Carrier 19XR- Manual

Carrier 19XR

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Table of Contents:

  • Page 2 – CONTENTS; Page
  • Page 5 – Fig. 1 — 19XR Identification
  • Page 6 – Fig. 2 — Typical 19XR Components; REAR VIEW
  • Page 7 – Fig. 3 — Refrigerant Motor Cooling and Oil Cooling Cycles
  • Page 9 – STARTING EQUIPMENT; Fig. 4 — Lubrication System
  • Page 10 – CONTROLS; LEGEND; Internal View; RediStart MICROTM Input/Output Card; Fig. 6 — Typical Starter External View
  • Page 11 – General —; The 19XR hermetic centrifugal liquid chiller; PIC II System Components —; The chiller control; TXV; Fig. 8 — Variable Frequency Drive (VFD) Starter Internal View
  • Page 12 – TOP VIEW; Fig. 9 — 19XR Controls and Sensor Locations
  • Page 13 – Table 1 — Major PIC II Components and; PIC II COMPONENT; Fig. 11 — Control Sensors
  • Page 16 – Fig. 16 — Example of Status Screen
  • Page 18 – Fig. 18 — 19XR Service Menu Structure
  • Page 20 – Fig. 19 — Example of Time Schedule
  • Page 21 – Fig. 20 — Example of Set Point Screen
  • Page 22 – Table 2 — CVC/ICVC Display Data; do not appear on
  • Page 33 – PIC II System Functions; VFD GAIN can be viewed and modified in the CAPACITY
  • Page 34 – Safety Controls —
  • Page 35 – Table 3 — Protective Safety Limits and Control Settings; Default Screen Freeze —; EVAP REFRIG TRIPPOINT
  • Page 37 – Table 4 — Capacity Overrides; Refrigerant Leak Detector —
  • Page 39 – Demand Limit Control Option —; Prevention with Default English Settings
  • Page 40 – Fig. 23 — Head Pressure Reference Output
  • Page 42 – WATER DEADBAND temperature.
  • Page 43 – Ice Build Control —
  • Page 44 – Attach to Network Device Control —; Fig. 24 — Example of Attach to Network
  • Page 45 – Service Operation —; Fig. 25 — Example of Holiday Period Screen
  • Page 46 – TACTS INPUT and press the; Fig. 26 — Control Sequence
  • Page 48 – Vacuum Indicator
  • Page 52 – PRESSURE
  • Page 53 – Fig. 31 — Dehydration Cold Trap
  • Page 54 – Red
  • Page 56 – BUS parameter. Press the
  • Page 57 – RediStart MICRO; Fig. 32 — Benshaw RediStart
  • Page 61 – Estimated Maximum Load Conditions:
  • Page 62 – Perform a Control Test —
  • Page 63 – Table 9 — Control Test Menu Functions; High Altitude Locations —
  • Page 64 – Preparation —
  • Page 65 – Fig. 33 — Correct Motor Rotation
  • Page 69 – Chillers with Storage Tanks —; Fig. 35 — 19XR Pumpout Unit Wiring Schematic
  • Page 70 – Chillers with Isolation Valves
  • Page 72 – Fig. 37 —Guide Vane Actuator Linkage
  • Page 74 – Fig. 38 — 19XR Float Valve Design
  • Page 75 – Fig. 39 — Optional Pumpout System Controls
  • Page 77 – Control Algorithms Checkout Procedure —; One; Control Test —; The Control Test feature can check all the
  • Page 78 – C. IN RECYCLE SHUTDOWN
  • Page 80 – G. NORMAL RUN WITH OVERRIDES; OIL SUMP TEMP
  • Page 81 – I. CHILLER PROTECT LIMIT FAULTS
  • Page 83 – Confirm valid settings in ISM_CONF screen.
  • Page 89 – INTEGRATED STARTER MODULE; INTERGRA; HIGH VOL; ARNING
  • Page 90 – Physical Data —; Fig. 43 — SCR Installation; Consult Benshaw Representative
  • Page 91 – Table 13A — Heat Exchanger Data (English); Condenser data: based on a condenser with standard wall tub-
  • Page 93 – Table 14 — 19XR Additional Data for Marine Waterboxes*; *Add to heat exchanger data for total weights or volumes.; Table 15 — Compressor Weights
  • Page 94 – Table 16 — 19XR Motor Weights Standard and High Efficiency Motors; *Stator weight includes stator and shell.
  • Page 95 – Table 17A — 19XR Waterbox Cover Weights — English (lb); RIG MACHINE COMPONENTS —; Marine Waterbox
  • Page 96 – Table 17B — 19XR Waterbox Cover Weights — SI (kg)
  • Page 97 – Table 19 — Additional Miscellaneous Weights; Variable Frequency Drive; Table 20 — Motor Voltage Code; Locked Rotor Amps
  • Page 98 – Compressor Assembly Torques; ITEM; VIEW A; Fig. 44 — Compressor Fits and Clearances; COMPRESSOR, TRANSMISSION AREA
  • Page 108 – Fig. 49 — Cutler-Hammer Wye Delta Unit Mounted Starter Sizes 3-5DP
  • Page 109 – Fig. 50 — Cutler-Hammer Wye Delta Unit Mounted Starter Size 6DP
  • Page 123 – INDEX; Apply Standing Vacuum Test, 72
  • Page 125 – INITIAL START-UP CHECKLIST
  • Page 126 – PIC II CAUTION; COMPRESSOR MOTOR AND CONTROL PANEL; MUST; BE PROPERLY AND INDIVIDUALLY; Yes
  • Page 136 – *Variable by job — refer to component nameplates and labels.; Selected line voltage
  • Page 137 – CVC/ICVC DISPLAY AND ALARM SHUTDOWN STATE RECORD SHEET; COMMUNICATION MESSAGE
Loading the manual

Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.

PC 211

Catalog No. 531-982

Printed in U.S.A.

Form 19XR-5SS

Pg 1

6-01

Replaces: 19XR-4SS

Book 2

Tab

5a

Star t-Up, Operation, and Maintenance Instructions

SAFETY CONSIDERATIONS

Centrifugal liquid chillers are designed to provide safe and
reliable service when operated within design specifica-
tions. 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 accor-
dance with the latest edition of ANSI/ASHRAE 15 (American
National Standards Institute/American Society of Heating, Refrigera-
tion, and Air Conditioning Engineers). The accumulation of refriger-
ant 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 irregular-
ities, 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 pres-
sures 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 inside-delta mechanical starter is used. Open the power
supply disconnect before touching motor leads or terminal

s.

D

O 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 qualified
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
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 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 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 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. Fol-
low safe practices when using ladders.
USE MECHANICAL EQUIPMENT (crane, hoist, etc.) to lift or
move inspection covers or other heavy components. Even if compo-
nents are light, use mechanical equipment when there is a risk of slip-
ping 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.
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 corro-
sion, 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.

19XR,XRV

Hermetic Centrifugal Liquid Chillers

50/60 Hz

With PIC II Controls and HFC-134a

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Summary

Page 2 - CONTENTS; Page

2 CONTENTS Page SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . 1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 ABBREVIATIONS AND EXPLANATIONS . . . . . . . . 4,5 CHILLER FAMILIARIZATION . . . . . . . . . . . . . . . . . . . . 5-7 Chiller Inform...

Page 5 - Fig. 1 — 19XR Identification

5 Factory-installed additional components are referred to as options in this manual; factory-supplied but field-installed ad-ditional components are referred to as accessories. The chiller software part number of the 19XR unit is located on the back of the CVC/ICVC. CHILLER FAMILIARIZATION (Fig. 1 a...

Page 6 - Fig. 2 — Typical 19XR Components; REAR VIEW

6 34 18 19 20 21 22 23 31 30 29 28 27 26 25 24 32 33 24 1 2 3 5 6 4 11 12 13 16 15 14 17 7 9 10 8 Fig. 2 — Typical 19XR Components LEGEND 1 — Guide Vane Actuator 2 — Suction Elbow 3 — Chiller Visual Controller/ International Chiller Visual Control (CVC/ICVC) 4 — Chiller Identification Nameplate 5 — ...

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