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Carrier XRV specifications Typical 19XR Components, Front View, Rear View

Models: 19XR XRV

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FRONT VIEW

FRONT VIEW

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LEGEND

1— Guide Vane Actuator

2— Suction Elbow

3— Chiller Visual Controller/ International Chiller Visual Control (CVC/ICVC)

4— Chiller Identification Nameplate

5— Cooler, Auto Reset Relief Valves

6— Cooler Pressure Transducer

7— Condenser In/Out Temperature Thermistors

8— Condenser Waterflow Device (ICVC Inputs available)

9— Cooler In/Out Temperature Thermistors

10— Cooler Waterflow Device (ICVC Inputs avail- able)

11— Refrigerant Charging Valve

12— Typical Flange Connection

13— Oil Drain Charging Valve

14— Oil Level Sight Glasses

15— Refrigerant Oil Cooler (Hidden)

16— Auxiliary Power Panel

17— Compressor Motor Housing

REAR VIEW

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22

34

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28 27

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LEGEND

18— Condenser Auto. Reset Relief Valves

23 19 — Compressor Motor Circuit Breaker

20— Solid-State Starter Control Display

21— Unit-Mounted Starter (Optional)

Solid-State Starter Shown

22— Motor Sight Glass

23— Cooler Return-End Waterbox Cover

24— ASME Nameplate (One Hidden)

25— Typical Waterbox Drain Port

26 — Condenser Return-End Waterbox Cover

27 — Refrigerant Moisture/Flow Indicator

28 — Refrigerant Filter/Drier

29— Liquid Line Isolation Valve (Optional)

30— Linear Float Valve Chamber

31— Vessel Take-Apart Connector

32— Discharge Isolation Valve (Optional)

33 — Pumpout Valve

34 — Condenser Pressure Transducer

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Fig. 2 — Typical 19XR Components

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Carrier XRV specifications Typical 19XR Components, Front View, Rear View

