Page 1: Table Of Contents
Inspect Wiring ......26 Economizer (if available) ..... . 5 Carrier Comfort Network (CCN) and ®...
Page 2: Safety Considerations
Manual Guide Vane Operation ....39 SAFETY CONSIDERATIONS Refrigeration Log ......39 Centrifugal liquid chillers are designed to provide safe and reli- PUMPOUT AND REFRIGERANT able service when operated within design specifications.
Page 3 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.
Page 4: Introduction
Control Panel This equipment uses, and can radiate, radio frequency ener- The control panel includes the Carrier PIC 6 HMI touchscreen. It gy. If not installed and used in accordance with the instruc- allows user interface for controlling the chiller. It regulates the tion manual, it may cause interference to radio communica- chiller’s capacity as required to maintain proper leaving chilled...
Page 5: Power Panel (19Xr2-E)
the cooler to absorb more heat when it evaporates and benefits Power Panel (19XR2-E) the overall cooling efficiency cycle. The power panel contains oil heater and oil pump contactors, as well as the envelope control/HGBP relay if specified. The Free-Standing/Factory-Mounted Starter or VFD power panel also contains transformers T1/T2 for 24 VAC con- The starter or VFD allows for the proper start and disconnect trol power, as well as the low voltage starter interlock and com-...
Page 6 51 3 19XR T* 64 – Description 19XR — High Efficiency Semi-Hermetic Special Order Indicator Centrifugal Liquid Chiller – — Standard 19XRV — High Efficiency Semi-Hermetic S — Special Order Centrifugal Liquid Chiller with Unit-Mounted VFD Motor Voltage Code Code Volts-Phase-Hertz 60 —...
Page 7 19XR – Description Special Order Indicator — High Efficiency Semi-Hermetic 19XR – — Standard Centrifugal Liquid Chiller S — Special Order Evaporator Size Code (Digits 6, 7, 8) Motor Voltage Code Code Volts-Phase-Hertz A40-A42 A45-A47 2 — 400-3-50 (19XR6 only) A4A-A4C* 4 —...
Page 8 Evaporator In/Out Temperature Thermistors — Evaporator Pressure Transducer — Refrigerant Storage Tank Connection — Control Panel 10 — Carrier Controller HMI 11 — Oil Drain/Charger Valve 12 — Oil Level Sightglass 13 — Power Panel 14 — Refrigerant Oil Cooler (not shown) 15 —...
Page 9 FRONT VIEW LEGEND 1 — Suction Elbow 2 — Chiller Identification Nameplate 3 — Condenser Auto Reset Relief Valves 4 — Condenser In/Out Temperature Thermistors 5 — Evaporator In/Out Temperature Thermistors 6 — Refrigerant Storage Tank Connection Valve (barely visible) 7 —...
Page 10 FRONT VIEW LEGEND 1 — Guide Vane Actuator* 2 — Suction Elbow 3 — Chiller Identification Nameplate 4 — Auxiliary Power Panel 5 — Condenser Auto. Reset Relief Valves 6 — Condenser Return End Waterbox Cover 7 — Evaporator Return End Waterbox Cover 8 —...
Page 11: Refrigeration Cycle
FLASC chamber vapor from entering the cooler. When liquid REFRIGERATION CYCLE refrigerant passes through the valve, some of it flashes to vapor The compressor continuously draws refrigerant vapor from the in the reduced pressure on the cooler side. In flashing, it re- cooler at a rate set by the amount of guide vane opening and moves heat from the remaining liquid.
Page 12: Motor And Oil Cooling Cycle
Fig. 7 — Refrigeration Cycle — 19XR(V) Two-Stage Compressor bottom of the motor casing and is then drained back into the MOTOR AND OIL COOLING CYCLE cooler through the motor refrigerant drain line. An orifice (in The motor and the lubricating oil are cooled by liquid refrigerant the motor shell) maintains a higher pressure in the motor shell taken from the bottom of the condenser vessel (Fig.
