Adding Refrigerant; Removing Refrigerant; Adjusting The Refrigerant Charge; Refrigerant Leak Testing - Carrier AquaEdge 19XRV series Operation, Maintenance And Installation Manual

Adding Refrigerant —
scribed in Trim Refrigerant Charge section, page 88.
CAUTION
Always use the compressor pumpdown function in the
Control Test table to turn on the cooler pump and lock out
the compressor when transferring refrigerant. Liquid refrig-
erant may flash into a gas and cause water in the heater
exchanger tubes to freeze when the chiller pressure is
below 35 psig (241 kPa) for HFC-134a, resulting in equip-
ment damage.
Removing Refrigerant —
tem is used, the 19XRV refrigerant charge may be transferred
to a pumpout storage tank or to the chiller condenser or cooler
vessels. Follow the procedures in the Pumpout and Refrigerant
Transfer Procedures section when transferring refrigerant from
one vessel to another.
Adjusting the Refrigerant Charge —
tion or removal of refrigerant is required to improve chiller
performance, follow the procedures given under the Trim
Refrigerant Charge section, page 88.
Refrigerant Leak Testing —
frigerant is above atmospheric pressure at room temperature,
leak testing can be performed with refrigerant in the chiller.
Use an electronic halide leak detector, soap bubble solution, or
ultrasonic leak detector. Ensure that the room is well ventilated
and free from concentration of refrigerant to keep false read-
ings to a minimum. Before making any necessary repairs to a
leak, transfer all refrigerant from the leaking vessel.
It is recommended by ASHRAE that chillers
Leak Rate —
be taken off line immediately and repaired if the refrigerant
leak rate for the entire chiller is more than 10% of the operating
refrigerant charge per year.
In addition, Carrier recommends that leaks totaling less than
the above rate, but more than a rate of 0.1% of the total charge
per year, should be repaired during annual maintenance or
whenever the refrigerant is transferred for other service work.
Test After Service, Repair, or Major Leak —
the refrigerant has been lost or if the chiller has been opened for
service, the chiller or the affected vessels must be pressure test-
ed and leak tested. Refer to the Leak Test Chiller section to per-
form a leak test.
WARNING
Refrigerant HFC-134a should not be mixed with air or
oxygen and pressurized for leak testing. In general, this
refrigerant should not be present with high concentrations
of air or oxygen above atmospheric pressures, because the
mixture can undergo combustion, which could result in
serious personal injury or death.
TESTING WITH REFRIGERANT TRACER — Use an en-
vironmentally acceptable refrigerant as a tracer for leak test
procedures. Use dry nitrogen to raise the machine pressure to
leak testing levels.
TESTING WITHOUT REFRIGERANT TRACER — An-
other method of leak testing is to pressurize with nitrogen only
and to use a soap bubble solution or an ultrasonic leak detector
to determine if leaks are present.

TO PRESSURIZE WITH DRY NITROGEN

NOTE: Pressurizing with dry nitrogen for leak testing should
not be done if the full refrigerant charge is in the vessel
because purging the nitrogen is very difficult.
Follow the procedures de-
If the optional pumpout sys-
If the addi-
Because HFC-134a re-
If all
1. Connect a copper tube from the pressure regulator on the
cylinder to the refrigerant charging valve. Never apply
full cylinder pressure to the pressurizing line. Follow the
listed sequence.
2. Open the charging valve fully.
3. Slowly open the cylinder regulating valve.
4. Observe the pressure gage on the chiller and close the
regulating valve when the pressure reaches test level. Do
not exceed 140 psig (965 kPa).
5. Close the charging valve on the chiller. Remove the
copper tube if it is no longer required.
Repair the Leak, Retest, and Apply Standing
After pressurizing the chiller, test for
Vacuum Test —
leaks with an electronic halide leak detector, soap bubble
solution, or an ultrasonic leak detector. Bring the chiller back to
atmospheric pressure, repair any leaks found, and retest.
After retesting and finding no leaks, apply a standing
vacuum test. Then dehydrate the chiller. Refer to the Standing
Vacuum Test and Chiller Dehydration section (pages 67 and
70) in the Before Initial Start-Up section.
Checking Guide Vane Linkage —
is off, the guide vanes are closed and the actuator mechanism is
in the position shown in Fig. 50. Slack in the guide vane actua-
tor's drive chain can only be removed with the guide vane
actuator fully closed and the chiller shut down. Complete the
following steps to adjust chain tension and position:
1. Remove the two set screws in the guide vane actuator
sprocket.
2. Loosen the guide vane actuator's holddown bolts.
3. Pull the guide vane actuator away from the suction hous-
ing along the slotted holes in the actuator bracket.
4. Rotate the guide vane sprocket fully clockwise and
spot-drill the guide vane actuator shaft. Spot-drilling is
necessary when the guide vane actuator sprocket set
screws on the guide vane actuator shaft need to be
re-seated. (Remember: Spot-drill and tighten the first set
screw before spot-drilling for the second set screw.)
Trim Refrigerant Charge —
frigerant, follow the procedure in Transfer Refrigerant from
Chiller to Pumpout Storage Tank Vessel section, page 85.
Refer to the Trimming Refrigerant Charge section on
page 80.

WEEKLY MAINTENANCE

Check the Lubrication System —
on the reservoir sight glass, and observe the level each week
while the chiller is shut down.
If the level goes below the lower sight glass, check the oil
reclaim system for proper operation. If additional oil is
required, add it through the oil drain charging valve (Fig. 2 and
3). A pump is required when adding oil against refrigerant
pressure. The oil charge for the 19XRV compressor depends on
the compressor Frame size:
• Frame 2 compressor — 8 gal (30 L)
• Frame 3 compressor — 8 gal (30 L)
• Frame 4 compressor — 10 gal (37.8 L)
• Frame 4 compressor with split ring diffuser — 12 gal
(45 L)
• Frame 5 compressor — 18 gal (67.8 L)
• Frame E compressor — 18 gal (67.8 L)
88
When the chiller
To remove any excess re-
Mark the oil level