOLING CYCLE LUBRICATION CYCLEUnit-Mounted Solid-State Starter Optional STARTING EQUIPMENTFig. 4 - Lubrication System Unit-Mounted Wye-Delta Starter Optional CONTROLS DefinitionsFig. 5 - Solid-State Starter Box Internal View Fig. 6 - Typical Starter External View Solid-State Starter ShownFig. 7 - Variable Frequency Drive VFD Fig. 8 - Variable Frequency Drive VFD Starter Internal ViewFig. 9 - 19XR Controls and Sensor Locations TOP VIEW COMPRESSOR DETAILTable 1 - Major PIC II Components and Panel Locations Fig. 10 - Control Sensors Temperature Fig. 11 - Control SensorsPressure Transducers, Typical Fig. 13 - Power Panel Fig. 12 - Control PanelFig. 15 - CVC/ICVC Service Screen Fig. 14 - CVC/ICVC Default ScreenCVC/ICVC Operation and Menus Fig Fig. 16 - Example of Status Screen Fig. 17 - 19XR Chiller Display Menu Structure CVC/ICVC Fig. 18 - 19XR Service Menu Structure Fig. 18 - 19XR Service Menu Structure cont CCN - Carrier Comfort Network CVC - Chiller Visual ControllerICVC - International Chiller Visual Controller ISM - Integrated Starter Module PIC II - Product Integrated ControlFig. 19 - Example of Time Schedule Operation Screen Fig. 20 - Example of Set Point Screen Table 2 - CVC/ICVC Display Data Table 2 - CVC/ICVC Display Data cont Table 2 - CVC/ICVC Display Data cont Table 2 - CVC/ICVC Display Data cont ISMSTATTable 2 - CVC/ICVC Display Data cont Table 2 - CVC/ICVC Display Data cont Table 2 - CVC/ICVC Display Data cont Table 2 - CVC/ICVC Display Data cont Table 2 - CVC/ICVC Display Data cont Table 2 - CVC/ICVC Display Data cont Table 2 - CVC/ICVC Display Data cont SURGE/HGBP DELTA T PIC II System Functions≤ SURGE/HGBP DELTA T high bearing temperature high motor winding temperature table. Adjust EVAP REFRIG TRIPPOINT for Table 3 - Protective Safety Limits and Control SettingsCONDENSER FREEZE POINT configured in more than 152 F 66.7 C, or Table 4 - Capacity Overrides ValueEvaporator Freeze Protection ICVC only - A Demand Limit Control Option - The demand limit control option 20 mA DEMAND LIMIT OPT is externally controlled by a 4 to 20 mA or 1 to 5 vdc signal from an energy management system EMS. The option is set up on the RAMPDEM screen. When enabled, 4 mA is the 100% de- mand set point with an operator-configured minimum demand at a 20 mA set point DEMAND LIMIT AT 20 mA Surge Protection Fixed Speed Chiller - The Fig. 23 - Head Pressure Reference OutputLead/Lag System Requirements 1. Lead chiller ramp loading must be complete and the ICE BUILD OPTION is enabled 20 mA DEMAND LIMIT OPT configured on RAMPDEM screenThe CONTROL POINT is forced to the ICE BUILD SET POINT The PIC II can be configured for ice build operationFig. 24 - Example of Attach to Network Device Screen Fig. 25 - Example of Holiday Period Screen START-UP/SHUTDOWN RECYCLE SEQUENCE Fig Fig. 26 - Control SequenceENTERING CONDENSER WATER temperature plus 3 F -1.6 C a recycle condition is present see Chilled Water Recycle Mode sectionBEFORE INITIAL START-UP Job Data Required Equipment RequiredFig. 