CONTENTS (cont)

Page

Inspect Relief Valves and Piping. . . . . . . . . . . . . . . . . 74

Compressor Bearing and Gear

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Inspect the Heat Exchanger Tubes

and Flow Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

COOLER AND FLOW DEVICES

CONDENSER AND FLOW DEVICES

Water Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Water Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Inspect the Starting Equipment. . . . . . . . . . . . . . . . . . 75

Check Pressure Transducers . . . . . . . . . . . . . . . . . . . . 75

Optional Pumpout System Maintenance . . . . . . . . . 75

OPTIONAL PUMPOUT COMPRESSOR OIL CHARGE

OPTIONAL PUMPOUT SAFETY CONTROL SETTINGS

Ordering Replacement Chiller Parts . . . . . . . . . . . . . 75

TROUBLESHOOTING GUIDE . . . . . . . . . . . . . . . . 76-122

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Checking Display Messages. . . . . . . . . . . . . . . . . . . . . 76

Checking Temperature Sensors . . . . . . . . . . . . . . . . . 76

RESISTANCE CHECK

VOLTAGE DROP

CHECK SENSOR ACCURACY

DUAL TEMPERATURE SENSORS

Checking Pressure Transducers. . . . . . . . . . . . . . . . . 76

UNITS EQUIPPED WITH CVC

UNITS EQUIPPED WITH ICVC

TRANSDUCER REPLACEMENT

Control Algorithms Checkout Procedure . . . . . . . . 77

Control Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Control Modules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

RED LED (Labeled as STAT)

GREEN LED (Labeled as COM)

Notes on Module Operation . . . . . . . . . . . . . . . . . . . . . 87 Chiller Control Module (CCM) . . . . . . . . . . . . . . . . . . . 88

INPUTS

OUTPUTS

Integrated Starter Module . . . . . . . . . . . . . . . . . . . . . . . 88

INPUTS

OUTPUTS

Replacing Defective Processor Modules . . . . . . . . 88

• INSTALLATION

Solid-State Starters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

TESTING SILICON CONTROL RECTIFIERS IN BENSHAW, INC. SOLID-STATE STARTERS

SCR REMOVAL/INSTALLATION

Physical Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123,124

INITIAL START-UP CHECKLIST FOR 19XR, XRV HERMETIC CENTRIFUGAL

LIQUID CHILLER . . . . . . . . . . . . . . . . . . . .CL-1 to CL-16

INTRODUCTION

Prior to initial start-up of the 19XR unit, those involved in the start-up, operation, and maintenance should be thoroughly familiar with these instructions and other necessary job data. This book is outlined to familiarize those involved in the start- up, operation and maintenance of the unit with the control sys- tem before performing start-up procedures. Procedures in this manual are arranged in the sequence required for proper chiller start-up and operation.

This unit uses a microprocessor control system. Do not short or jumper between terminations on circuit boards or modules; control or board failure may result.

Be aware of electrostatic discharge (static electricity) when handling or making contact with circuit boards or module connections. Always touch a chassis (grounded) part to dis- sipate body electrostatic charge before working inside con- trol center.

Use extreme care when handling tools near boards and when connecting or disconnecting terminal plugs. Circuit boards can easily be damaged. Always hold boards by the edges and avoid touching components and connections.

This equipment uses, and can radiate, radio frequency energy. If not installed and used in accordance with the instruction manual, it may cause interference to radio com- munications. It has been tested and found to comply with the limits for a Class A computing device pursuant to Sub- part J of Part 15 of FCC Rules, which are designed to pro- vide reasonable protection against such interference when operated in a commercial environment. Operation of this equipment in a residential area is likely to cause interfer- ence, in which case the user, at his own expense, will be required to take whatever measures may be required to cor- rect the interference.

Always store and transport replacement or defective boards in anti-static shipping bag.

ABBREVIATIONS AND EXPLANATIONS

Frequently used abbreviations in this manual include:

CCM

Chiller Control Module

CCN

Carrier Comfort Network

CCW

Counterclockwise

CVC

Chiller Visual Controller

CW

Clockwise

ECDW

Entering Condenser Water

ECW

Entering Chilled Water

EMS

Energy Management System

HGBP

Hot Gas Bypass

I/O

Input/Output

ICVC

International Chiller Visual Controller

ISM

Integrated Starter Module

LCD

Liquid Crystal Display

LCDW

Leaving Condenser Water

LCW

Leaving Chilled Water

LED

Light-Emitting Diode

OLTA

Overload Trip Amps

PIC II

Product Integrated Controls II

RLA

Rated Load Amps

SCR

Silicon Controlled Rectifier

SI

International System of Units

TXV

Thermostatic Expansion Valve

VFD

Variable Frequency Drive

Words printed in all capital letters or in italics may be viewed on the Chiller Visual Controller/International Chiller Visual Controller (CVC/ICVC) (e.g., LOCAL, CCN, ALARM, etc.).

Words printed in both all capital letters and italics can also be viewed on the CVC/ICVC and are parameters (e.g., CON-

TROL MODE, COMPRESSOR START RELAY, ICE BUILD OPTION, etc.) with associated values (e.g., modes, tempera- tures, percentages, pressures, on, off, etc.).

Words printed in all capital letters and in a box represent

softkeys on the CVC/ICVC control panel (e.g., ENTER ,

EXIT , INCREASE , QUIT , etc.).

4

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Carrier 19XR, XRV specifications Introduction, Abbreviations and Explanations

19XR, XRV specifications

The Carrier 19XR and 19XRV chillers are sophisticated cooling solutions that represent the forefront of HVAC technology. Designed for large commercial and industrial applications, these chillers provide exceptional performance, energy efficiency, and reliability, making them ideal for a variety of environments ranging from hospitals to manufacturing facilities.

One of the most significant features of the Carrier 19XR and 19XRV chillers is their advanced scroll compressor technology. These units employ a tandem scroll design that enhances efficiency while minimizing operational noise. This makes them ideal for urban environments where noise restrictions may be in place. Moreover, the compressors are equipped with variable speed drive options in the 19XRV model, which allows for greater energy savings by adjusting cooling output based on real-time demand.

In addition to their advanced compressors, the 19XR and 19XRV units incorporate the Carrier GreenChoice refrigerant, which has a lower global warming potential compared to traditional refrigerants. This innovative choice not only meets regulatory requirements but also contributes to sustainability goals, making these chillers a responsible choice for environmentally conscious organizations.

The units are engineered with a robust heat exchanger design, which enhances heat transfer efficiency and overall system performance. This ensures optimal operation even in extreme conditions. They feature a microprocessor-based control system that allows for precise monitoring and control of the chiller’s performance, enabling operators to make real-time adjustments to maximize energy efficiency.

The Carrier 19XR and 19XRV chillers also prioritize serviceability. The design incorporates easy access to key components, simplifying maintenance procedures and reducing downtime. This focus on maintainability extends the lifespan of the equipment, leading to lower lifecycle costs.

In terms of connectivity, these chillers are equipped with advanced Building Management System (BMS) integration capabilities. This allows for seamless monitoring and control of the chillers using a centralized platform, facilitating energy management and operational optimization.

Overall, the Carrier 19XR and 19XRV chillers stand out in the market for their blend of cutting-edge technology, energy efficiency, and user-friendly features. They are engineered to meet the demanding needs of modern commercial and industrial applications, making them a preferred choice for facility managers seeking reliable cooling solutions.