Page 13: Lubrication Cycle
The oil pump is a gerotor-style pump with external filters. A LUBRICATION CYCLE gerotor pump has two rotors, one inside the other; their center Summary points are offset with respect to each other. This type of pump provides a smooth continuous flow. It is also quieter than other The oil pump, oil filter, and oil cooler make up a package locat- designs.
Page 14 FWD MOTOR REAR MOTOR BEARING BEARING OIL SUPPLY TO FORWARD HIGH SPEED BEARING LABYRINTH GAS LINE REAR HIGH OIL PRESS SPD BRG MOTOR REGULATOR COOLING LINE OIL FILTER FLOW STRAINERS OIL PUMP TXV BULB AND MOTOR HEATER ISOLATION VALVES PRESSURE EDUCTORS TRANSDUCER OIL COOLER...
Page 15 LEGEND 1 — Gerotor Oil Pump 2 — Isolation Valve 3 — Oil Pressure Regulator Valve 4 — Oil Sump Pressure Transducer 5 — Oil Sump Drain 6 — Bearing Temperature Sensor Terminal Block 7 — Oil Heater Fig. 10 — 19XR2-E Gerotor Oil Pump LEGEND a19-2116 1 —...
Page 16: Starting Equipment
For 19XR6-7 it is typical that 3-phase power is field supplied to the Carrier control panel which pow- A solid-state, reduced-voltage starter operates by reducing the ers oil-pump, heater and controls. Consult specific wiring dia- starting voltage.
Page 17: Free-Standing Starters/Vfds
Free-Standing Starters/VFDs PIC 6 System Components In addition to unit-mounted starters the 19XR product line of- The chiller control system is called the PIC 6 (Product Integrated fers free-standing starter types of Across the Line, Solid State, Control 6). See Table 1. As with previous PIC versions, the PIC Auto-Transformer and VFD.
Page 18 Fig. 12 — Chiller Controls and Sensor Locations MOTOR TEMPERATURE SENSOR CABLE COMPRESSOR OIL DISCHARGE OIL RECLAIM PRESSURE CABLE SIGHT GLASS BEARING TEMPERATURE SENSOR CABLE COMPRESSOR OIL SUMP DIFFUSER PRESSURE PRESSURE CABLE AND DIFFUSER ACTUATOR CABLE (FRAME 4 & 5 COMPRESSOR ONLY) COMPRESSOR OIL SUMP TEMPERATURE CABLE...
Page 19: Start-Up/Shutdown
Five seconds later, the condenser pump relay energizes. Thirty START-UP/SHUTDOWN/ seconds later the PIC 6 control system monitors the chilled water RECYCLE SEQUENCE and condenser water flow devices and waits until the WATER Local Start/Stop Control FLOW VERIFY TIME (operator-configured, default 5 minutes) expires to confirm flow.
Page 20: Lubrication Control
Lubrication Control As part of the pre-start checks executed by the controls, the oil sump temperature is compared to the evaporator saturated re- frigerant temperature. If the oil temperature is less than 140F (60C) and less than evaporator saturated refrigerant tempera- ture plus 50F (27.8C), the start-up will be delayed until either of these conditions is no longer true.
Page 21: Tighten All Gasketed Joints
Tighten All Gasketed Joints Check Chiller Tightness Gaskets normally relax by the time the chiller arrives at the Figure 19 outlines the proper sequence and procedures for leak jobsite. Tighten all gasketed joints to ensure a leak-tight chiller testing. (does not apply to refrigerant joints covered by factory insula- The 19XR chillers are shipped with the refrigerant contained in tion).
Page 22 ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) Fig.
Page 23: Refrigerant Tracer
Slowly raise the system pressure to a maximum of Refrigerant Tracer 160 psig (1103 kPa) but no less than 35 psig (241 kPa) Carrier recommends the use of an environmentally acceptable for HFC-134a by adding refrigerant (below 35 psig refrigerant tracer for leak testing with an electronic detector.
