Carrier 19XR User Manual

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AquaEdge

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19XR

Two-Stage Semi-Hermetic Centrifugal Liquid Chillers

with PIC 5 Controls and HFC-134a

50/60 Hz

Start-Up, Operation, and Maintenance Instructions

SAFETY CONSIDERATIONS

Centrifugal liquid chillers are designed to provide safe and reliable service when operated within design specifications. When operating this equipment, use good judgment and safety precautions to avoid damage to equipment and property or injury to personnel.

Be sure you understand and follow the procedures and safety precautions contained in the chiller instructions as well as those listed in this guide.

DANGER

Failure to follow these procedures will result in severe personal injury or death.

DO NOT VENT refrigerant relief valves within a building. Outlet from rupture disc or relief valve must be vented outdoors in accordance with the latest edition of ANSI/ ASHRAE 15 (American National Standards Institute/ American Society of Heating, Refrigerating, and AirConditioning Engineers). The accumulation of refrigerant in an enclosed space can displace oxygen and cause asphyxiation.

PROVIDE adequate ventilation in accordance with ANSI/ ASHRAE 15, especially for enclosed and low overhead spaces. Inhalation of high concentrations of vapor is harmful and may cause heart irregularities, unconsciousness, or death. Misuse can be fatal. Vapor is heavier than air and reduces the amount of oxygen available for breathing. Product causes eye and skin irritation. Decomposition products are hazardous.

DO NOT USE OXYGEN to purge lines or to pressurize a chiller for any purpose. Oxygen gas reacts violently with oil, grease, and other common substances.

NEVER EXCEED specified test pressures; VERIFY the allowable test pressure by checking the instruction literature and the design pressures on the equipment nameplate.

DO NOT USE air for leak testing. Use only refrigerant or dry nitrogen.

DO NOT VALVE OFF any safety device. BE SURE that all pressure relief devices are properly

installed and functioning before operating any chiller. RISK OF INJURY OR DEATH by electrocution. High

voltage is present on motor leads even though the motor is not running when a solid-state or wye-delta mechanical starter is used. Open the power supply disconnect before touching motor leads or terminals.

WARNING

Failure to follow these procedures may result in personal injury or death.

DO NOT USE TORCH to remove any component. System contains oil and refrigerant under pressure.

To remove a component, wear protective gloves and goggles and proceed as follows:

a. Shut off electrical power to unit. b. Recover refrigerant to relieve all pressure from sys-

tem using both high-pressure and low pressure ports.

c. Traces of vapor should be displaced with nitrogen

and the work area should be well ventilated. Refrigerant in contact with an open flame produces toxic gases.

d. Cut component connection tubing with tubing cutter

and remove component from unit. Use a pan to catch any oil that may come out of the lines and as a gage for how much oil to add to the system.

e. Carefully unsweat remaining tubing stubs when nec-

essary. Oil can ignite when exposed to torch flame.

DO NOT USE eyebolts or eyebolt holes to rig chiller sections or the entire assembly.

DO NOT work on high-voltage equipment unless you are a qualified electrician.

DO NOT WORK ON electrical components, including control panels, switches, starters, or oil heater until you are sure ALL POWER IS OFF and no residual voltage can leak from capacitors or solid-state components.

LOCK OPEN AND TAG electrical circuits during servicing. IF WORK IS INTERRUPTED, confirm that all circuits are deenergized before resuming work.

AVOID SPILLING liquid refrigerant on skin or getting it into the eyes. USE SAFETY GOGGLES. Wash any spills from the skin with soap and water. If liquid refrigerant enters the eyes, IMMEDIATELY FLUSH EYES with water and consult a physician.

NEVER APPLY an open flame or live steam to a refrigerant cylinder. Dangerous over pressure can result. When it is necessary to heat refrigerant, use only warm (110 F [43 C]) water.

DO NOT REUSE disposable (nonreturnable) cylinders or attempt to refill them. It is DANGEROUS AND ILLEGAL. When cylinder is emptied, evacuate remaining gas pressure, loosen the collar and unscrew and discard the valve stem. DO NOT INCINERATE.

CHECK THE REFRIGERANT TYPE before adding refrigerant to the chiller. The introduction of the wrong refrigerant can cause damage or malfunction to this chiller.

(Warnings continued on next page.)

Manufacturer reserves the right to discontinue, or change at any time, specificatio ns or designs without not ice and without incurring obligations.

Catalog No. 04-53190038-01 Printed in U.S.A. Form 19XR-CLT-12SS Pg 1 12-15 Replaces: 19XR-CLT-11SS

WARNING

Operation of this equipment with refrigerants other than those cited herein should comply with ANSI/ASHRAE 15 (latest edition). Contact Carrier for further information on use of this chiller with other refrigerants.

DO NOT ATTEMPT TO REMOVE fittings, covers, etc., while chiller is under pressure or while chiller is running. Be sure pressure is at 0 psig (0 kPa) before breaking any refrigerant connection.

CAREFULLY INSPECT all relief valves, rupture discs, and other relief devices AT LEAST ONCE A YEAR. If chiller operates in a corrosive atmosphere, inspect the devices at more frequent intervals.

DO NOT ATTEMPT TO REPAIR OR RECONDITION any relief device when corrosion or build-up of foreign material (rust, dirt, scale, etc.) is found within the valve body or mechanism. Replace the device.

DO NOT install relief devices in series or backwards. USE CARE when working near or in line with a com-

pressed spring. Sudden release of the spring can cause it and objects in its path to act as projectiles.

CAUTION

Failure to follow these procedures may result in personal injury or damage to equipment.

DO NOT STEP on refrigerant lines. Broken lines can whip about and release refrigerant, causing personal injury.

DO NOT climb over a chiller. Use platform, catwalk, or staging. Follow safe practices when using ladders.

USE MECHANICAL EQUIPMENT (crane, hoist, etc.) to lift or move inspection covers or other heavy components. Even if components are light, use mechanical equipment when there is a risk of slipping or losing your balance.

BE AWARE that certain automatic start arrangements CAN ENGAGE THE STARTER, TOWER FAN, OR PUMPS. Open the disconnect ahead of the starter, tower fans, or pumps.

USE only repair or replacement parts that meet the code requirements of the original equipment.

DO NOT VENT OR DRAIN waterboxes containing industrial brines, liquid, gases, or semisolids without the permission of your process control group.

DO NOT LOOSEN waterbox cover bolts until the waterbox has been completely drained.

DO NOT LOOSEN a packing gland nut before checking that the nut has a positive thread engagement.

PERIODICALLY INSPECT all valves, fittings, and piping for corrosion, rust, leaks, or damage.

PROVIDE A DRAIN connection in the vent line near each pressure relief device to prevent a build-up of condensate or rain water.

DO NOT re-use compressor oil or any oil that has been exposed to the atmosphere. Dispose of oil per local codes and regulations.

DO NOT leave refrigerant system open to air any longer than the actual time required to service the equipment. Seal circuits being serviced and charge with dry nitrogen to prevent oil contamination when timely repairs cannot be completed.

Page

SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . . 1,2

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

ABBREVIATIONS AND EXPLANATIONS . . . . . . . . . . . . 4

CHILLER FAMILIARIZATION. . . . . . . . . . . . . . . . . . . . . . .4-6

Chiller Information Nameplate . . . . . . . . . . . . . . . . . . . . . . 4

System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Condenser. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Motor-Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Economizer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Free-Standing Starter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

REFRIGERATION CYCLE . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

MOTOR AND OIL COOLING CYCLE. . . . . . . . . . . . . . . . . 8

LUBRICATION CYCLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8,9

Summary

Details. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Bearings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Oil Reclaim System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

• PRIMARY OIL RECOVERY MODE

• SECONDARY OIL RECOVERY METHOD

STARTING EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Solid-State Starter (Optional) . . . . . . . . . . . . . . . . . . . . . 10

Freestanding Medium Voltage VFD (Optional) . . . . . 10

CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

• ANALOG SIGNAL

• DISCRETE SIGNAL

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

PIC 5 System Components . . . . . . . . . . . . . . . . . . . . 10,11

START-UP/SHUTDOWN/RECYCLE

SEQUENCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11,12

Local Start/Stop Control . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Lubrication Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

BEFORE INITIAL START-UP . . . . . . . . . . . . . . . . . . . . .13-28

Job Data Required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Equipment Required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Remove Shipping Packaging . . . . . . . . . . . . . . . . . . . . . . 13

Open Oil Circuit Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Tighten All Gasketed Joints . . . . . . . . . . . . . . . . . . . . . . . 13

Check Chiller Tightness . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Refrigerant Tracer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Leak Test Chiller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Standing Vacuum Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Chiller Dehydration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Inspect Water Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Check Relief Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Inspect Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Check Starter

• MECHANICAL STARTER

• SOLID-STATE STARTER

Oil Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Power Up the Controls and

Check the Oil Heater

Software Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Input the Design Set Points. . . . . . . . . . . . . . . . . . . . . . . 20

Input the Local Occupied Schedule. . . . . . . . . . . . . . . . 20

Input Service Configurations

•PASSWORD

• LOGIN/LOGOUT

• INPUT TIME AND DATE

• MODIFY CONTROLLER IDENTIFICATION

IF NECESSARY

• CONFIGURE SERVICE TABLES

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

. . . . . . . . . . . . . . . . . . . . . . . . . . . 19

. . . . . . . . . . . . . . . . . . . . . 20

CONTENTS (cont)

Page

Field Set Up and Verification . . . . . . . . . . . . . . . . . . . . . . .22

• LABEL LOCATIONS

• STARTER/DRIVE PROTECTION AND OTHER INCOMING WIRING

• FINE TUNING VPF (VARIABLE PRIMARY FLOW) SURGE PREVENTION

• MODIFY EQUIPMENT CONFIGURATION IF NECESSARY

Perform a Control Test (Quick Test) . . . . . . . . . . . . . . . .24

Charge Refrigerant Into Chiller

• CHILLER EQUALIZATION WITHOUT A PUMPOUT UNIT

• CHILLER EQUALIZATION WITH FREE-STANDING PUMPOUT UNIT

• TRIMMING REFRIGERANT CHARGE

INITIAL START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29,30

Preparation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

Check Motor Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

Check Oil Pressure and Compressor Stop . . . . . . . . .29

To Prevent Accidental Start-Up. . . . . . . . . . . . . . . . . . . . .29

Check Chiller Operating Condition . . . . . . . . . . . . . . . . .29

Instruct the Customer Operator . . . . . . . . . . . . . . . . . . . .29

• COOLER-CONDENSER

• OPTIONAL PUMPOUT STORAGE TANK AND PUMPOUT SYSTEM

• MOTOR COMPRESSOR ASSEMBLY

• MOTOR COMPRESSOR LUBRICATION SYSTEM

• ECONOMIZER

• CONTROL SYSTEM

• AUXILIARY EQUIPMENT

• DESCRIBE CHILLER CYCLES

• REVIEW MAINTENANCE

• SAFETY DEVICES AND PROCEDURES

• CHECK OPERATOR KNOWLEDGE

• REVIEW THE START-UP, OPERATION, AND MAINTENANCE MANUAL

OPERATING INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . 30,31

Operator Duties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

Prepare the Chiller for Start-Up. . . . . . . . . . . . . . . . . . . . .30

To Start the Chiller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

Check the Running System. . . . . . . . . . . . . . . . . . . . . . . . .30

To Stop the Chiller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

After Limited Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

Preparation for Extended Shutdown. . . . . . . . . . . . . . . .30

After Extended Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . .30

Cold Weather Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . .31

Manual Guide Vane Operation. . . . . . . . . . . . . . . . . . . . . .31

Refrigeration Log. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

PUMPOUT AND REFRIGERANT TRANSFER

PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31-36

Preparation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

Operating the Optional Pumpout Unit . . . . . . . . . . . . . .33

• TO READ REFRIGERANT PRESSURES

• POSITIVE PRESSURE CHILLERS WITH STORAGE

TANKS

• CHILLERS WITH ISOLATION VALVES

• DISTILLING THE REFRIGERANT

GENERAL MAINTENANCE . . . . . . . . . . . . . . . . . . . . . .36-38

Refrigerant Properties. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36

Adding Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36

Adjusting the Refrigerant Charge. . . . . . . . . . . . . . . . . . .36

Refrigerant Leak Testing . . . . . . . . . . . . . . . . . . . . . . . . . . .36

Leak Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36

. . . . . . . . . . . . . . . . . . . 25

Page

Test After Service, Repair, or Major Leak. . . . . . . . . . .36

• TESTING WITH REFRIGERANT TRACER

• TESTING WITHOUT REFRIGERANT TRACER

• TO PRESSURIZE WITH DRY NITROGEN

Repair the Leak, Retest, and Apply

Standing Vacuum Test. . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Checking Guide Vanes . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36

Trim Refrigerant Charge . . . . . . . . . . . . . . . . . . . . . . . . . . .38

WEEKLY MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . .38

Check the Lubrication System . . . . . . . . . . . . . . . . . . . . .38

SCHEDULED MAINTENANCE . . . . . . . . . . . . . . . . . . . 38-41

Service Ontime. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38

Inspect the Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . .38

Changing Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Oil Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Oil Changes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

• TO CHANGE THE OIL

Refrigerant Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Oil Reclaim Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Inspect Refrigerant Float System. . . . . . . . . . . . . . . . . . . 39

• ECONOMIZER FLOAT SYSTEM

• ECONOMIZER DAMPER VALVE

Inspect Relief Valves and Piping . . . . . . . . . . . . . . . . . . .40

Compressor Bearing and Gear

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

Inspect the Heat Exchanger Tubes

and Flow Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

• COOLER AND OPTIONAL FLOW DEVICES

• CONDENSER AND OPTIONAL FLOW DEVICES

Water Leaks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Water Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Inspect the Starting Equipment . . . . . . . . . . . . . . . . . . . .41

Recalibrate Pressure Transducers . . . . . . . . . . . . . . . . . 41

Optional Pumpout System Maintenance. . . . . . . . . . . .41

• OPTIONAL PUMPOUT COMPRESSOR OIL

CHARGE

• OPTIONAL PUMPOUT SAFETY CONTROL

SETTINGS

Ordering Replacement Chiller Parts. . . . . . . . . . . . . . . . 41

TROUBLESHOOTING GUIDE . . . . . . . . . . . . . . . . . . . . 42-87

Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

Checking Display Messages . . . . . . . . . . . . . . . . . . . . . . . 42

Checking Temperature Sensors. . . . . . . . . . . . . . . . . . . . 42

• RESISTANCE CHECK

• VOLTAGE DROP

• CHECK SENSOR ACCURACY

• DUAL TEMPERATURE SENSORS

Checking Pressure Transducers . . . . . . . . . . . . . . . . . . .46

• TRANSDUCER REPLACEMENT

• COOLER AND CONDENSER PRESSURE

TRANSDUCER CALIBRATION

• OPTIONAL THERMAL DISPERSION FLOW

SWITCH CALIBRATION

• HYDRAULIC STATUS

High Altitude Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . .46

Quick Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Pumpdown/Lockout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Physical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48

APPENDIX A — PIC 5 SCREEN AND

MENU STRUCTURE . . . . . . . . . . . . . . . . . . . . . . . .. .88-91

APPENDIX B — CCN COMMUNICATION WIRING

FOR MULTIPLE CHILLERS (TYPICAL) . . . . . . . . . . .92

APPENDIX C — MAINTENANCE SUMMARY

AND LOG SHEETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93-95

INDEX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

INITIAL START-UP CHECKLIST FOR

19XR SEMI-HERMETIC TWO-STAGE

CENTRIFUGAL LIQUID CHILLER. . . . . . .CL-1 to CL- 10

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. Procedures in this manual are arranged in the sequence required for proper chiller start-up and operation. This book also outlines the control system for those involved in the start-up, operation and maintenance of the unit before performing startup procedures. It is intended to be used in combination with the 19XR Two-Stage High-Efficiency Semi-Hermetic Centrifugal Liquid Chillers Controls Operation and Troubleshooting manual that describes PIC 5 controls in detail.

CAUTION

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 dissipate body electrostatic charge before working inside control 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 communications. The PIC 5 control boards have been tested and found to comply with the limits for a Class A computing device pursuant to International Standard in North America EN 61000-2/3 which are designed to provide reasonable protection against such interference when operated in a commercial environment. Operation of this equipment in a residential area is likely to cause interference, in which case the user, at his own expense, will be required to take whatever measures may be required to correct the interference.

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

CAUTION

Do NOT punch holes or drill into the top surface of the starter enclosure for field wiring. Knockouts are provided for field wiring connections.

CAUTION

PROVIDE MACHINE PROTECTION. Store machine and starter indoors, protected from construction dirt and moisture. Inspect under shipping tarps, bags or crates to be sure water has not collected during transit. Keep protective shipping covers in place until machine is ready for installation.

CAUTION

WHEN FLUSHING THE WATER SYSTEMS isolate the chiller from the water circuits to prevent damage to the heat exchanger tubes.

ABBREVIATIONS AND EXPLANATIONS

Frequently used abbreviations in this manual include:

CCN — Carrier Comfort Network ECDW — Entering Condenser Water ECW — Entering Chilled Water EMS — Energy Management System HGBP — Hot Gas Bypass HMI — Human Machine Interface I/O — Input/Output ISM — Integrated Starter Module LCDW — Leaving Condenser Water LCW — Leaving Chilled Water LED — Light-Emitting Diode OLTA — Overload Trip Amps PIC 5 — Product Integrated Controls 5 RLA — Rated Load Amps SCR — Silicon Controlled Rectifier TXV — Thermostatic Expansion Valve VFD — Variable Frequency Drive

Factory-installed additional components are referred to as options in this manual; factory-supplied but field-installed additional components are referred to as accessories.

CHILLER FAMILIARIZATION (Fig. 1 and 2) Chiller Information Nameplate —

nameplate is located on the right side of the chiller control panel.

The information

System Components — The components include the

cooler and condenser heat exchangers in separate vessels, motor-compressor, lubrication package, control panel, economizer, and motor starter. All connections from pressure vessels have external threads to enable each component to be pressure tested with a threaded pipe cap during factory assembly.

Cooler — This vessel (also known as the evaporator) is lo-

cated underneath the compressor. The cooler is maintained at lower temperature/pressure so evaporating refrigerant can remove heat from water flowing through its internal tubes.

Condenser — The condenser operates at a higher tem-

perature/pressure than the cooler and has water flowing through its internal tubes in order to remove heat from the refrigerant.

Motor-Compressor — This component maintains sys-

tem temperature and pressure differences and moves the heatcarrying refrigerant from the cooler to the condenser. The 19XR two-stage frame 6 and frame 7 compressors are twostage compressors with two impellers.

Control Panel — The control panel is the user interface

for controlling the chiller. It regulates the chiller’s capacity as required to maintain proper leaving chilled water temperature. The control panel:

• registers cooler, condenser, and lubricating system

pressures

• shows chiller operating condition and alarm shutdown

conditions

• records the total chiller operating hours

• sequences chiller start, stop, and recycle under micropro-

cessor control

• displays status of motor starter

• provides access to other CCN (Carrier Comfort Net-

• supports languages that may be pre-installed at factory,

work

) devices and energy management systems

including English, Chinese, Spanish, French, and

German.

Economizer — This chamber reduces the refrigerant pres-

636

Motor Size Code

Compressor Frame Size 6

G (2250 HP, copper rotor) H (2375 HP, copper rotor) J (2500 HP, copper rotor) K (2625 HP, copper rotor) L (2750 HP, copper rotor) N — 1500 HP P — 1625 HP Q — 1750 HP R — 1875 HP S — 2000 HP T — 2100 HP

Compressor Frame Size 7

U — 2250 HP V — 2375 HP W — 2500 HP

X — 2625 HP Y — 2750 HP Z — 2900 HP

Motor V oltage Code Code Volts-Phase-Hertz

Special Order Indicator – — Standard S — Special Order

Gear Code

Compressor Frame Size 6

E J M P

Compressor Frame Size 7

R T V X Y

Compressor Size Code

Frame Size (12th Digit)

6 — Frame Size 6 7 — Frame Size 7

Centrifugal Liquid Chiller

Description 19XR– — High Efﬁciency Semi-Hermetic

19XR–

A45

A47

Cooler Size Code (Digits 6, 7, 8)

A40-A42 A45-A47 A4A-A4C* A4F-A4H* A60-A62 A65-A67 A6A-A6C* A6F-A6H* B60-B62 B65-B67 B80-B82** B85-B-87** B6A-B6C* B6F-B6H* B8A-B8C** B8F-B8H C60-C62 C65-C67 C6A-C6C* C6F-C6H*

Condenser Size Code (Digits 9, 10, 11)

A40-A42 A45-A47 A4A-A4C* A4F-A4H* A60-A62 A65-A67 A6A-A6C* A6F-A6H* B40-B42 B45-B47 B4A-B4C* B4F-B4H* B60-B62 B65-B67 B6A-B6C* B6F-B6H* C60-C62 C65-C67 C80-C82 ** C85-C87** C6A-C6C* C6F-C6H* C8A-C8C** CF-C8H D60-D62 D65-D67 D6A-D6C* D6F-D6H*

Shroud Size (13th Digit)

1 2 3 4 (Frame Size 6 Only)

Impeller Diameter (14th Digit)

2 4 6 8 0

3000-3-50 3300-3-50

6300-3-50 10000-3-50 11000-3-50

2400-3-60

3300-3-60

4160-3-60

6900-3-60 11000-3-60 13800-3-60

— — — — — — — — — — —

4 5 6 7

8 E F

G H

Fig. 1 — 19XR Two-Stage Chiller Model Number Nomenclature

*Frame sizes with A-C and F-H are with 1-in. OD evaporator tubing.

sure to an intermediate level between the cooler and condenser vessels. In the economizer, vapor is separated from the liquid, the separated vapor flows to the second stage of the compressor, and the liquid flows into the cooler. The energy removed from the vaporized refrigerant in the economizer allows the

liquid refrigerant in the cooler to absorb more heat when it evaporates and benefits the overall cooling efficiency cycle.

Free-Standing Starter — The starter allows for the

proper start and disconnect of electrical energy for the compressor-motor, oil pump, oil heater, and control panel.

Week of Year

Year of Manufacture

SERIAL NUMBER STRUCTURE

12 15 Q 19843

Unique Number

Place of Manufacture

a19-2271

Fig. 2 — Typical 19XR 1500-3000 Ton Two-Stage Compressor Chiller Compone nts

(XR6 Shown)

REAR VIEW

FRONT VIEW

LEGEND

1—Guide Vane Actuator 2—Suction Elbow 3—Chiller Identification Nameplate 4—Control Panel 5—Condenser Auto. Reset Relief Valves 6—Condenser Return End Waterbox Cover 7—Cooler Return End Waterbox Cover 8—Cooler Auto. Reset Relief Valves

9—Cooler Pressure Transducer 10 — Liquid Line Isolation Valve (Optional) 11 — Refrigerant Storage Tank Connection Valve 12 — HMI (Human Machine Interface) Control Panel 13 — Typical Flange Connection 14 — Oil Level Sight Glasses 15 — Compressor Motor Housing

LEGEND

16 — Oil Cooler

17 — Oil Drain Changing Valve (Hidden)

18 — Motor Sight Glass

19 — Cooler In/Out Temperature Thermistors

20 — Typical Waterbox Drain Port

21 — Vessel Take-Apart Connector

22 — Condenser In/Out Temperature Thermistors

23 — ASME Nameplate

24 — Refrigerant Moisture/Flow Indicator

25 — Refrigerant Filter/Drier

26 — High Side Float Chamber

27 — High Side Float Ball Valve Assembly (Inside)

28 — Economizer Assembly 29 — Economizer Float Ball Assembly (Inside) 30 — Cooler Auto. Reset Relief Valve 31 — Condenser Pressure Transducer 32 — Refrigerant Charging Valve/Pumpout

Connection

33 — Damper Valve 34 — Discharge Isolation Valve (Optional)

REFRIGERATION CYCLE

Fig. 3 — Refrigeration Cycle — 19XR Two-Stage Compressor Frame Sizes 6 and 7

The compressor continuously draws refrigerant vapor from the cooler at a rate set by the amount of guide vane opening. As the compressor suction reduces the pressure in the cooler, the remaining refrigerant boils at a fairly low temperature (typically 38 to 42 F [3 to 6 C]). The energy required for boiling is obtained from the water flowing through the cooler tubes. With heat energy removed, the water becomes cold enough to use in an air-conditioning circuit or process liquid cooling.

After taking heat from the water, the refrigerant vapor is compressed. Compression adds still more heat energy and the refrigerant is quite warm (typically 98 to 102 F [37 to 40 C]) when it is discharged from the compressor into the condenser.

Relatively cool (typically 65 to 90 F [18 to 32 C]) water flowing into the condenser tubes removes heat from the refrigerant, and the vapor condenses to liquid. The liquid refrigerant passes through orifices into the FLASC (flash subcooler) chamber. Since the FLASC chamber is at a lower pressure, part of the liquid refrigerant flashes to vapor, thereby cooling the remaining liquid. The FLASC vapor is recondensed on the tubes which are cooled by entering condenser water. The liquid

ISOLATION VALVE (OPTION)

drains into a high side float valve chamber between the FLASC chamber and the economizer. The refrigerant is then metered into the economizer. In the economizer, due to lower pressure, as liquid enters the chamber, some liquid will flash into a vapor and cool the remaining liquid. The separated vapor flows to the second stage of the compressor for greater cycle efficiency. A damper valve located on the economizer line to the compressor acts as a pressure regulating device to stabilize low load, low condensing pressure operating conditions. The damper will back up gas flow and thereby raises the economizer pressure to permit proper refrigerant flow through the economizer valve during those conditions.

The cooled liquid left in the economizer flows through a low side float valve and then into the cooler. The float valve forms a liquid seal to keep vapor from entering the cooler. Liquid refrigerant passes through the low side valve into the cooler. The refrigerant is now at a temperature and pressure at which the cycle began. Fig. 3 summarizes the refrigeration cycle.

FLASC CHAMBER

THERMOSTATIC EXPANSION VALVE (TXV)

ROTOR

ORIFICE FITTING

OIL COOLER

TRANSMISSION

IMPELLERS

BACK PRESSURE ORIFICE (INTEGRAL TO MOTOR SHELL)

COMPRESSOR

HIGH SIDE FLOAT CHAMBER

HIGH SIDE FLOAT VALVE

DAMPER VALVE

REFRIGERANT

ISOLATION VALVE

ECONOMIZER

LOW SIDE FLOAT VALVE

HOT GAS BYPASS

HGBP VALVE

CONDENSER WATER

REFRIGERANT LIQUID

REFRIGERANT VAPOR

REFRIGERANT LIQUID/VAPOR

CHILLED WATER

COOLER ISOLATION VALVE (OPTION)

MOTOR AND OIL COOLING CYCLE

The motor and the lubricating oil are cooled by liquid refrigerant taken from the bottom of the condenser vessel (Fig. 3 and

4). Refrigerant flow is maintained by the pressure differential that exists due to compressor operation. After the refrigerant flows past an isolation valve, an in-line filter, and a sight glass/ moisture indicator, the flow is split between the motor cooling and oil cooling systems.

Flow to the motor cooling system passes through an orifice and into the motor. Once past the orifice, the refrigerant is directed over the motor by spray nozzles. The refrigerant collects in the bottom of the motor casing and is then drained back into the cooler through the motor refrigerant drain line. An orifice (in the motor shell) maintains a higher pressure in the motor shell than in the cooler. The motor is protected by a temperature sensor embedded in the stator windings. An increase in motor winding temperature past the motor override set point overrides the temperature capacity control to hold, and if the motor temperature rises 10 F (5.5 C) above this set point, the controls close the inlet guide vanes. If the temperature rises above the safety limit, the compressor shuts down.

Refrigerant that flows to the oil cooling system is regulated by expansion valves. The expansion valves regulate flow into the oil/refrigerant plate and frame-type heat exchanger (the oil cooler in Fig. 3), and control oil temperature to the bearings. The refrigerant leaving the oil cooler heat exchanger returns to the chiller cooler.

LUBRICATION CYCLE

Summary —

up a package located partially in the transmission casing of the compressor-motor assembly. The oil is pumped into a filter assembly to remove foreign particles and is then forced into an oil cooler heat exchanger where the oil is cooled to proper operational temperatures. After the oil cooler, part of the flow is directed to the gears and the high speed shaft bearings; the remaining flow is directed to the motor shaft bearings. Oil drains into the transmission oil sump to complete the cycle (Fig. 3 and

4).

The oil pump, oil filter, and oil cooler make

Details — Oil is charged into the lubrication system through

a hand valve. Two sight glasses in the oil reservoir permit oil level observation. Normal oil level is between the middle of the upper sight glass and the top of the lower sight glass when the compressor is shut down. The oil level should be visible in at least one of the 2 sight glasses during operation. Oil sump temperature is displayed on the HMI default screen. During compressor operation, the oil sump temperature ranges between 125 and 150 F (52 and 66 C).

The oil pump suction is fed from the oil reservoir. An oil pressure relief valve maintains differential pressure in the system at the pump discharge. A range of 18 to 40 psid (124 to 172 kPad) is normal. This differential pressure can be read directly from the default HMI screen. The oil pump discharges oil to the oil filter assembly. This filter can be closed to permit removal of the filter without draining the entire oil system. The oil is then piped to the oil cooler heat exchanger. The oil cooler uses refrigerant from the condenser as the coolant. The refrigerant cools the oil to a temperature between 120 and 140 F (49 and 60 C).

As the oil leaves the oil cooler, it passes the oil pressure transducer and the sensor for the refrigerant expansion valve on the oil cooler. The oil is then divided. Part of the oil flows to the thrust bearing, forward pinion bearing, and gear spray. The rest of the oil lubricates the motor shaft bearings and the rear pinion bearing. The oil temperature is measured in the bearing housing as it leaves the bearings. The oil then drains into the oil reservoir at the base of the compressor. The control measures the temperature of the oil in the sump and maintains the temperature during shutdown. This temperature is read on the HMI default screen. See the Controls Operation and Troubleshooting Manual for details.

During the chiller start-up, the oil pump is energized and provides 40 seconds of lubrication to the bearings after pressure is verified before starting the compressor. During shutdown, the oil pump runs for 60 seconds to ensure lubrication as the compressor coasts to a stop.

The oil pump is a gerotor-style pump with external filters. A gerotor pump has two rotors, one is inside the other; their center points are offset with respect to each other. This type of pump provides a smooth continuous flow. It is also quieter than other designs. See Fig. 5.

Bearings — The 19XR compressor assemblies include a

combination of radial bearings and thrust bearings. The low speed shaft assembly is supported by two journal bearings located on each end of the low speed shaft. The bearing closer to the bull gear includes a smaller babbitted thrust face, designed to handle axial forces.

Oil Reclaim System — The oil reclaim system returns

oil lost from the compressor housing back to the oil reservoir by recovering the oil from 2 areas on the chiller. The guide vane housing is the primary area of recovery. Oil is also recovered by skimming it from the operating refrigerant level in the cooler vessel.

PRIMARY OIL RECOVERY MODE — Oil is normally recovered through the guide vane housing on the chiller. This is possible because oil is normally entrained with refrigerant in the chiller. As the compressor pulls the refrigerant up from the cooler into the guide vane housing to be compressed, the oil normally drops out at this point and falls to the bottom of the guide vane housing where it accumulates. Using discharge gas pressure to power an eductor, the oil is drawn from the housing and is discharged into the oil reservoir.

SECONDARY OIL RECOVERY METHOD — The secondary method of oil recovery is significant under light load conditions, when the refrigerant going up to the compressor suction does not have enough velocity to bring oil along. Under these conditions, oil collects in a greater concentration at the top level of the refrigerant in the cooler. Using discharge gas to power eductors, this oil and refrigerant mixture is skimmed from the side of the cooler and is then drawn up to the guide vane housing. There is a filter in this line. Because the guide vane housing pressure is much lower than the cooler pressure, the refrigerant boils off, leaving the oil behind to be collected by the primary oil recovery method.