28 - 19XR Leak Test Procedures 1. If the pressure readings are normal for the chiller condition Page Table 5A - HFC-134a Pressure Temperature F Table 5B - HFC-134a Pressure Temperature CInspect Wiring Fig. 31 - Dehydration Cold TrapCheck Starter Software Configuration Input the Local Occupied Schedule OCCPC01S5. After the last digit is changed, the CVC/ICVC goes to the Table 6 - Benshaw RediStart MICRO Menu Structure Fig. 32 - Benshaw RediStart MICRO Default DisplayTable 7 - Benshaw RediStart MICRO Menu Items Accessing Password Protected Parameters - Although the VFD controller has been preconfigured as the factory, the user will need to be able to access the parameters to verify the job specific parameters are correct, tune the controller or correct a problem. The two passwords protecting the VFD configuration are Parameter Set Display password and Program Disable password. The Parameter Set Display password restricts view- ing. P.nnn parameters above 007 and all H.nnn and R.nnn screens. The password can be accessed at parameter P.006 and will switch between enabled and disabled each time the pass- word 107 is entered. The Program Disable password restricts the changing of the drive parameter set. To enable or disable changes select parameter P.051 and enter the password Set TARGET VFD SPEED to 0% VFD Cooling System Leak Inspection5. Set TARGET VFD SPEED to 0% Set VFD TARGET VFD SPEED to 100%5. Set TARGET VFD SPEED to 100% Error RatioEstimated Minimum Load Conditions Estimated Maximum Load Conditions1724 kPa. To calibrate these transducers Charge Refrigerant into Chiller Table 9 - Control Test Menu FunctionsINITIAL START-UP Table 10 - Refrigerant HFC-134a ChargeDry Run to Test Start-Up Sequence Check Motor RotationCheck Oil Pressure and Compressor Stop Fig. 33 - Correct Motor RotationTo Start the Chiller OPERATING INSTRUCTIONS Operator DutiesTo Stop the Chiller PUMPOUT AND REFRIGERANT TRANSFER PROCEDURES Operating the Optional Pumpout UnitFig. 34 - Refrigeration Log DATEPlant MACHINE MODEL NOFig. 35 - 19XR Pumpout Unit Wiring Schematic Fig. 36 - Optional Pumpout UnitChillers with Isolation Valves 1. Push refrigerant into the chiller condenserTurn on the pumpout compressor to push the liquid 2. Evacuate the refrigerant gas from chiller cooler vesselGENERAL MAINTENANCE Test After Service, Repair, or Major Leak - IfAccess the TERMINATE LOCKOUT function CVC ICVC from the CONTROL TEST table to view vesselWEEKLY MAINTENANCE Fig. 37 -Guide Vane Actuator LinkageSCHEDULED MAINTENANCE Check Safety and Operating Controls MonthlyInspect the Heat Exchanger Tubes and Flow Devices Compressor Bearing and Gear MaintenanceFig. 38 - 19XR Float Valve Design Ordering Replacement Chiller Parts - When Fig. 39 - Optional Pumpout System ControlsTROUBLESHOOTING GUIDE Checking Pressure TransducersLEGEND TO TABLES 11A-11J to calculate the chilled water/brineCustom Alarm/Alert Messages with Troubleshooting Guides Table 11 - CVC/ICVC Primary and Secondary Messages andA. MANUAL STOP B. READY TO STARTCustom Alarm/Alert Messages with Troubleshooting Guides cont Table 11 - CVC/ICVC Primary and Secondary Messages andE. START-UP IN PROGRESS F. NORMAL RUNCustom Alarm/Alert Messages with Troubleshooting Guides cont H. OUT-OF-RANGE SENSOR ALARMSCheck for high condenser water temperatures or Table 11 - CVC/ICVC Primary and Secondary Messages andI. CHILLER PROTECT LIMIT FAULTS Custom Alarm/Alert Messages with Troubleshooting Guides contTable 11 - CVC/ICVC Primary and Secondary Messages and Custom Alarm/Alert Messages with Troubleshooting Guides cont I. CHILLER PROTECT LIMIT FAULTS contCVC/ICVC, release the stop signal on the STATUS01 Table 11 - CVC/ICVC Primary and Secondary Messages andCustom Alarm/Alert Messages with Troubleshooting Guides cont I. CHILLER PROTECT LIMIT FAULTS contThe refrigerant leak detector’s output wired to ISM has detected a hardware fault and has resetCustom Alarm/Alert Messages with Troubleshooting Guides cont Table 11 - CVC/ICVC Primary and Secondary Messages andJ. CHILLER ALERTS cont Check for proper inlet guide vane and diffuserTable 12A - Thermistor Temperature F vs. Resistance/Voltage Drop Table 12B - Thermistor Temperature C vs. Resistance/Voltage Drop Control Modules Notes on Module OperationIntegrated Starter Module Fig Chiller Control Module CCM FigReplacing Defective Processor Modules Fig. 41 - Chiller Control Module CCM WARNING HIGH VOLTAGEFig. 