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Carrier XRV specifications 19XR Leak Test Procedures

Models: 19XR XRV

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Fig. 28 — 19XR Leak Test Procedures

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Fig. 28 — 19XR Leak Test Procedures

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Carrier XRV specifications 19XR Leak Test Procedures

Contents

Start-Up, Operation, and Maintenance Instructions SAFETY CONSIDERATIONSopen flame produces toxic gases High Discharge Temperature Control CONTENTSUsing the Optional Storage Tank ABBREVIATIONS AND EXPLANATIONS . . . . . . . . 4,5Power Up the Controls and CONTENTS contPUMPOUT AND REFRIGERANT TRANSFER PROCEDURES Check Safety and Operating ControlsOrdering Replacement Chiller Parts Optional Pumpout System MaintenanceControl Algorithms Checkout Procedure INITIAL START-UP CHECKLIST FOR 19XR, XRV HERMETIC CENTRIFUGALFig. 1 - 19XR Identification CHILLER FAMILIARIZATION Fig. 1 andFRONT VIEW Fig. 2 - Typical 19XR ComponentsREAR VIEW MOTOR AND LUBRICATING OIL COOLING CYCLE REFRIGERATION CYCLEFig. 3 - Refrigerant Motor Cooling and Oil Cooling Cycles LUBRICATION CYCLE VFD COOLING CYCLEUnit-Mounted Solid-State Starter Optional STARTING EQUIPMENTFig. 4 - Lubrication System CONTROLS Definitions Unit-Mounted Wye-Delta Starter OptionalFig. 5 - Solid-State Starter Box Internal View Fig. 6 - Typical Starter External View Solid-State Starter ShownFig. 8 - Variable Frequency Drive VFD Starter Internal View Fig. 7 - Variable Frequency Drive VFDTOP VIEW COMPRESSOR DETAIL Fig. 9 - 19XR Controls and Sensor LocationsTable 1 - Major PIC II Components and Panel Locations Fig. 10 - Control Sensors Temperature Fig. 11 - Control SensorsPressure Transducers, Typical Fig. 12 - Control Panel Fig. 13 - Power 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 CCN - Carrier Comfort Network CVC - Chiller Visual Controller Fig. 18 - 19XR Service Menu Structure contICVC - 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 ISMSTAT Table 2 - CVC/ICVC Display Data contTable 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 Value Table 4 - Capacity OverridesEvaporator 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 Fig. 23 - Head Pressure Reference Output Surge Protection Fixed Speed Chiller - TheLead/Lag System Requirements 1. Lead chiller ramp loading must be complete 20 mA DEMAND LIMIT OPT configured on RAMPDEM screen and the ICE BUILD OPTION is enabledThe 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 Fig. 26 - Control Sequence START-UP/SHUTDOWN RECYCLE SEQUENCE Figa recycle condition is present see Chilled Water Recycle Mode section ENTERING CONDENSER WATER temperature plus 3 F -1.6 CEquipment Required BEFORE INITIAL START-UP Job Data RequiredFig. 28 - 19XR Leak Test Procedures 1. If the pressure readings are normal for the chiller condition Page Table 5B - HFC-134a Pressure Temperature C Table 5A - HFC-134a Pressure Temperature FFig. 31 - Dehydration Cold Trap Inspect WiringCheck Starter Input the Local Occupied Schedule OCCPC01S Software Configuration5. 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 VFD Cooling System Leak Inspection Set TARGET VFD SPEED to 0%Set VFD TARGET VFD SPEED to 100% 5. Set TARGET VFD SPEED to 0%5. Set TARGET VFD SPEED to 100% Error RatioEstimated Maximum Load Conditions Estimated Minimum Load Conditions1724 kPa. To calibrate these transducers Table 9 - Control Test Menu Functions Charge Refrigerant into ChillerTable 10 - Refrigerant HFC-134a Charge INITIAL START-UPCheck Motor Rotation Dry Run to Test Start-Up SequenceCheck Oil Pressure and Compressor Stop Fig. 33 - Correct Motor RotationTo Start the Chiller OPERATING INSTRUCTIONS Operator DutiesTo Stop the Chiller Operating the Optional Pumpout Unit PUMPOUT AND REFRIGERANT TRANSFER PROCEDURESDATE Fig. 34 - Refrigeration LogPlant MACHINE MODEL NOFig. 