Carrier 19XL - Manual
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Table of Contents:
- Page 2 – CONTENTS; Page
- Page 5 – Fig. 1 — 19XL Identification
- Page 6 – Fig. 2A — Typical 19XL Components — Design I
- Page 7 – Fig. 2B — Typical 19XL Components — Design II
- Page 8 – Refrigerant that flows to the oil cooling system is reg-; LUBRICATION CYCLE; The oil pump, oil filter, and oil cooler make; Details —; Oil is charged into the lubrication system through; Fig. 3 — Refrigerant Motor Cooling and Oil Cooling Cycles
- Page 9 – Oil Reclaim System —; The oil reclaim system oper-; Fig. 4 — Lubrication System
- Page 10 – STARTING EQUIPMENT; Internal View
- Page 11 – Table 1 — Major PIC Components and
- Page 12 – with Options Module
- Page 13 – The spare temperature sensors must have the same; Fig. 12 — Power Panel with Options
- Page 15 – Fig. 15 − Example of Point Status Screen
- Page 20 – Fig. 19 — Example of Set Point Screen
- Page 21 – Table 2 — LID Screens
- Page 28 – PIC System Functions; The first type is called PROPORTIONAL INC BAND, and
- Page 29 – Safety Controls —; The PIC monitors all safety control; Default Screen Freeze —; Whenever an alarm; Motor Cooling Control —; Motor temperature is
- Page 30 – Table 3 — Protective Safety Limits and Control Settings
- Page 31 – Ramp Loading Control —; DOWN, and SELECT RAMP TYPE may be viewed/modified; Table 4 — Capacity Overrides
- Page 34 – Surge Protection —; Prevention; Fig. 21 — 19XL with Default Metric Settings
- Page 36 – Ice Build Control
- Page 37 – Attach to Network Device Control
- Page 38 – Service Operation —; Fig. 22 — Example of Attach to Network
- Page 39 – Fig. 23 — Example of Holiday Period Screen; Fig. 24 — Control Sequence
- Page 41 – Vacuum Indicator
- Page 43 – Standing Vacuum Test —
- Page 47 – Fig. 29 — Dehydration Cold Trap
- Page 48 – Carrier Comfort Network Interface —; Check Starter
- Page 49 – Power Stack
- Page 51 – Estimated Maximum Load Conditions:
- Page 53 – Table 7 — Control Test Menu Functions
- Page 54 – Table 8 — Refrigerant Charges*
- Page 55 – POSITION line and press the SELECT softkey.; Dry Run to Test Start-Up Sequence; Fig. 32 — Correct Motor Rotation
- Page 59 – Fig. 34 — 19XL Pumpout Unit; Fig. 35 — Optional Pumpout Unit
- Page 60 – Chillers with Isolation Valves
- Page 62 – Fig. 36 — Guide Vane Actuator Linkage
- Page 64 – Fig. 37 — 19XL Float Valve Designs
- Page 65 – Fig. 38 — Optional Pumpout System
- Page 67 – Control Algorithms Checkout Procedure —; The; These maintenance tables are very useful in determining; Control Test —; The Control Test feature can check all
- Page 68 – with Troubleshooting Guides; B. TIMING OUT OR TIMED OUT
- Page 69 – C. IN RECYCLE SHUTDOWN
- Page 71 – G. COMPRESSOR JUMPSTART AND REFRIGERANT PROTECTION
- Page 73 – K. CHILLER PROTECT LIMIT FAULTS
- Page 74 – M. SPARE SENSOR ALERT MESSAGES
- Page 76 – Table 10A — Thermistor Temperature (F) vs Resistance/Voltage Drop
- Page 77 – Table 10B — Thermistor Temperature (C) vs Resistance/Voltage Drop
- Page 78 – Fig. 39 — PSIO Module Address Selector Switch
- Page 79 – The options modules; LED Locations; Fig. 42 — Starter Management Module
- Page 80 – Replacing Defective Processor Modules —; Fig. 43 — Options Module
- Page 81 – Solid-State Starters —
- Page 84 – Table 11 — Benshaw, Inc. Solid-State Starter Troubleshooting Guide
- Page 85 – Physical Data —; vide additional information regarding compressor fits and; Table 12 — Heat Exchanger Data; COOLER; Table 13 — Additional Data for Marine Waterboxes*
- Page 86 – Table 14 — Waterbox Cover Weights*
- Page 88 – Fig. 47 — Compressor Fits and Clearances
- Page 89 – COMPRESSOR ASSEMBLY TORQUES
- Page 90 – Fig. 48 — Electronic PIC Controls Wiring Schematic
- Page 92 – Fig. 49 — Electronic PIC Controls Wiring Schematic
- Page 94 – and Motor Wiring Schematic
- Page 98 – INDEX
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.
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 Heat-
ing, Refrigeration, and Air Conditioning Engineers). The accumu-
lation 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 avail-
able for breathing. Product causes eye and skin irritation. Decom-
position 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.
DO NOT WELD OR FLAMECUT any refrigerant line or vessel
until all refrigerant (liquid and vapor) has been removed from chiller.
Traces of vapor should be displaced with dry air or nitrogen and
the work area should be well ventilated. Refrigerant in contact with
an open flame produces toxic gases.
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 quali-
fied electrician.
DO NOT WORK ON electrical components, including control pan-
els, 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 be-
fore 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, IMME-
DIATELY 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 dam-
age or malfunction to this chiller.
Operation of this equipment with refrigerants other than those
cited herein should comply with ANSI/ASHRAE-15 (latest edi-
tion). 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 devices, 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 compressed spring.
Sudden release of the spring can cause it and objects in its path to
act as projectiles.
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 com-
ponents are light, use mechanical equipment when there is a risk of
slipping or losing your balance.
BE AWARE that certain automatic start arrangements CAN EN-
GAGE 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 require-
ments 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.
DOUBLE-CHECK that coupling nut wrenches, dial indicators, or
other items have been removed before rotating any shafts.
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 cor-
rosion, rust, leaks, or damage.
PROVIDE A DRAIN connection in the vent line near each pres-
sure relief device to prevent a build-up of condensate or rain
water.
19XL
Hermetic Centrifugal Liquid Chillers
50/60 Hz
With HCFC-22 and HFC-134a
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Book 2
Tab
5a
PC 211
Catalog No. 531-971
Printed in U.S.A.
Form 19XL-4SS
Pg 1
7-96
Replaces: 19XL-3SS
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Summary
CONTENTS Page SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . 1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 ABBREVIATIONS AND EXPLANATIONS . . . . . . . 4 CHILLER FAMILIARIZATION . . . . . . . . . . . . . . . . . . 5 Chiller Information Plate . . . . . . . ...
CHILLER FAMILIARIZATION (Fig. 1, 2A, and 2B) Chiller Information Plate — The information plate is located on the right side of the chiller control centerpanel. System Components — The components include the cooler and condenser heat exchangers in separate vessels,motor-compressor, lubrication packag...
19XL FRONT VIEW 19XL REAR VIEW Fig. 2A — Typical 19XL Components — Design I LEGEND 1 — Unit-Mounted Starter2 — Refrigerant Filter Drier3 — Rigging Guide Bolt4 — Refrigerant Moisture Indicator5 — Motor Sight Glass6 — Refrigerant Motor Drain7 — Oil Filter Access Cover8 — Refrigerant Oil Cooler9 — Oil ...