Page 24 Table 5 — Pressure — Temperature (F) Table 6 — Pressure — Temperature (C) TEMPERATURE HFC-134a PRESSURE R-513A PRESSURE TEMPERATURE HFC-134a PRESSURE R-513A PRESSURE (PSIG) (PSIG) (kPa) (kPa) 6.50 9.22 –17.8 44.8 63.6 –16.7 7.52 10.32 51.9 71.1 –15.6 8.60 11.45 59.3 79.0...
Page 25: Chiller Dehydration
Carrier representative for the dehydration techniques required. assumes no responsibility for chiller damage resulting from untreated or improperly treated water.
Page 26: Mechanical Starter
6. Verify that the wiring to the terminal strip and the power to the starter/VFD, control panel (19XR6/7), power panel terminals is correct with no external power supplied to the (19XR2-E) and optional pumpout compressor. inputs of the Carrier/starter controls.
Page 27: Carrier Comfort Network ® (Ccn) And Local Equipment Network (Len) Interface
8. Ensure the customer’s contractor has verified proper oper- ation of the pumps, cooling tower fans, and associated Do not apply power unless a qualified Carrier technician is auxiliary equipment. This includes ensuring motors are present. Serious personal injury may result.
Page 28: Oil Charge
Fig. 21 — Main Menu Icon sight glass (Fig. 3-5). If oil is added, it must meet Carrier’s spec- ification for centrifugal compressor use as described in the Oil The Main Menu screen is displayed.
Page 29: Input Service Configurations
65535). IMPORTANT: Be sure to remember the password. Retain a copy for future reference. Without the password, access to will not be possible unless accessed by a Carrier representative. LOGIN/LOGOUT Press the lock icon on the home screen to enter the password.
Page 30 The applicable configuration tables are dependent upon the starter/ For constant speed machines verify all listed parameters in ISM VFD type and manufacturer. For all factory unit-mounted equip- Configuration. Similarly, for unit-mounted VFDs verify all pa- ment all starter configurations should be completed at the factory, rameters listed in UM VFD Configuration Tables 8-11.
Page 31: Field Set Up And Verification
Table 10 — Typical Job Site Parameters (Main MenuConfiguration MenuGeneral [for all Starter/VFD options]) PARAMETER TABLE GENCONF - 0=Base Demand, 1=4-20mA DEMAND LIMIT TYPE GENCONF - 0=Temperature, 1= Load PULLDOWN RAMP TYPE GENCONF - 0=Amperes, 1= kW DEMAND LIMIT SOURCE NOTE: Other parameters in this menu are normally left at the default settings;...
Page 32 AND TESTED IN CONFORMANCE WITH ANSI/ASHRAE 15 (LATEST REVISION), SAFETY CODE FOR MECHANICAL REFRIGERATION. THE COMPRESSOR MOTOR CONTROLLER AND OVERLOAD PROTECTION MUST BE a19-1881 IN ACCORDANCE WITH CARRIER SPECIFICATION Z-415. Tsmax=60 19XR05009801 TYPICAL CHILLER ID NAMEPLATE — CONSTANT SPEED STARTER OR FREESTANDING VFD Tsmax=70 Fig.
Page 33 • EVAPORATOR REFRIGERANT TEMP • EVAPORATOR PRESSURE • CONDENSER REFRIG TEMP • CONDENSER PRESSURE • ACTUAL GUIDE VANE POSITION Speed Factor =1.60 • AVERAGE LINE CURRENT If ACTUAL GUIDE VANE POSITION is less than 30%, go to Step 1. If ACTUAL GUIDE VANE POSITION is greater than Speed Factor 60%, then go to Step 3.
Page 34: Perform A Controls Test (Quick Test/Quick Calibration)
The Configuration Menu has other tables to select, view, or Menu. The Quick Test or Quick Calibration menu can be accessed modify parameters. Carrier’s certified drawings have the con- from the MAIN MENU. (The QUICK TEST screen can only be figuration values required for the jobsite.
Page 35 CHILLER EQUALIZATION WITHOUT A PUMPOUT UNIT 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. CAUTION Close valves 1a and 1b, and all pumpout unit valves. When equalizing refrigerant pressure on the 19XR chiller WARNING after service work or during the initial chiller start-up, do...