Contents

SAFETY CONSIDERATIONS Start-Up, Operation, and Maintenance Instructionsopen flame produces toxic gases Using the Optional Storage Tank CONTENTSHigh Discharge Temperature Control ABBREVIATIONS AND EXPLANATIONS . . . . . . . . 4,5PUMPOUT AND REFRIGERANT TRANSFER PROCEDURES CONTENTS contPower Up the Controls and Check Safety and Operating ControlsControl Algorithms Checkout Procedure Optional Pumpout System MaintenanceOrdering Replacement Chiller Parts INITIAL START-UP CHECKLIST FOR 19XR, XRV HERMETIC CENTRIFUGALCHILLER FAMILIARIZATION Fig. 1 and Fig. 1 - 19XR IdentificationFig. 2 - Typical 19XR Components FRONT VIEWREAR VIEW REFRIGERATION CYCLE MOTOR AND LUBRICATING OIL COOLING CYCLEFig. 3 - Refrigerant Motor Cooling and Oil Cooling Cycles VFD COOLING CYCLE LUBRICATION CYCLESTARTING EQUIPMENT Unit-Mounted Solid-State Starter OptionalFig. 4 - Lubrication System Fig. 5 - Solid-State Starter Box Internal View Unit-Mounted Wye-Delta Starter OptionalCONTROLS Definitions 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 DETAILFig. 10 - Control Sensors Temperature Fig. 11 - Control Sensors Table 1 - Major PIC II Components and Panel LocationsPressure Transducers, Typical Fig. 13 - Power Panel Fig. 12 - Control PanelFig. 14 - CVC/ICVC Default Screen Fig. 15 - CVC/ICVC Service 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 ICVC - International Chiller Visual Controller Fig. 18 - 19XR Service Menu Structure contCCN - Carrier Comfort Network CVC - 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 PIC II System Functions SURGE/HGBP DELTA T≤ SURGE/HGBP DELTA T high bearing temperature high motor winding temperature Table 3 - Protective Safety Limits and Control Settings table. Adjust EVAP REFRIG TRIPPOINT forCONDENSER 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 The CONTROL POINT is forced to the ICE BUILD SET POINT and the ICE BUILD OPTION is enabled20 mA DEMAND LIMIT OPT configured on RAMPDEM screen 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 Fig. 32 - Benshaw RediStart MICRO Default Display Table 6 - Benshaw RediStart MICRO Menu StructureTable 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 100% 5. Set TARGET VFD SPEED to 0%Set VFD 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 ChargeCheck Oil Pressure and Compressor Stop Dry Run to Test Start-Up SequenceCheck Motor Rotation Fig. 33 - Correct Motor RotationOPERATING INSTRUCTIONS Operator Duties To Start the ChillerTo Stop the Chiller PUMPOUT AND REFRIGERANT TRANSFER PROCEDURES Operating the Optional Pumpout UnitPlant Fig. 34 - Refrigeration LogDATE MACHINE MODEL NOFig. 35 - 19XR Pumpout Unit Wiring Schematic Fig. 36 - Optional Pumpout UnitTurn on the pumpout compressor to push the liquid Chillers with Isolation Valves1. Push refrigerant into the chiller condenser 2. Evacuate the refrigerant gas from chiller cooler vesselAccess the TERMINATE LOCKOUT function CVC GENERAL MAINTENANCETest After Service, Repair, or Major Leak - If ICVC from the CONTROL TEST table to view vesselWEEKLY MAINTENANCE Fig. 37 -Guide Vane Actuator LinkageSCHEDULED MAINTENANCE Check Safety and Operating Controls MonthlyCompressor Bearing and Gear Maintenance Inspect the Heat Exchanger Tubes and Flow DevicesFig. 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/brineA. MANUAL STOP Custom Alarm/Alert Messages with Troubleshooting GuidesTable 11 - CVC/ICVC Primary and Secondary Messages and B. READY TO STARTE. START-UP IN PROGRESS Custom Alarm/Alert Messages with Troubleshooting Guides contTable 11 - CVC/ICVC Primary and Secondary Messages and F. NORMAL RUNCheck for high condenser water temperatures or Custom Alarm/Alert Messages with Troubleshooting Guides contH. OUT-OF-RANGE SENSOR ALARMS Table 11 - CVC/ICVC Primary and Secondary Messages andCustom Alarm/Alert Messages with Troubleshooting Guides cont I. CHILLER PROTECT LIMIT FAULTSTable 11 - CVC/ICVC Primary and Secondary Messages and CVC/ICVC, release the stop signal on the STATUS01 Custom Alarm/Alert Messages with Troubleshooting Guides contI. CHILLER PROTECT LIMIT FAULTS cont Table 11 - CVC/ICVC Primary and Secondary Messages andThe refrigerant leak detector’s output wired to Custom Alarm/Alert Messages with Troubleshooting Guides contI. CHILLER PROTECT LIMIT FAULTS cont ISM has detected a hardware fault and has resetJ. CHILLER ALERTS cont Custom Alarm/Alert Messages with Troubleshooting Guides contTable 11 - CVC/ICVC Primary and Secondary Messages and 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 OperationChiller Control Module CCM Fig Integrated Starter Module FigReplacing Defective Processor Modules Fig. 42 - Integrated Starter Module ISM Fig. 41 - Chiller Control Module CCMWARNING HIGH VOLTAGE INTEGRATEDSTARTERMODULEFig. 43 - SCR Installation Cooler Table 13A - Heat Exchanger Data EnglishRefrigerant Weight lb 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 20 - Motor Voltage Code Table 19 - Additional Miscellaneous WeightsTable 18 - Optional Pumpout System Electrical Data 19EA47-748COMPRESSOR, TRANSMISSION AREA Compressor Assembly TorquesFig. 44 - Compressor Fits and Clearances 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 Circuit Breaker Fig. 50 - Cutler-Hammer Wye Delta Unit Mounted Starter Size 6DPDisconnect Switch Current TransformerVFD - Variable Frequency Drive Represents Twisted Wire To Door Fig. 51 - Ground Fault Phase Current OptionFig. 52 - Separate Metering Option L - Main Power Supply VM - Voltmeter Represents Twisted Wire To DoorPage Page FU - Fuse MTR - Motor PRESS - PressureSTAT - Status FU - Fuse MTR - Motor PRESS - PressureSTAT - 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 Resistor Chassis Ground Light Temperature Switch Common Potential LEGEND FOR FIGPressure Switch Compr Oil Pump Terminal Cartridge Fuse Earth Ground Dry Contact VFD TerminalINDEX INDEX cont INITIAL START-UP CHECKLIST FOR 19XR, XRV HERMETIC CENTRIFUGAL LIQUID CHILLERRemove and use for job file PIC II CAUTION 19XR, XRV PIC II SETPOINT TABLE CONFIGURATION SHEET NOTE Default setting is OCCUPIED 24 hours/day 19XR, XRV PIC II TIME SCHEDULE CONFIGURATION SHEET OCCPC01S19XR, XRV PIC II TIME SCHEDULE CONFIGURATION SHEET OCCPC03S 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 Manufacturer specifications or designsincurring obligations reserves