Fig. 4 — 19XR Two-Stage Compressor Lubrication System

LEGEND

1—Motor Stator 6— Oil Heater 2—Impellers 7— Oil Pump 3—Variable Inlet Guide Vanes 8— Oil Filters 4—Transmission 9— Motor Rotor 5—High Speed Shaft Bearings 10— Motor Shaft Bearings

a19-

Fig. 5 — Gerotor Oil Pump

a19-2116

LEGEND

1—Gerotor Oil Pump 2—Oil Pressure Regulator Valve 3—Oil Sump Pressure Transducer 4—Oil Sump Drain Valve 5—High Speed Compressor End Bearing,

Temperature Terminal Block

6—Low Speed Compressor End Bearing,

Temperature Cable

7—Compressor Oil Sump Temperature 8—Oil Heater

OIL LINE VENT LINE

STARTING EQUIPMENT

The 19XR chiller requires a motor starter to operate the centrifugal hermetic compressor motor, the oil pump, and various auxiliary equipment components. The starter is the main field wiring interface for the contractor.

See Carrier’s specification for specific starter requirements. All starters must meet these specifications in order to properly start and satisfy mechanical safety requirements.

It is possible that there are two separate circuit breakers inside the starter. These include (1) the main compressor motor circuit breaker, and (2) a circuit breaker which provides power to the chiller control panel. The latter is typically wired in parallel with the first so that power is provided to those services when the main breaker is open. The disconnect switch on the starter front cover is connected to the main breaker. Typically, separate 3-phase power sources as per job requirements are supplied to the control panel to power the oil pump, heater, and controls.

The display on the front of the solid-state starter is useful for

troubleshooting and starter checkout. The display indicates:

• line voltage

• control voltage status

• power indication

• proper phasing for rotation

• start circuit energized

• ground fault

• current unbalance

•run state The starter is further explained in the Check Starter section,

page 19.

Freestanding Medium Voltage VFD (Optional) —

can be combined with a VFD (variable frequency drive). This option is a freestanding, medium voltage current source drive that does not require a transformer between the power source and the drive. The drive meets IEEE-519 specifications.

For optimum efficiency, the 19XR chiller

WARNING

The main circuit breaker on the front of the starter disconnects the main motor power only. Power may be still energized for other circuits. Always check wiring diagrams before initiating any work on the chiller and follow applicable lock-out/tag-out procedures. Failure to disconnect power will result in personal injury.

All starters must include a Carrier control module called the Integrated Starter Module (ISM). This module controls and monitors all aspects of the starter. See the Controls Operation and Troubleshooting guide for additional ISM information. Contact Carrier’s Replacement Component Division (RCD) for replacement parts.

Solid-State Starter (Optional) — The 19XR chiller

may be equipped with a solid-state, reduced-voltage starter. This starter’s primary function is to provide on-off control of the compressor motor. This type of starter reduces the peak starting torque, controls the motor inrush current, and decreases mechanical shock. This capability is summed up by the phrase “soft starting.” Consult E-Cat for full information about starter offerings. The solid-state starter manufacturer’s name is located inside the starter access door.

A solid-state, reduced-voltage starter operates by reducing the starting voltage. The starting torque of a motor at full voltage is typically 125% to 175% of the running torque. When the voltage and the current are reduced at start-up, the starting torque is reduced as well. The object is to reduce the starting voltage to adjust the voltage necessary to develop the torque required to get the motor moving. The voltage is reduced by silicon controlled rectifiers (SCRs). The voltage and current are then ramped up in a desired period of time. Once full voltage is reached, a bypass contactor is energized to bypass the SCRs.

WARNING

When voltage is supplied to the solid-state circuitry (CB1 is closed), the heat sinks in the starter as well as the wires leading to the motor and the motor terminal are at line voltage. Do not touch the heat sinks, power wiring, or motor terminals while voltage is present or serious injury will result.

CONTROLS

Definitions

ANALOG SIGNAL — An analog signal varies in proportion to the monitored source. It quantifies values between operating limits. (Example: A temperature sensor is an analog device because its resistance changes in proportion to the temperature, generating many values.)

DISCRETE SIGNAL — A discrete signal is a 2-position representation of the value of a monitored source. (Example: A switch produces a discrete signal indicating whether a value is above or below a set point or boundary by generating an on/off, high/low, or open/closed signal.)

General — The 19XR centrifugal liquid chiller contains a

microprocessor-based control center that monitors and controls all operations of the chiller. The microprocessor control system matches the cooling capacity of the chiller to the cooling load while providing state-of-the-art chiller protection. The system controls cooling load within the set point plus the deadband by sensing the leaving chilled water or brine temperature and regulating the inlet guide vane via a mechanically linked actuator motor. The guide vane is a variable flow pre-whirl assembly that controls the refrigeration effect in the cooler by regulating the amount of refrigerant vapor flow into the compressor. An increase in guide vane opening increases capacity. A decrease in guide vane opening decreases capacity. The microprocessorbased control center protects the chiller by monitoring the digital and analog inputs and executing capacity overrides or safety shutdowns, if required.

PIC 5 System Components — The chiller control

system is called the PIC 5 (Product Integrated Control 5). See Table 1. As with previous PIC versions, the PIC 5 system controls the operation of the chiller by monitoring all operating conditions. The PIC 5 control system can diagnose a problem and let the operator know what the problem is and what to check. It promptly positions the guide vanes to maintain leaving chilled water temperature. It can interface with auxiliary equipment such as pumps and cooling tower fans to turn them on when required. It continually checks all safeties to prevent any unsafe operating condition. It also regulates the oil heater while the compressor is off and regulates the hot gas bypass valve, if installed. The PIC 5 controls provide critical protection for the compressor motor and control the motor starter.

Table 1 — Major PIC 5 Components and

Fig. 6 — Chiller Start/Stop Icon

Fig. 7 — Local On

a19-2118

Panel Locations

PIC 5 COMPONENT PANEL LOCATION

Chiller Human Machine Interface (HMI) and Display

Integrated Starter Module (ISM) Starter Cabinet Chiller IO Boards Control Panel Oil Heater Contactor (1C) Control Panel Oil Pump Contactor (2C) Control Panel Hot Gas Bypass Relays (HCLR, HOPR)

(Optional) Control Transformers (T1, T2, T3) Control Panel Temperature Sensors See Fig. 2 and Fig. 5 Pressure Transducers See Fig. 2 and Fig. 5

HMI Control Panel

Control Panel

NOTE: For detailed information about the PIC 5 HMI (human machine interface), see the 19XR with PIC 5 Controls Operation and Troubleshooting manual.

START-UP/SHUTDOWN/

RECYCLE SEQUENCE

Local Start/Stop Control —

start-up) is initiated by pressing the the gray Start/Stop icon on the HMI interface. See Fig. 6.

This initiates the PIC 5 starting sequence by displaying the list of operating modes. Press Local On to initiate start-up. See Fig. 7.

Local start-up (or manual

When start-up is initiated the status screen displays the start-

up progress and the Start/Stop icon blinks green.

Once local start-up begins, the PIC 5 control system performs a series of pre-start tests to verify that all pre-start alerts and safeties are within acceptable limits. Table 2 shows appropriate Prestart Alerts/Alarms conditions. If a test is not successful, the start-up is delayed or aborted. If the tests are successful, the start-up will be in progress and the COMPRESSOR RUN STATUS shall be “Startup.” The control shall then energize the chilled water/brine pump relay.

Five seconds later, the condenser pump relay energizes. Thirty seconds later the PIC 5 control system monitors the chilled water and condenser water flow devices and waits until the WATER FLOW VERIFY TIME (operator-configured, default 5 minutes) expires to confirm flow. After flow is verified, the chilled water temperature is compared to CONTROL POINT plus 1/2 CHILLED WATER DEADBAND. If the temperature is less than or equal to this value, the PIC 5 control system turns off the condenser pump relay and goes into a Recycle mode.

If the water/brine temperature is high enough, the start-up sequence continues and checks the guide vane position. If the guide vanes are more than 4% open, the start-up waits until the PIC 5 control system closes the vanes. If the vanes are closed and the oil pump pressure is less than 4 psi (27.6 kPa), the oil pump relay energizes. The PIC 5 control system then waits until the oil pressure (OIL PRESS VERIFY TIME, operator-configured, default of 40 seconds) reaches a maximum of 18 psi (124 kPa). After oil pressure is verified, the PIC control system waits 40 seconds, and the compressor start relay (1CR) energizes to start the compressor.

Compressor ontime and service ontime timers start, and the compressor STARTS IN 12 HOURS counter and the number of starts over a 12-hour period counter advance by one.

Failure to verify any of the requirements up to this point will result in the PIC 5 control system aborting the start and displaying the applicable pre-start alert alarm state number near the bottom of the home screen on the HMI panel. A prestart failure does not advance the STARTS IN 12 HOURS counter. Any fail- ure after the 1CR relay has energized results in a safety shutdown, advances the starts in 12 hours counter by one, and displays the applicable shutdown status on the display.

The minimum time to complete the entire prestart sequence is approximately 185 seconds. See Fig. 8 for normal start-up timing sequence. See Table 2 for a list of prestart checks.

Unit Start/Stop

NOTE: Prior to start-up the start-to-start timer and the stop-tostart timer must have elapsed and all alarms must be cleared (see Troubleshooting Guide section on page 42).

Table 2 — Prestart Checks

CDE

O/A

A—START INITIATED: Pre-start checks are made; evaporator pump

started.*

B—Condenser water pump started (5 seconds after A). C—Water flows verified (30 seconds to 5 minutes maximum after B).

Chilled water temperatures checked against control point. Guide vanes checked for closure. Oil pump started; tower fan control enabled.

D—Oil pressure verified (15 seconds minimum, 300 seconds maximum

after C).

E—Compressor motor starts; compressor ontime and service ontime

start, 15-minute inhibit timer starts (10 seconds after D), total compressor starts advances by one, and the number of starts over a 12-hour period advances by one.

F—SHUTDOWN INITIATED — Compressor motor stops; compressor

ontime and service ontime stop, and 1-minute inhibit timer starts.

G—Oil pump and evaporator pumps deenergized (60 seconds after F).

Condenser pump and tower fan control may continue to operate if condenser pressure is high. Evaporator pump may continue if in RECYCLE mode.

O/A — Restart permitted (both inhibit timers expired: minimum of 15 min-

utes after E; minimum of 1 minute after F).

Fig. 8 — Control Timing Sequence

for Normal Start-Up

* Auto Restart After Power Failure Timing sequence will be faster.

Fig. 9 — Confirm Stop

a19-2122

Unit Start/Stop

PRESTART CHECK CONDITION* STATE NUMBER

STARTS IN 12 HOURS 8 (not counting recycle restarts or auto restarts after power failure) Alert – 100 OIL SUMP TEMP 140° F (60° C) and OIL SUMP TEMP EVAP_SAT + 50° F (27.8° C) Alert – 101 COND PRESSURE COND PRESS OVERRIDE – 20 psi Alert – 102 #RECYCLE RESTARTS LAST 4 HOURS > 5 Alert – 103 COMP BEARING TEMPS COMP BEARING ALERT– 10° F (5.6° C) Alarm – 230 COMP MOTOR WINDING TEMP COMP MOTOR WINDING– 10° F (5.6° C) Alarm – 231 COMP DISCHARGE TEMPERATURE COMP DISCHARGE ALERT– 10° F (5.6° C) Alarm – 232 EVAP_SAT <Evap trip point** + EVAP OVERRIDE DELTA T Alarm – 233 EVAP REFRIG LIQUID TEMP <Evap trip point** + EVAP OVERRIDE DELTA T Alarm – 233 AVERAGE LINE VOLTAGE UNDERVOLTAGE THRESHOLD Alarm – 234 AVERAGE LINE VOLTAGE OVERVOLTAGE THRESHOLD Alarm – 235 CHECK FOR GUIDE VANE CALIBRATION Alarm – 236

* If Prestart Check Condition is True, then resulting State is as indicated in the State Number column.

†

See the Controls Operation and Troubleshooting guide for alarm and alert codes.

**Evap trip point = 33 F (0.6 C) (water) or EVAP REFRIG TRIPPOINT (brine)

The oil heater relay is energized whenever the chiller compressor is off and the oil sump temperature is less than 140 F (60 C) or the oil sump temperature is less than the evaporator saturated refrigerant temperature plus 53° F (29.4° C). The oil heater is turned off when either of the following conditions is true:

• Oil sump temperature is more than 152 F (66.7 C)

• Oil sump temperature is more than 144 F (62.2 C) and

more than the evaporator saturated refrigerant tempera-

ture plus 55° F (30.6° C) The oil heater is always off when the compressor is running.

The oil pump is also energized for 30 seconds after each 30 minutes of oil heat relay being energized in order to stir the oil for more evenly distributed heating.

Shutdown — The unit can be stopped locally using the

HMI by pressing the green Start/Stop icon . The Unit Start/ Stop screen is displayed. Press Confirm Stop (see Fig. 9).

†

Lubrication Control — As part of the prestart checks

executed by the controls, the oil sump temperature is compared to the evaporator saturated refrigerant temperature. If the oil temperature is less than 140 F (60 C) and less than evaporator saturated refrigerant temperature plus 50° F (27.8° C), the start-up will be delayed until either of these conditions is no longer true. Once this temperature is confirmed, the start-up continues.

BEFORE INITIAL START-UP

Fig. 10 — Typical Wet-Bulb Type

Vacuum Indicator

Job Data Required

• list of applicable design temperatures and pressures (product data submittal)

• chiller certified prints

• starting equipment details and wiring diagrams

• diagrams and instructions for special controls or options

• 19XR Installation Instructions

Equipment Required

• mechanic’s tools (refrigeration)

• digital volt-ohmmeter (DVM)

• true RMS (root mean square) digital multimeter with clamp-on current probe or true RMS digital clamp-on ammeter for at least 480 vac

• electronic leak detector

• absolute pressure manometer or wet-bulb vacuum indicator (see Fig. 10)

• insulation tester for compressor motor rated at motor design voltage

Remove Shipping Packaging — Remove any pack-

aging material from the unit and starter.

Open Oil Circuit Valves — Check to ensure the oil fil-

ter isolation valves are open by removing the valve cap and checking the valve stem.

Tighten All Gasketed Joints — Gaskets normally

relax by the time the chiller arrives at the jobsite. Tighten all gasketed joints to ensure a leak-tight chiller (does not apply to refrigerant joints covered by factory insulation). Gasketed joints (excluding O-rings) may include joints at some or all of the following:

• waterbox covers

• compressor suction elbow flanges (at compressor and at the cooler)

• compressor discharge flange

• compressor discharge line spacer (both sides) if no isolation valve

• cooler inlet line spacer (both sides) if no isolation valve

• hot gas bypass valve (both sides of valve)

• hot gas bypass flange at compressor

See Tables 3 and 4 for bolt torque requirements.

Check Chiller Tightness — Figure 11 outlines the

proper sequence and procedures for leak testing.

The 19XR chillers are shipped with the refrigerant con-

tained in the condenser shell and the oil charge in the compressor. The cooler is shipped with a 15 psig (103 kPa) refrigerant charge. Units may be ordered with the refrigerant shipped separately, along with a 15 psig (103 kPa) nitrogen-holding charge in each vessel.

To determine if there are any leaks, the chiller should be

charged with refrigerant. Use an electronic leak detector to check all flanges and solder joints after the chiller is pressurized. If any leaks are detected, follow the leak test procedure (page 16).

If the chiller is spring isolated, keep all springs blocked in

both directions to prevent possible piping stress and damage during the transfer of refrigerant from vessel to vessel during the leak test process, or any time refrigerant is being transferred. Adjust the springs when the refrigerant is in operating condition and the water circuits are full.

Table 3 — Bolt Torque Requirements, Foot Pounds

SAE 8

HEX HEAD

SA354 GR BD

BOLT SIZE

(in.)

SAE 2, A307 GR A

HEX HEAD

NO MARKS

LOW CARBON STEEL

SOCKET HEAD OR HEX

WITH 3 RADIAL LINES, OR SA499

MEDIUM CARBON STEEL

SAE 5

WITH 6 RADIAL LINES OR

MEDIUM CARBON STEEL

MINIMUM MAXIMUM MINIMUM MAXIMUM MINIMUM MAXIMUM

46 69913

811 13182028 13 19 22 31 32 46 21 30 35 50 53 75 32 45 53 75 80 115 46 65 75 110 115 165 65 95 105 150 160 225

105 150 175 250 260 370 140 200 265 380 415 590

1 210 300 410 580 625 893

330 475 545 780 985 1,410 460 660 770 1,100 1,380 1,960 620 885 1,020 1,460 1,840 2,630

740 1060 1,220 1,750 2,200 3,150 1010 1450 1,670 2,390 3,020 4,310 1320 1890 2,180 3,110 3,930 5,610 1630 2340 2,930 4,190 5,280 7,550

2 1900 2720 3,150 4,500 5,670 8,100

2180 3120 4,550 6,500 8,200 11,710 3070 4380 5,000 7,140 11,350 16,210 5120 7320 8,460 12,090 15,710 22,440

3 6620 9460 11,040 15,770 19,900 28,440

Table 4 — Bolt Torque Requirements, Foot Pounds (Metric Bolts)

BOLT SIZE

(METRIC)

MINIMUM MAXIMUM MINIMUM MAXIMUM

M4 1.75 2.5 2.5 3.5 M6 69812

M8 14 20 20 30 M10 28 40 40 57 M12 48 70 70 100 M16 118 170 170 240 M20 230 330 330 470 M24 400 570 570 810 M27 580 830 820 1175

CLASS 8.8 CLASS 10.9

5 AND 6)

Fig. 11 — 19XR Leak Test Procedures

a19-1151tf.eps

Refrigerant Tracer — Carrier recommends the use of an

environmentally acceptable refrigerant tracer for leak testing with an electronic detector.

Ultrasonic leak detectors can also be used if the chiller is

under pressure.

WARNING

Do not use air or oxygen as a means of pressurizing the chiller. Mixtures of HFC-134a and air can undergo combustion, resulting in equipment damage and possible personal injury.

Leak Test Chiller — Due to regulations regarding refrig-

erant emissions and the difficulties associated with separating contaminants from the refrigerant, Carrier recommends the following leak test procedure. Refer to Tables 5 and 6 for refrigerant pressure/temperature values.

1. If the pressure readings are normal for the chiller condition:

a. Evacuate the holding charge from the vessels, if

present.

b. Raise the chiller pressure, if necessary, by adding

refrigerant until pressure is at the equivalent saturated pressure for the surrounding temperature. Follow pumpout procedures in the Transfer Refrigerant from Pumpout Storage Tank to Chiller section, Steps 1a-e, page 34.

CAUTION

Never charge liquid refrigerant into the chiller if the pressure in the chiller is less than 35 psig (241 kPa) for HFC134a. Charge as a gas only, with the cooler and condenser pumps running, until this pressure is reached, using PUMPDOWN/LOCKOUT (located in the Maintenance menu) and TERMINATE LOCKOUT mode on the PIC 5 control interface. Flashing of liquid refrigerant at low pressures can cause tube freeze-up and considerable damage.

c. Leak test chiller as outlined in Steps 3 to 9.

2. If the pressure readings are abnormal for the chiller condition:

a. Prepare to leak test chillers shipped with refriger-

ant (Step 2h).

b. Check for large leaks by connecting a nitrogen bottle

and raising the pressure to 30 psig (207 kPa). Soap test all joints. If the test pressure holds for 30 minutes,

prepare the test for small leaks (Steps 2g and 2h). c. Plainly mark any leaks that are found. d. Release the pressure in the system. e. Repair all leaks. f. Retest the joints that were repaired. g. After successfully completing the test for large

leaks, remove as much nitrogen, air, and moisture

as possible, given the fact that small leaks may be

present in the system. This can be accomplished by

following the dehydration procedure outlined in

the Chiller Dehydration section, page 18. h. Slowly raise the system pressure to a maximum of

160 psig (1103 kPa) but no less than 35 psig

(241 kPa) for HFC-134a by adding refrigerant.

Proceed with the test for small leaks (Steps 3 to 9).

3. Check the chiller carefully with an electronic leak detector or soap bubble solution.

4. Leak Determination — If an electronic leak detector indicates a leak, use a soap bubble solution, if possible, to confirm. Total all leak rates for the entire chiller. Leakage at rates greater than 0.1% of the total charge per year must be repaired. Note the total chiller leak rate on the start-up report.

5. If no leak is found during the initial start-up procedures, complete the transfer of refrigerant gas from the storage tank to the chiller. Retest for leaks.

6. If no leak is found after a retest: a. Transfer the refrigerant to the storage tank and per-

form a standing vacuum test as outlined in the Standing Vacuum Test section, below.

b. If the chiller fails the standi ng vacuum test, check

for large leaks (Step 2b).

c. If the chiller passes the standing vacuum test,

dehydrate the chiller. Follow the procedure in the Chiller Dehydration section, page 18. Charge the chiller with refrigerant.

7. If a leak is found after a retest, pump the refrigerant back into the storage tank or, if isolation valves are present, pump the refrigerant into the non-leaking vessel. See the Transfer Refrigerant from Pumpout Storage Tank to Chiller section on page 34.

8. Transfer the refrigerant until the chiller pressure is at 18 in. Hg (40 kPa absolute).

9. Repair the leak and repeat the procedure, beginning from Step 2h, to ensure a leak-tight repair. (If the chiller is opened to the atmosphere for an extended period, evacuate it before repeating the leak test.)

Standing Vacuum Test — When performing the

standing vacuum test or chiller dehydration, use a manometer or a wet bulb indicator. Dial gages cannot indicate the small amount of acceptable leakage during a short period of time.

1. Attach an absolute pressure manometer or wet bulb indicator to the chiller.

2. Evacuate the vessel to at least 18 in. Hg vac (41 kPa [abs]), using a vacuum pump or the pumpout unit.

3. Valve off the pump to hold the vacuum and record the manometer or indicator reading.

4. a.

5. Repair the leak, retest, and proceed with dehydration.

If the leakage rate is less than 0.05 in. Hg (0.17 kPa) in 24 hours, the chiller is sufficiently tight.

b. If the leakage rate exceeds 0.05 in. Hg (0.17 kPa)

24 hours, re-pressurize the vessel and test for leaks if refrigerant is available. If not, use nitrogen and a refrigerant tracer. Raise the vessel pressure in increments until the leak is detected. If refrigerant is used, the maximum gas pressure is approximately 70 psig (483 kPa) for HFC-134a at normal ambient temperature. If nitrogen is used, limit the leak test pressure to 160 psig (1103 kPa) maximum.

Table 5 — HFC-134a Pressure —

Temperature (F)

Table 6 — HFC-134a Pressure —

Temperature (C)

TEMPERATURE

(F)

0 6.50 2 7.52 4 8.60 6 9.66 8 10.79

10 11.96 12 13.17 14 14.42 16 15.72 18 17.06

20 18.45 22 19.88 24 21.37 26 22.90 28 24.48

30 26.11 32 27.80 34 29.53 36 31.32 38 33.17

40 35.08 42 37.04 44 39.06 46 41.14 48 43.28

50 45.48 52 47.74 54 50.07 56 52.47 58 54.93

60 57.46 62 60.06 64 62.73 66 65.47 68 68.29

70 71.18 72 74.14 74 77.18 76 80.30 78 83.49

80 86.17 82 90.13 84 93.57 86 97.09 88 100.70

90 104.40 92 108.18 94 112.06 96 116.02 98 120.08

100 124.23 102 128.47 104 132.81 106 137.25 108 141.79

110 146.43 112 151.17 114 156.01 116 160.96 118 166.01

120 171.17 122 176.45 124 181.83 126 187.32 128 192.93

130 198.66 132 204.50 134 210.47 136 216.55 138 222.76 140 229.09

PRESSURE

(PSIG)

TEMPERATURE

(C)

–18.0 44.8 –16.7 51.9 –15.6 59.3 –14.4 66.6 –13.3 74.4

–12.2 82.5 –11.1 90.8 –10.0 99.4

–8.9 108.0 –7.8 118.0

–6.7 127.0 –5.6 137.0 –4.4 147.0 –3.3 158.0 –2.2 169.0

–1.1 180.0

0.0 192.0

1.1 204.0

2.2 216.0

3.3 229.0

4.4 242.0

5.0 248.0

5.6 255.0

6.1 261.0

6.7 269.0

7.2 276.0

7.8 284.0

8.3 290.0

8.9 298.0

9.4 305.0

10.0 314.0

11.1 329.0

12.2 345.0

13.3 362.0

14.4 379.0

15.6 396.0

16.7 414.0

17.8 433.0

18.9 451.0

20.0 471.0

21.1 491.0

22.2 511.0

23.3 532.0

24.4 554.0

25.6 576.0

26.7 598.0

27.8 621.0

28.9 645.0

30.0 669.0

31.1 6

32.2 7

33.3 746.0

34.4 773.0

35.6 800.0

36.7 828.0

37.8 857.0

38.9 886.0

40.0 916.0

41.1 946.0

42.2 978.0

43.3 1010.0

44.4 1042.0

45.6 1076.0

46.7 1110.0

47.8 1145.0

48.9 1180.0

50.0 1217.0

51.1 1254.0

52.2 1292.0

53.3 1330.0

54.4 1370.0

55.6 1410.0

56.7 1451.0

57.8 1493.0

58.9 1536.0

60.0 1580.0

PRESSURE

(KPA)

94.0

20.0

Chiller Dehydration — Dehydration is recommended if

Fig. 12 — Dehydration Cold Trap

the chiller has been open for a considerable period of time, if the chiller is known to contain moisture, or if there has been a complete loss of chiller holding charge or refrigerant pressure.

CAUTION

Do not start or megohm-test the compressor motor or oil pump motor, even for a rotation check, if the chiller is under dehydration vacuum. Insulation breakdown and severe damage may result.

WARNING

Starters must be disconnected by an isolation switch before placing the machine under a vacuum. To be safe, isolate any starter before evacuating the chiller if you are not sure if there are live leads to the hermetic motor.

Dehydration can be done at room temperatures. Using a cold trap (Fig. 12) may substantially reduce the time required to complete the dehydration. The higher the room temperature, the faster dehydration takes place. At low room temperatures, a very deep vacuum is required to boil off any moisture. If low ambient temperatures are involved, contact a qualified service representative for the dehydration techniques required.

Perform dehydration as follows:

1. Connect a high capacity vacuum pump (5 cfm [.002 m or larger is recommended) to the refrigerant charging valve (Fig. 2). Tubing from the pump to the chiller should be as short in length and as large in diameter as possible to provide least resistance to gas flow.

2. Use an absolute pressure manometer or a wet bulb vacuum indicator to measure the vacuum. Open the shutoff valve to the vacuum indicator only when taking a reading. Leave the valve open for 3 minutes to allow the indicator vacuum to equalize with the chiller vacuum.

3. If the entire chiller is to be dehydrated, open all isolation valves (if present).

4. With the chiller ambient tem perature at 60 F (15.6 C) or higher, operate the vacuum pump until the manometer reads 185 psig (1275 kPa), or a vacuum indicator reads 35 F (1.7 C). Operate the pump an additional 2 hours.

Do not apply a greater vacuum than 29.82 in. Hg vac (757.4 mm Hg) or go below 33 F (0.56 C) on the wet bulb vacuum indicator. At this temperature and pressure, isolated pockets of moisture can turn into ice. The slow rate of evaporation (sublimation) of ice at these low temperatures and pressures greatly increases dehydration time.

5. Valve off the vacuum pump, stop the pump, and record the instrument reading.

6. After a 2-hour wait, take another instrument reading. If the reading has not changed, dehydration is complete. If the reading indicates vacuum loss, repeat Steps 4 and 5.

7. If the reading continues to change after several attempts, perform a leak test up to the maximum 160 psig (1103 kPa) pressure. Locate and repair the leak, and repeat dehydration.

8. Once dehydration is complete, the evacuation process can continue. The final vacuum prior to charging the unit with refrigerant should in all cases be 29.9 in Hg (500 microns,

0.07 kPa [abs]) or less.

/s]

Inspect Water Piping — Refer to piping diagrams pro-

vided in the certified drawings and the piping instructions in the 19XR Installation Instructions manual. Inspect the piping to the cooler and condenser. Be sure that the flow directions are correct and that all piping specifications have been met.

Piping systems must be properly vented with no stress on waterbox nozzles and covers. Water flows through the cooler and condenser must meet job requirements. Measure the pressure drop across the cooler and the condenser.

CAUTION

Water must be within design limits, clean, and treated to ensure proper chiller performance and to reduce the potential of tube damage due to corrosion, scaling, or erosion. Carrier assumes no responsibility for chiller damage resulting from untreated or improperly treated water.

Check Relief Valves — Be sure the relief valves have

been piped to the outdoors in compliance with the latest edition of ANSI/ASHRAE Standard 15 and applicable local safety codes. Piping connections must allow for access to the valve mechanism for periodic inspection and leak testing.

The standard 19XR relief valves are set to relieve at 185 psig (1275 kPa) chiller design pressure.

Inspect Wiring

WARNING

Do not check the voltage supply without proper equipment and precautions. Serious injury may result. Follow power company recommendations.

CAUTION

Do not apply any kind of test voltage, even for a rotation check, if the chiller is under a dehydration vacuum. Insulation breakdown and serious damage may result.

1. Examine the wiring for conformance to the job wiring diagrams and all applicable electrical codes.

2. Compare the ampere rating on the starter nameplate to rating on the compressor nameplate. The overload trip amps must be 108% to 120% of the rated load amps.

3. The starter for a centrifugal compressor motor must contain the components and terminals required for PIC 5 controls platform. Check the certified drawings.

4. Check the voltage to the components and compare it to the nameplate values.

5. Ensure that fused disconnects or circuit breakers have been supplied for the control panel.

6. Ensure all electrical equipment and controls are properly grounded in accordance with job drawings, certified drawings, and all applicable electrical codes.

7. Ensure the customer’s contractor has verified proper operation of the pumps, cooling tower fans, and associated auxiliary equipment. This includes ensuring motors are properly lubricated and have proper electrical supply and proper rotation.

8. Test the chiller compressor motor and its power lead insulation resistance with an insulation tester such as a megohmmeter. (Use a tester rated for motor voltage.)

a. Open the starter main disconnect switch and follow

lockout/tagout rules.

CAUTION

Ensure the starter (with relay 1CR closed) goes through a complete and proper start cycle.

SOLID-STATE STARTER

WARNING

This equipment is at line voltage when AC power is connected. Pressing the STOP button does not remove voltage.

CAUTION

An isolation switch or circuit breaker must be open ahead of any solid-state starter when the chiller is in a vacuum. If not, damage to the machine may result.

If the motor starter is a solid-state starter, the motor leads must be disconnected from the starter before an insulation test is performed. The voltage generated from the tester can damage the starter solid-state components.

b. With the tester connected to the motor leads, take

10-second and 60-second megohm readings as follows:

3-Lead Motor and test between the group and ground.

c. Divide the 60-second resistance reading by the

10-second reading. The ratio, or polarization index, must be one or higher. Both the 10 and 60-second readings must be at least 50 megohms.

If the readings on a field-installed starter are unsatisfactory, repeat the test at the motor with the power leads disconnected. Satisfactory readings in this second test indicate the fault is in the power leads.

— Tie terminals 1, 2, and 3 together

Check Starter

WARNING

BE AWARE that certain automatic start arrangements can engage the starter. Open the disconnect ahead of the starter

in addition to shutting off the chiller or pump. Failure to follow this procedure may result in personal injury by electric shock.