Page 36 REFRIGERANT CHARGING VALVE CHILLER CONDENSER VESSEL REFRIGERANT CHARGING VALVE CHILLER COOLER VESSEL COOLER TEE FOR REFRIGERANT CHARGING PRESSURE ISOLATION RELIEF SAFETY VALVE STORAGE VALVE TANK LIQUID VALVE LIQUID LINE SEPARATOR SERVICE VALVE PUMPOUT PUMPOUT COMPRESSOR CONDENSER SERVICE VALVE ON SERVICE VALVE ON CHILLER (FIELD PUMPOUT PUMPOUT UNIT...
Page 37: Initial Start-Up
INITIAL START-UP IMPORTANT: Startup engineer is to be properly certified for the starter/VFD. Extended VFD warranty may be affected. Preparation Before starting the chiller, verify: 1. Power is on to the main starter, oil pump relay, tower fan starter, oil heater relay, and the chiller control panel. 2.
Page 38: Operating Instructions
Consult the For 19XR6/7: The bearing temperature accessed from the water treatment company for details. Carrier is not responsible for waterside corrosion. Temperatures menu should be 140 to 210°F (60 to 99°C) for...
Page 39: After Extended Shutdown
Schrader fittings on the waterside flow devices for fouling, if Data Collection module and a Building Supervisor. Contact a necessary. Carrier representative for more information. Check the cooler pressure on the HMI panel and compare it to PUMPOUT AND REFRIGERANT the original holding charge that was left in the chiller.
Page 40 REFRIGERATION LOG CARRIER 19XR SEMI-HERMETIC CENTRIFUGAL REFRIGERATION MACHINE PLANT___________________________ MACHINE MODEL NO. ________________________ MACHINE SERIAL NO. _____________________________ DATE COMPRESSOR COOLER CONDENSER ECON. REFRIGERANT FLOW TEMP. REFRIGERANT FLOW TEMP. REFRIG. BEARING TEMPS. MOTOR OPERATOR REMARKS INITIALS FLA/AMPS TIME PRESS. TEMP. GPM IN OUT PRESS. TEMP. GPM IN OUT PRESS. #1 LS...
Page 41: Operating The Optional Pumpout Unit (Fig. 37)
POSITIVE PRESSURE CHILLERS WITH STORAGE TANKS DANGER In the Valve/Condition tables that accompany these instruc- tions, the letter “C” indicates a closed valve. Figures 33 and 34 During transfer of refrigerant into and out of the optional show the locations of the valves. storage tank, carefully monitor the storage tank level gage.
Page 42 Transfer Refrigerant from Pumpout Storage Tank to Chiller 2. Transfer the remaining liquid. a. Turn off pumpout condenser water. Place valves in the following positions: WARNING During transfer of refrigerant into and out of the 19XR stor- VALVE age tank, carefully monitor the storage tank level gage. Do CONDITION not fill the tank more than 90% of capacity to allow for re- b.
Page 43 h. Turn off the pumpout compressor. Return Refrigerant to Normal Operating Conditions 2. Evacuate gas from chiller cooler vessel. 1. Be sure that the chiller vessel that was opened has been a. Close liquid line service valves 2 and 5; open valves 3 evacuated.
Page 44: General Maintenance
(Remember: Spot-drill and tighten the first set per year. screw before spot-drilling for the second set screw.) In addition, Carrier recommends that leaks totaling less than Trim Refrigerant Charge the above rate but more than a rate of 0.1% of the total charge...
Page 45 SUCTION GUIDE VANE GUIDE VANE HOUSING ACTUATOR ACTUATOR SHAFT SCREWS GUIDE VANE ACTUATOR SPROCKET DRIVE CHAIN ACTUATOR BRACKET CHAIN GUARD HOLDDOWN BOLTS (3) GUIDE VANE SHAFT GUIDE VANE a19-1731 SPROCKET Fig. 39 — 19XR2,3,4,5,E Guide Vane Actuator Linkage Fig. 40 — Guide Vane Actuator, Frame Size C...