36 - Optional Pumpout Unit Fig. 35 - 19XR Pumpout Unit Wiring Schematic1. Push refrigerant into the chiller condenser Chillers with Isolation ValvesTurn on the pumpout compressor to push the liquid 2. Evacuate the refrigerant gas from chiller cooler vesselTest After Service, Repair, or Major Leak - If GENERAL MAINTENANCEAccess the TERMINATE LOCKOUT function CVC ICVC from the CONTROL TEST table to view vesselFig. 37 -Guide Vane Actuator Linkage WEEKLY MAINTENANCECheck Safety and Operating Controls Monthly SCHEDULED MAINTENANCEInspect the Heat Exchanger Tubes and Flow Devices Compressor Bearing and Gear MaintenanceFig. 38 - 19XR Float Valve Design Fig. 39 - Optional Pumpout System Controls Ordering Replacement Chiller Parts - WhenChecking Pressure Transducers TROUBLESHOOTING GUIDEto calculate the chilled water/brine LEGEND TO TABLES 11A-11JTable 11 - CVC/ICVC Primary and Secondary Messages and Custom Alarm/Alert Messages with Troubleshooting GuidesA. MANUAL STOP B. READY TO STARTTable 11 - CVC/ICVC Primary and Secondary Messages and Custom Alarm/Alert Messages with Troubleshooting Guides contE. START-UP IN PROGRESS F. NORMAL RUNH. OUT-OF-RANGE SENSOR ALARMS Custom Alarm/Alert Messages with Troubleshooting Guides contCheck 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 I. CHILLER PROTECT LIMIT FAULTS cont Custom Alarm/Alert Messages with Troubleshooting Guides contCVC/ICVC, release the stop signal on the STATUS01 Table 11 - CVC/ICVC Primary and Secondary Messages andI. CHILLER PROTECT LIMIT FAULTS cont Custom Alarm/Alert Messages with Troubleshooting Guides contThe refrigerant leak detector’s output wired to ISM has detected a hardware fault and has resetTable 11 - CVC/ICVC Primary and Secondary Messages and Custom Alarm/Alert Messages with Troubleshooting Guides contJ. 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 Notes on Module Operation Control ModulesIntegrated Starter Module Fig Chiller Control Module CCM FigReplacing Defective Processor Modules WARNING HIGH VOLTAGE Fig. 41 - Chiller Control Module CCMFig. 42 - Integrated Starter Module ISM INTEGRATEDSTARTERMODULEFig. 43 - SCR Installation Refrigerant Weight lb Table 13A - Heat Exchanger Data EnglishCooler CondenserTable 13B - Heat Exchanger Data SI Table 14 - 19XR Additional Data for Marine Waterboxes Table 15 - Compressor WeightsTable 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 18 - Optional Pumpout System Electrical Data Table 19 - Additional Miscellaneous WeightsTable 20 - Motor Voltage Code 19EA47-748Fig. 44 - Compressor Fits and Clearances Compressor Assembly TorquesCOMPRESSOR, TRANSMISSION AREA VIEW A LOW SPEED SHAFT THRUST DISKVIEW B - HIGH SPEED SHAFT 19XR COMPRESSOR CLEARANCES Fig. 44 - Compressor Fits and Clearances contFig. 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 Disconnect Switch Fig. 50 - Cutler-Hammer Wye Delta Unit Mounted Starter Size 6DPCircuit Breaker Current TransformerFig. 52 - Separate Metering Option Fig. 51 - Ground Fault Phase Current 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 Pressure Switch Compr Oil Pump Terminal Cartridge Fuse Earth Ground LEGEND FOR FIGResistor 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 OCCPC03S 19XR, XRV PIC II TIME SCHEDULE CONFIGURATION SHEET OCCPC01SNOTE 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 CVC/ICVC DISPLAY AND ALARM SHUTDOWN STATE RECORD SHEET MENUPage incurring obligations specifications or designsManufacturer reserves