Carrier 19XL - Manuals

4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 19XL FRONT VIEW 31 30 29 28 27 26 25 41 40 39 38 37 36 35 34 33 32 15 42 19XL REAR VIEW Fig. 2B — Typical 19XL Components — Design II LEGEND 1 — Unit-Mounted Starter2 — Refrigerant Filter Drier3 — Rigging Guide Bolt4 — Motor Sight Glass5 — Ref...

Refrigerant that flows to the oil cooling system is reg- ulated by a thermostatic expansion valve. There is alwaysa minimum flow bypassing the TXV, which flows throughan orifice. The TXV valve regulates flow into the oil/refrigerant plate and frame-type heat exchanger. The bulbfor the expansion valv...

journal bearings within the bearing housing. The oil then drainsinto the oil reservoir at the base of the compressor. The PIC(Product Integrated Control) measures the temperature of theoil in the sump and maintains the temperature during shut-down (see Oil Sump Temperature Control section, page 32)....

STARTING EQUIPMENT The 19XL requires a motor starter to operate the centrif- ugal hermetic compressor motor, the oil pump, and variousauxiliary equipment. The starter serves as the main fieldwiring interface for the contractor. Three types of starters are available from Carrier Cor- poration: solid-...

• overtemperature• ground fault• current unbalance• run state These LEDs are further explained in the Check Starter and Troubleshooting Guide section, page 66. Unit-Mounted Wye-Delta Starter (Optional) — The 19XL chiller may be equipped with a wye-delta starter mountedon the unit (Fig. 7). This star...

Fig. 8 — 19XL Controls and Sensor Locations Fig. 9 — Control Sensors (Temperature) Fig. 10 — Control Sensors (Pressure Transducer, Typical) LEGEND 1 — LID2 — PSIO3 — 8-Input Module (One of 2 Available)4 — 5-Volt Transducer Power Supply5 — 6-Pack Relay Board6 — Circuit Breakers (4) Fig. 11 — Control ...

PROCESSOR MODULE (PSIO) — The PSIO is the brainof the PIC (Fig. 11). This module contains all the operatingsoftware needed to control the chiller. The 19XL uses 3 pres-sure transducers and 8 thermistors to sense pressures and tem-peratures. These are connected to the PSIO module. The PSIOalso provid...

• Press EXIT to return to the previous screen level. • Press INCREASE or DECREASE to change the high- lighted point value. TO VIEW POINT STATUS (Fig. 15) — Point Status is theactual value of all of the temperatures, pressures, relays, andactuators sensed and controlled by the PIC. 1. On the Menu scr...

TO VIEW AND CHANGE SET POINTS (Fig. 19) 1. To view the Set Point table, at the Menu screen press SETPOINT . 2. There are 4 set points on this screen: Base Demand Limit; LCW Set Point (leaving chilled water set point); ECWSet Point (entering chilled water set point); and ICE BUILDset point (PSIO Soft...

Table 2 — LID Screens NOTES:1. Only 12 lines of information appear on the LID screen at any given time. Press NEXT or PREVIOUS to highlight a point or to view points below or above the current screen. 2. The LID may be configured in English or SI units, as required, through the LID configuration scr...

PIC System Functions NOTE: Throughout this manual, words printed in capital let-ters and italics represent values that may be viewed on theLID. See Table 2 for examples of LID screens. Point namesare listed in the Description column. An overview of LIDoperation and menus is given in Fig. 13-19. CAPA...

Safety Controls — The PIC monitors all safety control inputs, and if required, shuts down the chiller or limits theguide vanes to protect the chiller from possible damage fromany of the following conditions: • high bearing temperature• high motor winding temperature• high discharge temperature• low ...

Table 3 — Protective Safety Limits and Control Settings MONITORED PARAMETER LIMIT APPLICABLE COMMENTS TEMPERATURE SENSORSOUT OF RANGE –40 to 245 F (–40 to 118.3 C) Must be outside range for 2 seconds PRESSURE TRANSDUCERSOUT OF RANGE 0.08 to 0.98 Voltage Ratio Must be outside range for 2 seconds.Rati...

Ramp Loading Control — The ramp loading control slows down the rate at which the compressor loads up. Thiscontrol can prevent the compressor from loading up duringthe short period of time when the chiller is started, and thechilled water loop has to be brought down to normal designconditions. This h...