Use the instruction and service manual supplied by the starter manufacturer to verify the starter has been installed correctly, to set up and calibrate the starter, and for complete troubleshooting information.

WARNING

The main disconnect on the starter front panel may not deenergize all internal circuits. Open all internal and remote disconnects before servicing the starter. Failure to follow this procedure may result in personal injury by electric shock.

MECHANICAL STARTER

1. Check all field wiring connections for tightness, clearance from moving parts, and correct connection.

2. Check the contactor(s) to ensure they move freely. Check all other electro-mechanical devices, such as relays, for free movement. If the devices do not move freely, contact the starter manufacturer for replacement components.

3. Reapply starter control power (not main chiller power) to check the electrical functions.

1. Ensure all wiring connections are properly terminated to the starter.

2. Verify the ground wire to the starter is installed properly and is sufficient size.

3. Verify the motors are properly grounded to the starter.

4. Verify the proper ac input voltage is brought into the starter according to the certified drawings.

5. Apply power to the starter.

Oil Charge — The oil charge for the 19XR two-stage com-

pressor frame size 6 is 29 gal (110 L); for frame size 7 the oil charge is 44.5 gal (168 L).

The chiller is shipped with oil in the compressor. When the sump is full, the oil level should be no higher than the middle of the upper sight glass, and minimum level is the bottom of the lower sight glass (Fig. 2). If oil is added, it must meet Carrier’s specification for centrifugal compressor use as described in the Oil Specification section on page 39. Charge the oil through the oil charging valve located near the bottom of the transmission housing. The oil must be pumped from the oil container through the charging valve due to higher refrigerant pressure. The pumping device must be able to lift from 0 to 200 psig (0 to 1380 kPa) or above unit pressure. Oil should only be charged or removed when the chiller is shut down.

Power Up the Controls and Check the Oil Heater —

sor and the chiller is not in a vacuum before energizing the controls. Typically a circuit breaker in the starter energizes the oil heater and the control circuit.

The oil heater is energized by powering the control circuit. This should be done several hours before start-up to minimize oil-refrigerant migration. The oil heater is controlled by the PIC 5 and is powered through a contactor in the control panel. A separate circuit breaker powers the heater, oil pump, and the control circuit. This arrangement allows the heater to energize when the main motor circuit breaker is off for service work or extended shutdowns.

Ensure that an oil level is visible in the compres-

Software Configuration

WARNING

Do not operate the chiller before the control configurations have been checked and a Control Test has been satisfactorily completed. Protection by safety controls cannot be assumed until all control configurations have been confirmed.

See the 19XR with PIC 5 Controls Operation and Troubleshooting manual for instructions on using the PIC 5 interface to configure the 19XR unit. As the unit is configured, all configuration settings should be written down. A log, such as the one

shown on pages CL-1 to CL-8, provides a list for configuration

Fig. 13 — Main Menu Icon

Fig. 14 — Main Menu — Setpoint Table Icon

a19-2121

SETPOINT - Setpoint Table

Fig. 15 — Setpoint Table Screen

values.

Input the Design Set Points — To access the set

point screen, press the Main Menu icon on the home screen. See Fig. 13.

The Main Menu screen is displayed. Press the Setpoint Ta-

ble icon (Fig. 14).

Main Menu

The Setpoint screen is displayed (see Fig. 15). Set the base demand limit set point, and either the LCW set point or the ECW set point. To set a value, press the appropriate set point, enter the value, and press OK. For more information, see the the 19XR with PIC 5 Controls Operation and Troubleshooting manual.

Input the Local Occupied Schedule — Access

the schedule screen and set up the occupied time schedule according to the customer’s requirements. If no schedule is available, the default is factory set for 24 hours occupied, 7 days per week including holidays. The Schedule Menu as well as the Holiday Menu can be reached through the Configuration Menu (see Appendix A on page 88 for an overview of the available menus). When the control mode is LOCAL SCHEDULE, the chiller will be automatically started if the configured local schedule is occupied; it will be shut down by the unoccupied schedule, EMSTOP software point, STOP button on HMI screen, or remote emergency stop contact.

The Network Schedule should be configured if a CCN system is being installed. When control mode is NETWORK, the chiller can be started and stopped by the CHIL_S_S software point as written by other equipment through the network command and network schedule. The chiller can be shut down by EMSTOP software point and remote emergency stop contact.

For more information about setting time schedules, see the 19XR with PIC 5 Controls Operation and Troubleshooting manual.

Input Service Configurations — For specific values

for the following configurations, refer to the chiller performance data or job-specific data sheet:

• password

• log in/logout

• input time and date

• service parameters

• equipment configuration

• automated control test PASS W OR D — The PIC 5 control system provides different

levels of access: Basic access, User access, Advanced User/ Service access and Factory access. User access provides basic access to the chiller controls. Advanced User access has access to all Service tables, and Factory user has access to factory tables. The PIC 5 default password configurations are as follows:

• Basic: No password required

• User: 1111

• Advanced User / Service Access: 2222

• Factory: 4444

When accessing the SERVICE tables, a password must be entered. The password can be changed from the Configuration Menu. USER CONFIGURATION allows change of the User access password. SERVICE PARAMETERS allows change of the Advanced User/Service password, and FACTORY PARAMETERS allows change of the Factory password. Passwords must be from 1 to 5 digits (range from 1 to 65535).

IMPORTANT: Be sure to remember the password. Retain a copy for future reference. Without the password, access to the SERVICE menu will not be possible unless accessed by a Carrier representative.

Fig. 16 — Lock Icon

User Login Screen

Fig. 17 — User Login Screen

The User Login Screen is displayed. Enter the password on this screen. See Fig 17. The language and system of measurement can also be changed on this screen. For details, see the 19XR with PIC 5 Controls Operation and Troubleshooting guide.

INPUT TIME AND DATE — Set day and time and if applicable Holidays through MAIN MENU CONFIGURATION MENU  DATE/TIME CONFIGURATION. See the Controls Operation and Troubleshooting guide for details. Because a schedule is integral to the chiller control sequence, the chiller will not start until the time and date have been set.

NOTE: The date format is MM-DD-YY for English units and

MODIFY CONTROLLER IDENTIFICATION IF NECESSARY — The module address can be changed from the Configuration Menu. Change this address under CONTROL IDENTIFICATION for each chiller if there is more than one chiller at the jobsite. Write the new address on the HMI module for future reference.

CONFIGURE SERVICE TABLES — Access the SERVICE tables through MAIN MENU  CONFIGURATION MENU to modify or view the job site parameters shown in Table 7. For details, see the 19XR with PIC 5 Controls Operation and Troubleshooting guide.

DD-MM-YY for SI units.

Table 7 — Job Site Parameters

PARAMETER TABLE

Starter Type Motor Rated Line Voltage CONF_ISM — Motor rated voltage from chiller information nameplate. Volt Transformer Ratio Motor Rated Load Amps CONF_ISM — Per chiller nameplate data. RL AMPS on compressor nameplate.

Motor Locked Rotor Trip CONF_ISM — Per chiller iden tification nameplate. Starter LRA Rating

Motor Current CT Ratio Current % Imbalance CONF_ISM — Current imbalance trip threshold. Enter up to 100% for starter type 3 (VFD).

Ground Fault Current Transformers CONF_ISM — Ent er 0 if no ground fault CTs are wired to terminal J5 of ISM. Enter 1 if gr ound fault CTs are used. Ground Fault CT Ratio CONF_ISM — Enter ratio (reduced to a ratio to 1) of ground fault CT. Single Cycle Dropout CONF_ISM — ENABLE if motor protection required from drop in line voltage within one cycle. Line Frequency CONF_ISM — Enter YES for 60 Hz or NO for 50 Hz. Line Frequency Faulting CONF_ISM — ENABLE if motor protection required for drop in line frequency.

Hot Gas Bypass Option Minimum Load Points (Tsmin, IGVmin) CFGSURGE — Per job data — See modify load points section. Refer to table located in the control panel. Full (Maximum) Load Points (Tsmax, IGVmax) Surge Line Shape Factor (shapefac) CFGSURGE — Per Chiller Requisition (shapefac). Refer to table located in the control panel.

Chilled Medium FACTORY — Enter water or brine. Evaporator Refrigerant Trippoint CFGLIMIT — Usually 3° F (1.7° C) below design refrigerant temperature. Evaporator Flow Delta P Cutout CFGLIMIT — Per Chiller Requisition if available or enter 50% of design pressure drop to 0.5 psi (3.4 kPa).* Condenser Flow Delta P Cutout CFGLIMIT — Per Chiller Requisition if available or enter 50% of design pressure drop to 0.5 psi (3.4 kPa).* High Condenser Water Delta P CFGLIMIT — Enter the maximum allowable value for condenser water pressure drop.

Motor Rated Kilowatts

*With variable flow systems this point may be configured to the lower end of the range.

NOTE: Other parameters: Screens are normally left at the default settings; they may be changed as required. The time and persistence settings on the CONF_ISM table can be adjusted to increase or decrease the sensitivity to a fault condition. Increasing time or persistence decreases sensitivity. Decreasing time or persistence increases sensitivity to the fault condition.

CONF_ISM — Select 0 for full voltage, 1 for reduced voltage, 2 for solid state, or 3 for freestanding variable frequency drive.

CONF_ISM — Enter ratio (reduced to a ratio to 1) of power transformer wired to ter minal J3 of ISM. If no transf ormer is used enter 1.

CONF_ISM — Enter value from nameplate in starter cabinet MAXIMUM FUSE. This value shall always be “9999” for Benshaw RediStart MX3 wye-delta and solid-state starters.

CONF_ISM — Enter ratio (reduced to a ratio to 1) of current transf ormers wired to terminal J4 of ISM. This value shall always be “100” for Benshaw RediStart MX3 and solid-state starters.

CONF_OPT — 1 = HGBP for Surge Correction; 2 = HGBP for Low Load Operation; 3 = Combination HGBP; 0 = no HGBP or HGBP is Disabled.

CFGSURGE — Chiller Requisition (TSmin, IGV min) or per job data — See modify load points section. Refer to table located in the control panel.

FACTORY — Enter value from chiller requisition form (product data submittal) if DEMAND LIMIT SOURCE is set to kW.

Field Set Up and Verification

SAFETY CODE CERTIFICATION

COMPRESSOR MOTOR DATA

R-

REFRIGERATION MACHINE

CARRIER CHARLOTTE 9701 OLD STATESVILLE ROAD CHARLOTTE, NORTH CAROLINA 28269 MADE IN USA PRODUCTION YEAR: 20XX

19XR05009801

A United Technologies Company

THIS UNIT IS DESIGNED,CONSTRUCTED, AND TESTED IN CONFORMANCE WITH ANSI/ASHRAE 15 (LATEST REVISION),

SPECIFICATION Z-415.

IN ACCORDANCE WITH CARRIER

AND OVERLOAD PROTECTION MUST BE

THE COMPRESSOR MOTOR CONTROLLER

REFRIGERATION.

SAFETY CODE FOR MECHANICAL

TEST PRESSURE

DESIGN PRESSURE CLR.WATER PRESSURE COND.WATER PRESSURE

PSI PSI PSI PSI

KPA KPA KPA KPA

CAZTREH/ESAHP/STLOV RL AMPS OLT AMPS

LR AMPS Y-

LR AMPS DMAX FUSE/CIRCUIT BKR MIN. CIRCUIT AMPACITY

LBS. CHARGED

KGS.REFRIGERANT

MODEL NUMBER

SERIAL NO. MACHINE COMP'R COOLER CONDENSER ECON STOR TANK

RATED iKW

RATED TONS

Fig. 18 — Machine Identification Nameplate

CHILLER ID NAMEPLATE — CONSTANT SPEED CHILLER

a19-1881

IMPORTANT: Some parameters are specific to the chiller configuration and will need to be verified prior to operation. All command functions must be initiated from the HMI.

Use the HMI touch screen to confirm that the ISM values match the chiller paramter labels and Chiller Builder design data sheet. The ISM values can be located from MAIN MENU CONFIGURATION MENU ISM CONFIGURATION.

LABEL LOCATIONS — Verify the following labels have been installed properly and match the chiller requisition:

• Surge Parameters — Located inside the chiller control panel.

• Chiller identification nameplate — Located on the right side of the control panel. (See Fig. 18.)

STARTER/DRIVE PROTECTION AND OTHER INCOMING WIRING

1. Verify that the branch disconnects or other local disconnects are open and properly tagged out.

2. Verify that the branch circuit protection and AC input wiring to the starter are in accordance with NEC/CEC (National Electrical Code/California Energy Commission) and all other local codes.

3. Verify that the fuses are per the field wiring diagram.

4. Verify that the incoming source does not exceed the SCCR (short circuit current rating) of the equipment marking.

5. Verify the power lugs in the starter/VFD and branch protection are properly secured. Inspect the ground cable and ensure it is properly connected at the branch and to the

6. Verify the conduit for the power wiring in securely con-

ground lug in the starter.

nected to the starter flanged cover and runs continuously to the branch protection.

7. Ensure the control and signal wires connected to the chiller controller or the starter/VFD are in separate conduits.

FINE TUNING VPF (VARIABLE PRIMARY FLOW) SURGE PRE VENTION — Figures 19-22 show how the parameters defined below will affect the configured surge line. The menu can be found under MAIN MENU CONFIGU- RATION MENU SURGE CORRECTION CONFIG.

NOTE: Before tuning surge prevention, check for VFD (variable frequency drive) speed limitation or capacity overrides. If the source of low capacity is found in one of these places, do not proceed with an attempt to tune the Surge Prevention configurations.

If capacity is not reached and

1. ACTUAL GUIDE VANE POSITION < GUIDE VANE TRAVEL RANGE

and

2. SURGE PREVENTION ACTIVE = YES (can be identified in MAIN MENU  MAINTENANCE MENU  SURGE CORRECTION)

and

3. PERCENT LINE CURRENT < 100%

then the surge line is probably too conservative. Note the following parameters from HMI when maximum

ACTUAL LINE CURRENT achieved:

• EVAPORATOR REFRIGERANT TEMP

• EVAPORATOR PRESSURE

• CONDENSER REFRIG TEMP

• CONDENSER PRESSURE

• ACTUAL GUIDE VANE POSITION

• ACTUAL LINE CURRENT The ACTIVE DELTA Tsat and the CALC REF DELTA

TSAT can be monitored on the MAINTENANCE MENU  SURGE CORRECTION screen. When DELTA TSAT exceeds CALC REF DELTA TSAT + ENVELOPE LINE OFFSET surge prevention will occur.

If ACTUAL GUIDE VANE POSITION is less than 30%,

then increase SURGE DELTA TSMIN in steps of 2º F (1.2º C) until one of the three conditions listed above no longer applies. Do not change SURGE DELTA TSMAX.

If ACTUAL GUIDE VANE POSITION is greater than

60%, then increase SURGE DELTA TSMAX in steps of 2º F (1.2º C) until cooling capacity is reached or one of conditions listed above no longer applies. Do not change SURGE/HGBP DELTA TSMIN.

If ACTUAL GUIDE VANE POSITION is more than 30%

AND less than 60%, then:

1. Increase SURGE DELTA TSMIN in steps of 2º F (1.2º C).

2. Increase SURGE DELTA TSMAX in steps of 2º F (1.2º C).

3. Repeat Steps 1 and 2 until one of the conditions listed above no longer applies.

NOTE: DELTA TSMIN should seldom need to be increased more than 10 degrees above the selection program value. Likewise, DELTA TSMAX rarely requires more than a 2º F (1.2º C) increase.

If surge is encountered then the surge line is probably too optimistic or high. Note following parameters from HMI at surge:

• EVAPORATOR REFRIGERANT TEMP

• EVAPORATOR PRESSURE

• CONDENSER REFRIG TEMP

• CONDENSER PRESSURE

• ACTUAL GUIDE VANE POSITION

• AVERAGE LINE CURRENT

Fig. 19 — Effect of SURGE DELTA TSMIN on

Surge Prevention

a19-1959

0 102030405060708090100110

Tsmax= 60

Tsmax= 70

Tsmax= 80

GV_POS

Delta Tsat

Fig. 20 — Effect of SURGE DELTA TSMAX on

Surge Prevention

a19-1960

Fig. 21 — Effect of SURGE LINE SHAPE FACTOR

on Surge Prevention

a19-1961

0.00

5.00

10.00

15.00

20.00

25.00

30.00

35.00

40.00

0 102030405060708090100110

Speed Factor =1.60

Speed Factor =1.85

Speed Factor =2.00

GV_POS

Delta Tsat

Fig. 22 — Effect of SURGE LINE SPEED FACTOR

on Surge Prevention

a19-1962

Delta Tsat

0 102030405060708090100110

60.00

55.00

50.00

45.00

40.00

35.00

30.00

Delta Tsat

25.00

20.00

15.00

10.00

5.00

0.00 0 10 20 30 40 50 60 70 80 90 100 110

GV_POS

Tsmin= 30

Tsmin= 40

Tsmin= 50

Shape factor = -0.020

Shape factor = -0.040

Shape factor = -0.050

If ACTUAL GUIDE VANE POSITION is less than 30%, go to Step 1. If ACTUAL GUIDE VANE POSITION is greater than 60%, then go to Step 3.

1. Do not change SURGE LINE SHAPE FACTOR from the value selected by Chiller Builder (ECAT). Decrease SURGE DELTA TSMIN in 1° F steps up to 5 times. Monitor chiller for surge.

2. If ACTUAL GUIDE VANE POSITION is still less than 30 and Step 1 failed, then increase the value of SURGE LINE SHAPE FACTOR in steps of 0.01 up to 2 times. For example, if surge is encountered when shape factor is –0.06, increase the SURGE LINE SHAPE FACTOR to –0.05. If this does not solve the problem, go to Step 5, even if ACTUAL GUIDE VANE POSITION is less than 30%.

3. Do not change SURGE LINE SHAPE FACTOR from the value selected by Chiller Builder (ECAT). Decrease SURGE DELTA TSMAX by 1° F steps up to 5 times. Monitor chiller for surge.

4. If ACTUAL GUIDE VANE POSITION is greater than 60% and Step 3 failed to eliminate surge, then set SURGE DELTA TSMAX to 5° F below the value specified by Chiller Builder (ECAT). Increase the value of the SURGE LINE SHAPE FACTOR in steps of 0.01 up to 2 times. For example, if surge is encountered when the SURGE LINE SHAPE FACTOR is –0.06, increase the SURGE LINE SHAPE FACTOR to –0.05. If this does not solve the problem, go to Step 5, even if ACTUAL GUIDE VANE POSITION is greater than 60%.

5. If ACTUAL GUIDE VANE POSITION is greater than 30% but less than 60% or if Step 2 failed (with ACTUAL GUIDE VANE POSITION less than 30) or if Step 4 failed (with ACTUAL GUIDE VANE POSITION greater than 60), then perform this step. Do not change SURGE LINE SHAPE FACTOR from the value specified by Chiller Builder (ECAT). Reset SURGE DELTA TSMIN and SURGE DELTA TSMAX to the value specified by Chiller Builder (ECAT). Decrease SURGE DELTA TSMIN and SURGE DELTA TSMAX in steps of 1° F up to 5 times. Monitor chiller for surge.

If the chiller is equipped with a VFD and the drive does not slow down adequately at part load, then the machine is likely operating at a point above the configured “software” surge line and the machine is in surge prevention mode. Check for a surge protection message on the HMI. If the unit is not in a surge protection state, then the ENVELOPE SPEED FACTOR may

need to be increased (more aggressive surge line protection) in combination with a decrease in the SURGE LINE SHAPE FACTOR.

MODIFY EQUIPMENT CONFIGURATION IF NECESSARY — The EQUIPMENT SERVICE table has screens to select, view, or modify parameters. Carrier’s certified drawings have the configuration values required for the jobsite. Modify these values only if requested. Modifications can include:

• Chilled water reset

• Entering chilled water control (Enable/Disable)

• 4 to 20 mA demand limit

• Auto restart option (Enable/Disable)

• Remote contact option (Enable/Disable) See the 19XR with PIC 5 Controls Operation and Trouble-

shooting guide for more details about these functions.

Perform a Controls Test (Quick Test) — Check

the safety controls status by performing an automated controls test. The path to the QUICK TEST is MAIN MENU  QUICK TEST TABLE. (The QUICK TEST screen can only be accessed when the chiller is in STOP mode.) On the

QUICK TEST table screen, select a test to be performed (see Table 8).

The Quick Test checks all outputs and inputs for function. In order to successfully proceed with the controls test, the compressor should be off, no alarms showing, and voltage should be within ±10% of rating plate value. Each test asks the operator to confirm the operation is occurring and whether or not to continue. If an error occurs, the operator can try to address the problem as the test is being done or note the problem and proceed to the next test.

NOTE: If during the controls test the guide vanes do not open, verify the low pressure alarm is not active. (An active low pressure alarm causes the guide vanes to close.)

NOTE: The oil pump test will not energize the oil pump if cooler pressure is below –5 psig (–35 kPa).

When the controls test is finished the test stops and the QUICK TEST menu displays. If a specific automated test procedure is not completed, access the particular control test to test the function when ready. For information about calibration, see the sections Checking Pressure Transducers, page 46, and High Altitude Locations, page 46.

Table 8 — Quick Test Table

CCN TABLE NAME: QCK_TEST PIC 5 PATH: Main Menu  Quick Test

LINE PIC 5 DESCRIPTION CCN NAME RANGE

1 Quick Test Enable QCK_TEST DSABLE/ENABLE DSABLE RW 2 GV 1 Calibration Enable GV1_CAL DSABLE/ENABLE DSABLE RW 3 GV1 Calibration Status

0=No Calibration or Failure

1=In Progress, 2=Completed 4 Guide Vane 1 Actual Ohms GV1_OHM 0.00 to 12000.00 RO 5 Guide Vane 1 Actual mA GV1_MAF 0.0 to 20.8 mA RO 6 Guide Vane 1 Forced Position Q_GV1POS 0.0 to 100.0 0.0 % RW 7 Quick Test GV1 Open Q_GV1OP OFF/ON OFF RW 8 Quick Test GV1 Close Q_GV1CL OFF/ON OFF RW 9 Quick Test Oil Pump Q_OILP OFF/ON OFF RW

10 Oil Pres Test Passed OP_PASS NO/YES RO 11 Oil Pump Delta Pressure OIL_PDQ –6.7 t o 420.0 psig RO 12 Quick Test Oil Heater Q_OILH OFF/ON OFF RW 13 Quick Test HGBP Open Q_HGBPOP OFF/ON OFF RW 14 Quick Test HGBP Close Q_HGBPCL OFF/ON OFF RW 15 Quick Test Damper Open Q_DMPOP OFF/ON OFF RW 16 Quick Test Damper Close Q_DMPCL OFF/ON OFF RW 17 Quick Test Cond Pump Q_CDWP OFF/ON OFF RW 18 Condenser Water Flow CDW_FLOW NO/YES RO 19 Quick Test Chilled Pump Q_CHWP OFF/ON OFF RW 20 Chileld Water Flow CHW_FLOW NO/YES RO 21 Condenser Water Flow CDW_FLOW NO/YES RO 22 Chilled Water Flow CHW_FLOW NO/YES RO 23 Quick Test Head Val Pos Q_HDP 0.0 to 100.0 0.0 % RW 24 Quick Test Diffuser Pos Q_SRD 0.0 to 100.0 0.0 % RW 25 Quick Test Chiller Status Q_CHST 4.0 to 20.0 4.0 mA RW 26 Quick Test Oil EXV Q_EXV 4.0 to 20.0 4.0 mA RW 27 Condenser Water Delta T CDW_DT –40.0 to 245.0 °F RO 28 Chilled Water Delta T CHW_DT –40.0 to 245.0 °F RO 29 Cond Water Deviation CDWT_DV OFF/ON RO 30 Chilled Water Deviation CHWT_DV OFF/ON RO 31 Quick Test Alarm Output Q_ALM OFF/ON OFF RW 32 Quick Test Alert Output Q_ALE OFF/ON OFF RW 33 Guide Vane 1 Ohms 100% GV1_MAXO 0.00 to 12000.00 RO 34 Guide Vane 1 Ohms 0% GV1_MINO 0.00 to 12000.00 RO 35 Guide Vane 1 mA 100% GV1_MAXA 0.0 to 20.8 mA RO 36 Guide Vane 1 mA 0% GV1_MINA 0.0 to 20.8 mA RO

LEGEND

GV — Guide Vane HGBP — Hot Gas Bypass RO — Read Onl y RW — Read Write

*Default value is shown only if configurable in this table.

GV1_STAT 0 to 2 RO

NOTES:

1. Quick Test ENABLE defaults back to DISABLE after 1 hour.

2. During any of the tests, an out-of-range reading will have an asterisk (*) next to the reading and a message will be displayed if the diffuser control is enabled.

DEFAULT

VALUE*

UNIT READ/WRITE

Charge Refrigerant into Chiller

CAUTION

The transfer, addition, or removal of refrigerant in spring isolated chillers may place severe stress on and damage external piping if springs have not been blocked in both up and down directions.

CAUTION

Always operate the condenser and chilled water pumps during charging operations to prevent freeze-ups.

1. Access the terminate lockout function on the PUMPDOWN/LOCKOUT screen (located in the Maintenance Menu).

2. IMPORTANT: Turn on the chilled water and condenser water pumps to prevent freezing.

3. Open valve 4 on the pumpout unit and open valves 1a and 1b on the chiller cooler and condenser, Fig. 23 and 24. Slowly open valve 2 on the pumpout unit to equalize the pressure. This process takes approximately 15 minutes.

4. Once the pressures have equalized, the discharge isolation valve, cooler isolation valve, optional hot gas bypass isolation valve, and the refrigerant isolation valve can be opened. Close valves 1a and 1b, and all pumpout unit valves.

The standard 19XR chiller is shipped with the refrigerant already charged in the vessels. However, the 19XR chiller may be ordered with a nitrogen holding charge of 15 psig (103 kPa). Evacuate the nitrogen from the entire chiller, and charge the chiller from refrigerant cylinders.

CHILLER EQUALIZATION WITHOUT A PUMPOUT UNIT

CAUTION

When equalizing refrigerant pressure on the 19XR chiller after service work or during the initial chiller start-up, do not use the discharge isolation valve to equalize. A charging hose (connected between the charging valves on top of the cooler and condenser) should be used as the equalization valve. Failure to follow this procedure may damage equipment.

To equalize the pressure differential on a refrigerant isolated 19XR chiller, use the terminate lockout function of PUMPDOWN/LOCKOUT (located in the Maintenance Menu). This helps to turn on pumps and advises the operator on proper procedures.

The following steps describe how to equalize refrigerant pressure in an isolated 19XR chiller without a pumpout unit.

1. Access terminate lockout function on the Maintenance Menu. (Alternatively, the Quick Test provides a means for cooler and condenser pump control.)

2. IMPORTANT: Turn on the chilled water and condenser water pumps to prevent freezing.

3. Slowly open the refrigerant charging valves. The chiller cooler and condenser pressures will gradually equalize. This process takes approximately 15 minutes.

4. Once the pressures have equalized, the cooler isolation valve, the condenser isolation valve, and the hot gas isolation valve may now be opened. Refer to Fig. 23 and 24 for the location of the valves.

WARNING

Whenever turning the discharge isolation valve, be sure to reattach the valve locking device. This prevents the valve from opening or closing during service work or during chiller operation. Failure to follow this procedure may damage equipment and result in bodily injury.

CHILLER EQUALIZATION WITH FREE-STANDING PUMPOUT UNIT — The following steps describe how to equalize refrigerant pressure on an isolated 19XR chiller using the pumpout unit.

WARNING

The full refrigerant charge on the 19XR chiller will vary with chiller components and design conditions, as indicated on the job data specifications. An approximate charge may be determined by adding the condenser charge to the cooler charge as listed in the Heat Exchanger Data tables in the Physical Data section that begins on page 48.

CAUTION

Always operate the condenser and chilled water pumps whenever charging, transferring, or removing refrigerant from the chiller. Always confirm that water flow is established. Failure to follow this procedure may result in equipment damage.

Use the PUMPDOWN/LOCKOUT terminate lockout function to monitor conditions and start the pumps.

If the chiller has been shipped with a holding charge refrigerant is added through the pumpout charging connection (Fig. 23 and 24, valve 1b). First evacuate the nitrogen holding charge from the chiller vessels. Charge the refrigerant as a gas until the system pressure exceeds 35 psig (241 kPa) for HFC134a. After the chiller is beyond this pressure the refrigerant should be charged as a liquid until all the recommended refrigerant charge has been added. The charging valve (Fig. 23 and 24, valve 7) can be used to charge liquid to the cooler if the cooler isolation valve (11) is present and is closed. Do not charge liquid through the linear float to the condenser.

TRIMMING REFRIGERANT CHARGE — The 19XR chiller is shipped with the correct charge for the design duty of the chiller. Trimming the charge can best be accomplished when the design load is available. To trim the charge, check the temperature difference between the leaving chilled water temperature and cooler refrigerant temperature at full load design conditions. If necessary, add or remove refrigerant to bring the temperature difference to design conditions or minimum differential. See the 19XR Installation Instructions manual for required chiller refrigerant charge.

The 19XR chiller refrigerant charges are shown in Tables 9 and 10. Total refrigerant charge is the sum of the cooler, condenser, and economizer charge.

, the

STORAGE

TANK LIQUID

VALVE

OIL SEPARATOR

PUMPOUT CONDENSER WATER SUPPLY AND RETURN

PUMPOUT CONDENSER

STORAGE TANK VAPOR VALVE

PRESSURE RELIEF SAFETY VALVE

PUMPOUT COMPRESSOR

TEE FOR CHARGING

REFRIGERANT CHARGING VALVE

COOLER REFRIGERANT ISOLATION VALVE

LIQUID LINE SERVICE VALVE

CHILLER CONDENSER VESSEL

CHILLER COOLER VESSEL

SERVICE VALVE ON PUMPOUT UNIT

SERVICE VALVE ON CHILLER (FIELD SUPPLIED)

MAINTAIN AT LEAST 2 FT (610mm) CLEARANCE AROUND STORAGE TANK FOR SERVICE AND OPERATION WORK.

REFRIGERANT CHARGING VALVE

Fig. 23 — Typical Optional Pumpout System Piping Schematic with Storage Tank

a19-1721

OIL SEPARATOR

PUMPOUT CONDENSER WATER SUPPLY AND RETURN

PUMPOUT CONDENSER

PRESSURE RELIEF SAFETY VALVE

PUMPOUT COMPRESSOR

COOLER REFRIGERANT ISOLATION VALVE

REFRIGERANT CHARGING VALVE

CHILLER CONDENSER VESSEL

CHILLER COOLER VESSEL

SERVICE VALVE ON PUMPOUT UNIT

SERVICE VALVE ON CHILLER

LIQUID LINE SERVICE VALVE

REFRIGERANT CHARGING VALVE

Fig. 24 — Typical Freestanding Pumpout System Piping Schematic without Storage Tan k

a19-1722

Table 9 — 19XR Two-Stage Compressor Frame Size 6 Heat Exchanger Refrigerant Charge

ENGLISH SI

CODE*

COOLER ONLY CONDENSER ONLY ECONOMIZER ONLY COOLER ONLY CONDENSER ONLY ECONOMIZER ONLY

A40 1647 927 360 747 420 163 A41 1773 927 360 804 420 163 A42 1887 927 360 856 420 163 A45 1599 927 360 725 420 163 A46 1714 927 360 777 420 163 A47 1837 927 360 833 420 163

A60 1878 1074 360 852 48 7 163 A61 2022 1074 360 917 48 7 163 A62 2152 1074 360 976 48 7 163 A65 1823 1074 360 827 48 7 163 A66 1954 1074 360 886 48 7 163 A67 2095 1074 360 950 48 7 163

A4A 1681 861 360 762 391 163 A4B 1792 861 360 813 391 163 A4C 1897 861 360 860 391 163 A4F 1626 861 360 738 391 163 A4G 1736 861 360 787 391 163 A4H 1890 861 360 857 391 163

A6A 1917 998 360 870 453 163 A6B 2044 998 360 927 453 163 A6C 2164 998 360 982 453 163 A6F 1854 998 360 841 453 163 A6G 1979 998 360 898 453 163 A6H 2156 998 360 978 453 163

MACHINE CHARGE MACHINE CHARGE

REFRIGERANT WEIGHT (lb) REFRIGERANT WEIGHT (kg)

B40 — 1233 360 — 559 163 B41 — 1233 360 — 559 163 B42 — 1233 360 — 559 163 B45 — 1233 360 — 559 163 B46 — 1233 360 — 559 163 B47 — 1233 360 — 559 163

B60 — 1423 360 — 645 163 B61 — 1423 360 — 645 163 B62 — 1423 360 — 645 163 B65 — 1423 360 — 645 163 B66 — 1423 360 — 645 163 B67 — 1423 360 — 645 163

B4A — 1148 360 — 521 163 B4B — 1148 360 — 521 163 B4C — 1148 360 — 521 163 B4F — 1148 360 — 521 163 B4G — 1148 360 — 521 163 B4H — 1148 360 — 521 163

B6A — 1326 360 — 601 163 B6B — 1326 360 — 601 163 B6C — 1326 360 — 601 163 B6F — 1326 360 — 601 163 B6G

H — 1326 360 — 60

*See Model Number Nomenclature on page 5.