Page 46 GUIDE VANE ACTUATOR a19-2123 Fig. 41 — Guide Vane Actuator, Frame Size 6 GUIDE VANE ACTUATOR Fig. 42 — Guide Vane Actuator, Frame Size 7 GUIDE VANE ACTUATOR SET SCREW ACTUATOR BRACKET GUIDE VANE COUPLING a19-2128 HOLDDOWN NOTE: Rotate coupling clockwise to close guide vanes. BOLTS (4) Rotate coupling counterclockwise to open guide vanes.
Page 47: Weekly Maintenance
Oil Specification If oil is added, it must meet Carrier specifications. For units us- SCHEDULED MAINTENANCE ing R-134a/R-513A, use inhibited polyolester-based synthetic Establish a regular maintenance schedule based on your actual...
Page 48: Vfd Refrigerant Strainer (If Equipped)
condition indicates a need for more frequent replacement. Change the filter by closing the filter isolation valves (Fig. 3-5) and slowly opening the flare fittings with a wrench and back-up wrench to relieve the pressure. A moisture indicator sight glass is located beyond this filter to indicate the volume and moisture in the refrigerant.
Page 49: Inspect Relief Valves And Piping
Contact valve outlet and carefully inspect the valve body and your Carrier representative to obtain these brushes. Do not use mechanism for any evidence of internal corrosion or rust, wire brushes.
Page 50: Inspect The Starting Equipment Or Vfd
19XR Positive Pressure Storage System Installation, Start-Up, Ordering Replacement Chiller Parts and Service Instructions. When ordering Carrier specified parts, the following informa- OPTIONAL PUMPOUT COMPRESSOR OIL CHARGE tion must accompany an order: Use oil conforming to Carrier specifications for reciprocating •...
Page 51: Troubleshooting Guide
TROUBLESHOOTING GUIDE Checking Display Messages The first area to check when troubleshooting the 19XR is the Overview HMI display. Status messages are displayed at the bottom of The PIC 6 control system has many features to help the opera- the screen, and the alarm icon indicates a fault. For a complete tor and technician troubleshoot a 19XR chiller.
Page 52 Table 13 — Thermistor Temperature (F) vs. Resistance/Voltage Drop TEMPERATURE RESISTANCE TEMPERATURE RESISTANCE TEMPERATURE RESISTANCE VOLTAGE VOLTAGE VOLTAGE (OHMS) (OHMS) (OHMS) DROP (V) DROP (V) DROP (V) –25 4.700 97,706 2.565 6,568 0.630 –24 4.690 94,549 2.533 6,405 0.619 –23 4.680 91,474 2.503...
Page 53 Table 14 — Thermistor Temperature (C) vs. Resistance/Voltage Drop TEMPERATURE PIC VOLTAGE RESISTANCE TEMPERATURE PIC VOLTAGE RESISTANCE DROP (V) (OHMS) DROP (V) (OHMS) –33 4.722 105 616 1.338 2 272 –32 4.706 99 640 1.300 2 184 –31 4.688 93 928 1.263 2 101 –30...
Page 54 CHECK SENSOR ACCURACY sensor, apply a pipe sealant or thread sealant to the sensor threads. Place the sensor in a medium of known temperature and com- An additional thermistor, factory installed in the bottom of the pare that temperature to the measured reading. The thermome- cooler barrel, is displayed as Evap Refrig Liquid Temp on the ter used to determine the temperature of the medium should be TEMPERATURES display screen.
Page 55: Checking Pressure Transducers
ratio of the transducer. To obtain the voltage ratio, divide the Checking Pressure Transducers voltage (dc) input from the transducer by the supply voltage There are 4 typically factory-installed pressure transducers signal or measure across the positive (+ red) and negative (– measuring refrigerant and oil pressure and, if equipped, a fifth black) leads of the transducer.
