Check Optional Pumpout System Controls And Compressor; Charge Refrigerant Into Chiller - Carrier AquaEdge 19XR Series Start-Up, Operation And Maintenance Instructions Manual

Quick Calibration, which is also located in the Main Menu, is used
to calibrate inlet guide vanes and devices with 4-20mA feedback.
Calibration is mandatory for chiller function and controls will not
allow the chiller to start if calibration is not completed.
Check Optional Pumpout System Controls and
Compressor
Controls include an on/off switch, a 0.5-amp fuse, the compres-
sor overloads, an internal thermostat, a compressor contactor, re-
frigerant low pressure cut-out, and a refrigerant high pressure
cutout. The high pressure cutout is factory set to open at 185 psig
(1276 kPa) and reset at 140 psig (965 kPa). The low pressure
cutout is factory set to open at 7 psia (–15.7 in. HG) and close at
9 psia (–11.6 in. HG). Ensure the water-cooled condenser has
been connected. Ensure oil is visible in the compressor sight
glass. Add oil if necessary.
See the Pumpout and Refrigerant Transfer Procedures and Option-
al Pumpout System Maintenance sections, pages 41 and 52, for
details on the transfer of refrigerant, oil specifications, etc.

Charge Refrigerant into Chiller

CAUTION
The transfer, addition, or removal of refrigerant in spring iso-
lated 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.
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 refrig-
erant cylinders.
NOTE: Since R-513A is a blend, be sure to remove only liquid
when charging or trimming chiller refrigerant charge. Vapor
charging could shift refrigerant composition.
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 (con-
nected 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 PUMPDOWN/LOCK-
OUT (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.)
IMPORTANT: Turn on the chilled water and condenser
water pumps to prevent freezing.
2. Slowly open the refrigerant charging valves. The chiller
cooler and condenser pressures will gradually equalize.
This process takes approximately 15 minutes.
3. Once the pressures have equalized, the cooler isolation
valve, the condenser isolation valve, and the hot gas isola-
tion valve may now be opened. Refer to Fig. 40 and 41 for
the location of the valves.
Whenever turning the discharge isolation valve, be sure to re-
attach the valve locking device. This prevents the valve from
opening or closing during service work or during chiller opera-
tion. Failure to follow this procedure may damage equipment
and result in bodily injury.
CHILLER EQUALIZATION WITH
PUMPOUT UNIT
The following steps describe how to equalize refrigerant pressure
on an isolated 19XR chiller using the pumpout unit.
1. Access the terminate lockout function on the PUMP-
DOWN/LOCKOUT screen (located in the Maintenance
Menu).
IMPORTANT: Turn on the chilled water and condenser
water pumps to prevent freezing.
2. Open valve 4 on the pumpout unit and open valves 1a and
1b on the chiller cooler and condenser, Fig. 40 and 41.
Slowly open valve 2 on the pumpout unit to equalize the
pressure. This process takes approximately 15 minutes.
3. Once the pressures have equalized, the discharge isolation
valve, cooler isolation valve, optional hot gas bypass isola-
tion valve, and refrigerant isolation valve can be opened.
Close valves 1a and 1b, and all pumpout unit valves.
Whenever turning the discharge isolation valve, be sure to re-
attach the valve locking device. This prevents the valve from
opening or closing during service work or during chiller opera-
tion. 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 be-
gins on page 57.
Always operate the condenser and chilled water pumps when-
ever 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, the refriger-
ant is added through the pumpout charging connection (Fig. 40
and 41, 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 HFC-134a or 39 psig
(268 kPa) for R-513A. After the chiller is beyond this pressure the
refrigerant should be charged as a liquid until all the recommend-
ed refrigerant charge has been added. The charging valve (Fig. 40
and 41, 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 backwards through any of the floats to the condenser.
37
WARNING
FREE-STANDING
WARNING
CAUTION