— 1326 360 — 601 163

1 163

Table 10 — 19XR Two-Stage Compressor Frame Size 7 Heat Exchanger Refrigerant Charge

ENGLISH SI

CODE*

COOLER ONLY CONDENSER ONLY ECONOMIZER ONLY COOLER ONLY CONDENSER ONLY ECONOMIZER ONLY

B60 2273 — 646 1031 — 293 B61 2355 — 646 1068 — 293 B62 2460 — 646 1116 — 293 B65 2185 — 646 991 — 293 B66 2275 — 646 1032 — 293 B67 2379 — 646 1079 — 293

B6A 2081 — 646 944 — 293 B6B 2162 — 646 981 — 293 B6C 2256 — 646 1023 — 293

B6F 1951 — 646 885 — 293 B6G 2019 — 646 916 — 293 B6H 2120 — 646 962 — 293

C60 2647 1610 646 1201 730 293

C61 2751 1610 646 1248 730 293

C62 2875 1610 646 1304 730 293

C65 2562 1610 646 1162 730 293

C66 2666 1610 646 1209 730 293

C67 2793 1610 646 1267 730 293

C6A 2443 1497 646 1108 679 293 C6B 2534 1497 646 1149 679 293 C6C 2627 1497 646 1192 679 293

C6F 2334 1497 646 1059 679 293 C6G 2415 1497 646 1095 679 293 C6H 2500 1497 646 1134 679 293

MACHINE CHARGE MACHINE CHARGE

REFRIGERANT WEIGHT (lb) REFRIGERANT WEIGHT (kg)

D60 — 2097 646 — 951 293

D61 — 2097 646 — 951 293

D62 — 2097 646 — 951 293

D65 — 2097 646 — 951 293

D66 — 2097 646 — 951 293

D67 — 2097 646 — 951 293

D6A — 1947 646 — 883 293 D6B — 1947 646 — 883 293 D6C — 1947 646 — 883 293

D6F — 1947 646 — 883 293 D6G — 1947 646 — 883 293 D6H — 1947 646 — 883 293

*See Model Number Nomenclature on page 5.

INITIAL START-UP

Fig. 25 — Correct Motor Rotation

Preparation —

1. Power is on to the main starter, oil pump relay, tower fan starter, oil heater relay, and the chiller control panel.

2. Cooling tower water is at proper level and at-or-below design entering temperature.

3. Chiller is charged with refrigerant and all refrigerant and oil valves are in their proper operating positions.

4. Oil is at the proper level in the reservoir sight glasses.

5. Oil reservoir temperature is above 140 F (60 C) or above CALC EVAP SAT TEMP plus 50 F (28 C).

6. Valves in the evaporator and condenser water circuits are open.

NOTE: If the pumps are not automatic, ensure water is circulating properly.

Before starting the chiller, verify:

CAUTION

Do not permit water or brine that is warmer than 110 F (43 C) to flow through the cooler or condenser. Refrigerant overpressure may discharge through the relief valves and result in the loss of refrigerant charge.

7. Access the PUMPDOWN/LOCKOUT feature from the Maintenance Menu. Press the End Lockout button on the touch screen and accept the “press OK to Terminate Lockout?” prompt. The unit is reset to operating mode. The chiller is locked out at the factory in order to prevent accidental start-up.

Check Motor Rotation

1. Disengage the main starter disconnect and engage the control panel power circuit breaker.

NOTE: The circuit breaker may be located in the starter if the disconnect and step down transformer option was ordered with the starter. If located in the starter, close the door securely after this step.

2. Close the starter enclosure door.

3. The ISM (integrated starter module) mounted in the starter enclosure checks for proper phase rotation as soon as power is applied to the starter and the PIC 5 controls power up.

4. An alarm message will appear on the HMI screen if the phase rotation is incorrect. If this occurs reverse any 2 of the 3 incoming power leads to the starter and reapply power. The motor is now ready for a rotation check.

5. Start the chiller by Local On (assumes LOCAL operation mode) by pressing the Start/Stop button on the HMI and following the prompts. The PIC 5 control performs startup checks.

6. When the starter is energized and the motor begins to turn, check for clockwise motor rotation (Fig. 25).

IMPORTANT: Do not check motor rotation during coastdown. Rotation may have reversed during equalization of vessel pressures.

Check Oil Pressure and Compressor Stop

1. When the motor is at full speed, note the differential oil pressure reading on the HMI default screen. It should be between 18 and 40 psid (124 and 206 kPad). The oil pump will geenrate design oil pressure only with the correct electrical phasing of ABC.

2. Press the Stop button and listen for any unusual sounds from the compressor as it coasts to a stop.

To Prevent Accidental Start-Up — A chiller STOP

override setting may be entered to prevent accidental start-up during service or whenever necessary. From the Main Menu, access the General Parameters Menu and use the down arrow to reach Stop Override on the GENUNIT table. Change Stop Override to Yes; then execute the command by touching the lightning button. The message “ALM-276 Protective Limit Stop Override” will appear in the Home Screen message area. To restart the chiller, access the same screen change the Stop Override option to No.

Check Chiller Operating Condition — Check to

be sure that chiller temperatures, pressures, water flows, and oil and refrigerant levels indicate the system is functioning properly.

Instruct the Customer Operator — Ensure the op-

erator(s) understand all operating and maintenance procedures. Point out the various chiller parts and explain their function as part of the complete system.

COOL ER-CON DENSE R — High side float chamber, relief valves, refrigerant charging valve, temperature sensor locations, pressure transducer locations, Schrader fittings, waterboxes and tubes, and vents and drains.

OPTIONAL PUMPOUT STORAGE TANK AND PUMPOUT SYSTEM — Transfer valves and pumpout system, refrigerant charging and pumpdown procedure, and relief devices.

MOTOR COMPRESSOR ASSEMBLY — Guide vane actuator, transmission, motor cooling system, oil cooling system, temperature and pressure sensors, oil sight glasses, integral oil pump, isolatable oil filter, extra oil and motor temperature sensors, synthetic oil, and compressor serviceability.

MOTOR COMPRESSOR LUBRICATION SYSTEM — Oil pump, cooler filter, oil heater, oil charge and specification, operating and shutdown oil level, temperature and pressure, and oil charging connections.

ECONOMIZER — Float valve, drain valve, Schrader fitting, damper valve.

CONTROL SYSTEM — CCN and LOCAL start, reset, menu, softkey functions, HMI operation, occupancy schedule, set points, safety controls, and auxiliary and optional controls.

AUXILIARY EQUIPMENT — Starters and disconnects, separate electrical sources, pumps, and cooling tower.

DESCRIBE CHILLER CYCLES — Refrigerant, motor cooling, lubrication, and oil reclaim.

REVIEW MAINTENANCE — Scheduled, routine, and extended shutdowns, importance of a log sheet, importance of water treatment and tube cleaning, and importance of maintaining a leak-free chiller.

SAFETY DEVICES AND PROCEDURES — Electrical disconnects, relief device inspection, and handling refrigerant.

CHECK OPERATOR KNOWLEDGE — Start, stop, and shutdown procedures, safety and operating controls, refrigerant and oil charging, and job safety.

REVIEW THE START-UP, OPERATION, AND MAINTENANCE MANUAL.

OPERATING INSTRUCTIONS

Operator Duties

1. Become familiar with the chiller and related equipment before operating the chiller.

2. Prepare the system for start-up, start and stop the chiller, and place the system in a shutdown condition.

3. Maintain a log of operating conditions and document any abnormal readings.

4. Inspect the equipment, make routine adjustments, and perform a Control Test. Maintain the proper oil and refrigerant levels.

5. Protect the system from damage during shutdown periods.

6. Maintain the set point, time schedules, and other PIC functions.

Prepare the Chiller for Start-Up — Follow the steps

described in the Initial Start-Up section, page 29.

To Start the Chiller

1. Start the water pumps, if they are not automatic.

2. Press the Start/Stop icon on the HMI home screen to start the system. If the chiller is in the OCCUPIED mode and the start timers have expired, the start sequence will start. Follow the procedure described in the Start-Up/Shutdown/Recycle Sequence section, page 11.

Check the Running System — After the compres-

sor starts, the operator should monitor the display and observe the parameters for normal operating conditions:

1. The oil reservoir temperature should be above 120 F (49 C) during shutdown.

2. The bearing oil temperature accessed from the Temperatures menu should be 120 to 165 F (49 to 74 C) for compressors with rolling element bearings. If the bearing temperature reads more than 180 F (83 C) with the oil pump running, stop the chiller and determine the cause of the high temperature. Do not restart the chiller until corrected.

3. The oil level should be visible anywhere in one of the two sight glasses. Foaming oil is acceptable as long as the oil pressure and temperature are within limits.

4. The oil pressure should be between 18 and 40 psid (124 and 207 kPad) differential, as seen on the HMI Transmission Status screen. Typically the reading will be 18 to 35 psid (124 to 241 kPad) at initial start-up.

5. The moisture indicator sight glass on the ref rigerant motor cooling line should indicate refrigerant flow and a dry condition.

6. The condenser pressure and temperature varies with the chiller design conditions. Typically the pressure will range between 60 and 135 psig (390 and 950 kPa) with a corresponding temperature range of 60 to 105 F (15 to 41 C). The condenser entering water temperature should be controlled below the specified design entering water

temperature to save on compressor kilowatt requirements.

7. Cooler pressure and temperature also will vary with the design conditions. Typical pressure range will be between

29.5 and 40.1 psig (203.4 and 276.4 kPa), with temperature ranging between 34 and 45 F (1.1 and 7.2 C).

8. The compressor may operate at full capacity for a short time after the pulldown ramping has ended, even though the building load is small. The active electrical demand setting can be overridden to limit the compressor kW, or the pulldown rate can be decreased to avoid a high demand charge for the short period of high demand operation. Pulldown rate can be based on load rate or temperature rate and is accessed on the MAINTENANCE MENU  CAPACITY CONTROLS  RAMP_DEM (Ramping Demand Limit Value).

9. The economizer (if installed) has two sight glasses that look into the float chamber. When the chiller is operating, the top sight glass is empty and the bottom sight glass is full.

To Stop the Chiller

The occupancy schedule starts and stops the chiller automatically once the time schedule is configured.

The unit can be stopped manually using the HMI by pressing the green Start/Stop icon . The Unit Start/Stop screen is displayed. Press Confirm Stop. The compressor will then follow the normal shutdown sequence as described in the StartUp/Shutdown/Recycle Sequence section on page 11. The chiller is now in the OFF control mode.

IMPORTANT: Do not attempt to stop the chiller by opening an isolating knife switch. High intensity arcing may occur.

If the chiller is stopped by an alarm condition, do not restart the chiller until the problem is diagnosed and corrected.

After Limited Shutdown — No special preparations

should be necessary. Follow the regular preliminary checks and starting procedures.

Preparation for Extended Shutdown — The refrig-

erant should be transferred into the pumpout storage tank (if supplied; see Pumpout and Refrigerant Transfer Procedures on page 31) to reduce chiller pressure and the possibility of leaks. Maintain a holding charge of 5 to 10 lb (2.27 to 4.5 kg) of refrigerant or nitrogen to prevent air from leaking into the chiller.

If freezing temperatures are likely to occur in the chiller area, drain the chilled water, condenser water, and the pumpout condenser water circuits to avoid freeze-up. Keep the waterbox drains open. It is recommended not to store the refrigerant in the unit if below freezing temperatures are anticipated. A nitrogen holding charge is recommended in this case.

Leave the oil charge in the chiller with the oil heater and controls energized to maintain the minimum oil reservoir temperature.

After Extended Shutdown — Ensure the water sys-

tem drains are closed. It may be advisable to flush the water circuits to remove any soft rust that may have formed. This is a good time to brush the tubes and inspect the Schrader fittings on the waterside flow devices for fouling, if necessary.

Check the cooler pressure on the HMI panel and compare it to the original holding charge that was left in the chiller. If (after adjusting for ambient temperature changes) any loss in pressure is indicated, check for refrigerant leaks. See Check Chiller Tightness section, page 13.

Recharge the chiller by transferring refrigerant from the pumpout storage tank (if supplied). Follow the Pumpout and Refrigerant Transfer Procedures section on page 31. Observe freeze-up precautions.

Carefully make all regular preliminary and running system checks. If the compressor oil level appears abnormally high, the oil may have absorbed refrigerant. Ensure that the oil temperature is above 40 F (4.4 C) or above the EVAP SAT TEMP plus 50 F (27 C).

Cold Weather Operation — When the entering con-

denser water temperature drops very low, the operator should automatically cycle the cooling tower fans off to keep the temperature up. Piping may also be arranged to bypass the cooling tower.

IMPORTANT: A field-supplied water temperature control system for condenser water should be installed. The system should maintain the leaving condenser water temperature at a temperature that is at least 20 F (11C) above the leaving chilled water temperature.

Manual Guide Vane Operation — It is possible to

manually operate the guide vanes in order to check control operation or to control the guide vanes in an emergency. Manual operation is possible by overriding the target guide vane position.

NOTE: Manual control overrides the configured pulldown rate during start-up and permits the guide vanes to open at a faster rate. Motor current above the electrical demand setting, capacity overrides, and chilled water temperature below the control point override the manual target and close the guide vanes. For descriptions of capacity overrides and set points, see the 19XR with PIC 5 Controls Operation and Troubleshooting guide.

Refrigeration Log — A refrigeration log (as shown in

Fig. 26), is a convenient checklist for routine inspection and maintenance and provides a continuous record of chiller performance. It is also an aid when scheduling routine maintenance and diagnosing chiller problems.

Keep a record of the chiller pressures, temperatures, and liquid levels on a sheet similar to the one in Fig. 26. Automatic recording of data is possible by using CCN devices such as the

Data Collection module and a Building Supervisor. Contact a Carrier representative for more information.

PUMPOUT AND REFRIGERANT

TRANSFER PROCEDURES

Preparation —

with an optional pumpout storage tank, pumpout system, or pumpout compressor. The refrigerant can be pumped for service work to either the chiller compressor vessel or chiller condenser vessel by using the optional pumpout system. If a pumpout storage tank is supplied, the refrigerant can be isolated in the storage tank. The following procedures describe how to transfer refrigerant from vessel to vessel and perform chiller evacuation.

The 19XR chiller may come equipped

CAUTION

The power to the pumpout compressor oil heater must be on whenever any valve connecting the pumpout compressor to the chiller or storage tank is open. Leaving the heater off will result in oil dilution by refrigerant and can lead to compressor failure.

If the compressor is found with the heater off and a valve open, the heater must be on for at least 4 hours to drive the refrigerant from the oil. When heating the oil the compressor suction must be open to a vessel to give the refrigerant a means to leave the compressor.

CAUTION

Always run the chiller cooler and condenser water pumps and always charge or transfer refrigerant as a gas when the chiller pressure is less than 35 psig (241 kPa). Below these pressures, liquid refrigerant flashes into gas, resulting in extremely low temperatures in the cooler/condenser tubes and possibly causing tube freeze-up.

REFRIGERATION LOG CARRIER 19XR SEMI-HERMETIC CENTRIFUGAL REFRIGERATION MACHINE

PLANT___________________________ MACHINE MODEL NO. ________________________ MACHINE SERIAL NO. _____________________________

DATE

TIME

REFRIGERANT FLOW TEMP. REFRIGERANT FLOW TEMP. REFRIG. BEARING TEMPS. OIL MOTOR

PRESS. TEMP. GPM IN OUT PRESS. TEMP. GPM IN OUT PRESS.

COOLER CONDENSER ECON.

#1 LSME#2 LSCE#3 HSME#4 HSCEPRESS.

COMPRESSOR

DIFF.

SUMP TEMP

LEVEL

FLA/AMPS POSITION)

(OR VANE

OPER-

ATOR

INITIALS

REMARKS

REMARKS: Indicate shutdowns on safety controls, repairs made and oil or refrigerant added or removed. Include amounts.

Fig. 26 — Refrigeration Log

DANGER

COMPRESSOR

OIL

SEPARATOR

CONDENSER

LEAVING

WATER

ENTERING

WATER

VALVE

CONTROL

PANEL

FRAME

ASSEMBLY

OIL

HEATER

VALVE

OIL FILL FITTING

Fig. 27 — Pumpout Unit

a23-1546

2 OL

2 OL 2 OL

MTR-1

L1 L2

PUMP OUT

COMPRESSOR

CRANKCASE HEATER

240-600v

27-40 WA TT

GND

H1 H4

X1 X2

HIGH PRESSURE

SAFETY

NC OPEN > 185psig

CONTROL POWER

TRANSFORMER

XFMR-1

69 VA

C C C

8 7

HTR-1

FU1

0.25A

FU2

0.25A

FU3

0.5A

1 2

SS-1 OFF

AUTO ON

LOW PRESSURE CONTROL NC OPEN < 7 psia (-15.7 in. HG) CLOSE > 9 psia (-11.6 in. HG)

FIELD POWER SUPPLY

L2 L3

Fig. 28 — Pumpout Unit Wiring Schematic

a23-1615

LEGEND

C—Contactor FU — Fuse GND — Ground HTR — Heater MTR — Motor NC — Normally Closed OL — Overload SS — Selector Switch

During transfer of refrigerant into and out of the optional storage tank, carefully monitor the storage tank level gage. Do not fill the tank more than 90% of capacity to allow for refrigerant expansion. Overfilling may result in damage to the tank or the release of refrigerant which will result in personal injury or death.

CAUTION

Do not mix refrigerants from chillers that use different compressor oils. Compressor damage can result.

Operating the Optional Pumpout Unit (Fig. 27) —

pressor sight glass under all operating conditions and during shutdown. If oil is low, add oil as described under Optional Pumpout System Maintenance section, page 41. The pumpout unit control wiring schematic is detailed in Fig. 28.

TO READ REFRIGERANT PRESSURES (during pumpout or leak testing):

1. The display on the chiller control panel is suitable for determining refrigerant-side pressures and low (soft) vacuum. To assure the desired range and accuracy when measuring evacuation and dehydration, use a quality vacuum indicator or manometer. This can be placed on the Schrader connections on each vessel by removing the pressure transducer (Fig. 2).

2. To determine pumpout storage tank pressure, a 30 in. Hg vacuum -0-400 psi (-101-0-2769 kPa) gage is attached to the storage tank.

3. Refer to Fig. 23 and 24 for valve locations and numbers.

Oil should be visible in the pumpout unit com-

POSITIVE PRESSURE CHILLERS WITH STORAGE TANKS — In the Valve/Condition tables that accompany these instructions, the letter “C” indicates a closed valve. Figures 23 and 24 show the locations of the valves.

CAUTION

Always run chiller cooler and condenser water pumps and always charge or transfer refrigerant as a gas when chiller vessel pressure is less than 35 psig (241 kPa). Below these pressures, liquid refrigerant flashes into gas, resulting in extremely low temperatures in the cooler/condenser tubes and possibly causing tube freeze-up.

CAUTION

Transfer, addition, or removal of refrigerant in springisolated chillers may place severe stress on and damage external piping if springs have not been blocked in both up and down directions.

Transfer Refrigerant from Pumpout Storage Tank to Chiller

WARNING

During transfer of refrigerant into and out of the 19XR storage tank, carefully monitor the storage tank level gage. Do not fill the tank more than 90% of capacity to allow for refrigerant expansion. Overfilling may result in damage to the tank and personal injury.

1. Equalize refrigerant pressure. a. Turn on chiller water pumps and monitor chiller

pressures.

b. Close pumpout and storage tank valves 2 , 4, 5, and

10, and close refrigerant charging valve 7; open chiller isolation valve 11 and any other chiller isolation valves, if present.

c. Open pumpout and storage tank valves 3 and 6;

open chiller valves 1a and 1b.

VALVE 1A1B2345671011

CONDITION C C C C C

d. Gradually crack open valve 5 to increase chiller

pressure to 35 psig (241 kPa). Slowly feed refrigerant to prevent freeze-up.

e. Open valve 5 fully after the chiller pressure rises

above the freezing point of the refrigerant. Let the storage tank and chiller pressure equalize. Open refrigerant charging valve 7 and storage tank charging valve 10 to let liquid refrigerant drain into the chiller.

VALVE 1A1B2345671011

CONDITION C C

2. Transfer remaining refrigerant. a. Close valve 5 and open valve 4. Turn off the

pumpout condenser water, and turn on the pumpout compressor in manual mode to push liquid refrigerant out of the storage tank. Monitor

the storage tank level until the tank is empty. b. Close refrigerant charging valves 7 and 10. c. Turn off the pumpout compressor. d. Turn off the chiller water pumps. e. Close valves 3 and 4. f. Open valves 2 and 5.

VALVE 1A1B2345671011

CONDITION C C C C

g. Turn on pumpout condenser water. h. Run the pumpout compressor in manual mode until

the storage tank pressure reaches 5 psig (34 kPa),

18 in. Hg vacuum (41 kPa absolute). i. Turn off the pumpout compressor. j. Close valves 1a, 1b, 2, 5, and 6.

VALVE 1A1B2345671011

CONDITIONCCCCCCCCC

k. Turn off pumpout condenser water.

Transfer the Refrigerant from Chiller to Pumpout Storage Tank

1. Equalize refrigerant pressure. a. Valve positions:

VALVE 1A1B2345671011

CONDITION C C C C C

b. Slowly open valve 5 and refrigerant charging

valves 7 and 10 to allow liquid refrigerant to drain by gravity into the storage tank.

VALVE 1A1B2345671011

CONDITION C C

2. Transfer the remaining liquid. a. Turn off pumpout condenser water. Place valves in

the following positions:

VALVE 1A1B2345671011

CONDITION C C

b. Run the pumpout compressor in automatic mode

until vacuum switch is satisfied and compressor stops. Close valves 7 and 10.

VALVE 1A1B2345671011

CONDITION C C C C

c. Turn off the pumpout compressor.

3. Remove any remaining refrigerant. a. Turn on chiller water pumps. b. Turn on pumpout condenser water. c. Place valves in the following positions:

VALVE 1A1B2345671011

CONDITION C C C C

d. Run the pumpout compressor until the chiller pres-

sure reaches 35 psig (241 kPa); then, shut off the pumpout compressor. Warm chiller condenser water will boil off any entrapped liquid refrigerant and chiller pressure will rise.

e. When chiller pressure rises to 40 psig (276 kPa),

turn on the pumpout compressor until the pressure again reaches 35 psig (241 kPa), then, turn off the pumpout compressor. Repeat this process until the chiller pressure no longer rises; then, turn on the pumpout compressor and pump out until the chiller pressure reaches 18 in. Hg vacuum (41 kPa absolute). This can be done in On or Automatic mode.

f. Close valves 1a, 1b, 3, 4, and 6.

VALVE 1A1B2345671011

CONDITIONCCCCCCCCC

g. Turn off the pumpout condenser water.

4. Establish vacuum for service. To conserve refrigerant, operate the pumpout compressor as described in Step 3e until the chiller pressure is reduced to 18 in. Hg vacuum (41 kPa absolute).

This operation can be done in Automatic or On mode. In Automatic mode, the compressor will stop automatically at approximately 15 in. Hg vacuum (51 kPa absolute).

CHILLERS WITH ISOLATION VALVES — The va l v es referred to in the following instructions are shown in Fig. 23 and

24. Valve 7 remains closed. Transfer All Refrigerant to Chiller Condenser Vessel

1. Push refrigerant into chiller condenser vessel. a. Turn on the chiller water pumps and monitor the

chiller pressure.

b. Valve positions:

VALVE 1A1B234511

CONDITION C C

c. Equalize the refrigerant in the chiller cooler and

condenser.

d. Turn off chiller water pumps and pumpout con-

denser water supply.

e. Turn on pumpout compressor to push liqu id out of

the chiller cooler vessel.

f. When all liquid has been pushed into the chiller

condenser vessel, close the cooler refrigerant isola-

tion valve (11). g. Turn on the chiller water pumps. h. Turn off the pumpout compressor.

2. Evacuate gas from chiller cooler vessel. a. Close liquid line service valves 2 and 5; open

valves 3 and 4.

VALVE 1A1B234511

CONDITION C C C

b. Turn on pumpout condenser water. c. Run pumpout compressor until the chiller cooler

vessel pressure reaches 18 in. Hg vacuum (41 kPa absolute). Monitor pressures on the chiller control panel and on refrigerant gages.

This operation can be done in Automatic or On mode. In Automatic mode, the compressor will stop automatically at approximately 15 in. Hg vacuum (51 kPa absolute).

d. Close valve 1a. e. Turn off pumpout compressor. f. Close valves 1b, 3, and 4.

VALVE 1A1B234511

CONDITION CCCCCCC

g. Turn off pumpout condenser water. h. Turn off chiller water pumps and lock out chiller

compressor.

Transfer All Refrigerant to Chiller Cooler Vessel

1. Push refrigerant into the chiller cooler vessel. a. Turn on the chiller water pumps and monitor the

chiller pressure.

b. Valve positions:

VALVE 1A1B234511

CONDITION C C

c. Equalize the refrigerant in the chiller cooler and

condenser.

d. Turn off chiller water pumps and pumpout con-

denser water.

e. Turn on pumpout compressor to push refrigerant

out of the chiller condenser.

f. When all liquid is out of the chiller condenser,

close valve 11 and any other liquid isolation valves on the chiller.

g. Turn off the pumpout compressor.

2. Evacuate gas from chiller condenser vessel. a. Turn on chiller water pumps. b. Make sure that liquid line servi ce valves 3 and 4

are closed and valves 2 and 5 are open.

VALVE 1A1B234511

CONDITION C C C

c. Turn on pumpout condenser water.

d. Run the pumpout compressor until t he chiller con-

denser reaches 18 in. Hg vacuum (41 kPa absolute) in Manual or Automatic mode. Monitor pressure at

the chiller control panel and refrigerant gages. e. Close valve 1b. f. Turn off pumpout compressor. g. Close valves 1a, 2, and 5.

VALVE 1A1B234511

CONDITION CCCCCCC

h. Turn off pumpout condenser water. i. Turn o ff chiller water pumps and lock out chiller

compressor.

Return Refrigerant to Normal Operating Conditions

1. Be sure that the chiller vessel that was opened has been evacuated.

2. Turn on chiller water pumps.

3. Open valves 1a, 1b, and 3.

VALVE 1A1B234511

CONDITION C C C C

4. Crack open valve 5, gradually increasing pressure in the evacuated chiller vessel to 35 psig (241 kPa). Feed refrigerant slowly to prevent tube freeze-up.

5. Leak test to ensure chiller vessel integrity.

6. Open valve 5 fully.

VALVE 1A1B234511

CONDITION C C C

7. Close valves 1a, 1b, 3, and 5.

8. Open chiller isolation valve 11 and any other isolation valves, if present.

VALVE 1A1B234511

CONDITION CCCCCC

9. Turn off chiller water pumps.

DISTILLING THE REFRIGERANT

1. Transfer the refrigerant from the chiller to the pumpout storage tank as described in the Transfer the Refrigerant from Chiller to Pumpout Storage Tank section on page 34.

2. Equalize the refrigerant pressure. a. Turn on chiller water pumps and monitor chiller

pressures.

b. Close pumpout and storage tank valves 2, 4, 5, and

10, and close chiller charging valve 7; open chiller isolation valve 11 and any other chiller isolation valves, if present.

c. Open pumpout and storage tank valves 3 and 6;

open chiller valves 1a and 1b.

VALVE 1A1B2345671011

CONDITION C C C C C

d. Gradually crack open valve 5 to increase chiller

pressure to 35 psig (241 kPa). Slowly feed refrigerant to prevent freeze-up.

e. Open valve 5 fully after the chiller pressure rises

above the freezing point of the refrigerant. Let the storage tank and chiller pressure equalize.

3. Transfer remaining refrigerant. a. Close valve 3. b. Open valve 2.

VALVE 1A1B2345671011

CONDITION C C C C

c. Turn on pumpout condenser water. d. Run the pumpout compressor until the storage tank

pressure reaches 5 psig (34 kPa), 18 in. Hg vacuum

(41 kPa absolute) in Manual or Automatic mode. e. Turn off the pumpout compressor. f. Close valves 1a, 1b, 2, 5, and 6. g. Turn off pumpout condenser water.

VALVE 1A1B2345671011

CONDITIONCCCCCCCCC

4. Drain the contaminants from the bottom of the storage tank into a container. Dispose of contaminants safely.

GENERAL MAINTENANCE

Refrigerant Properties —

the 19XR chiller is HFC-134a. At normal atmospheric pressure, HFC-134a will boil at –14 F (–25 C) and must, therefore, be kept in pressurized containers or storage tanks. The refrigerant is practically odorless when mixed with air and is noncombustible at atmospheric pressure. Read the Material Safety Data Sheet and the latest ASHRAE Safety Guide for Mechanical Refrigeration to learn more about safe handling of this refrigerant.

The standard refrigerant for

DANGER

HFC-134a will dissolve oil and some nonmetallic materials, dry the skin, and, in heavy concentrations, may displace enough oxygen to cause asphyxiation. When handling this refrigerant, protect the hands and eyes and avoid breathing fumes.

Adding Refrigerant — Follow the procedures de-

scribed in Trim Refrigerant Charge section, page 38.

CAUTION

Always use the compressor pumpdown function in the PUMPDOWN/LOCKOUT feature to turn on the cooler pump and lock out the compressor when transferring refrigerant. Liquid refrigerant may flash into a gas and cause possible freeze-up when the chiller pressure is below 30 psig (207 kPa) for HFC-134a.

Adjusting the Refrigerant Charge — If the addi-

tion or removal of refrigerant is required to improve chiller performance, follow the procedures given under the Trim Refrigerant Charge section, page 38.

Refrigerant Leak Testing — Because HFC-134a is

above atmospheric pressure at room temperature, leak testing can be performed with refrigerant in the chiller. Use an electronic halogen leak detector, soap bubble solution, or ultrasonic leak detector. Ensure that the room is well ventilated and free from concentration of refrigerant to keep false readings to a minimum. Before making any necessary repairs to a leak, transfer all refrigerant from the leaking vessel.

Leak Rate — It is recommended by ASHRAE that chillers

be taken off line immediately and repaired if the refrigerant

leak rate for the entire chiller is more than 10% of the operating refrigerant charge per year.

In addition, Carrier recommends that leaks totalling less than the above rate but more than a rate of 0.1% of the total charge per year should be repaired during annual maintenance or whenever the refrigerant is transferred for other service work.