42 - Integrated Starter Module ISM INTEGRATEDSTARTERMODULEFig. 43 - SCR Installation Table 13A - Heat Exchanger Data English Refrigerant Weight lbCooler CondenserTable 13B - Heat Exchanger Data SI Table 15 - Compressor Weights Table 14 - 19XR Additional Data for Marine WaterboxesTable 16 - 19XR Motor Weights Standard and High Efficiency Motors Table 17A - 19XR Waterbox Cover Weights - English lb Table 17B - 19XR Waterbox Cover Weights - SI kg Table 19 - Additional Miscellaneous Weights Table 18 - Optional Pumpout System Electrical DataTable 20 - Motor Voltage Code 19EA47-748Compressor Assembly Torques Fig. 44 - Compressor Fits and ClearancesCOMPRESSOR, TRANSMISSION AREA VIEW A LOW SPEED SHAFT THRUST DISKFig. 44 - Compressor Fits and Clearances cont VIEW B - HIGH SPEED SHAFT 19XR COMPRESSOR CLEARANCESFig. 45 - Allen-Bradley Wye-Delta Unit-Mounted Starter Fig. 45 - Allen-Bradley Wye-Delta Unit-Mounted Starter cont Fig. 45 - Allen-Bradley Wye-Delta Unit-Mounted Starter cont AUX - Auxiliary BRG - Bearing C - Contactor Page Page Page Fig. 48 - Power Panel Wiring Schematic Fig. 49 - Cutler-Hammer Wye Delta Unit Mounted Starter Sizes 3-5DP Fig. 50 - Cutler-Hammer Wye Delta Unit Mounted Starter Size 6DP Disconnect SwitchCircuit Breaker Current TransformerFig. 51 - Ground Fault Phase Current Option Fig. 52 - Separate Metering OptionVFD - Variable Frequency Drive Represents Twisted Wire To Door L - Main Power Supply VM - Voltmeter Represents Twisted Wire To DoorPage Page MTR - Motor PRESS - Pressure FU - FuseSTAT - Status MTR - Motor PRESS - Pressure FU - FuseSTAT - Status Page Fig. 57 - Typical Variable Frequency Drive VFD Wiring Schematic Fig. 57 - Typical Variable Frequency Drive VFD Wiring Schematic cont Fig. 57 - Typical Variable Frequency Drive VFD Wiring Schematic cont Fig. 57 - Typical Variable Frequency Drive VFD Wiring Schematic cont Fig. 57 - Typical Variable Frequency Drive VFD Wiring Schematic cont Fig. 57 - Typical Variable Frequency Drive VFD Wiring Schematic cont LEGEND FOR FIG Pressure Switch Compr Oil Pump Terminal Cartridge Fuse Earth GroundResistor Chassis Ground Light Temperature Switch Common Potential Dry Contact VFD TerminalINDEX INDEX cont FOR 19XR, XRV HERMETIC CENTRIFUGAL LIQUID CHILLER INITIAL START-UP CHECKLISTRemove and use for job file PIC II CAUTION 19XR, XRV PIC II SETPOINT TABLE CONFIGURATION SHEET 19XR, XRV PIC II TIME SCHEDULE CONFIGURATION SHEET OCCPC01S 19XR, XRV PIC II TIME SCHEDULE CONFIGURATION SHEET OCCPC03SNOTE Default setting is OCCUPIED 24 hours/day NOTE Default setting is UNOCCUPIED 24 hours/dayCUT ALONG DOTTED LINECUT ALONG DOTTED LINE 19XR, XRV PIC II OPTIONS TABLE CONFIGURATION SHEET 19XR, XRV PIC II SETUP1 TABLE CONFIGURATION SHEET 19XR, XRV PIC II SETUP2 TABLE CONFIGURATION SHEET 19XR, XRV PIC II LEADLAG TABLE CONFIGURATION SHEET 19XR, XRV PIC II RAMPDEM TABLE CONFIGURATION SHEET BROADCAST BRODEF CONFIGURATION SHEET Variable by job - refer to component nameplates and labels LOCAL MENU CVC/ICVC DISPLAY AND ALARM SHUTDOWN STATE RECORD SHEETPage specifications or designs incurring obligationsManufacturer reserves