The algorithm first determines if corrective action is nec- essary. This is done by checking 2 sets of operator con-figured data points, which are the MINIMUM and theMAXIMUM Load Points, (T1/P1;T2/P2). These points havedefault settings for each type of refrigerant, HCFC-22 orHFC-134a, as defined on ...

4. Lead chiller temperature pulldown rate of the CHILLED WATER temperature is less than 0.5° F (0.27° C) perminute. 5. The lag chiller status indicates it is in CCN mode and is not faulted. If the current lag chiller is in an alarm con-dition, then the standby chiller becomes the active lag chiller,...

START-UP/RECYCLE OPERATION — If the chiller is notrunning when ice build activates, then the PIC checks thefollowing parameters, based on the ICE BUILD TERMINA-TION value, to avoid starting the compressor unnecessarily:• if ICE BUILD TERMINATION is set to the temperature only option (zero) and the E...

ATTACHING TO OTHER CCN MODULES — If the chillerPSIO has been connected to a CCN Network or other PICcontrolled chillers through CCN wiring, the LID can be usedto view or change parameters on the other controllers. OtherPIC chillers can be viewed and set points changed (if theother unit is in CCN con...

6. Press NEXT to highlight the holiday table that you wish to view or change. Each table is one holiday pe-riod, starting on a specific date, and lasting up to 99 days. 7. Press SELECT to access the holiday table. The Con- figuration Select table now shows the holiday start monthand day, and how man...

Safety Shutdown — A safety shutdown is identical to a manual shutdown with the exception that the LID will dis-play the reason for the shutdown, the alarm light will blinkcontinuously, and the spare alarm contacts will be ener-gized. A safety shutdown requires that the RESET softkeybe pressed in ord...

procedures in the Transfer Refrigerant from StorageTank to Chiller section, Steps 1a-e, page 59. Never charge liquid refrigerant into the chiller ifthe pressure in the chiller is less than 68 psig(469 kPa) for HCFC-22 and 35 psig (241 kPa) forHFC-134a. Charge as a gas only, with the coolerand conden...

Chiller Dehydration — Dehydration is recommended if the chiller has been open for a considerable period of time,if the chiller is known to contain moisture, or if there hasbeen a complete loss of chiller holding charge or refrigerantpressure. Do not start or megohm test the compressor motor oroil pu...

6. Be sure that fused disconnects or circuit breakers have been supplied for the oil pump, power panel, andpumpout unit. 7. Check that all electrical equipment and controls are prop- erly grounded in accordance with job drawings, certi-fied drawings, and all applicable electrical codes. 8. Make sure...

3. Some dashpot-type magnetic overload relays must be filled with oil on the jobsite. If the starter is equipped with de-vices of this type, remove the fluid cups from these mag-netic overload relays. Add dashpot oil to cups per instructionssupplied with the starter. The oil is usually shipped in as...

MODIFY CONTROLLER IDENTIFICATION IF NECES-SARY — The controller identification screen is used to changethe PSIO module address. Change this address for each chillerif there is more than one chiller at the jobsite. Write the newaddress on the PSIO module for future reference. Change the LID address i...

Loosen the compressor holddown bolts to allow free springtravel. Open the compressor suction and discharge servicevalves. Check that oil is visible in the compressor sight glass.Add oil if necessary. See Pumpout and Refrigerant Transfer Procedures and Optional Pumpout System Maintenance sections, pa...

19XL CHILLER EQUALIZATION WITH PUMPOUTUNIT — The following procedure describes how to equal-ize refrigerant pressure on an isolated 19XL chiller using thepumpout unit.1. Access the TERMINATE LOCKOUT mode in the Con- trol Test. 2. Turn on the chilled water and condenser water pumps to prevent possibl...

INITIAL START-UP Preparation — Before starting the chiller, check that the: 1. Power is on to the main starter, oil pump relay, tower fan starter, oil heater relay, and the chiller control center. 2. Cooling tower water is at proper level, and at or below design entering temperature. 3. Chiller is c...

PUMPOUT AND REFRIGERANT TRANSFER PROCEDURES Preparation — The 19XL may come equipped with an optional storage tank or pumpout system, or a pump-out compressor. The refrigerant can be pumped for servicework to either the cooler/compressor vessel or the condenservessel by using the optional pumpout sy...