Test After Service, Repair, or Major Leak —

If all the refrigerant has been lost or if the chiller has been opened for service, the chiller or the affected vessels must be pressure tested and leak tested. Refer to the Leak Test Chiller section on page 16 to perform a leak test.

WARNING

HFC-134a should not be mixed with air or oxygen and pressurized for leak testing. In general, this refrigerant should not be present with high concentrations of air or oxygen above atmospheric pressures, because the mixture can undergo combustion.

TESTING WITH REFRIGERANT TRACER — Use an environmentally acceptable refrigerant as a tracer for leak test procedures. Use dry nitrogen to raise the machine pressure to leak testing levels.

TESTING WITHOUT REFRIGERANT TRACER — Another method of leak testing is to pressurize with nitrogen only and to use a soap bubble solution or an ultrasonic leak detector to determine if leaks are present.

TO PRESSURIZE WITH DRY NITROGEN NOTE: Pressurizing with dry nitrogen for leak testing should

not be done if the full refrigerant charge is in the vessel because purging the nitrogen is very difficult.

1. Connect a copper tube from the pressure regulator on the cylinder to the refrigerant charging valve. Never apply full cylinder pressure to the pressurizing line. Follow the listed sequence.

2. Open the charging valve fully.

3. Slowly open the cylinder regulating valve.

4. Observe the pressure gage on the chiller and close the regulating valve when the pressure reaches test level. Do not exceed 140 psig (965 kPa).

5. Close the charging valve on the chiller. Remove the copper tube if it is no longer required.

Repair the Leak, Retest, and Apply Standing Vacuum Test —

leaks with an electronic halide leak detector, soap bubble solution, or an ultrasonic leak detector. Bring the chiller back to atmospheric pressure, repair any leaks found, and retest.

After retesting and finding no leaks, apply a standing vacuum test. Then dehydrate the chiller. Refer to the Standing Vacuum Test and Chiller Dehydration sections (pages 16 and 18) in the Before Initial Start-Up section.

After pressurizing the chiller, test for

Checking Guide Vanes — During normal shutdown,

when the chiller is off, the guide vanes are closed. Check that the coupling is tight on the shaft and make sure that the guide vane shaft is closed. Complete the following steps to adjust position (see Fig. 29-31):

1. Remove the set screw in the guide vane coupling.

2. Loosen the holddown bolts on the guide vane actuator.

3. Pull the guide vane actuator away from the suction housing.

GUIDE VANE ACTUATOR

Fig. 29 — Guide Vane Actuator, Frame Size 6

a19-2123

GUIDE VANE ACTU ATOR

Fig. 30 — Guide Vane Actuator, Frame Size 7

GUIDE VANE

Fig. 31 — Guide Vane Actuator Detail

a19-2128

NOTE: Rotate coupling clockwise to close guide vanes. Rotate coupling counterclockwise to open guide vanes.

ACTUATOR

SET SCREW

ACTUATOR BRACKET

GUIDE VANE COUPLING

HOLDDOWN BOLTS (4)

4. If required, rotate the guide vane sprocket fully clockwise and spot-drill the guide vane actuator shaft. Spot-drilling is necessary when the guide vane actuator sprocket set screws on the guide vane actuator shaft need to be re-seated. (Remember: Spot-drill and tighten the first set screw before spot-drilling for the second set screw.)

Trim Refrigerant Charge — If to obtain optimal

chiller performance it becomes necessary to adjust the refrigerant charge, operate the chiller at design load and then add or remove refrigerant slowly until the difference between the leaving chilled water temperature and the cooler refrigerant temperature reaches design conditions or becomes a minimum. Do

not overcharge.

Refrigerant may be added either through the storage tank or directly into the chiller as described in the Charge Refrigerant into Chiller section.

To remove any excess refrigerant, follow the procedure in Transfer Refrigerant from Chiller to Pumpout Storage Tank section, Steps 1a and b, page 34.

WEEKLY MAINTENANCE

Check the Lubrication System —

el on the reservoir sight glass, and observe the level each week while the chiller is shut down.

If the level goes below the lower sight glass, check the oil reclaim system for proper operation. If additional oil is required, add it through the oil drain charging valve (Fig. 2). A pump is required when adding oil against refrigerant pressure. The oil charge for the 19XR two-stage compressor frame size 6 is 29 gal. (110 L); for frame size 7 the oil charge is 44.5 gal (168 L).

The added oil must meet Carrier specifications for the 19XR chiller. Refer to Changing Oil Filter and Oil Changes sections on page 39. Any additional oil that is added should be logged by noting the amount and date. Any oil that is added due to oil loss that is not related to service will eventually return to the sump. It must be removed when the level is high.

An oil heater is controlled by the PIC 5 control system to maintain oil temperature (see the 19XR with PIC 5 Controls Operation and Troubleshooting manual) when the compressor

Mark the oil lev-

is off. If the PIC 5 control system shows that the heater is energized and if the sump is still not heating up, the power to the oil heater may be off or the oil level may be too low. Check the oil level, the oil heater contactor voltage, and oil heater resistance.

The PIC 5 control system does not permit compressor startup if the oil temperature is too low. The PIC 5 control system continues with start-up only after the temperature is within allowable limits.

SCHEDULED MAINTENANCE

Establish a regular maintenance schedule based on your actual chiller requirements such as chiller load, run hours, and water quality. The time intervals listed in this section are of-

fered as guides to service only.

Service Ontime — The HMI will display a SERVICE

ONTIME value on the MAIN MENU  RUN TIMES screen. This value should be reset to zero by the service person or the operator each time major service work is completed so that the time between service events can be viewed and tracked.

Inspect the Control Panel — Maintenance consists of

general cleaning and tightening of connections. Vacuum the cabinet to eliminate dust build-up. If the chiller control malfunctions, refer to the Troubleshooting Guide section on page 42 for control checks and adjustments.

WARNING

Ensure power to the starter is isolated when cleaning and tightening connections inside the starter enclosure. Failure to disconnect power could result in electrocution. The oil filter housing is at a high pressure. Relieve this pressure slowly. Failure to do so could result in serious personal injury.

Changing Oil Filter — Change the oil filter on a

yearly basis or when the chiller is opened for repairs. The 19XR chiller has an isolatable oil filter so that the filter may be changed with the refrigerant remaining in the chiller. Use the following procedure:

1. Ensure the compressor is off and the disconnect for the compressor is open.

2. Disconnect the power to the oil pump.

3. Close the oil filter isolation valves.

4. Close the isolation valves located on both ends of the oil filter. Have rags and a catch basin available to collect oil spillage.

5. Equalize the filter’s higher internal pressure to ambient by connecting an oil charging hose to the Schrader valve on the oil filter housing. Collect the oil-refrigerant mixture which is discharged.

6. Remove the oil filter assembly by loosening the hex nuts on both ends of the filter assembly.

7. Insert the replacement filter assembly with the arrow on the housing pointing away from the oil pump.

8. Rotate the assembly so that the Schrader drain valve is oriented at the bottom, and tighten the connection nut on each end to a torque of approximately 30 ft-lb (41 N-m).

WARNING

The oil filter housing is at a high pressure. Relieve this pressure slowly. Failure to do so could result in serious personal injury.

9. Evacuate the filter housing by placing a vacuum pump on the charging valve. Follow the normal evacuation procedures. Shut the charging valve when done and reconnect the valve so that new oil can be pumped into the filter housing. Fill with the same amount that was removed; then close the charging valve.

10. Remove the hose from the charging valve, open the isolation valves to the filter housing, and turn on the power to the pump and the motor.

Oil Specification — If oil is added, it must meet the fol-

lowing Carrier specifications:

Oil Type for units using R-134a . . . . . . . . . . . . . . . . . .Inhibited

polyolester-based synthetic

compressor oil formatted for

use with HFC, gear-driven,

hermetic compressors.

ISO Viscosity Grade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

The polyolester-based oil (P/N: PP23BZ103) may be

ordered from your local Carrier representative.

Oil Changes — Carrier recommends that a yearly oil

analysis be performed to determine when to change oil and when to perform a compressor inspection. However, if yearly analysis is not performed or available, the time between oil changes should be no longer than 5 years. Additionally Carrier recommends vibration measurement done at regular intervals to obtain a signature of the moving compressor parts as part of a total productive maintenance (TPM) program.

TO CHANGE THE OIL

1. Transfer the refrigerant into the chiller condenser vessel (for isolatable vessels) or to a pumpout storage tank.

2. Mark the existing oil level.

3. Open the control and oil heater circuit breaker.

4. When the chiller pressure is 5 psig (34 kPa) or less, drain the oil reservoir by opening the oil charging valve (Fig. 2). Slowly open the valve against refrigerant pressure.

5. Change the oil filter at this time. See Changing Oil Filter section.

6. Change the refrigerant filter at this time, see the next section, Refrigerant Filter.

7. Charge the chiller with oil. Charge until the oil level is equal to the oil level marked in Step 2. Turn on the power to the oil heater and let the PIC 5 warm it up to at least 140 F (60 C). Operate the oil pump manually, using the Control Test function, for 2 minutes. For shutdown conditions, the oil level should be full in the lower sight glass. If the oil level is above move the excess oil. The oil level should now be equal to the amount shown in Step 2.

/2 full in the upper sight glass, re-

Refrigerant Filter — A refrigerant filter/drier, located on

the refrigerant cooling line to the motor, should be changed once a year or more often if filter condition indicates a need for more frequent replacement. Change the filter by closing the filter isolation valves (Fig. 2) and slowly opening the flare fittings with a wrench and back-up wrench to relieve the pressure. A moisture indicator sight glass is located beyond this filter to indicate the volume and moisture in the refrigerant. If the moisture indicator indicates moisture, locate the source of water immediately by performing a thorough leak check.

Oil Reclaim Filter — The oil reclaim system has a

strainer on the eductor suction line, a strainer on the discharge pressure line, and a filter on the cooler scavenging line. Replace the filter once every 5 years or when the machine is opened for service. This filter does not contain desiccant for moisture removal, so changing the filter will not change the moisture indicator status. Change the filter by closing the filter isolation valves and slowly opening the flare fitting with a wrench and back-up wrench to relieve the pressure. Change the strainers once every 5 years or whenever refrigerant is evacuated from the cooler.

Inspect Refrigerant Float System — Perform this

inspection only if the following symptoms are seen.

• There is a simultaneous drop in cooler pressure and increase in condenser pressure. This will be accompanied by an increase in kW/Ton.

• The liquid line downstream of the float valve feels warm. This indicates condenser gas flowing past the float. An increase in kW/Ton will also occur.

1. Transfer the refrigerant into the cooler vessel or into a pumpout storage tank.

2. Remove the float access cover.

3. Clean the chamber and valve assembly thoroughly. Be sure the valve moves freely. Ensure that all openings are free of obstructions.

4. Examine the cover gasket and replace if necessary. Inspect the orientation of the float slide pin. It must be pointed toward the bubbler tube for proper operation.

ECONOMIZER FLOAT SYSTEM — For two-stage compressors, the economizer has a low side ball type float system. The float refrigerant level can be observed through the two sight glasses located on the float cover under the condenser. See Fig. 32 for float detail. Inspect the float every five years. Clean the chamber and the float valve assembly. Be sure that the float moves freely and the ball bearings that the float moves on are clean.

ECONOMIZER DAMPER VALVE — The damper valve should be inspected every 5 years or when the condenser is opened for service. Check the economizer damper actuator’s movement and wiring.

Inspect Relief Valves and Piping — The relief valves

TOP VIEW

Fig. 32 — Economizer Float System (Two-Stage Compressor Chiller)

LEGEND

1—Float Ball 2—Refrigerant Exit 3—Bearings

a19-2124

on this chiller protect the system against the potentially dangerous effects of overpressure. To ensure against damage to the equipment and possible injury to personnel, these devices must be kept in peak operating condition.

As a minimum, the following maintenance is required.

1. At least once a year, disconnect the vent piping at the valve outlet and carefully inspect the valve body and mechanism for any evidence of internal corrosion or rust, dirt, scale, leakage, etc.

2. If corrosion or foreign material is found, do not attempt to repair or recondition. Replace the valve.

3. If the chiller is installed in a corrosive atmosphere or the relief valves are vented into a corrosive atmosphere, inspect the relief valves at more frequent intervals.

Compressor Bearing and Gear Maintenance —

The key to good bearing and gear maintenance is proper lubrication. Use the proper grade of oil, maintained at recommended level, temperature, and pressure. Inspect the lubrication system regularly and thoroughly. Annual oil analysis and vibration measurements are recommended.

Excessive bearing wear can sometimes be detected through increased vibration or increased bearing temperature. Gears, babbitted journal bearings, and thrust bearings should be examined for signs of wear based on the results of the annual oil analysis and vibration levels. To inspect the bearings, a complete compressor teardown is required. Only a trained service technician should remove and examine the bearings. The frequency of examination is determined by the hours of chiller operation, load conditions during operation, and the condition of the oil and the lubrication system. High speed shaft rolling element bearings cannot be field inspected; excessive vibration is the primary sign of wear or damage. If either symptom appears, contact an experienced and responsible service organization for assistance.

Inspect the Heat Exchanger Tubes and Flow Devices

COOLER AND OPTIONAL FLOW DEVICES — Inspect and clean the cooler tubes at the end of the first operating season. Because these tubes have internal ridges, a rotary-type tube cleaning system is needed to fully clean the tubes. Inspect the tubes’ condition to determine the scheduled frequency for future cleaning and to determine whether water treatment in the chilled water/brine circuit is adequate. Inspect the entering and leaving chilled water temperature sensors and flow devices for signs of corrosion or scale. Replace a sensor or Schrader fitting if corroded or remove any scale if found.

CONDENSER AND OPTIONAL FLOW DEVICES — Since this water circuit is usually an open-type system, the tubes may be subject to contamination and scale. Clean the condenser tubes with a rotary tube cleaning system at least once per year and more often if the water is contaminated. Inspect the entering and leaving condenser water sensors and flow devices for signs of corrosion or scale. Replace the sensor or Schrader fitting if corroded or remove any scale if found.

Higher than normal condenser pressures, together with the inability to reach full refrigeration load, usually indicate dirty tubes or air in the chiller. If the refrigeration log indicates a rise above normal condenser pressures, check the condenser refrigerant temperature against the leaving condenser water temperature. If this reading is more than what the design difference is supposed to be, the condenser tubes may be dirty or water flow may be incorrect. Because HFC-134a is a high-pressure refrigerant, air usually does not enter the chiller.

During the tube cleaning process, use brushes specially designed to avoid scraping and scratching the tube wall. Contact your Carrier representative to obtain these brushes. Do not use wire brushes.

Hard scale may require chemical treatment for its preven-

CONTACTOR

TERMINAL

STRIP

FUSES

TRANSFORMER

SWITCH

Fig. 33 — Pumpout Control Box (Interior)

a19-1569

tion or removal. Consult a water treatment specialist for proper treatment.

Water Leaks — The refrigerant moisture indicator on the

refrigerant motor cooling line (Fig. 2) indicates whether there is water leakage during chiller operation. Water leaks should be repaired immediately.

CAUTION

The chiller must be dehydrated after repair of water leaks or damage may result. See Chiller Dehydration section, page 18.

Water Treatment — Untreated or improperly treated

water may result in corrosion, scaling, erosion, or algae. The services of a qualified water treatment specialist should be obtained to develop and monitor a treatment program.

CAUTION

Water must be within design flow limits, clean, and treated to ensure proper chiller performance and reduce the potential of tube damage due to corrosion, scaling, erosion, and algae. Carrier assumes no responsibility for chiller damage resulting from untreated or improperly treated water.

Inspect the Starting Equipment — Before work-

ing on any starter, shut off the chiller, open and tag all disconnects supplying power to the starter.

CAUTION

The motor leads must be disconnected from the starter before an insulation test is performed. The voltage generated from the tester can damage the starter components.

Optional Pumpout System Maintenance — For

pumpout unit compressor maintenance details, refer to the 19XR Positive Pressure Storage System Installation, Start-Up, and Service Instructions.

OPTIONAL PUMPOUT COMPRESSOR OIL CHARGE — Use oil conforming to Carrier specifications for reciprocating compressor usage. Oil requirements are as follows:

ISO Viscosity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 or 220

Carrier Part Number . . . . . . . . . . . PP23BZ103 or PP23BZ104

The total oil charge is 13 oz. (0.5 L).

Oil should be visible in the pumpout compressor sight glass both during operation and at shutdown. Always check the oil level before operating the pumpout compressor. Before adding changing oil, relieve the refrigerant pressure through the access valves.

Relieve refrigerant pressure and add oil to the pumpout unit as follows:

1. Close service valves 2 and 4.

2. Run the pumpout compressor in Automatic mode for one minute or until the vacuum switch is satisfied and compressor shuts off.

3. Move the pumpout selector switch to OFF. Pumpout compressor shell should now be under vacuum.

4. Oil can be added to the shell with a hand oil pump through the access valve in the compressor base.

NOTE: The compressor access valve has a self-sealing fitting which will require a hose connection with a depressor to open.

OPTIONAL PUMPOUT SAFETY CONTROL SETTINGS (Fig. 33) — The optional pumpout system high-pressure switch opens at 185 psig (1276 kPa) and closes at 140 psig (965 kPa). Check the switch setting by operating the pumpout compressor and slowly throttling the pumpout condenser water.

WARNING

The disconnect on the starter front panel does not always de-energize all internal circuits. Open all internal and remote disconnects before servicing the starter. Failure to follow this procedure may result in personal injury by electric shock.

Periodically vacuum accumulated debris on the internal

parts. Use electrical cleaner for electrical parts as required.

Power connections on newly installed starters may relax and loosen after a month of operation. Turn power off and retighten. Recheck annually thereafter.

CAUTION

Loose power connections can cause voltage spikes, overheating, malfunctioning, or failures.

Recalibrate Pressure Transducers — Once a

year, the pressure transducers should be checked against a pressure gage reading. Check all eight transducers: the 2 oil differential pressure transducers, the condenser pressure transducer, the cooler pressure transducer, and the optional waterside pressure transducer pairs (consisting of 4 flow devices: 2 cooler, 2 condenser). For details, see page 46.

Ordering Replacement Chiller Parts —

When ordering Carrier specified parts, the following infor-

mation must accompany an order:

• chiller model number and serial number

• name, quantity, and part number of the part required

• delivery address and method of shipment.

TROUBLESHOOTING GUIDE

Overview —

to help the operator and technician troubleshoot a 19XR chiller.

• The HMI shows the chiller’s actual operating conditions and can be viewed while the unit is running.

• The HMI default screen indicates when an alarm occurs. Once all alarms have been cleared (by correcting the problems), the HMI default screen indicates normal operation. For information about displaying and resetting alarms and a list of alert codes, see the 19XR with PIC 5 Controls Operation and Troubleshooting manual.

• The Configuration menu screens display information that helps to diagnose problems with chilled water temperature control, chilled water temperature control overrides, hot gas bypass, surge algorithm status, and time schedule operation.

• The quick test feature facilitates the proper operation and test of temperature sensors, pressure transducers, the guide vane actuator, diffuser actuator (if equipped), oil pump, water pumps, tower control, and other on/off out puts while the compressor is stopped. It also has the ability to lock off the compressor and turn on water pum ps for pumpout operation. The HMI shows the temperatures and pressures required during these operations.

• If an operating fault is detected, an alarm indicator is is displayed on the HMI default screen. A more detailed message — along with a diagnostic message — is also stored in the Current Alarms table.

• Review the Alarms History table to view other less critical events which may have occurred. Compare timing of relevant events and alarms.

For detailed information about alarms, see the 19XR with

PIC 5 Controls Operation and Troubleshooting manual. Press the bell icon in the top right corner of the home screen to access current alarms and alarm history, and to reset alarms.

The PIC 5 control system has many features

Checking Display Messages — The first area to

check when troubleshooting the 19XR is the HMI display. Status messages are displayed at the bottom of the screen, and the alarm icon indicates a fault. For a complete list of alarms, see the 19XR with PIC 5 Controls Operation and Troubleshooting manual.

Checking Temperature Sensors — All tempera-

ture sensors are thermistor-type sensors. This means that the resistance of the sensor varies with temperature. All sensors have the same resistance characteristics. If the controls are on, determine sensor temperature by measuring voltage drop; if the controls are powered off, determine sensor temperature by measuring resistance. Compare the readings to the values listed in Tables 11 and 12.

RESISTANCE CHECK — Turn off the control power and, from the module, disconnect the terminal plug of the sensor in question. With a digital ohmmeter, measure sensor resistance between receptacles as designated by the wiring diagram. The resistance and corresponding temperature are listed in Tables 11 and 12. Check the resistance of both wires to ground. This resistance should be infinite.

VOLT A G E DR O P — The voltage drop across any energized sensor can be measured with a digital voltmeter while the control is energized. Table 11 or 12 lists the relationship between temperature and sensor voltage drop (volts dc measured across the energized sensor). Exercise care when measuring voltage to prevent damage to the sensor leads, connector plugs, and modules. Sensors should also be checked at the sensor plugs.

CAUTION

Relieve all refrigerant pressure or drain the water before removing any thermowell threaded into the refrigerant pressure boundary. Failure to do so could result in personal injury and equipment damage.

Table 11 — Thermistor Temperature (F) vs. Resistance/Voltage Drop

TEMPERATURE

(F)

PIC

VOLTAGE

DROP (V)

RESISTANCE

(OHMS)

–25 4.700 97,706 –24 4.690 94,549 –23 4.680 91,474 –22 4.670 88,480 –21 4.659 85,568 –20 4.648 82,737 –19 4.637 79,988 –18 4.625 77,320 –17 4.613 74,734 –16 4.601 72,229 –15 4.588 69,806 –14 4.576 67,465 –13 4.562 65,205 –12 4.549 63,027 –11 4.535 60,930 –10 4.521 58,915

–9 4.507 56,981 –8 4.492 55,129 –7 4.477 53,358 –6 4.461 51,669 –5 4.446 50,062 –4 4.429 48,536 –3 4.413 47,007 –2 4.396 45,528 –1 4.379 44,098

0 4.361 42,715 1 4.344 41,380 2 4.325 40,089 3 4.307 38,843 4 4.288 37,639 5 4.269 36,476 6 4.249 35,354 7 4.229 34,270 8 4.209 33,224

9 4.188 32,214 10 4.167 31,239 11 4.145 30,298 12 4.123 29,389 13 4.101 28,511 14 4.079 27,663 15 4.056 26,844 16 4.033 26,052 17 4.009 25,285 18 3.985 24,544 19 3.960 23,826 20 3.936 23,130 21 3.911 22,455 22 3.

6 21,800

23 3.861 21,163 24 3.835 20,556 25 3.808 19,967 26 3.782 19,396 27 3.755 18,843 28 3.727 18,307 29 3.700 17,787 30 3.672 17,284 31 3.644 16,797 32 3.617 16,325 33 3.588 15,868 34 3.559 15,426 35 3.530 14,997 36 3.501 14,582 37 3.471 14,181 38 3.442 13,791 39 3.412 13,415 40 3.382 13,050 41 3.353 12,696 42 3.322 12,353 43 3.291 12,021 44 3.260 11,699 45 3.229 11,386 46 3.198 11,082 47 3.167 10,787 48 3.135 10,500 49 3.104 10,221 50 3.074 9,949 51 3.042 9,689 52 3.010 9,436 53 2.978 9,190 54 2.946 8,951 55 2.914 8,719 56 2.882 8,494 57 2.850 8,275 58 2.819 8,062 59 2.788 7,855 60 2.756 7,655 61 2.724 7,460 62 2.692 7,271 63 2.660 7,088 64 2.628 6,909 65 2.596 6,736

TEMPERATURE

(F)

PIC

VOLTAGE

DROP (V)

RESISTANCE

(OHMS)

66 2.565 6,568 67 2.533 6,405 68 2.503 6,246 69 2.472 6,092 70 2.440 5,942 71 2.409 5,796 72 2.378 5,655 73 2.347 5,517 74 2.317 5,382 75 2.287 5,252 76 2.256 5,124 77 2.227 5,000 78 2.197 4,880 79 2.167 4,764 80 2.137 4,650 81 2.108 4,539 82 2.079 4,432 83 2.050 4,327 84 2.021 4,225 85 1.993 4,125 86 1.965 4,028 87 1.937 3,934 88 1.909 3,843 89 1.881 3,753 90 1.854 3,667 91 1.827 3,582 92 1.800 3,500 93 1.773 3,420 94 1.747 3,342 95 1.721 3,266 96 1.695 3,192 97 1.670 3,120 98 1.644 3,049

99 1.619 2,981 100 1.595 2,914 101 1.570 2,849 102 1.546 2,786 103 1.523 2,724 104 1.499 2,663 105 1.476 2,605 106 1.453 2,547 107 1.430 2,492 108 1.408 2,437 109 1.386 2,384 110 1.364 2,332 111 1.343 2,282 112 1.321 2,232 113 1.

300

2,184

114 1.279 2,137 115 1.259 2,092 116 1.239 2,047 117 1.219 2,003 118 1.200 1,961 119 1.180 1,920 120 1.161 1,879 121 1.143 1,840 122 1.124 1,801 123 1.106 1,764 124 1.088 1,727 125 1.070 1,691 126 1.053 1,656 127 1.036 1,622 128 1.019 1,589 129 1.002 1,556 130 0.986 1,524 131 0.969 1,493 132 0.953 1,463 133 0.938 1,433 134 0.922 1,404 135 0.907 1,376 136 0.893 1,348 137 0.878 1,321 138 0.864 1,295 139 0.849 1,269 140 0.835 1,244 141 0.821 1,219 142 0.808 1,195 143 0.795 1,172 144 0.782 1,149 145 0.769 1,126 146 0.756 1,104 147 0.744 1,083 148 0.731 1,062 149 0.719 1,041 150 0.707 1,021 151 0.696 1,002 152 0.684 983 153 0.673 964 154 0.662 945 155 0.651 928 156 0.640 910

TEMPERATURE

(F)

PIC

VOLTAGE

DROP (V)

RESISTANCE

(OHMS)

157 0.630 893 158 0.619 876 159 0.609 859 160 0.599 843 161 0.589 827 162 0.579 812 163 0.570 797 164 0.561 782 165 0.551 768 166 0.542 753 167 0.533 740 168 0.524 726 169 0.516 713 170 0.508 700 171 0.499 687 172 0.491 675 173 0.484 663 174 0.476 651 175 0.468 639 176 0.460 628 177 0.453 616 178 0.445 605 179 0.438 595 180 0.431 584 181 0.424 574 182 0.418 564 183 0.411 554 184 0.404 544 185 0.398 535 186 0.392 526 187 0.385 516 188 0.379 508 189 0.373 499 190 0.367 490 191 0.361 482 192 0.356 474 193 0.350 466 194 0.344 458 195 0.339 450 196 0.333 442 197 0.328 435 198 0.323 428 199 0.318 421 200 0.313 414 201 0.308 407 202 0.304 400 203 0.299 393 204 0

294 387

205 0.290 381 206 0.285 374 207 0.281 368 208 0.277 362 209 0.272 356 210 0.268 351 211 0.264 345 212 0.260 339 213 0.256 334 214 0.252 329 215 0.248 323 216 0.245 318 217 0.241 313 218 0.237 308 219 0.234 303 220 0.230 299 221 0.227 294 222 0.224 289 223 0.220 285 224 0.217 280 225 0.214 276 226 0.211 272 227 0.208 267 228 0.205 263 229 0.203 259 230 0.198 255 231 0.195 251 232 0.192 248 233 0.190 244 234 0.187 240 235 0.184 236 236 0.182 233 237 0.179 229 238 0.176 226 239 0.174 223 240 0.172 219 241 0.169 216 242 0.167 213 243 0.164 210 244 0.162 207 245 0.160 204 246 0.158 201 247 0.155 198 248 0.153 195

Table 12 — Thermistor Temperature (C) vs. Resistan ce/Voltage Drop

TEMPERATURE

(C)

–33 4.722 105 616 –32 4.706 99 640 –31 4.688 93 928 –30 4.670 88 480 –29 4.650 83 297 –28 4.630 78 377 –27 4.608 73 722 –26 4.586 69 332 –25 4.562 65 205 –24 4.538 61 343 –23 4.512 57 745 –22 4.486 54 411 –21 4.458 51 341 –20 4.429 48 536 –19 4.399 45 819 –18 4.368 43 263 –17 4.336 40 858 –16 4.303 38 598 –15 4.269 36 476 –14 4.233 34 484 –13 4.196 32 613 –12 4.158 30 858 –11 4.119 29 211 –10 4.079 27 663

–9 4.037 26 208 –8 3.994 24 838 –7 3.951 23 545 –6 3.906 22 323 –5 3.861 21 163 –4 3.814 20 083 –3 3.765 19 062 –2 3.716 18 097 –1 3.667 17 185

0 3.617 16 325 1 3.565 15 513 2 3.512 14 747 3 3.459 14 023 4 3.406 13 341 5 3.353 12 696 6 3.298 12 087 7 3.242 11 510 8 3.185 10 963

9 3.129 10 444 10 3.074 9 949 11 3.016 9 486 12 2.959 9 046 13 2.901 8 628 14 2.844 15 2.788 7 855 16 2.730 7 499 17 2.672 7 160 18 2.615 6 839 19 2.559 6 535 20 2.503 6 246 21 2.447 5 972 22 2.391 5 711 23 2.335 5 463 24 2.280 5 226 25 2.227 5 000 26 2.173 4 787 27 2.120 4 583 28 2.067 4 389 29 2.015 4 204 30 1.965 4 028 31 1.914 3 861 32 1.865 3 701 33 1.816 3 549 34 1.768 3 404 35 1.721 3 266 36 1.675 3 134 37 1.629 3 008 38 1.585 2 888 39 1.542 2 773 40 1.499 2 663 41 1.457 2 559 42 1.417 2 459 43 1.377 2 363

PIC

VOLTAGE

DROP (V)

RESISTANCE

(OHMS)

8 23

TEMPERATURE

(C)

44 1.338 2 272 45 1.300 2 184 46 1.263 2 101 47 1.227 2 021 48 1.192 1 944 49 1.158 1 871 50 1.124 1 801 51 1.091 1 734 52 1.060 1 670 53 1.029 1 609 54 0.999 1 550 55 0.969 1 493 56 0.941 1 439 57 0.913 1 387 58 0.887 1 337 59 0.861 1 290 60 0.835 1 244 61 0.811 1 200 62 0.787 1 158 63 0.764 1 117 64 0.741 1 079 65 0.719 1 041 66 0.698 1 006 67 0.677 971 68 0.657 938 69 0.638 906 70 0.619 876 71 0.601 846 72 0.583 818 73 0.566 791 74 0.549 765 75 0.533 740 76 0.518 715 77 0.503 692 78 0.488 670 79 0.474 648 80 0.460 628 81 0.447 608 82 0.434 588 83 0.422 570 84 0.410 552 85 0.398 535 86 0.387 518 87 0.376 502 88 0.365 487 89 0.355 472 90 0.344 458 91 0.335 92 0.325 431 93 0.316 418 94 0.308 405 95 0.299 393 96 0.291 382 97 0.283 371 98 0.275 360

99 0.267 349 100 0.260 339 101 0.253 330 102 0.246 320 103 0.239 311 104 0.233 302 105 0.227 294 106 0.221 286 107 0.215 278 108 0.210 270 109 0.205 262 110 0.198 255 111 0.193 248 112 0.188 242 113 0.183 235 114 0.178 229 115 0.174 223 116 0.170 217 117 0.165 211 118 0.161 205 119 0.157 200 120 0.153 195

PIC

VOLTAGE

DROP (V)

RESISTANCE

(OHMS)

444

CHECK SENSOR ACCURACY — Place the sensor in a

a19-2216

Fig. 34 — Bearing 1 Sensor Wiring from Back of Terminal Block

TERMINAL BLOCKS LOCATED BETWEEN HEATER AND OIL PUMP

Fig. 35 — Bearings 2-4 Sensor Wiring from Back of Terminal Block

a19-2125

medium of known temperature and compare that temperature to the measured reading. The thermometer used to determine the temperature of the medium should be of laboratory quality with 0.5 F (0.25 C) graduations. The sensor in question should be accurate to within 2 F (1.2 C).