Page 56 Fig. 51 — Inputs for Optional Waterside Delta P Transducers for IOB4 SCHRADER VALVE NPTF TEE, BRASS WATERBOX NOZZLE BALL VALVE TWO (2) 2” PIPE NIPPLES - 18 NPT Fig. 52 — Suggested Installation of Pressure Transducers into Water Nozzles Using Flushable Dirt Leg Trap...
Page 57 Table 15 — 19XR Heat Exchanger Weights ENGLISH Dry Rigging Weight (lb) * Machine Charge Dry Rigging Weight (kg) * Machine Charge CODE † Refrigerant Weight (lb) Water Weight (lb) Refrigerant Weight (kg) Water Weight (kg) Evaporator Condenser Evaporator Condenser Only Only Only...
Page 58 Table 15 — 19XR Heat Exchanger Weights (cont) ENGLISH Dry Rigging Weight (lb) * Machine Charge Dry Rigging Weight (kg) * Machine Charge CODE † Refrigerant Weight (lb) Water Weight (lb) Refrigerant Weight (kg) Water Weight (kg) Evaporator Condenser Evaporator Condenser Only Only...
Page 59 Table 15 — 19XR Heat Exchanger Weights (cont) ENGLISH Dry Rigging Weight (lb) * Machine Charge Dry Rigging Weight (kg) * Machine Charge CODE † Refrigerant Weight (lb) Water Weight (lb) Refrigerant Weight (kg) Water Weight (kg) Evaporator Condenser Evaporator Condenser Only Only...
Page 60 Table 15 — 19XR Heat Exchanger Weights (cont) ENGLISH Dry Rigging Weight (lb) * Machine Charge Dry Rigging Weight (kg) * Machine Charge CODE † Refrigerant Weight (lb) Water Weight (lb) Refrigerant Weight (kg) Water Weight (kg) Evaporator Condenser Evaporator Condenser Only Only...
Page 61 Table 16 — Economizer Weight DRY WEIGHT REFRIGERANT OPERATION DRY WEIGHT REFRIGERANT OPERATION FRAME SIZE (lb)* WEIGHT (lb) WEIGHT (lb) (kg)* WEIGHT (kg) WEIGHT (kg) XRC (fr 5 HX) 1019 1229 XRC (fr 6,7 HX) 1252 1502 1054 1337 1589 1949 2749 3395...
Page 62 Table 18 — 19XRV Additional Data for Marine Waterboxes (19XR6/7)* ENGLISH (lb) SI (kg) HEAT EXCHANGER COUPLING TYPE Rigging Weight Water Weight Rigging Weight Water Weight FRAME, PASS psig Cooler Condenser Cooler Condenser Cooler Condenser Cooler Condenser Victaulic 2,794 2,582 1267 1171 SIZE 6,...
Page 63 (compressor weight column), stator, rotor, and end bell included. Applicable to standard compressors only. For high lift com- cover weights. pressors, contact Carrier Chiller Marketing for weights. † See Model Number Nomenclature. †† Stator weight includes the stator and shell.
Page 64 (compressor weight column), stator, rotor, and end bell included. Applicable to standard compressors only. For high lift com- cover weights. pressors, contact Carrier Chiller Marketing for weights. † See Model Number Nomenclature. †† Stator weight includes the stator and shell.
Page 65 (compressor weight column), stator, rotor, and end bell included. Applicable to standard compressors only. For high lift com- cover weights. pressors, contact Carrier Chiller Marketing for weights. † See Model Number Nomenclature. †† Stator weight includes the stator and shell.
Page 66 (compressor weight column), stator, rotor, and end bell included. Applicable to standard compressors only. For high lift com- cover weights. pressors, contact Carrier Chiller Marketing for weights. † See Model Number Nomenclature. †† Stator weight includes the stator and shell.
Page 67 Table 23 — 19XR,XRC Compressor and Motor Weights*— Standard and High-Efficiency Motors Compressor Frame Size C† ENGLISH 50Hz 60Hz 50Hz 60Hz Motor Compressor Compressor Stator Rotor Stator Rotor Stator Rotor Stator Rotor Code Weight** Cover Weight** Cover Weight†† Weight Weight†† Weight Weight††...