2. Transfer remaining refrigerant. a. Close valve 5 and open valve 4. VALVE 1a 1b 2 3 4 5 6 7 8 10 11 12 13 14 CONDITION C C C b. Turn off the chiller water pumps through the LID.c. Turn off the pumpout condenser water, and turn on the pumpout compressor to push liquid out of the storagetank. d. Clo...

HCFC-22 and HFC-134a should not be mixed withair or oxygen and pressurized for leak testing. In gen-eral, neither refrigerant should not be allowed to be pre-sent with high concentrations of air or oxygen aboveatmospheric pressures, as the mixture can undergocombustion. REFRIGERANT TRACER — Use an e...

Inspect Refrigerant Float System — Perform inspection every 5 years or when the condenser is openedfor service. Transfer the refrigerant into the cooler vessel orinto a storage tank. Remove the float access cover. Clean thechamber and valve assembly thoroughly. Be sure that thevalve moves freely. Ma...

Water Treatment — Untreated or improperly treated wa- ter may result in corrosion, scaling, erosion, or algae. Theservices of a qualified water treatment specialist should beobtained to develop and monitor a treatment program. Water must be within design flow limits, clean, and treatedto ensure prop...

If the transducer value is not within the calibration range,the transducer will return to the original reading. Ifthe LID pressure value is within the allowed range (notedabove), check the voltage ratio of the transducer. To ob-tain the voltage ratio, divide the voltage (dc) input fromthe transducer...

Table 9 — LID Primary and Secondary Messages and Custom Alarm/Alert Messages with Troubleshooting Guides A. SHUTDOWN WITH ON/OFF/RESET-OFF PRIMARY MESSAGE SECONDARY MESSAGE PROBABLE CAUSE/REMEDY MANUALLY STOPPED — PRESS CCN OR LOCAL TO START PIC in OFF mode, press the CCN or local softkeyto start un...

Table 9 — LID Primary and Secondary Messages and Custom Alarm/Alert Messages with Troubleshooting Guides (cont) C. IN RECYCLE SHUTDOWN PRIMARY MESSAGE SECONDARY MESSAGE PROBABLE CAUSE/REMEDY RECYCLE RESTART PENDING OCCUPIED MODE Unit in recycle mode, chilled water temperature is nothigh enough to st...

Table 9 — LID Primary and Secondary Messages and Custom Alarm/Alert Messages with Troubleshooting Guides (cont) G. COMPRESSOR JUMPSTART AND REFRIGERANT PROTECTION PRIMARY MESSAGE SECONDARY MESSAGE ALARM MESSAGE/PRIMARY CAUSE ADDITIONAL CAUSE/REMEDY UNAUTHORIZEDOPERATION UNIT SHOULD BESTOPPED CA P Em...

Table 9 — LID Primary and Secondary Messages and Custom Alarm/Alert Messages with Troubleshooting Guides (cont) K. CHILLER PROTECT LIMIT FAULTS Excessive numbers of the same fault can lead to severechiller damage. Seek service expertise. PRIMARY MESSAGE SECONDARY MESSAGE ALARM MESSAGE/PRIMARY CAUSE ...

Table 9 — LID Primary and Secondary Messages and Custom Alarm/Alert Messages with Troubleshooting Guides (cont) L. CHILLER ALERTS PRIMARY MESSAGE SECONDARY MESSAGE ALARM MESSAGE/PRIMARY CAUSE ADDITIONAL CAUSE/REMEDY RECYCLE ALERT HIGH AMPS AT SHUTDOWN High Amps at Recycle: Check guide vanedrive. Che...

Table 10A — Thermistor Temperature (F) vs Resistance/Voltage Drop TEMPERATURE VOLTAGE RESISTANCE (F) DROP (V) (Ohms) −25 4.821 98,010 −24 4.818 94,707 −23 4.814 91,522 −22 4.806 88,449 −21 4.800 85,486 −20 4.793 82,627 −19 4.786 79,871 −18 4.779 77,212 −17 4.772 74,648 −16 4.764 72,175 −15 4.757 69,...

Table 10B — Thermistor Temperature (C) vs Resistance/Voltage Drop TEMPERATURE VOLTAGE RESISTANCE (C) DROP (V) (Ohms) −40 4.896 168 230 −39 4.889 157 440 −38 4.882 147 410 −37 4.874 138 090 −36 4.866 129 410 −35 4.857 121 330 −34 4.848 113 810 −33 4.838 106 880 −32 4.828 100 260 −31 4.817 94 165 −30 ...