Note that the PIC 5 control module, MAINTENANCE menu, offers a temperature sensor calibration feature where the sensor temperature can be offset. To use this feature, place the sensor at 32 F (0 C) or other known temperature. Read the raw temperature and calculate offset based on the reading seen in the TEMP_CAL menu. Enter and execute the offset, which cannot exceed ± 2 F (1.2 C).

See Fig. 2 for sensor locations. The sensors are immersed directly in the refrigerant or water circuits. When installing a

BEARING #1

new sensor, apply a pipe sealant or thread sealant to the sensor threads.

An additional thermistor, factory installed in the bottom of the cooler barrel, is displayed as Evap Refrig Liquid Temp on the TEMPERATURES display screen. This thermistor provides additional protection against a loss of water flow.

DUAL TEMPERATURE SENSORS — For servicing convenience, there are 2 redundant sensors each on the bearing and motor temperature sensors. If one of the sensors is damaged, the other can be used by simply moving a wire. The number 2 terminal in the sensor terminal box is the common line. To use the second sensor, move the wire from the number 1 position to the number 3 position. See Fig. 34 or Fig. 35.

TERMINAL BLOCK LOCATED ON END OF MOTOR COVER

Checking Pressure Transducers — There are 4

factory-installed pressure transducers measuring refrigerant and oil pressure, and a fifth pressure transducer measuring economizer pressure.

These transducers can be calibrated if necessary. It is necessary to calibrate at initial start-up, particularly at high altitude locations, to ensure the proper refrigerant temperature/ pressure relationship. Each transducer is supplied with 5 vdc power. If the power supply fails, a transducer voltage reference alarm occurs. If the transducer reading is suspected of being faulty, check the TRANSDUCER VOLTAGE REF supply voltage. It should be 5 vdc ± 0.5 v as displayed in MAINTENANCE MENU  MAINTENANCE OTHERS, where all the transducer voltages are shown. If the TRANSDUCER VOLTAGE REF supply voltage is correct, the transducer should be recalibrated or replaced.

Also check that inputs have not been grounded and are not receiving anything other than a 4 to 20 mA signal.

TRANSDUCER REPLACEMENT — Since the transducers are mounted on Schrader-type fittings, there is no need to remove refrigerant from the vessel when replacing the transducers. Disconnect the transducer wiring. Do not pull on the trans- ducer wires. Unscrew the transducer from the Schrader fitting. When installing a new transducer, do not use pipe sealer (which can plug the sensor). Put the plug connector back on the sensor and snap into place. Check for refrigerant leaks.

WARNING

Be sure to use a back-up wrench on the Schrader fitting whenever removing a transducer, since the Schrader fitting may back out with the transducer, causing a large leak and possible injury to personnel.

COOLER AND CONDENSER PRESSURE TRANSDUCE R CALI BRATIO N — Calibration can be checked by comparing the pressure readings from the transducer to an accurate refrigeration gage reading. These readings can be viewed or calibrated from the HMI screen. The transducer can be checked and calibrated at 2 pressure points. These calibration points are 0 psig (0 kPa) and between 25 and 250 psig (173 and 1724 kPa). Wiring is shown in Fig. 36. To calibrate these transducers:

1. Shut down the compressor, cooler, and condenser pumps. NOTE: There should be no flow through the heat

exchangers.

2. Disconnect the transducer in question from its Schrader fitting for cooler or condenser transducer calibration. For oil pressure or flow device calibration, leave the transducer in place.

NOTE: If the cooler or condenser vessels are at 0 psig (0 kPa) or are open to atmospheric pressure, the transducers can be calibrated for zero without removing the transducer from the vessel.

3. Access the PRESSURE or HYDRAULIC STATUS screen and view the particular transducer reading. To calibrate oil pressure or waterside flow device, view the particular reading. It should read 0 psig (0 kPa). If the reading is not 0 psig (0 kPa), but within ± 5 psig (35 kPa), the value may be set to zero from the Maintenance Menu while the appropriate transducer parameter is highlighted. The value will now go to zero.

If the transducer value is not within the calibration range, the transducer returns to the original reading. If the pressure is within the allowed range (noted above), check the voltage ratio of the transducer. To obtain the voltage ratio, divide the voltage (dc) input from the transducer by the supply voltage signal or measure across the positive

(+ red) and negative (– black) leads of the transducer. The input to reference voltage ratio must be between 0.80 and

0.11 for the software to allow calibration. Rotate the waterside flow pressure device from the inlet nozzle to the outlet nozzle and repeat this step. If rotating the waterside flow device does not allow calibration, then pressurize the transducer until the ratio is within range. Then attempt calibration again.

4. Pressures can be calibrated between 100 and 250 psig (689.5 and 1723.7 kPa) by attaching a regulated 250 psig (1724 kPa) pressure (usually from a nitrogen cylinder). For calibration, access the Pressure Sensor Calibration Menu from the Maintenance Menu and calibrate the appropriate sensor.

The PIC 5 control system does not allow calibration if the transducer is too far out of calibration. In this case, a new transducer must be installed and re-calibrated. If calibration problems are encountered on the OIL PRESSURE DELTA P channel, sometimes swapping the compressor oil discharge pressure transducer and the oil sump pressure transducer will offset an adverse transducer to to proceed.

OPTIONAL THERMAL DISPERSION FLOW SWITCH CALI BRA TIO N — Set the flow through the water circuit to the minimum safe flow that will be encountered. Thermal dispersion switch inputs are shown in Fig. 37. The Water Pressure Option must be enabled.

Reduce the sensitivity of the switch by turning the adjustment counter-clockwise until the yellow LED turns off. This indicates that the switch is now open.

Increase the sensitivity of the flow switch by turning the adjustment potentiometer clockwise until the yellow LED is lit.

In case of nuisance trips at low flow increase the sensitivity of the switch by turning the potentiometer clockwise.

HYDRAULIC STATUS — The HYDRAULIC STATUS screen (access from the Main Menu) provides a convenient way to detect if any of the cooler/condenser pressure switches (if installed) are in need of calibration. With no flow and no added resistors the water delta should read zero psig (0 kPa). If it does not, the value may be set to zero using PRESSURE SENSOR CALIB located in the Maintenance Menu.

lerance stack

up and allow the calibration

High Altitude Locations — Because the chiller is ini-

tially calibrated at sea level, it is necessary to recalibrate the pressure transducers if the chiller has been moved to a high altitude location. See the calibration procedure in the 19XR with PIC 5 Controls Operation and Troubleshooting guide. Note that Atmospheric Pressure can be adjusted in the Service Parameters Menu (located in the Configuration Menu).

a19-2292

Fig. 36 — Inputs for Optional Waterside Delta P Transducers for IOB4

4.3 kOhm

Fig. 37 — Inputs for Optional Thermal Dispersion Switches for IOB4

(Evaporator Flow Switch, Condenser Flow Switch)

4.3 kOhm

TB (FIELD SUPPLIED)

EVAP FS

COND FS

(+) (G)

(-)

(+) (G)

(-)

CONTROL BOARD.

Quick Test — The Quick Test feature is located in the

Main Menu. Through this feature one can perform guide vane calibration, test chiller status, test the status of various actuators, view water temperature deltas, test oil pump and oil heater relays, as well as control inlet guide vane, hot gass bypass, economizer damper, alarms, condenser and chilled water pumps. The tests can help to determine whether a switch is defective or a pump relay is not operating, as well as other useful troubleshooting issues. During pumpdown operations, the pumps are energized to prevent freeze-up and the vessel pressures and temperatures are displayed.

CHILLED WA TER PUMP

CONDENSER WA TER PUMP

TOWER FAN HIGH

TOWER FAN LOW

a19-2284

Pumpdown/Lockout — The Pumpdown/Lockout fea-

ture, available from the Maintenance Menu, prevents compressor start-up when there is no refrigerant in the chiller or if the vessels are isolated. The Terminate Lockout feature ends the Pumpdown/Lockout after the pumpdown procedure is reversed and refrigerant is added.

Physical Data — Tables 13-32 and Fig. 38-50 provide

additional information on component weights, compressor fits and clearances, physical and electrical data, and wiring schematics for the operator’s convenience during troubleshooting.

Table 13 — 19XR Two-Stage Compressor Frame Size 6

Heat Exchanger Weights (English)

CODE†

A40 16,877 18,542 1647 927 4328 4553 A41 17,270 19,062 1773 927 4557 4890 A42 17,690 19,565 1887 927 4816 5213 A45 16,968 18,493 1599 927 4453 4582 A46 17,371 19,063 1714 927 4701 4949 A47 17,761 19,578 1837 927 4941 5281

A60 18,354 20,139 1878 1074 4721 5029 A61 18,807 20,745 2022 1074 4984 5415 A62 19,295 21,330 2152 1074 5280 5786 A65 18,469 20,095 1823 1074 4859 5060 A66 18,936 20,758 1954 1074 5144 5482 A67 19,389 21,357 2095 1074 5419 5862

A4A 15,540 17,089 1681 861 4183 4524 A4B 15,794 17,472 1792 861 4392 4859 A4C 16,063 17,812 1897 861 4615 5137 A4F 15,592 17,076 1626 861 4322 4588

A4G 15,845 17,405 1736 861 4531 4867

A4H 16,249 17,821 1890 861 4865 5219

A6A 16,465 18,359 1917 998 4555 4996 A6B 16,758 18,806 2044 998 4794 5368 A6C 17,070 19,202 2164 998 5050 5698 A6F 16,535 18,356 1854 998 4709 5068

A6G 16,829 18,739 1979 998 4948 5387

A6H 17,296 19,225 2156 998 5331 6156

DRY RIGGING WEIGHT (lb)* REFRIGERANT WEIGHT (lb) WATER WEIGHT (lb)

COOLER

ONLY

CONDENSER

ONLY

COOLER

ONLY

CONDENSER

ONLY

COOLER

ONLY

CONDENSER

ONLY

B40 — 21,217 — 1233 — 5850 B41 — 21,965 — 1233 — 6333 B42 — 22,581 — 1233 — 6729 B45 — 21,173 — 1233 — 5904 B46 — 21,909 — 1233 — 6379 B47 — 22,653 — 1233 — 6859

B60 — 23,061 — 1423 — 6464 B61 — 23,932 — 1423 — 7018 B62 — 24,649 — 1423 — 7473 B65 — 23,022 — 1423 — 6521 B66 — 23,879 — 1423 — 7066 B67 — 24,745 — 1423 — 7617

B4A — 19,217 — 1148 — 5756 B4B — 19,793 — 1148 — 6243 B4C — 20,254 — 1148 — 6633 B4F — 19,217 — 1148 — 5852

B4G — 19,721 — 1148 — 6279

B4H — 20,318 — 1148 — 6785

B6A — B6B — 21,465 — 1326 — 6915 B6C — 22,002 — 1326 — 7362 B6F — 20,806 — 1326 — 6462

B6G — 21,393 — 1326 — 6951

B6H — 22,088 — 1326 — 8379

*Rigging weights are for standard tubes of standard wall thickness (0.025-in. [0.635 mm] wall) and do not include refrigerant weight. †See Model Number Nomenclature on page 5.

20,794 — 1326 — 6

NOTES:

1. Cooler weight includes the suction elbow and the distribution piping to the economizer and two-pass Victaulic dished heads.

2. Condenser weight includes the high side float chamber, discharge pipe, and mizer to the float chamber and two-pass Victaulic dished heads.

the distribution piping weight from the econo-

357

Table 14 — 19XR Two-Stage Compressor Frame Size 6

Heat Exchanger Weights (SI)

CODE†

A40 7655 8 410 747 420 1963 2065 A41 7833 8 646 804 420 2067 2218 A42 8024 8 875 856 420 2184 2365 A45 7697 8 388 725 420 2020 2078 A46 7879 8 647 777 420 2132 2245 A47 8056 8 880 833 420 2241 2395

A60 8325 9 135 852 487 2141 2281 A61 8531 9 410 917 487 2261 2456 A62 8752 9 675 976 487 2395 2624 A65 8377 9 115 827 487 2204 2295 A66 8589 9 416 886 487 2333 2487 A67 8795 9 687 950 487 2458 2659

A4A 7049 7 751 762 391 1897 2052 A4B 7164 7 925 813 391 1992 2204 A4C 7286 8 079 860 391 2093 2330

A4F 7072 7 746 738 391 1960 2081 A4G 7187 7 895 787 391 2055 2208 A4H 7370 8 083 857 391 2207 2367

A6A 7468 8 328 870 453 2066 2266 A6B 7601 8 530 927 453 2175 2435 A6C 7743 8 710 982 453 2291 2585

A6F 7500 8 326 841 453 2136 2299 A6G 7633 8 500 898 453 2244 2444 A6H 7845 8 730 978 453 2418 2792

DRY RIGGING WEIGHT (kg)* REFRIGERANT WEIGHT (kg) WATER WEIGHT (kg)

COOLER

ONLY

CONDENSER

ONLY

COOLER

ONLY

CONDENSER

ONLY

COOLER

ONLY

CONDENSER

ONLY

B40 — 9 624 — 559 — 2653

B41 — 9 963 — 559 — 2873

B42 — 10 243 — 559 — 3052

B45 — 9 604 — 559 — 2678

B46 — 9 938 — 559 — 2893

B47 — 10 275 — 559 — 3111

B60 — 10 460 — 645 — 2932

B61 — 10 855 — 645 — 3183

B62 — 11 181 — 645 — 3390

B65 — 10 442 — 645 — 2958

B66 — 10 831 — 645 — 3205

B67 — 11 224 — 645 — 3455

B4A — 8 717 — 521 — 2611 B4B — 8 978 — 521 — 2832 B4C — 9 187 — 521 — 3009

B4F — 8 717 — 521 — 2654 B4G — 8 945 — 521 — 2848 B4H — 9 216 — 521 — 3078

B6A — B6B — 9 736 — 601 — 3137 B6C — 9 980 — 601 — 3339

B6F — 9 487 — 601 — 2931 B6G — 9 704 — 601 — 3153 B6H — 10 019 — 601 — 3801

*Rigging weights are for standard tubes of standard wall thickness (0.025-in. [0.635 mm] wall) and do not include refrigerant weight. †See Model Number Nomenclature on page 5.

9 432 — 601 — 2

NOTES:

1. Cooler weight includes the suction elbow and the distribution piping to the economizer and two-pass Victaulic dished heads.

2. Condenser weight includes the high side float chamber, discharge pipe, and mizer to the float chamber and two-pass Victaulic dished heads.

the distribution piping weight from the econo-

883

Table 15 — 19XR Two-Stage Compressor Frame Size 7

Heat Exchanger Weights (English)

CODE†

B60 24,704 — 2273 — 6340 — B61 25,337 — 2355 — 6737 — B62 25,964 — 2460 — 7116 — B65 25,014 — 2185 — 6485 — B66 25,631 — 2275 — 6873 — B67 26,264 — 2379 — 7255 —

B6A 22,819 — 2081 — 6159 — B6B 23,299 — 2162 — 6568 — B6C 23,829 — 2256 — 6993 — B6F 23,139 — 1951 — 6344 —

B6G 23,648 — 2019 — 6774 —

B6H 24,171 — 2120 — 7194 —

C60 30,825 29,857 2647 1610 8475 8,630 C61 31,536 30,881 2751 1610 8924 9,275 C62 32,467 31,871 2875 1610 9474 9,916 C65 31,135 29,982 2562 1610 8645 8,684 C66 31,851 31,064 2666 1610 9097 9,362 C67 32,777 32,186 2793 1610 9644 10,078

C6A 28,641 27,676 2443 1497 6898 8,675 C6B 29,167 28,315 2534 1497 7352 9,216 C6C 29,750 28,918 2627 1497 7823 9,752 C6F 28,929 27,774 2334 1497 7724 8,710

C6G 29,478 28,457 2415 1497 8194 9,283

C6H 30,083 29,223 2500 1497 8681 9,935

DRY RIGGING WEIGHT (lb)* REFRIGERANT WEIGHT (lb) WATER WEIGHT (lb)

COOLER ONLY CONDENSER ONLY COOLER ONLY

CONDENSER

ONLY

COOLER ONLY CONDENSER ONLY

D60 — 38,296 — 2097 — 11,473 D61 — 39,624 — 2097 — 12,309 D62 — 41,031 — 2097 — 13,210 D65 — 37,624 — 2097 — 11,617 D66 — 38,837 — 2097 — 12,387 D67 — 40,460 — 2097 — 13,410

D6A — 35,286 — 1947 — 11,401 D6B — 36,328 — 1947 — 12,255 D6C — 37,288 — 1947 — 13,078 D6F — 34,447 — 1947 — 11,448

D6G — 35,637 — 1947 — 12,408

D6H — 36,663 — 1947 — 13,278

*Rigging weights are for standard tubes of standard wall thickness (0.025-in. [0.635 mm] wall) and do not include refrigerant weight. †See Model Number Nomenclature on page 5.

NOTES:

1. Cooler weight includes the suction elbow and the distribution piping to the economizer and two-pass Victaulic dished heads.

2. Condenser weight includes the high side float chamber, discharge pipe, and mizer to the float chamber and two-pass Victaulic dished heads.

the distribution piping weight from the econo-

Table 16 — 19XR Two-Stage Compressor Frame Size 7

Heat Exchanger Weights (SI)

CODE†

B60 11 206 — 1031 — 2876 — B61 11 493 — 1068 — 3056 — B62 11 777 — 1116 — 3228 — B65 11 346 — 991 — 2941 — B66 11 626 — 1032 — 3118 — B67 11 913 — 1079 — 3291 —

B6A 10 351 — 944 — 2794 — B6B 10 568 — 981 — 2979 — B6C 10 809 — 1023 — 3172 — B6F 10 496 — 885 — 2878 —

B6G 10 727 — 916 — 3073 —

B6H 10 964 — 962 — 3263 —

C60 13 982 13 543 1201 730 3841 3914 C61 14 304 14 007 1248 730 4048 4207 C62 14 727 14 456 1304 730 4297 4498 C65 14 123 13 600 1162 730 3921 3939 C66 14 447 14 090 1209 730 4126 4247 C67 14 867 14 599 1267 730 4374 4571

C6A 12 991 12 554 1108 679 3129 3935 C6B 13 230 12 843 1149 679 3325 4180 C6C 13 494 13 117 1192 679 3553 4423 C6F 13 122 12 508 1059 679 3504 3951

C6G 13 371 12 908 1095 679 3717 4211

C6H 13 645 13 255 1134 679 3938 4506

DRY RIGGING WEIGHT (kg)* REFRIGERANT WEIGHT (kg) WATER WEIGHT (kg)

COOLER ONLY CONDENSER ONLY COOLER ONLY

CONDENSER

ONLY

COOLER ONLY CONDENSER ONLY

D60 — 17 371 — 951 — 5204 D61 — 17 973 — 951 — 5583 D62 — 18 611 — 951 — 5992 D65 — 17 066 — 951 — 5269 D66 — 17 616 — 951 — 5619 D67 — 18 352 — 951 — 6083

D6A — 16 005 — 883 — 5171

D6B — 16 478 — 883 — 5559 D6C — 16 914 — 883 — 5932

D6F — 15 625 — 883 — 5193

D6G — 16 165 — 883 — 5628 D6H — 16 630 — 883 — 6023

*Rigging weights are for standard tubes of standard wall thickness (0.025-in. [0.635 mm] wall) and do not include refrigerant weight. †See Model Number Nomenclature on page 5.

NOTES:

1. Cooler weight includes the suction elbow and the distribution piping to the economizer and two-pass Victaulic dished heads.

2. Condenser weight includes the high side float chamber, discharge pipe, and mizer to the float chamber and two-pass Victaulic dished heads.

the distribution piping weight from the econo-

Table 17 — 19XR Two-Stage Compressor Frame Sizes 6 and 7

Economizer Weight

FRAME SIZE

XR6 1589 360 1949 721 163 884 XR7 2749 646 3395 1247 293 1540

*Includes economizer weight and all the connecting piping to the compressor.

DRY WEIGHT

(lb)*

REFRIGERANT

WEIGHT (lb)

OPERATION WEIGHT (lb)

DRY WEIGHT

(kg)*

REFRIGERANT

WEIGHT (kg)

OPERATION WEIGHT

Table 18 — Additional Weights for 19XR 150 psig (1034 kPa) Marine Waterboxes*

Two-Stage Compressors, Frame Size 6†

FRAME

*Add to cooler and condenser weights for total weights. Condenser weights may be found in Tables 13 and 14. The first digit of the heat exchanger code (first column) is the heat exchanger frame size. †Values are for Victaulic nozzles, two-pass dished head design.

NUMBER

PASSES

A 2 1618 2603 1396 2253 734 1181 633 1022 B 2 — — 1414 3222 — — 641 1461

COOLER CONDENSER COOLER CONDENSER

RIGGING

WGT

ENGLISH (lb) SI (kg)

WATER

WGT

RIGGING

WGT

WATER

WGT

RIGGING

WGT

WATER

WGT

RIGGING

WGT

Table 19 — Additional Weights for 19XR 300 psig (2068 kPa) ASME Marine Waterboxes*

Two-Stage Compressors, Frame Size 6 — English (lb)

NUMBER

FRAME

A 2 5174 5554 1738 4383 4763 1605 B 2 — — — 6171 6671 2064

*Add to cooler and condenser weights for total weights. Condenser weights may be found in Tables 13 and 14. The first digit of the heat exchanger code (first column) is the heat exchanger frame size.

PASSES

Rigging Wgt

Victaulic Flange Victaulic Flange

COOLER CONDENSER

Water Wgt

Rigging Wgt

(kg)

WATER

WGT

Water Wgt

Table 20 — Additional Weights for 19XR 300 psig (2068 kPa) ASME Marine Waterboxes*

Two-Stage Compressors, Frame Size 6 — SI (kg)

NUMBER

FRAME

A 2 2347 2519 788 1988 2160 728 B 2 — — — 2799 3026 936

*Add to cooler and condenser weights for total weights. Condenser weights may be found in Tables 13 and 14. The first digit of the heat exchanger code (first column) is the heat exchanger frame size.

PASSES

Rigging Wgt

Victaulic Flange Victaulic Flange

COOLER CONDENSER

Water Wgt

Rigging Wgt

Water Wgt

Table 21 — Additional Weights for 19XR 150 psig (1034 kPa)

Two-Stage Compressors, Frame Size 7†

Marine Waterboxes*

FRAME

*Add to cooler and condenser weights for total weights. Cooler and condenser weights may be found in Tables 15 and 16. The first digit of the heat exchanger code (first column) is the heat exchanger frame size.

NUMBER

PASSES

B 2 2253 3758 — — 1022 1705 — — C 2 2748 4818 2907 4439 1246 2185 1319 2013 D 2 — — 3692 5679 — — 1675 2576

COOLER CONDENSER COOLER CONDENSER

RIGGING

WGT

ENGLISH (lb) SI (kg)

WATER

WGT

RIGGING

WGT

WATER

WGT

†Values are for Victaulic nozzles, two-pass dished head design.

RIGGING

WGT

WATER

WGT

RIGGING

WGT

Table 22 — Additional Weights for 19XR 300 psig (2068 kPa) ASME Marine Waterboxes*

Two-Stage Compressors, Frame Size 7 — English (lb)

NUMBER

FRAME

B 2 6651 7151 1938 — — — C 2 9330 9830 2128 7,935 8,565 2642 D 2 — — — 11,262 11,892 3080

PASSES

Rigging Wgt

Victaulic Flange Victaulic Flange

COOLER CONDENSER

Water Wgt

Rigging Wgt

Table 23 — Additional Weights for 19XR 300 psig (2068 kPa) ASME Marine Waterboxes*

Two-Stage Compressors, Frame Size 7 — SI (kg)

WATER

WGT

Water Wgt

NUMBER

FRAME

B 2 3017 3244 879 — — — C 2 4232 4459 965 3599 4021 1198 D 2 — — — 5108 5394 1397

PASSES

Rigging Wgt

Victaulic Flange Victaulic Flange

COOLER CONDENSER

Water Wgt

Rigging Wgt

Water Wgt

Table 24 — 19XR Compressor and Motor Weights* — High-Efficiency Motors

Compressor Frame Size 6, 50 Hz

ENGLISH SI

MOTOR

CODE

Voltage: 3000-3-50

N 10,622 5918 1212 1021 4818 2684 550 463 P 10,622 6006 1230 1021 4818 2724 558 463

Q 10,622 6094 1248 1021 4818 2764 566 463

R 10,622 6184 1264 1021 4818 2805 573 463 S 10,622 6274 1280 1021 4818 2846 581 463 T 10,622 6296 1280 1021 4818 2856 581 463

Voltage: 3300-3-50

N 10,622 5913 1212 1021 4818 2682 550 463 P 10,622 6007 1230 1021 4818 2725 558 463

Q 10,622 6101 1248 1021 4818 2767 566 463

R 10,622 6192 1264 1021 4818 2809 573 463 S 10,622 6283 1280 1021 4818 2850 581 463 T 10,622 6266 1280 1021 4818 2842 581 463

Voltage: 6300-3-50

N 10,622 6277 1280 1021 4818 2847 581 463 P 10,622 6333 1298 1021 4818 2873 589 463

Q 10,622 6389 1316 1021 4818 2898 600 463

R 10,622 6473 1316 1021 4818 2936 600 463 S 10,622 6556 1316 1021 4818 2974 600 463 T 10,622 6609 1351 1021 4818 2998 613 463

Voltage: 10000-3-50

N 10,622 6281 1280 1021 4818 2849 581 463 P 10,622 6281 1281 1021 4818 2849 581 463

Q 10,622 6281 1281 1021 4818 2849 581 463

R 10,622 6441 1316 1021 4818 2922 600 463 S 10,622 6600 1351 1021 4818 2994 613 463 T 10,622 6156 1351 1021 4818 2792 613 463

Voltage: 11000-3-50

N 10,622 6600 1351 1021 4818 2994 613 463 P 10,622 6600 1351 1021 4818 2994 613 463

Q 10,622 6600 1351 1021 4818 2994 613 463

R 10,622 6765 1385 1021 4818 3069 628 463 S 10,622 T 10,622 6930 1419 1021 4818 3143 644 463

*Total compressor weight is the sum of the compressor aerodynamic components (compressor weight column), stator, rotor, and end bell cover weights. †Compressor aerodynamic component weight only, motor weight not included. Applicable to standard compressors only.

COMPRESSOR

WEIGHT†

(lb)

STATOR AND

HOUSING

WEIGHT

(lb)

6930

ROTOR AND

SHAFT

WEIGHT

(lb)

1419 1021 4818 3143 644 463

END BELL

COVER

WEIGHT

(lb)

COMPRESSOR

WEIGHT†

(kg)

STATOR AND

HOUSING

WEIGHT

(kg)

ROTOR AND

SHAFT

WEIGHT

(kg)

END BELL

COVER

WEIGHT

(kg)

Table 25 — 19XR Compressor and Motor Weights* — High-Efficiency Motors

Two-Stage Compressor Frame Size 6, 60 Hz

ENGLISH SI

MOTOR

CODE

Voltage: 2400-3-60

N 10,622 5929 1212 1021 4818 2689 550 463 P 10,622 6021 1230 1021 4818 2731 558 463 Q 10,622 6112 1248 1021 4818 2772 566 463 R 10,622 6190 1264 1021 4818 2808 573 463 S 10,622 6268 1280 1021 4818 2843 581 463 T 10,622 6259 1280 1021 4818 2839 581 463

Voltage: 3300-3-60

N 10,622 5927 1212 1021 4818 2688 550 463 P 10,622 6019 1230 1021 4818 2730 558 463 Q 10,622 6110 1248 1021 4818 2771 566 463 R 10,622 6187 1264 1021 4818 2806 573 463 S 10,622 6263 1280 1021 4818 2841 581 463 T 10,622 6277 1280 1021 4818 2847 581 463

Voltage: 4160-3-60

N 10,622 6103 1247 1021 4818 2768 566 463 P 10,622 6103 1248 1021 4818 2768 566 463 Q 10,622 6103 1248 1021 4818 2768 566 463 R 10,622 6185 1264 1021 4818 2805 573 463 S 10,622 6268 1280 1021 4818 2843 581 463 T 10,622 6268 1280 1021 4818 2843 581 463

Voltage: 6900-3-60

N 10,622 6558 1316 1021 4818 2975 600 463 P 10,622 6559 1316 1021 4818 2975 600 463 Q 10,622 6559 1316 1021 4818 2975 600 463 R 10,622 6566 1316 1021 4818 2978 600 463 S 10,622 6574 1316 1021 4818 2982 600 463 T 10,622 6604 1351 1021 4818 2996 613 463

Voltage: 11000-3-60

N 10,622 6587 1351 1021 4818 2988 613 463 P 10,622 6587 1351 1021 4818 2988 613 463 Q 10,622 6587 1351 1021 4818 2988 613 463 R 10,622 6716 1385 1021 4818 3036 628 463 S 10 T 10,622 6844 1419 1021 4818 3104 644 463

Voltage: 13800-3-60

N 10,622 6554 1351 1021 4818 2973 613 463 P 10,622 6554 1351 1021 4818 2973 613 463 Q 10,622 6554 1351 1021 4818 2973 613 463 R 10,622 6709 1385 1021 4818 3043 628 463 S 10,622 6864 1419 1021 4818 3113 644 463 T 10,622 6864 1419 1021 4818 3113 644 463

COMPRESSOR

WEIGHT†

(lb)

,622 68

STATOR AND

HOUSING

WEIGHT

(lb)

ROTOR AND

SHAFT

WEIGHT

(lb)

44 1419 1021 4818 3104 644 463

END BELL

COVER

WEIGHT

(lb)

COMPRESSOR

WEIGHT†

(kg)

STATOR AND

HOUSING

WEIGHT

(kg)

ROTOR AND

SHAFT

WEIGHT

(kg)

END BELL

COVER

WEIGHT

(kg)

Table 26 — 19XR Compressor and Motor Weights* — High-Efficiency Motors

Two-Stage Compressor Frame Size 7, 50 Hz

ENGLISH SI

MOTOR

CODE

Voltage: 3000-3-50

U 14,309 6725 1443 983 6490 3050 654 446 V 14,309 6716 1443 983 6490 3046 654 446

W 14,309 6706 1443 983 6490 3042 654 446

X 14,309 6802 1460 983 6490 3085 662 446 Y 14,309 6899 1476 983 6490 3129 670 446 Z 14,309 7066 1509 983 6490 3205 684 446

Voltage: 3300-3-50

U 14,309 6743 1443 983 6490 3059 654 446 V 14,309 6739 1443 983 6490 3057 654 446

W 14,309 6734 1443 983 6490 3054 654 446

X 14,309 6826 1460 983 6490 3096 662 446 Y 14,309 6917 1476 983 6490 3137 670 446 Z 14,309 7075 1509 983 6490 3209 684 446

Voltage: 6300-3-50

U 14,309 6743 1443 983 6490 3059 654 446 V 14,309 6900 1476 983 6490 3130 670 446

W 14,309 7058 1509 983 6490 3201 684 446

X 14,309 7130 1526 983 6490 3234 692 446 Y 14,309 7203 1542 983 6490 3267 699 446 Z 14,309 7203 1542 983 6490 3267 699 446

Voltage: 10000-3-50

U 14,309 6904 1476 983 6490 3132 670 446 V 14,309 6907 1476 983 6490 3133 670 446

W 14,309 6910 1476 983 6490 3134 670 446

X 14,309 7074 1509 983 6490 3209 684 446 Y 14,309 7238 1542 983 6490 3283 699 446 Z 14,309 7401 1575 983 6490 3357 714 446

Voltage: 11000-3-50

U 14,309 7139 1509 983 6490 3238 684 446 V 14,309 7186 1526 983 6490 3260 692 446

W 14,309 7234 1542 983 6490 3281 699 446

X 14,309 7234 1542 983 6490 3281 699 446 Y 14,309 Z 14,309 7383 1575 983 6490 3349 714 446

COMPRESSOR

WEIGHT†

(lb)

STATOR AND

HOUSING

WEIGHT

(lb)

7234

ROTOR AND

SHAFT

WEIGHT

(lb)

1542 983 6490 3281 699 446

END BELL

COVER

WEIGHT

(lb)

COMPRESSOR

WEIGHT†

(kg)

STATOR AND

HOUSING

WEIGHT

(kg)

ROTOR AND

SHAFT

WEIGHT

(kg)

END BELL

COVER

WEIGHT

(kg)

Table 27 — 19XR Compressor and Motor Weights* — High-Efficiency Motors

Two-Stage Compressor Frame Size 7, 60 Hz

ENGLISH SI

MOTOR

CODE

Voltage: 2400-3-60

U 14,309 6719 1443 983 6490 3048 654 446 V 14,309 6718 1443 983 6490 3047 654 446

W 14,309 6717 1443 983 6490 3047 654 446

X 14,309 6811 1460 983 6490 3089 662 446 Y 14,309 6906 1476 983 6490 3132 670 446 Z 14,309 7073 1509 983 6490 3208 684 446

Voltage: 3300-3-60

U 14,309 6723 1443 983 6490 3049 654 446 V 14,309 6730 1443 983 6490 3053 654 446

W 14,309 6736 1443 983 6490 3055 654 446

X 14,309 6816 1460 983 6490 3092 662 446 Y 14,309 6895 1476 983 6490 3128 670 446 Z 14,309 7055 1509 983 6490 3200 684 446

Voltage: 4160-3-60

U 14,309 6739 1443 983 6490 3057 654 446 V 14,309 6721 1443 983 6490 3049 654 446

W 14,309 6703 1443 983 6490 3040 654 446

X 14,309 6778 1460 983 6490 3074 662 446 Y 14,309 6853 1476 983 6490 3108 670 446 Z 14,309 7069 1509 983 6490 3206 684 446

Voltage: 6900-3-60

U 14,309 6730 1443 983 6490 3053 654 446 V 14,309 6909 1476 983 6490 3134 670 446

W 14,309 7088 1509 983 6490 3215 684 446

X 14,309 7076 1509 983 6490 3210 684 446 Y 14,309 7064 1509 983 6490 3204 684 446 Z 14,309 7141 1542 983 6490 3239 699 446

Voltage: 11000-3-60

U 14,309 7042 1509 983 6490 3194 684 446 V 14,309 7085 1526 983 6490 3214 692 446

W 14,309 7128 1542 983 6490 3233 699 446

X 14,309 Y 14,309 7135 1542 983 6490 3236 699 446 Z 14,309 7313 1575 983 6490 3317 714 446

Voltage: 13800-3-60

U 14,309 7073 1509 983 6490 3208 684 446 V 14,309 7109 1526 983 6490 3225 692 446

W 14,309 7146 1542 983 6490 3241 699 446

X 14,309 7146 1542 983 6490 3241 699 446 Y 14,309 7146 1542 983 6490 3241 699 446 Z 14,309 7295 1575 983 6490 3309 714 446

*Total compressor weight is the sum of the compressor aerodynamic components (compressor weight column), stator, rotor, and end bell cover weights.