Page 68 Table 24 — 19XR,XRV Compressor and Motor Weights*— Standard and High-Efficiency Motors Compressor Frame Size E† ENGLISH 60 Hz 50 Hz 60 Hz 50 Hz End Bell End Bell MOTOR Compressor Compressor Cover Cover Stator Rotor Stator Rotor Stator Rotor Stator Rotor CODE...
Page 69 (compressor weight column), stator, rotor, and end bell included. Applicable to standard compressors only. For high lift com- cover weights. pressors, contact Carrier Chiller Marketing for weights. † See Model Number Nomenclature. †† Stator weight includes the stator and shell.
Page 70 Table 25 — 19XR Compressor and Motor Weights* — High-Efficiency Motors Two-Stage Compressor Frame Size 6, 60 Hz ENGLISH STATOR AND ROTOR AND END BELL STATOR AND ROTOR AND END BELL MOTOR COMPRESSOR COMPRESSOR HOUSING SHAFT COVER HOUSING SHAFT COVER CODE WEIGHT†...
Page 71 Table 25 — 19XR Compressor and Motor Weights* — High-Efficiency Motors Two-Stage Compressor Frame Size 6, 60 Hz (cont) ENGLISH STATOR AND ROTOR AND END BELL STATOR AND ROTOR AND END BELL MOTOR COMPRESSOR COMPRESSOR HOUSING SHAFT COVER HOUSING SHAFT COVER CODE WEIGHT†...
Page 72 Table 26 — 19XR Compressor and Motor Weights* — High-Efficiency Motors Two-Stage Compressor Frame Size 6, 50 Hz ENGLISH STATOR AND ROTOR END BELL STATOR AND ROTOR END BELL MOTOR COMPRESSOR COMPRESSOR HOUSING AND SHAFT COVER HOUSING AND SHAFT COVER CODE WEIGHT†...
Page 73 Table 27 — 19XR Compressor and Motor Weights* — High-Efficiency Motors Two-Stage Compressor Frame Size 7, 60 Hz ENGLISH MOTOR STATOR AND ROTOR AND END BELL STATOR AND ROTOR AND END BELL COMPRESSOR COMPRESSOR CODE HOUSING SHAFT COVER HOUSING SHAFT COVER WEIGHT†...
Page 74 Table 28 — 19XR Compressor and Motor Weights* — High-Efficiency Motors Two-Stage Compressor Frame Size 7, 50 Hz ENGLISH MOTOR STATOR AND ROTOR AND END BELL STATOR AND ROTOR AND END BELL COMPRESSOR COMPRESSOR CODE HOUSING SHAFT COVER HOUSING SHAFT COVER WEIGHT†...
Page 75 Table 29 — 19XR Waterbox Cover Weights Cooler Frames 2, 3 ENGLISH (LB) METRIC (KG) COOLER COOLER WATERBOX DESCRIPTION FRAME 2 FRAME 3 FRAME 2 FRAME 3 NOZZLES FLANGED NOZZLES FLANGED NOZZLES FLANGED NOZZLES FLANGED NIH, 1 Pass Cover, 150 psig (1034 kPa) NIH, 2 Pass Cover, 150 psig (1034 kPa) NIH, 3 Pass Cover, 150 psig (1034 kPa) MWB End Cover, 150 psig (1034 kPa)
Page 76 Table 31 — 19XR Waterbox Cover Weights Cooler Frames 4, 5 ENGLISH (LB) METRIC (KG) COOLER COOLER WATERBOX DESCRIPTION FRAME 4 FRAME 5 FRAME 4 FRAME 5 NOZZLES FLANGED NOZZLES FLANGED NOZZLES FLANGED NOZZLES FLANGED NIH, 1 Pass Cover, 150 psig (1034 kPa) NIH, 2 Pass Cover, 150 psig (1034 kPa) NIH, 3 Pass Cover, 150 psig (1034 kPa) MWB End Cover, 150 psig (1034 kPa)
Page 77 Table 33 — 19XR Waterbox Cover Weights Cooler Frames 6, 7 ENGLISH (LB) METRIC (KG) COOLER COOLER WATERBOX DESCRIPTION FRAME 6 FRAME 7 FRAME 6 FRAME 7 NOZZLES FLANGED NOZZLES FLANGED NOZZLES FLANGED NOZZLES FLANGED NIH, 1 Pass Cover, 150 psig (1034 kPa) NIH, 2 Pass Cover, 150 psig (1034 kPa) NIH, 3 Pass Cover, 150 psig (1034 kPa) 1250...