Control Modules Turn controller power off before servicing controls. Thisensures safety and prevents damage to controller. The Processor module (PSIO), 8-input (Options) mod- ules, Starter Management Module (SMM), and the LocalInterface Device (LID) module perform continuous di-agnostic evaluations ...

Processor Module (PSIO) (Fig. 41) INPUTS — Each input channel has 3 terminals; only 2 ofthe terminals are used. Application of chiller determines whichterminals are normally used. Always refer to individual unitwiring for terminal numbers. OUTPUTS — Output is 20 vdc. There are 3 terminals peroutput,...

Terminal block connections are provided on the options modules. All sensor inputs are field wired and installed.Options module number 1 can be factory or field-installed.Options module 2 is shipped separately and must be fieldinstalled. For installation, refer to the unit or field wiringdiagrams. Be...

Solid-State Starters — Troubleshooting guides and in- formation pertaining to the operation of the solid-state startermay be found in Fig. 44-46 and Table 11. Attempt to solve the problem by using the following preliminary checks before consulting the troubleshootingtable. When the power is off:• In...

Table 11 — Benshaw, Inc. Solid-State Starter Troubleshooting Guide PROBLEM PROBABLE CAUSES AREA OF CORRECTION AK board phase correct noton. 1. L1 and L3 switch phases reversed. 2. Missing phase voltage.3. Improper line voltage. 1. Switch incoming phases L1 and L3 at top of CD1 or CB1. 2. Check for m...

Physical Data — Tables 12-17 and Fig. 47-51 pro- vide additional information regarding compressor fits and clearances, physical and electrical data, and wiring sche-matics for operator convenience during troubleshooting. Table 12 — Heat Exchanger Data COOLER VESSEL HEAT EXCHANGER CODE NUMBER OF TUBE...

Table 14 — Waterbox Cover Weights* ENGLISH (lb) HEAT EXCHANGER WATERBOX DESCRIPTION FRAME 4, STANDARD NOZZLES FRAME 4, FLANGED FRAME 5, STANDARD NOZZLES FRAME 5, FLANGED 150 psig 300 psig 150 psig 300 psig 150 psig 300 psig 150 psig 300 psig COOLERS NIH, 1 PASS COVER 284 414 324 491 412 578 452 655 ...

NOTES:1. Dimensions are in inches with rotor in the thrust position.2. All clearances listed are new chiller tolerances.3. All radial clearances are diametrical. NOTE: Radial clearances shown are diametrical. Fig. 47 — Compressor Fits and Clearances 88

COMPRESSOR ASSEMBLY TORQUES ITEM DESCRIPTION TORQUE ft-lb N•m 1* Oil Heater Grommet Nut 10 14 2 Impeller Retaining Bolt 44-46 60-62 3 Bull Gear Retaining Bolt 80-85 108-115 4 Motor Terminals (Low Voltage) 50 68 5 Demister Bolts 15-19 20-26 6* Guide Vane Shaft Seal Nut 25 34 7* Motor Terminals (High ...

LEGEND BRG — Bearing C — Contact CB — Circuit Breaker CLR — Clear COM — Common COMM — Communication ConnectorEXT — External G.V. — Guide Vane HGBP — Hot Gas Bypass INT — Internal J — Module Connector K — Relay Designation LID — Local Interface Device MA — Milliampere NC — Normally Closed NO — Normal...

LEGEND BRG — Bearing C — Contact CB — Circuit Breaker CLR — Clear COM — Common COMM — Communication ConnectorEXT — External G.V. — Guide Vane HGBP — Hot Gas Bypass INT — Internal J — Module Connector K — Relay Designation LID — Local Interface Device MA — Milliampere NC — Normally Closed NO — Normal...

LEGEND 1M — Main Starter Contactor C — Contactor CB — Circuit Board CR — Control Relay COMM — Communications ConnectorJ — Connector N.C. — Normally Closed N.O. — Normally Open OL — Overload OS — 3-Phase Current Power Source PR — Pilot Relay PWR — PowerRLA — Rated Load Amps SMM — Starter Management M...

INDEX Abbreviations and Explanations, 4Adding Refrigerant, 61Adjusting the Refrigerant Charge, 61After Extended Shutdown, 57After Limited Shutdown, 57Attach to Network Device Control, 37Automatic Soft-Stop Amps Threshold, 40Auto. Restart After Power Failure, 33Before Initial Start-Up, 41Calibrate Mo...