Carrier 19XR User Manual

AquaEdge

™

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.

CONTENTS

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

2

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

3

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.

4

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

M

N7

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

J

K

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

5

12 15 Q 19843

Unique Number

Place of Manufacture

a19-2271

15

1

2

3

4

5

6

7

8

9

10

11

12

13

14

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

31

32

33

34

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)

6

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)

7

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.

8

10

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-

1

2

3

4

5

6

7

8

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

9

OIL LINE
VENT LINE

1

2

3

4

5

6

7

8

9

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.

10

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).

11

Table 2 — Prestart Checks

AB

CDE

F

G

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.

12

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.

13

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

1

/

4

5

/

16

3

/

8

7

/

16

1

/

2

9

/

16

5

/

8

3

/

4

7

/

8

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

1

/

1

8

1

/

1

4

3

1

/

8

1

/

1

2

5

/

1

8

3

1

/

4

7

/

1

8

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

1

/

2

4

1

/

2

2

3

/

2

4

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

14

5 AND 6)

5 AND 6)

Fig. 11 — 19XR Leak Test Procedures

a19-1151tf.eps

15

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.

in

16

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

17

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.

3

/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.

18

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

19

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.

LOGIN/LOGOUT — Press the lock icon on the home screen
to enter the password. See Fig. 16.

20

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.

21

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

T

M

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

22

40

Fig. 19 — Effect of SURGE DELTA TSMIN on

Surge Prevention

a19-1959

0

5

10

15

20

25

30

35

40

45

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

35

30

25

20

Delta Tsat

15

10

5

0

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

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

23

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

24

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

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.

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

25

STORAGE

TANK LIQUID

VALVE

OIL
SEPARATOR

PUMPOUT
CONDENSER
WATER SUPPLY
AND RETURN

PUMPOUT
CONDENSER

STORAGE TANK
VAPOR VALVE

2

3

4

5

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

10

6

7

11

1a

1b

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

2

3

4

5

PRESSURE
RELIEF SAFETY
VALVE

PUMPOUT
COMPRESSOR

COOLER
REFRIGERANT
ISOLATION
VALVE

REFRIGERANT
CHARGING
VALVE

CHILLER
CONDENSER
VESSEL

CHILLER
COOLER
VESSEL

7

11

1a

1b

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

26

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

B6

*See Model Number Nomenclature on page 5.

— 1326 360 — 601 163

1 163

27

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.

28

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.

29

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.

30