COMPRESSOR

WEIGHT†

(lb)

STATOR AND

HOUSING

WEIGHT

(lb)

7131

ROTOR AND

SHAFT

WEIGHT

(lb)

1542 983 6490 3235 699 446

END BELL

COVER

WEIGHT

(lb)

COMPRESSOR

WEIGHT†

(kg)

†Compressor aerodynamic component weight only, motor weight not included. Applicable to standard compressors only.

STATOR AND

HOUSING

WEIGHT

(kg)

ROTOR AND

SHAFT

WEIGHT

(kg)

END BELL

COVER

WEIGHT

(kg)

Table 28 — 19XR Waterbox Cover Weights, Two-Stage Compressor Frame 6 — English (lb)

Two-Stage Compressor Frame 6; Cooler Frame A

WATERBOX DESCRIPTION PASSES

STANDARD NOZZLES FLANGED

Dished Head, 150 psig MWB End Cover, 150 psig MWB End Cover (ASME), 300 psig

LEGEND NOTES:

ASME— American Society of Mechanical Engineers MWB — Marine Waterbox

Two-Stage Compressor Frame 6; Condenser Frame A and B

WATERBOX DESCRIPTION PASSES

Dished Head, 150 psig MWB End Cover, 150 psig MWB End Cover (ASME), 300 psig

LEGEND NOTES:

ASME— American Society of Mechanical Engineers MWB — Marine Waterbox

2 2 2

1. Consult factory for 1 and 3 pass data.

2. Weights for dished head cover and MWB end cover 150 psig are included in the heat exchanger weights shown in Tables 13 and 14.

STANDARD

NOZZLES

2 2 2

1084 1280 1193 1453 1084 1280 1193 1453 2117 2117 2675 2675

1. Consult factory for 1 and 3 pass data.

2. Weights for dished head cover and MWB end cover 150 psig are included in the heat exchanger weights shown in Tables 13 and 14.

COOLER

FRAME A

1132 1440 1132 1440 2460 2460

CONDENSER

FRAME A FRAME B

FLANGED

STANDARD

NOZZLES

FLANGED

Table 29 — 19XR Waterbox Cover Weights, Two-Stage Compressor Frame 6 — SI (kg)

Two-Stage Compressor Frame 6; Cooler Frame A

WATERBOX DESCRIPTION PASSES

Dished Head, 1034 kPa MWB End Cover, 1034 kPa MWB End Cover (ASME), 2068 kPa

LEGEND NOTES:

ASME— American Society of Mechanical Engineers MWB — Marine Waterbox

Two-Stage Compressor Frame 6; Condenser Frame A and B

WATERBOX DESCRIPTION PASSES

Dished Head, 1034 kPa MWB End Cover, 1034 kPa MWB End Cover (ASME), 2068 kPa

LEGEND NOTES:

ASME— American Society of Mechanical Engineers MWB — Marine Waterbox

2 2 2

1. Consult factory for 1 and 3 pass data.

2. Weights for dished head cover and MWB end cover 1034 kPa are included in the heat exchanger weights shown in Tables 13 and 14.

STANDARD

NOZZLES

2 2 2

492 581 541 659 492 581 541 659 960 960 1213 1213

1. Consult factory for 1 and 3 pass data.

2. Weights for dished head cover and MWB end cover 1034 kPa are included in the heat exchanger weights shown in Tables 13 and 14.

COOLER FRAME A

STANDARD NOZZLES FLANGED

513 653 513 653

1116 1116

CONDENSER

FRAME A FRAME B

FLANGED

STANDARD

NOZZLES

FLANGED

Table 30 — 19XR Waterbox Cover Weights, Two-Stage Compressor Fr ame 7 — English (lb)

Two-Stage Compressor Frame 7; Cooler Frames B, C

WATERBOX DESCRIPTION PASSES

STANDARD NOZZLES FLANGED STANDARD NOZZLES FLANGED

Dished Head, 150 psig MWB End Cover, 150 psig MWB End Cover (ASME), 300 psig

LEGEND NOTES:

ASME— American Society of Mechanical Engineers MWB — Marine Waterbox

2 2 2

Two-Stage Compressor Frame 7; Condenser Frames C, D

WATERBOX DESCRIPTION PASSES

STANDARD NOZZLES FLANGED STANDARD NOZZLES FLANGED

Dished Head, 150 psig MWB End Cover, 150 psig MWB End Cover (ASME), 300 psig

LEGEND NOTES:

ASME— American Society of Mechanical Engineers MWB — Marine Waterbox

2 2 2

FRAME B FRAME C

1588 1848 2075 2335 1588 1848 2075 2335 3365 3365 4747 4747

1. Consult factory for 1 and 3 pass data.

2. Weights for dished head cover and MWB end cover 150 psig are included in the heat exchanger weights shown in Tables 15 and 16.

FRAME C FRAME D

1614 1944 2072 2402 1614 1944 2072 2402 3639 3639 5188 5188

1. Consult factory for 1 and 3 pass data.

2. Weights for dished head cover and MWB end cover 150 psig are included in the heat exchanger weights shown in Tables 15 and 16.

COOLER

CONDENSER

Table 31 — 19XR Waterbox Cover Weights, Two-Stage Compressor Frame 7 — SI (kg)

Two-Stage Compressor Frame 7; Cooler Frames B, C

WATERBOX DESCRIPTION PASSES

STANDARD NOZZLES FLANGED STANDARD NOZZLES FLANGED

Dished Head, 1034 kPa MWB End Cover, 1034 kPa MWB End Cover (ASME), 2068 kPa

LEGEND NOTES:

ASME— American Society of Mechanical Engineers MWB — Marine Waterbox

2 2 2

Two-Stage Compressor Frame 7; Condenser Frames C, D

WATERBOX DESCRIPTION PASSES

STANDARD NOZZLES FLANGED STANDARD NOZZLES FLANGED

Dished Head, 1034 kPa MWB End Cover, 1034 kPa MWB End Cover (ASME), 2068 kPa

LEGEND NOTES:

ASME— American Society of Mechanical Engineers MWB — Marine Waterbox

2 2 2

FRAME B FRAME C

720 838 941 1059 720 838 941 1059

1526 1526 2153 2153

1. Consult factory for 1 and 3 pass data.

2. Weights for dished head cover and MWB end cover 1034 kPa are included in the heat exchanger weights shown in Tables 15 and 16.

FRAME C FRAME D

732 882 940 1090 732 882 940 1090

1651 1651 2353 2353

1. Consult factory for 1 and 3 pass data.

2. Weights for dished head cover and MWB end cover 1034 kPa are included in the heat exchanger weights shown in Tables 15 and 16.

COOLER

CONDENSER

Table 32 — Compressor Component Weights

COMPONENT

TRANSMISSION ASSEMBLY (INCLUDING BULL GEAR AND HIGH SPEED SHAFT) 1,940 880 3,147 1427 BULL GEAR 121 55 220 100 HIGH SPEED SHAFT ASSEMBLY 523 237 700 318 SUCTION ASSEMBLY (INCLUDING BLADE RING) 1,520 689 2,078 943 BLADE RING ASSEMBLY 109 49 384 174 COMPRESSOR BASE 4,919 2231 6,972 3162 MOTOR END COVER 1,021 463 983 446 INTAKE WALL 220 100 719 326 DISCHARGE WALL 172 78 296 134 DIAPHRAGM 289 131 473 215 OIL PUMP 124 56 124 56 TOTAL WEIGHT (EXCLUDING MOTOR) 10,622 4818 14,309 6490

XR6 WEIGHTS XR7 WEIGHTS

lb kg lb kg

19XR TWO-STAGE COMPRESSOR FRAMES 6 AND 7 FITS AND CLEARANCES

LOW SPEED BEARING

MOTOR END

SEE DETAIL D

LOW SPEED BEARING

COMPRESSOR END

SEE DETAIL B

AERO

SEE DETAIL A

LOW SPEED BEARING

MOTOR END

SEE DETAIL C

a19-2217

Fig. 38 — Compressor Fits and Clearances — Two-Stage Compressor, Frame Sizes 6 and 7

ITEM

A Low Speed Journal — Compressor End 0.006/0.007 0.15/0.18 0.006/0.008 0.15/0.19 B Low Speed Journal —Motor End 0.004/0.005 0.10/0.11 0.004/0.006 0.10/0.15 C Low Speed Labyrinth — Compressor End 0.009/0.013 0.23/0.32 0.009/0.013 0.23/0.33 D Low Speed Shaft Thrust Float 0.008/0.020 0.20/0.50 0.008/0.020 0.20/0.50 E Impeller Bore to Shaft — 1st Impeller –0.002/0.000 –0.05/0.01 –0.002/0.000 –0.05/–0.01

F Impeller Bore to Shaft — 2nd Impeller –0.002/0.000 –0.06/0.01 –0.002/0.000 –0.05/–0.01 G Low Speed Bearing Labyrinth to Shaft — Motor End 0.009/0.013 0.23/0.33 0.010/0.012 0.25/0.30 H Low Speed Bearing to Cover Assembly 0.002/0.004 0.04/0.10 0.001/0.003 0.03/0.08

I Bull Gear to Low Speed Shaft –0.001/0.000 –0.03/0.00 –0.0013/0.0000 –0.033/0.000

J High Speed Shaft Labyrinth to High Speed Labyrinth Sleeve 0.006/0.009 0.15/0.23 0.006/0.009 0.15/0.23 K Balance Piston Labyrinth to 2nd Stage Impeller 0.008/0.012 0.20/0.30 0.008/0.012 0.20/0.30

L 2nd Stage Eye Labyrinth to Impeller 0.008/0.012 0.20/0.30 0.012/0.016 0.30/0.40 M Interstage Labyrinth Spacer to High Speed Shaft 0.001/0.002 0.02/0.05 0.001/0.003 0.04/0.07 N Interstage Labyrinth Seal 0.011/0.017 0.29/0.42 0.009/0.012 0.23/0.30 O 1st Stage Eye Labyrinth to Impeller 0.016/0.020 0.41/0.50 0.024/0/028 0.62/0.72

NOTES:

1. All clearances for cylindrical surfaces are diametrical.

2. Dimensions shown are with rotors in the thrust position.

3. High speed shaft and bearing assembly cannot be pulled from impeller end. The transmission assembly must be removed from the compressor casting (after the impeller is removed) and the

COMPRESSOR

DESCRIPTION

FRAME 6 (in.) FRAME 6 (mm) FRAME 7 (in.) FRAME 7 (mm)

bearing temperature sensor must be removed from the high speed shaft and bearing assembly before the high speed shaft and bearing assembly can be separated from the transmission.

4. If any components within a rolling element high speed shaft and bearing assembly are damaged it is recommended that the entire high speed shaft and bearing assembly be replaced.

SEE DETAIL E

ITEM M

ITEM O

ITEM N

ITEM K

ITEM L

DETAIL A

AERO

ITEM F

ITEM E

SECTION B-B

a19-2277

ITEM D

ITEM A

ITEM C

SECTION C-C

ITEM I

DETAIL B

LOW SPEED BEARING

COMPRESSOR END

a19-2278

Fig. 38 — Compressor Fits and Clearances — Two-Stage Compressor, Frames Size 6 and 7 (cont)

LEGEND

1—1st Stage Eye Labyrinth 10 — High Speed Shelf Labyrinth Sleeve 2—1st Stage Impeller Shim 11 — 2nd Stage Impeller 3—Intake Wall 12 — 2nd Stage Impeller Key 4—2nd Stage Eye Labyrinth 13 — Interstage Labyrinth Spacer 5—Diaphragm 14 — 1st Stage Impeller 6—Discharge Wall 15 — 1st Stage Impeller Key 7—Balance Piston Labyrinth 16 — Impeller Locknut 8—High Speed Shelf Labyrinth 17 — Nose Piece 9—High Speed Shelf Labyrinth Shaft

DETAIL D

LOW SPEED BEARING

MOTOR END

ITEM H

ITEM G

ITEM B

a19-2279

DETAIL E

HIGH SPEED BEARING

COMPRESSOR END

ITEM J

a19-2280

Fig. 38 — Compressor Fits and Clearances — Two-Stage Compressor, Frame Sizes 6 and 7 (cont)

a19-2220

DETAIL C

HIGH SPEED BEARING

MOTOR END

CAUTION

USE COPPER CONDUCTORS ONLY UTILISEZ DES CONDUCTEURS EN CUIVRE SEULMENT

ALWAYS USE 2 WRENCHES TO TIGHTEN

• TERM INSULATOR TO MOTOR – 15-35 ft. lb.

• BRASS NUT TO TERM INSULATOR – 3 ft. lb. max

• ADAPTOR TO TERM STUD – 20-35 ft. lb.

• LUG BOLTS (1/2")– 32-45 ft. lb. Insulate entire connection with electrical insulation

including 1 inch of cable insulation and 1 inch of the term insulator.

TERMINAL STUD

INSULATION

ADAPTER

BRASS NUT

TERMINAL INSULATOR

MOTOR LEAD INSTALLATION LABEL

19XR TWO-STAGE COMPRESSOR ASSEMBLY TORQUES

Fig. 39 — Compressor Assembly Torques — 19XR Two-Stage Compressors Frame Sizes 6 and 7

COMPRESSOR FRAME 6 FRAME 7

Oil Heater Retaining Nut — ft-lb (N·m) 40-60 (54-81) 40-60 (54-81) Bull Gear Retaining Bolt — ft-lb (N·m) 72-88 (98-119) 72-88 (98-119) Demister Bolts — ft-lb (N·m) 15-19 (20-26) 15-19 (20-26) Impeller Nut (Inner Locknut) — ft-lb (N·m) 243-257 (329-348) 243-257 (329-348) Impeller Nut (Outer) — ft-lb (N·m) 95-105 (129-142) 95-105 (129-142) Guide Vane Shaft Seal Nut/Bolts — ft-lb (N·m) 23-27 (31-37) 48-70 (64-94)

a19-1642

a19-1643

Fig. 40 — HMI Panel

7TB IN HMI PANEL FOR CUSTOMER COMMUNICATION CONNECTION A (+)

a19-2251

C (G) B (-)

a19-2252

Fig. 41 — Control Panel, IOB Layer

1TB

2TB

a19-2374

1TB — CUSTOMER 3-PHASE POWER CONNECTION FOR CONTROL PANEL 2TB — FIELD WIRING CONNECTION FROM STARTER

Fig. 42 — Control Panel, Bottom Layer

LEGEND FOR FIG. 43

19XR with Free-Standing Starter (Medium Voltage)

REFERENCE

NUMBER

3 Phase Under/Over Voltage Phase Loss/Imbalance/Reversal Motor Overload Protection Frequency Shift kW Transducer/kW Hours/Demand kW Single Cycle Dropout Motor/Starter Overcurrent Control Power Transformer (3KVA) (Integral)

2 Compressor Motor Starter Branch Disconnect A Evaporator Liquid Pump Starter Disconnect B Evaporator Liquid Pump Motor Starter C Condenser Liquid Pump Starter Disconnect D Condenser Liquid Pump Motor Starter E Cooling Tower Fan Motor Starter Disconnect (Low Fan/#1)

F Cooling Tower Fan Motor Starter (Low Fan/#1) G Cooling Tower Fan Motor Starter Disconnect (High/#2) H Cooling Tower Fan Motor Starter (High Fan/#2)

L Remote Alarm See Note 3.3

M Remote Annunciator See Note 3.3

N Lug Adapters See Note 2.1

See Notes on page 70.

Controls and Oil Heater Circuit Breaker (integral) Oil Pump Circuit Breaker Oil Pump Circuit Breaker with Transformer 3 Phase Analog Volts/Amps Meter Package Power Factor Correction Package Lightning/Surge Arrestor Package Auxiliary Run Status Contacts N.O./N.C. Run Indicating Light Emergency Stop Switch Phase to Ground Fault Detection

EXPLANATION

COMPRESSOR MOTOR STARTER

a19-2254

Fig. 43 — 19XR Typical Field Wiring with Free-Standing Starter (Medium Voltage)

NOTE: See Legend on page 67.

2TB

Fig. 43 — 19XR Typical Field Wiring with Free- Standing Starter (Medium Voltage) (cont)

CONTROL PANEL

1TB

HMI CONTROL PANEL

7TB

GROUNDING

FOR HMI

–

NOTES FOR FIG. 43

19XR with Free-Standing Starter (Medium Voltage)

I. GENERAL

1.0 Starters shall be designed and manufactured in accordance with Carrier Engineering Requirement Z-415.

1.1 All field-supplied conductors, devices, and the field installation wiring, termination of conductors and devices, must be in compliance with all applicable codes and job specifications.

CAUTION

To prevent damage to machine, do NOT punch holes or drill into the top surface of the starter enclosure for field wiring. Knockouts are provided on the side of the starter enclosure for field wiring connections.

1.2 The routing of field-installed conduit and conductors and the location of field-installed devices must not interfere with equipment access or the reading, adjusting, or servicing of any component.

1.3 Equipment installation and all starting and control devices, must comply with details in equipment submittal drawings and literature.

1.4 Contacts and switches are shown in the position they would assume with the circuit de-energized and chiller shutdown.

1.5 WARNING — Do not use aluminum conductors.

1.6 Installer is responsible for any damage caused by improper wiring between starter and machine.

1.7 All field-installed wiring is field-supplied.

POWER WIRING TO STARTER

II.

2.0 Provide a means of disconnecting power to starter.

2.1 Lug adapters may be required if installation conditions dictate that conductors be sized beyond the minimum ampacity required. Contact starter supplier for lug information.

2.2 Compressor motor and controls must be grounded by using equipment grounding lug provided inside starter enclosure.

CONTROL WIRING

III.

3.0 Field supplied control conductors to be at least 18 AWG or larger.

3.1 Ice build start/terminate device contacts, remote start/stop device contacts and spare safety device contacts (devices not supplied by Carrier), must have 24 VAC rating. MAX current is 60 mA, nominal current is 10 mA. Switches with gold plated bifurcated contacts are recommended.

3.2 Remove jumper wire between J2-1 and J2-2 before connecting auxiliary safeties between these terminals.

3.3 Each integrated contact output can control loads (VA) for evaporator pump, condenser pump, tower fan low, tower fan high, and alarm annunciator devices rated 5 amps at 115 VAC and up to 3 amps at 277 VAC.

3.8 Spare 4-20 mA output signal is designed for controllers with a non-grounded 4-20 mA input signal and a maximum input impedance of 500 ohms.

POWER WIRING BETWEEN FREE-STANDING STARTER

IV.

AND COMPRESSOR MOTOR

4.0 Medium voltage (over 600 volts) compressor motors have (3) terminals. Connections are compression lug with a single 9/16-in. diameter hole can be connected directly to the stud or 3 adapters are supplied for connecting a NEMA lug. Use suitable connectors and insulation for high voltage alternating current cable terminations (these items are not supplied by Carrier). Compressor motor starter must have nameplate stamped as to conforming with Carrier Engineering requirement “Z-415.”

4.1 Power conductor rating must meet minimum unit nameplate voltage and compressor motor RLA. Refer to the label located on the side of the chiller control panel, equipment subm itta l docu ment ation or equipment product data catalog for conductor sizing data. (Conductor as defined below may be a single lead or multiple smaller ampacity leads in parallel for the purpose of carrying the equivalent or higher current of a single larger lead.)

When (3) conductors are used: Minimum ampacity per conductor = 1.25 x compressor RLA

4.2 When more than one conduit is used to run conductors from starter to compressor motor terminal box, an equal number of leads from each phase (conductor) must be in each conduit to prevent excessive heating. (For example, conductors to motor terminals 1, 2, and 3 in one conduit, and those to 4, 5, and 6 in another).

4.4 Compressor motor power conductors may enter terminal box through top, left side or bottom left using holes cut by contractor to suit conduit. Flexible conduit should be used for the last few feet to the terminal box for unit vibration isolation. Use of stress cones may require an oversize (special) motor terminal box (not supplied by Carrier).

4.3 Compressor motor frame to be grounded in accordance with the National Electrical Code (NFPA-70) and applicable codes. Means for grounding compressor motor is a #4 AWG to 500 MCM pressure connector, supplied and located in the lower left side corner of the compressor motor terminal box.

4.5 Do not allow motor terminals to support weight of wire cables. Use cable supports and strain reliefs as required.

4.6 Use backup wrench when tightening lead connectors to motor terminal studs. Torque to 30-35 ft-lb max.

/16-in. threaded stud. A

CAUTION

Control wiring for Carrier to start pumps and tower fan motors and establish flows must be provided to assure machine protection. If primary pump, tower fan, and flow control is by other means, also provide parallel means for control by Carrier. Failure to do so could result in machine freeze-up or overpressure.

Do not use control transformers in the control center as the power source for external or field-supplied contactor coils, actuator motors or any other loads.

3.4 Do not route control wiring carrying 30 v or less within a conduit which has wires carrying 50 v or higher or along side wires carrying 50 v or higher.

3.5 Control wiring between starter and control panel must be separate shielded cables with minimum rating 600 v, 80 C. Ground shield at starter.

3.6 If optional circuit breaker is not supplied within the starter enclosure, it must be located within sight of machine w ith wiring routed to suit.

3.7 When providing conductors for oil pump motor and oil heater power, refer to sizing data on label located on the chiller control panel, equipment submittal documentation or equipment product data catalog.

LEGEND FOR FIG. 44

AC — Alternating Current ACB — Analog Control Board AWG — American Wire Gage CBx — Circuit Breaker CPTx — Control Power Transformer CTx — Current Transformer DI — Drive Input Contactor DI-IV — Drive Input Contactor Intellivac Module DIC — Drive Input Control Relay DICR1 — Drive Input Contactor Pilot Relay DIIS — Drive Input Isolating Switch DILR — Drive Input Line Reactor DIOL — Drive Input Overload DIOLx — Drive Input Overload Auxiliary Relay DITB — Drive Input Contactor Terminal Blocks DSx — Disconnect Switch EMC — Electro-Magnetic Choke ES — Ethernet Switch FLT — Fault Relay Fx — Fuse GFCT — Ground Fault Current Transformer GND — Ground GRD — Ground HECSU — Hall Effect Current Sensor (U Phase) HECSW — Hall Effect Current Sensor (W Phase) HPR — High Pressure Relay IFM — Interface Module ISM — Integrated Starter Module LFC — Line Filter Capacitors LFRNx — Line Reactor Fan x LV — Low Voltage LVx — External Low Voltage Supply MFC — Motor Filter Capacitors MFN1C — Main Fan Contactor MFN1MP — Main fan Motor Protector MOV — Metal Oxide Varistor MSR — Monitoring Safety Relay MSRXx — Monitoring Safety Relay Auxiliary Relay x MV — Medium Voltage NR — Neutral Resistor PE — Earth Ground PFN1 — Powerflex Interface Board PP — Carrier Power Panel PS1A — AC/DC Converter PS2 — DC/DC Converter PS4 — AC/DC Converter RUN — Run Relay SS — Surge Suppressor ST — Shunt Trip VFD — Variable Frequency Drive VSBx — Voltage Sensing Board WRN

— Warning Relay

XIO

x — External Inputs/Outputs 1M — Start Relay 66 Carrier ISM to be programmed by Carrier before

start-up. Relay contacts shown without

signal

power applied.

71 Calibrate for 4-20 mA; 0-5 vdc (Default 0-10 vdc). 100 WARNING: Ground must be connected to prevent

high voltages from being applied to drive control boards.

104 Located in drive low voltage control section. 105 Device is mounted on the low voltage door of the

drive.

WIRING Factory Wiring Field Wiring

Mechanically Connected Conductor, Crossing of Paths or Conductors Not

Connected Conductor, Junction of Connected Paths, Con-

ductors or Wires Conductor, Separable or Jacks Engaged Terminal

Terminal (Rockwell Automation use only) Terminal Blocks

— Barrier Wired To/From Destination

SWITCHES AND INPUT DEVICES Contact Normally Open (Make)

Contact Normally Closed (Break) OUTPUT DEVICES

Fan (3 Phase Induction Motor)

Induction Machine RESISTORS, CAPS, WINDINGS AND

GROUND Capacitor

Winding Transformer, Current

PROTECTION Circuit Breaker, Control/Power

Fuse, Control/Power Surge Suppressor

POWER ELECTRONIC DEVICES Symmetrical Gate-Commutated Thyristor and

Gate Driver Board MISCELLANEOUS Note Number Indicator

Contact Location Description

Relay Location Description

Key Interlock on Isolation Switch Key Interlock on MV Door Multiple Barrel Key Interlock on Isolation Switch Multiple Barrel Key Interlock on MV Door Transfer Block

DRIVE INPUT ISOLATING SWITCH

POTENTIAL TRANSFORMER

CONTROL POWER TRANSFORMER

DRIVE INPUT CONTACTOR

DRIVE INPUT OVERLOAD

CARRIER ISM MODULE

DRIVE INPUT LINE REACTOR

LINE FILTER CAPACITORS

COMMON MODE CHOKE

MOTOR FILTER CAPACITORS

CHILLER MOTOR

MAIN COOLING FAN

MAIN FAN CONTACTOR

MAIN FAN MOTOR PROTECTOR

DISCONNECT SWITCH 1

CONTROL POWER TRANSFORMER

ISOLATED GATE DRIVE POWER SUPPLY

LINE VOLTAGE

FIELD SUPPLIED

FOR VFD USE ONLY, CHILLER CONTROL POWER MUST BE FIELD SUPPLIED SEPARATELY

1200A

12R

400A

SEE TABLE FOR CABLE MINIMUM INSULATION REQUIREMENTS*

4000:1

SEE TABLE FOR CABLE MINIMUM INSULATION REQUIREMENTS*

T1, T2, T3

16A

3 Ø LV and 1 Ø 115 POWER SUPPLY IS REQUIRED AND MUST BE FIELD SUPPLIED WITH BRANCH CIRCUIT PROTECTION (8 kVA MINIMUM REQUIRED)

a19-2382

Fig. 44 — 19XR Typical Field Wiring with Free-Standing Variable Frequency Drive (VFD) (Medium Voltage)

*See page 80.

MAIN COOLING FAN

COMMON MODE CHOKE

SECTION

INVERTER

RECTIFIER

SECTION

CAP

DRIVE INPUT LINE REACTOR

3-PHASE POWER FIELD-SUPPLIED

WITH BRANCH CIRCUIT PROTECTION

(8 kVa REQUIRED)

FIELD-SUPPLIED

GROUND

FIELD-SUPPLIED

GROUND

FIELD-SUPPLIED

GROUND

LINE VOLTAGE

FIELD-SUPPLIED

CONTROL PANEL

2TB

1TB

3-PHASE FIELD-SUPPLIED

CONTROL POWER

TO ISM J7-A,B,C

a19-2383

Fig. 44 — Typical Field Wiring with Free-Standing Variable Frequency Drive (VFD) (Medium Voltage) (cont)

ISM INPUTS AND

OUTPUTS FOR

FIELD USE

CUSTOMER USE

DRIVE TERMINAL BLOCK 1

VFD UNIT SECTION 3A

DRIVE TERMINAL BLOCK 1

(CONT)

TO DRIVE INPUT

CONTACTOR TERMINAL

BLOCK

TO DRIVE INPUT

CONTACTOR TERMINAL

BLOCK

TO DRIVE INPUT

CONTACTOR TERMINAL

BLOCK

TO CARRIER

CHILLER

CONTROL PANEL

DRIVE INPUT CONTACTOR

TERMINAL BLOCK

VFD UNIT SECTION 1A

FIELD USE

WIRE TO DRIVE

TERMINAL BLOCK 1

#12 AWG

WIRE TO DRIVE

TERMINAL BLOCK 1

#12 AWG

WIRE TO DRIVE

TERMINAL BLOCK 1

#12 AWG

TO CARRIER CHILLER

POWER PANEL

WIRE TO DRIVE

INPUT CONTACTOR

TERMINAL BLOCK

DRIVE TERMINAL BLOCK

VFD UNIT SECTION 5A

DRIVE TERMINAL BLOCK 2

VFD UNIT SECTION 3A

TO DRIVE UNIT

SECTION 5A

a19-2384

Note: see fig 27 for limitations

and IOB wiring

Fig. 44 — Typical Field Wiring with Free-Standing Variable Frequency Drive (VFD) (Medium Voltage) (cont)

THE CONTROL POWER TRANSFORMER IS FOR VFD CONTROL POWER ONLY.

CHILLER CONTROL POWER MUST BE PROVIDED AS A SEPARATE SOURCE,

FIELD-SUPPLIED.

VFD UNIT SECTION 1A MODULE WIRING

Fig. 44 — Typical Field Wiring with Free-Standing Variable Frequency Drive (VFD) (Medium Voltage) (cont)

a19-2062

CHILLER

MOTOR

Fig. 44 — Typical Field Wiring with Free-Standing Variable Freq uency Drive (Medium Voltage) (VFD) (cont)

a19-2063

MAIN COOLING

FAN

FIELD-SUPPLIED GROUND

NOTE: ISM CAN BE CONFIGURED FOR EITHER

0 TO 5 VDC OR 0 TO 10 VDC

VFD SPEED FREQUENCY INPUT.

a19-2386

Fig. 44 — Typical Field Wiring with Free-Standing Variable Frequency Drive (VFD) (Medium Voltage) (cont)

CONTINUED ON NEXT PAGE

a19-2064

Fig. 44 — Typical Field Wiring with Free-Standing Variable Frequency Drive (VFD)

(Medium Voltage) (cont)

CONTINUED

Fig. 44 — Typical Field Wiring with Free-Standing Variable Frequency Drive (VFD)

(Medium-Voltage) (cont)

a19-2066

FROM PREVIOUS PAGE

NOTES FOR FIG. 44

19XR with Free-Standing Medium Voltage VFD

I. GENERAL

1.0 Variable Frequency Drive (VFD) shall be designed and manufactured in accordance with Carrier Engineering Requirement Z-416.

1.1 All field-supplied conductors, devices, and the field installation wiring, termination of conductors and devices, must be in compliance with all applicable codes and job specifications.

CAUTION

To prevent damage to machine, do NOT punch holes or drill into the top surface of the VFD enclosure for field wiring. Field wiring knockouts are provided on the top and side of the VFD enclosure for field wiring connections.

1.3 Equipment installation and all starting and control devices, must comply with details in equipment submittal drawings and literature.

1.4 Contacts and switches are shown in the position they would assume with the circuit de-energized and chiller shutdown.

1.5 WARNING - Do not use aluminum conductors.

1.6 Installer is responsible for any damage caused by improper wiring between VFD and machine.

1.7 All field-installed wiring is field-supplied.

POWER WIRING TO VFD

II.

2.0 Provide a means of disconnecting power to VFD.

2.1 Lug adapters may be required if installation conditions dictate that conductors be sized beyond the minimum ampacity required. Contact VFD supplier for lug information.

2.2 Compressor motor and controls must be grounded by using equipment grounding lug provided inside VFD enclosure.

CONTROL WIRING

III.

3.0 Field supplied control conductors to be at least 18 AWG or larger.

3.1 Optional Ice build start/terminate device contacts, optional remote start/stop device contacts and optional spare safety device contacts (devices not supplied by Carrier), must have 24 VAC rating. MAX current is 60 mA, nominal current is 10 mA. Switches with gold plated bifurcated contacts are recommended.

3.2 Remove jumper wire between ISM J2-1 and ISM J2-2 before connecting auxiliary safeties between these terminals.

3.3 Each integrated contact output can control loads (VA) fo r evaporator pump, condenser pump, tower fan low, tower fan high, and alarm annunciator devices rated 5 amps at 115 VAC and up to 3 amps at 277 VAC.

CAUTION

Do not use control transformers in the control center as the power source for external or field-supplied contactor coils, actuator motors or any other loads.

3.4 Do not route control wiring carrying 30 v or less within a conduit which has wires carrying 50 v or higher or along side wires carrying 50 v or higher.

3.5 Control wiring between VFD and power panel must be separate shielded cables with minimum rating 600 v, 80 C. Ground shield at VFD.

3.6 If optional pumpout/oil pump circuit breaker is not supplied within the starter enclosure, it must be located within sight of machine with wiring routed to suit.

3.7 When providing conductors for oil pump motor and oil heater power, refer to sizing data on label located on the chiller power panel, equipment submittal documentation or equipment product data catalog.

3.8 Spare 4-20 mA output signal is designed for controllers with a non-grounded 4-20 mA input signal and a maximum input impedance of 500 ohms.

IV.

POWER WIRING BETWEEN FREE-STANDING VFD AND COMPRESSOR MOTOR

4.0 Medium voltage (over 600 volts) compressor motors have (3) terminals. Connections are 9/16-in. threaded stud. A compression lug with a single connected directly to the stud or 3 adapters are supplied for connecting a NEMA lug. Use suitable connectors and insulation for high voltage alternating current cable terminations (these items are not supplied by Carrier). Compressor motor starter must have nameplate stamped as to conforming with Carrier Engineering requirement "Z-416."

4.1 Power conductor rating must meet minimum unit nameplate voltage and compressor motor RLA. Refer to the label located on the side of the chiller control panel, equipment submittal documentation or equipment product data catalog for conductor sizing data. (Conductor as defined below may be a single lead or multiple smaller ampacity leads in parallel for the purpose of carrying the equivalent or higher current of a single larger lead.)

When (3) conductors are used: Minimum ampacity per conductor = 1.25 x compressor RLA When 96) conductors are used: Minimum ampacity per conductor = 1.25 x compressor

RLA/2

4.2 When more than one conduit is used to run conductors from VFD to compressor motor terminal box, an equal number of leads from each phase (conductor) must be in each conduit to prevent excessive heating (for example, conductors to motor terminals 1, 2, and 3 in one conduit, and to 1, 2, and 3 in another conduit).

4.5 Do not allow motor terminals to support weight of wire cables. Use cable supports and strain reliefs as required.

4.6 Use backup wrench when tightening lead connectors to motor terminal studs. Torque to 30-35 ft-lb max.

4.7 Do not exceed 100 ft. maximum power cable length between the VFD and motor terminals without consulting Carrier for special requirements.

/16-in. diameter hole can be

CABLE INSULATION REQUIREMENTS

SYSTEM

VOLTAGE

2400 > 2.20 > 2.20 3000 > 2.75 > 2.75 3300 > 3.00 > 3.00 4160 > 3.80 > 3.80 6000 > 5.50 > 5.50 6300 > 5.80 > 5.80 6600 > 6.00 > 6.00

CABLE INSULATION RATING (kV)

(MAX. PEAK LINE-TO-GROUND)

LINE SIDE MACHINE SIDE

LEGEND FOR FIG. 45-50

Control Abbreviations — Fig. 45-50 Wiring Codes — Fig. 45-50

CDWP — Condenser Water Pump CDWP-V — Condenser Water Pump (Variable) CHWP — Chilled Water Pump CHWP_V — Chilled Water Pump (Variable) COND_EWP — Entering Condenser Water Pressure COND_FL — Condenser Water Flow Measurement COND_FS — Condenser Water Flow Switch COND_LWP — Leaving Condenser Water Pressure COND_P — Condenser Pressure DGT — Compressor Discharge Temperature DMP_CL — Economizer Damper Valve Close DMP_FC — Damper Valve Feedback Fully Close DMP_FO — Damper Valve Feedback Fully Open DMP_OP — Economizer Damper Valve Open ECDW — Entering Condenser Water Temperature ECON_P — Economizer Pressure ECW — Entering Chilled Water Temperature EVAP_EWP — Entering Evaporator Water Pressure EVAP_FL — Evaporator Water F low Measurement EVAP_LWP — Leaving Evaporator Water Pressure EVAP_P — Evaporator Pressure EVAP_T — Evaporator Refrigerant Temperature FS_LOCK — Fire Alarm Interlock GV1-ACT — IGV1 Position Input HDPV_OUT — Head Pressure Output HGBP_CL — Hot Gas Bypass (HGBP) Valve Close HGBP_FC — Hot Gas Bypass Valve Feedback Fully Close HGBP_FO — Hot Gas Bypass Valve Feedback Fully Open HGBP_OP — Hot Gas Bypass Valve Open HP_SW — High Pressure Switch ICE_CON — Ice Build Contact LCDW — Leaving Condenser Water Temperature LCW — Leaving Chilled Water Temperature MTRB1 — Low Speed Motor End Bearing Temperature

MTRB2 — Low Speed Compressor End Bearing MTRB3 — High Speed Motor End Bearing Temperature MTRB4 — High Speed Compressor End Bearing MTRW1 — Motor Winding Temperature 1

MTRW2 — Motor Winding Temperature 2 MTRW3 — Motor Winding Temperature 3 OIL_HEAT — Oil Heater On/Off OIL_PUMP — Oil Pump On/Off OILP_DIS — Oil Pump Discharge Pressure OILP_SMP — Oil Sump Pressure OILT_SMP — Oil Sump Temperature REM_CON — Remote Connect Input REM_LOCK — Chiller Lockout Input REM_STP — Remote Stop Lock SAFETY — Spare Safety SHFT_DIS TFR_HIGH — Tower Fan High TFR_LOW — Tower Fan Low TOW_FAN — Tower Fan (Variable)

(Thermistor/PT100) Temperature (Thermistor/PT100) (Thermistor/PT100) Temperature (Thermistor/PT100)

— Bearing Shaft D

isplacement Switch

1C — Oil Heater Contactor 2C — Oil Pump Contactor 1CB — Micro Circuit Breaker, Control Box 2CB — Micro Circuit Breaker, HMI 3FU1,2 — Transformer 1 Primary Fuse 3FU3,4 — Transformer 1 Secondary Fuse 1R — Alarm Relay 1T — Transformer 1 2T — Transformer 2 3T — Transformer 3 1TB — Terminal Block for Customer Power Connection 2TB — Terminal Block for Field Connection 3TB — Terminal Block for Customer Optional Connection 4TB — HMI Terminal Block Field CCN Connection 5TB — Terminal Block for Control Panel Internal Connection 6TB — Terminal Block for Guide Vane, HGBP amd Damper

7TB — Terminal Block for Guide Vane Actuator (220 v) A01 — IGV/Stage 1 IGV A03 — Discharge Gas Temperature Thermistor A04 — High Pressure Switch A06 — Bearing Displacement Switch C11 — HGBP Valve Actuator E01 — Evaporator Pressure Transducer E03 — Leaving Chilled Water Temperature Thermistor E05 — Evaporator Refrigerant Liquid Temperature Thermistor EC01 — Economizer Pressure Transducer EC06 — Damper Valve Actuator HMI — Human Interface Panel ISM — Integrated Starter Module M01 — Motor Winding Temperature 1 (Thermistor/PT100) M02 — Motor Winding Temperature 2 (Thermistor/PT100) M03 — Motor Winding Temperature 3 (Thermistor/PT100) MSP — Motor Starter Protection SAIA — SAIA Touch Screen and Main Board T01 — Low Speed Motor End Bearing Temperature

T02 — Low Speed Compressor End Bearing Temperature T03 — High Speed Motor End Bearing Temperature T04 — High Speed Compressor End Bearing Temperature T05 — Oil Sump Temperature Thermistor

T07 — Oil Sump Pressure Transducer T08 — Oil Pump Discharge Pressure Transducer T10 — Oil H T11

Valve

(Thermistor/PT100) (Thermistor/PT100) (Thermistor/PT100) (Thermistor/PT100)

eater

— Oil Pump

LEGEND — FIG. 45-50

Fig. 45 — Controls Diagram

a19-287

CHILLER RUN STATUS (mA)

Fig. 46 — IOB 1

REMOTE LOCKOUT

FIRE SECURITY INTERLOCK

(+) (G)

(-)

(+) (G)

(-)

REMOTE CONTACT

REMOTE STOP

ALARM RELAY

ALERT RELAY

a19-2245

a19-2288

Fig. 47 — IOB 2

a19-2289

Fig. 48 — IOB 3

a19-2285

Fig. 49 — IOB 4

Fig. 50 — Starter Wiring

a19-2290

APPENDIX A — PIC 5 SCREEN AND MENU STRUCTURE

HOME

MAIN MENU LOG IN/LOG OUT CONFIRM STOP CHOOSE OPERATING MODE ALARM MENU

a19-2238

Main Menu

General Parameters

Inputs Status

Run Times

Temperatures

Outputs Status

Modes

Pressures

Hydraulic Status

Trending

Reset alarms Current Alarms History Alarms

Fig. A — Screen Structure, Basic Level (All) Access (No Password Required)

APPENDIX A — PIC 5 SCREEN AND MENU STRUCTURE (cont)

HOME

MAIN MENU LOG IN/LOG OUT CONFIRM STOP CHOOSE OPERATING MODE ALARM MENU

a19-2239

Main Menu

General Parameters

Temperatures Pressures

Inputs Status

Outputs Status

Hydraulic Status

Run Times

Modes Setpoint

Reset alarms Current Alarms History Alarms

Main Menu

Main MMMenunununu

Configuration Menu

Trending

Prognostics

Main Menu

a19-2281

Fig. B — Screen Structure, User Level Access (User Password Required)

APPENDIX A — PIC 5 SCREEN AND MENU STRUCTURE (cont)

HOME

MAIN MENU LOG IN/LOG OUT CONFIRM STOP CHOOSE OPERATING MODE ALARM MENU

Main Menu

General Parameters

Temperatures Pressures

Inputs Status

Outputs Status

Hydraulic Status

Run Times

Modes Setpoint

Reset alarms Current Alarms History Alarms

Configuration Menu

Quick Test

Maintenance Menu

Trending

Prognostics

a19-2282

Fig. C — Screen Structure, Service (Advanced User)/Factory Level Access Password Required)

APPENDIX A — PIC 5 SCREEN AND MENU STRUCTURE (cont)

Main Menu Description

ICON DISPLAYED TEXT* ACCESS ASSOCIATED TABLE†

General Parameters

Temperatures

Pressures

Inputs Status

Outputs Status

Hydraulic Status

Run Times

Modes

Setpoint User, Service (Advanced User), Factory SETPOINT

Configuration Menu User, Service (Advanced User), Factory CONFIG

Basic, User, Service (Advanced User), Factory

GENUINT

TEMP

PRESSURE

INPUTS

OUTPUTS

HYDRLIC

RUNTIME

MODES

Quick Test Service (Advanced User), Factory QCK_TEST

Maintenance Menu Service (Advanced User), Factory MAINTAIN

Trending

Prognostics User, Service (Advanced User), Factory HEALTH

*Displayed text depends on the selected language (default is English). †See the 19XR Controls Operation and Troubleshooting manual for table details.

Basic, User, Service (Advanced User), Factory

TRENDING

APPENDIX B — CCN COMMUNICATION WIRING FOR MULTIPLE CHILLERS (TYPICAL)

a19-2133

NOTE: Field-supplied terminal strip must be located in control panel.

DRAIN WIRE

BLACK (G) WHITE (–)

RED (+)

APPENDIX C — MAINTENANCE SUMMARY AND LOG SHEETS

19XR Maintenance Interval Requirements

WEEKLY

COMPRESSOR Check Oil Level. CONTROLS Review PIC 5 Alarm/Alert History.

COOLER None. STARTER None.

CONDENSER None. OIL RECLAIM None.

MONTHLY

COMPRESSOR None. CONTROLS Perform an Automated Controls test.

COOLER None. STARTER None.

CONDENSER None. OIL RECLAIM None.

FIRST YEAR

COMPRESSOR

COOLER

CONDENSER

COMPRESSOR

COOLER

CONDENSER

STARTING

EQUIPMENT

COMPRESSOR None. CONTROLS None.

COOLER Perform eddy current test. STARTER None.

CONDENSER

COMPRESSOR

COOLER None. STARTER None.

CONDENSER None. OIL RECLAIM

COMPRESSOR None. CONTROLS Do not disconnect control power.

COOLER

CONDENSER

NOTE: Equipment failures caused by lack of adherence to the Maintenance Interval Requirements are not covered under warranty.

Change oil filter. Send oil sample out for analysis. Change oil if required by analysis. Leak test.

Inspect and clean cooler tubes. Inspect relief valves. Leak test. Verify water pressure differential. Inspect water pumps and cooling tower.

Replace refrigerant filter/drier. Inspect and clean condenser tubes. Inspect relief valves. Leak test. Verify water pressure differential. Inspect water pumps and cooling tower.

Change oil filter. Send oil sample out for analysis. Change oil if required by analysis. Leak test.

Inspect and clean cooler tubes. Inspect relief valves. Leak test. Verify water pressure differential. Inspect water pumps and cooling tower.

Replace refrigerant filter/drier. Inspect and clean condenser tubes. Inspect relief valves. Leak test. Verify water pressure differential. Inspect water pumps and cooling tower.

Follow all lockout-tagout procedures. Inspect inside of enclosure for contaminant build-up. Vacuum any accumulated dust or debris from internal parts. Use electronic cleaner as required.

spect float valve and strainer. Perfo

In current test.

Change oil charge (if required based on oil analysis or if oil analysis has not been performed). Inspect compressor shafts and bearings (every 5-10 years).

Isolate and drain waterbox. Remove waterbox cover from one end. Use compressed air to clear tubes.

rm eddy

SEASONAL SHUTDOWN

CONTROLS

STARTER

OIL RECLAIM Inspect oil sump strainer.

ANNUALLY

CONTROLS

STARTER Perform general cleaning. Tighten connections.

OIL RECLAIM None.

EVERY 3-5 YEARS

OIL RECLAIM None.

EVERY 5 YEARS

CONTROLS None.

STARTER None.

OIL RECLAIM None.

Perform general cleaning. Tighten connections. Check pressure transducers. Confirm accuracy of thermistors.

Perform general cleaning. Tighten connections. Change VFD refrigerant strainer.

Perform general cleaning. Tighten connections. Check pressure transducers. Confirm accuracy of thermistors.

Inspect oil sump strainer. Inspect oil sump heater. Replace the oil reclaim filter.

APPENDIX C — MAINTENANCE SUMMARY AND LOG SHEETS (cont)

19XR Monthly Maintenance Log

MONTH 123456789101112

DATE / / / / / / / / / / / / / / / / / / / / / / / /

OPERATOR

UNIT SECTION ACTION UNIT ENTRY

Change Oil Charge yes/no Change Oil Filter yes/no

COMPRESSOR

COOLER

CONDENSER

CONTROLS

STARTER General Tightening and Cleaning Connections yes/no

OIL RECLAIM

NOTE: Equipment failures caused by lack of adherence to the Maintenance Interval Requirements are not covered under warranty.

Send Oil Sample Out for Analysis yes/no Leak Test ppm Inspect Compressor Rotors yes/no Bearing Inspection yes/no Inspect and Clean Cooler Tubes yes/no Inspect Relief Valves yes/no Leak Test ppm Record Water Pressure Differential (PSI) PSI Inspect Water Pumps yes/no Eddy Current Test yes/no Leak Test ppm Inspect and Clean Condenser Tubes yes/no Record Water Pressure Differential (PSI) PSI Inspect Water Pumps and Cooling Tower yes/no Inspect Relief Valves yes/no Replace Refrigerant Filter Drier yes/no Inspect Float Valve and Strainer yes/no Eddy Current Test yes/no General Cleaning and Tightening Connections yes/no Check Pressure Transducers yes/no Confirm Accuracy of Thermistors yes/no Perform Automated Controls Test yes/no

Inspect Oil Sump Strainer yes/no Inspect Oil Sump Heater yes/no

APPENDIX C — MAINTENANCE SUMMARY AND LOG SHEETS (cont)

19XR Seasonal Shutdown Log

MONTH 123456789101112

DATE / / / / / / / / / / / / / / / / / / / / / / / /

OPERATOR

UNIT SECTION ACTION ENTRY

Isolate and Drain Waterbox

COOLER

CONDENSER

CONTROLS Do Not Disconnect Control Power

NOTE: Equipment failures caused by lack of adherence to the Maintenance Interval Requirements are not covered under warranty.

Remove Waterbox Cover from One End Use Compressed Air to Clean Tubes Isolate and Drain Waterbox Remove Waterbox Cover from One End Use Compressed Air to Clean Tubes

Abbreviations and explanations, 4 Bearing and gear maintenance, 40 Bearings, 8 Bolt torque requirements, 14 Chiller Components, 6 Dehydration, 18 Familiarization, 4 Identification, 5 Information nameplate, 4 Leak test, 16 Limited shutdown, operation after, 30 Operating condition, checking, 29 Preparing for start-up, 30 Replacement parts, ordering, 41 Starting, 30 Stopping, 30 Tightness, checking, 13 Cold weather operation, 31 Compressor Assembly torques, 65 Bearing and gear maintenance, 40 Description, 4 Fits and clearances, 62 Condenser

Description, 4

Control Panel Description, 4 Inspecting, 38 Controller identification, modifying, 21 Controls Description, 10 PIC 5 system components, 10 Powering up, 19 Cooler Description, 4 Display messages, checking, 42 Economizer Damper valve, 39 Description, 5 Float system, 39 Equipment required, 13 Extended shutdown Preparing for, 30 Operation after, 30 Field set up and verification, 22 Gasketed joints, tightening, 13 Guide vanes Checking, 36 Operation, manual, 31 Heat exchanger tubes and flow devices, maintenance, 40 Heat exchanger refrigerant charge, 27 High altitude locations, 46 Initial start-up, 29 Initial start-up checklist, CL-1 Inspecting equipment, 41 Instructing customer operator, 29 Job data required, 13 Job site parameters, 21 Leak test procedures (chart), 15 Limited shutdown, operation after, 30 Local start/stop control, 11 Login/logout, 20 Lubrication control, 12 Lubrication cycle, 8 Lubrication system, checking, 38 Maintenance General, 36 Scheduled, 38 Summary and log sheets, 93 Weekly, 38 Motor and oil cooling cycle, 8 Motor rotation, checking, 29 Oil changes, 39

INDEX

Oil charge, 19 Oil circuit valves, opening, 13 Oil filter, changing, 39 Oil heater, checking, 19 Oil pressure and compressor stop, checking, 29 Oil pump, 9 Oil reclaim filter, 39 Oil reclaim system, 8 Oil recovery, 8 Oil specification, 39 Operating instructions, 30 Operator duties, 30 Passwords, 20 Physical data, 48 PIC 5 Screen and menu reference, 88 System components, 10 Piping Inspecting before start-up, 18 Maintenance, 40 Pressure transducers Calibration, 46 Checking, 46 Recalibrating, 41 Pumpdown/lockout, 48 Pumpout and refrigerant transfer, 31 Pumpout unit Maintenance, 41 Operating, 33 Quick test Table, 24 Use in troubleshooting 48 Refrigerant

Adding, 36

Adjusting charge, 36 Charging into chiller, 25 Filter, 39 Float system, inspecting, 39 Leak rate, 36 Leak testing, 36 Properties, 36 Testing after service, repair, or major leak, 36 Tracer, 16 Trimming charge, 38 Refrigeration cycle, 7 Refrigeration log, 31 Relief valves Checking before start-up, Maintenance, 40 Replacement parts, ordering, 41 Running system, checking, 30 Safety considerations, 1 Schedule, inputting local occupied, 20 Sensor accuracy, checking, 45 Service configurations, inputting, 20 Service ontime, 38 Service tables, configuring, 21 Set points, inputting design, 20 Shipping packaging, removing, 13 Shutdown After extended, 30 After limited, 30 Local (with HMI), 12 Preparation for extended, 30 Software configuration, 19 Standing vacuum test, 16 Starter Free-standing, description, 5 Mechanical, checking, 19 Solid-state, description, 10 Solid-state, checking, 19 Starting equipment, 10

Start-Up Accidental, preventing, 29 Before initial, 13 Chiller dehydration, 18 Equipment required, 13 Field set up and verification, 22 Gasketed joints, tightening, 13 Initial, 29 Inspecting water piping, 18 Job data required, 13 Leak test, 16 Oil charge, 19 Oil circuit valves, opening, 13 Oil heater, checking, 19 Controls, powering up, 19 Control test (quick test), 24 Refrigerant, charging into chiller, 25 Relief valves, checking, 18 Schedule, inputting local occupied, 20 Service configurations, inputting, 20 Set points, inputting design, 20 Shipping packaging, removing, 13 Software configuration, 19 Standing vacuum test, 16 Starter, checking, 19 Timing sequence, 12 Tracer, 16 Wiring, inspecting, 18 Start-up/shutdown/recycle sequence, 11 Surge prevention, 22 System components, 4 Temperature sensors, checking, 42 Thermal dispersion switch calibration, 46 Thermistor temperature vs. resistance/ voltage drop (C) 44 Thermistor temperature vs. resistance/ voltage drop (F) 43 Time and date, inputting, 21 Troubleshooting guide, 42 VFD, free-standing, 10 Water Leaks, 41 Treatment, 41 Weights Component, 61 Compressor and motor (50 Hz), 55, 57 Compressor and motor (60 Hz), 56, 58 Economizer, 53 Heat exchanger (English), 49, 51 Heat exchanger (SI), 50, 52 Marine waterboxes, 150 psig, 53, 54 Marine waterboxes, 300 psig (English), 53, 54 Marine waterboxes, 300 psig (SI), 53, 54 Waterbox cover (English), 59, 60 Waterbox cover (SI), 59, 60 Wiring Bearing sensors, 45 CCN for multiple chillers, 92 Control panel bottom layer, 66 Control panel IOB layer, 66 Free-standing starter field wiring, 68 Free-standing VFD field wiring, 72 HMI panel, 65 IOB 1, 83 IOB 2, 84 IOB 3, 85 IOB 4, 86 Inspecting, 18 Pumpout unit schematic, 33 SAIA control board, 82 Starter, 87

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

Catalog No. 04-53190038-01 Printed in U.S.A. Form 19XR-CLT-12SS Pg 98 12-15 Replaces: 19XR-CLT-11SS

INITIAL START-UP CHECKLIST

FOR 19XR SEMI-HERMETIC TWO-STAGE CENTRIFUGAL LIQUID CHILLER

(Remove and use for job file.)

NOTE: To avoid injury to personnel and damage to equipment or property when completing the procedures listed in this start-up checklist, use good judgment and follow safe practices as outlined in preceding sections of this Start-Up, Operation and Maintenance Instructions document.

MACHINE INFORMATION: NAME JOB NO.

ADDRESS MODEL CITY STATE ZIP S/N

DESIGN CONDITIONS:

TONS BRINE

COOLER ******

CONDENSER ******

FLOW

RATE

TEMPERATUREINTEMPERATURE

OUT

PRESSURE

DROP

PASS

SUCTION

TEMPERATURE

CONDENSER

TEMPERATURE

COMPRESSOR: Volts RLA OLTA STARTER: Mfg Type S/N OIL PUMP: Volts RLA OLTA

CONTROL PANEL SUPPLY: Voltage __________ Hertz ________ REFRIGERANT: Type:

Charge

CARRIER OBLIGATIONS: Assemble... . . . . . . . . . . . . . . . . Yes  No 

Leak Test . . . . . . . . . . . . . . . . . . . Yes  No 

Dehydrate . . . . . . . . . . . . . . . . . . Yes  No 

Charging . . . . . . . . . . . . . . . . . . . Yes  No 

Operating Instructions Hrs.

START-UP TO BE PERFORMED IN ACCORDANCE WITH APPROPRIATE MACHINE START-UP INSTRUCTIONS JOB DATA REQUIRED:

1. Machine Installation Instructions . . . . . . . . . . . . . . . . . . Yes

 No 

2. Machine Assembly, Wiring and Piping Diagrams. . . . . . Yes  No 

3. Starting Equipment Details and Wiring Diagrams. . . . . . Yes  No 

4. Applicable Design Data (see above). . . . . . . . . . . . . . . . Yes  No 

5. Diagrams and Instructions for Special Controls . . . . . . . Yes  No 

INITIAL MACHINE PRESSURE:

YES NO Was Machine Tight? If Not, Were Leaks Corrected? Was Machine Dehydrated After Repairs?

Manufacturer reserves the right to discontinue, or change at any time, specificatio ns or designs without not ice and without incurring obligations.

Catalog No. 04-53190038-01 Printed in U.S.A. Form 19XR-CLT-12SS Pg CL-1 12-15 Replaces: 19XR-CLT-11SS

CHECK OIL LEVEL AND RECORD: ADD OIL: Yes  No 

1/2 Top sight glass

1/2 Bottom sight glass

3/4

1/4

3/4 1/4

Amount:

RECORD PRESSURE DROPS: Cooler Condenser CHARGE REFRIGERANT: Initial Charge Final Charge After Trim INSPECT WIRING AND RECORD ELECTRICAL DATA:

RATINGS: Motor Voltage

Motor(s) Amps Oil Pump Voltage Starter LRA Rating

Line Voltages: Motor Oil Pump Controls/Oil Heater

RECORD THE FOLLOWING POWER ON CHECKS:

Line Voltage: Phase - Phase A-B: B-C: A-C: Line Voltage: Phase - Ground A-G: B-G: C-G:

What type and size of transformer supplies power to the unit? Delta with No Ground _____ Corner Grounded Delta _____ Wye with Center Ground _____ Wye with No Ground _____ Transformer Size _____kVa

CONTROLS: SAFETY, OPERATING, ETC. Perform Controls Test (Yes/No)

CAUTION

COMPRESSOR MOTOR AND CONTROL PANEL MUST BE PROPERLY AND INDIVIDUALLY CONNECTED BACK TO THE EARTH GROUND IN THE STARTER (IN ACCORDANCE WITH CERTIFIED DRAWINGS).

Yes

WATER/BRINE PUMP CONTROL: Can the Carrier controls independently start the pumps?

Condenser Water Pump Yes  No  Chilled Water Pump Yes  No 

RUN MACHINE: Do these safeties shut down machine?

Condenser Water Flow Yes  No  Chilled Water Flow Yes  No  Pump Interlocks Yes  No 

INITIAL START: Line Up All Valves in Accordance With Instruction Manual: Start Water Pumps and Establish Water Flow Oil Level OK and Oil Temperature OK Check Oil Pump Rotation-Press ur e Check Compressor Motor Rotation (Motor End Sight Glass) and Record: Clockwise Restart Compressor, Bring Up To Speed. Shut Down. Any Abnormal Coastdown Noise? Yes*  No 

*If yes, determine cause.

CUT ALONG DOTTED LINE CUT ALONG DOTTED LINE

CL-2

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -- - - - - - - - - - - - - - - - - - - -

Carrier 19XR User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

SAFETY CONSIDERATIONS

CONTENTS

INTRODUCTION

ABBREVIATIONS AND EXPLANATIONS

REFRIGERATION CYCLE

MOTOR AND OIL COOLING CYCLE

LUBRICATION CYCLE

STARTING EQUIPMENT

CONTROLS

Definitions

BEFORE INITIAL START-UP

Job Data Required

Equipment Required

Inspect Wiring

SOLID-STATE STARTER

Check Starter

MECHANICAL STARTER

Software Configuration

Field Set Up and Verification

Charge Refrigerant into Chiller

CHILLER EQUALIZATION WITHOUT A PUMPOUT UNIT

INITIAL START-UP

Check Motor Rotation

Check Oil Pressure and Compressor Stop

OPERATING INSTRUCTIONS

Operator Duties

To Start the Chiller

To Stop the Chiller

DISTILLING THE REFRIGERANT

GENERAL MAINTENANCE

WEEKLY MAINTENANCE

SCHEDULED MAINTENANCE

Inspect the Heat Exchanger Tubes and Flow Devices

TROUBLESHOOTING GUIDE

Economizer Weight

APPENDIX A — PIC 5 SCREEN AND MENU STRUCTURE

Main Menu Description

APPENDIX B — CCN COMMUNICATION WIRING FOR MULTIPLE CHILLERS (TYPICAL)

APPENDIX C — MAINTENANCE SUMMARY AND LOG SHEETS

INDEX