Page 78 Table 35 — 19XR Waterbox Cover Weights Cooler Frame 8 ENGLISH (LB) METRIC (KG) COOLER COOLER WATERBOX DESCRIPTION FRAME 8 FRAME 8 STD NOZZLES FLANGED STD NOZZLES FLANGED NIH, 1 Pass Cover, 150 psig (1034 kPa) NIH, 2 Pass Cover, 150 psig (1034 kPa) NIH, 3 Pass Cover, 150 psig (1034 kPa) 1629 1687...
Page 79 Table 37 — 19XR Waterbox Cover Weights, Two-Stage Compressor Frame 6 Cooler Frame A ENGLISH (LB) METRIC (KG) COOLER COOLER WATERBOX DESCRIPTION PASSES FRAME A FRAME A STANDARD STANDARD FLANGED FLANGED NOZZLES NOZZLES Dished Head, 150 psig 1006 1171 MWB End Cover, 150 psig MWB End Cover (ASME), 300 psig 2460 2460...
Page 80 Table 39 — 19XR Waterbox Cover Weights, Two-Stage Compressor Frame 7 Cooler Frames B, C ENGLISH (LB) METRIC (KG) COOLER COOLER WATERBOX DESCRIPTION PASSES FRAME B FRAME C FRAME B FRAME C FLANGED FLANGED FLANGED FLANGED NOZZLES NOZZLES NOZZLES NOZZLES Dished Head, 150 psig (1034 kPa) 1380 1545...
Page 81 Table 41 — 19XR2-E Component Weights FRAME 2 FRAME 3 FRAME 4 FRAME 5 FRAME C FRAME E COMPRESSOR* COMPRESSOR* COMPRESSOR* COMPRESSOR* COMPRESSOR COMPRESSOR COMPONENT SUCTION ELBOW DISCHARGE ELBOW CONTROL PANEL† OPTIONAL COOLER INLET ISOLATION VALVE OPTIONAL DISCHARGE ISOLATION VALVE STD TIER VFD —...
Page 82 High Speed Journal-Gear End .0050/.0040 .0048/.0038 .0062/.0052 Depends on impeller size, contact your Carrier Service Representa- removed) and the bearing temperature sensor must be removed from the high speed shaft and bearing assembly before the high speed tive for more information.
Page 83 THRUST THRUST a19-1637 a19-1636 VIEW A1 VIEW A2 LOW SPEED SHAFT THRUST DISK LOW SPEED SHAFT THRUST DISK FRAME 2 COMPRESSORS FRAME 3, 4, AND 5 COMPRESSORS NOTE 5 THRUST IMPELLER SHIMMING TO BE DETERMINED AT ASSEMBLY SEE VIEW C a19-1639 VIEW B —...
Page 84 +0.0007 -0.0007 0.0050 0.025 0.0020 0.005 +0.0007 -0.0007 THRUST 0.0011 0.0013 INTERFERENCE 0.0011 a19-1640 0.0013 INTERFERENCE 0.0012 0.0004 VIEW B — HIGH SPEED SHAFT WITH ROLLING ELEMENT BEARINGS a19-1641 VIEW C — HIGH SPEED SHAFT RING SEAL Fig. 53 — Compressor Fits and Clearances — Single-Stage Compressors (cont)
Page 85 Table 44 — 19XR Compressor Frame C, E Fits and Clearances COMPRESSOR FRAME C FRAME E ITEM CODE C21-C09 E21-E69 DESCRIPTION ROLLING ELEMENT BEARINGS ROLLING ELEMENT BEARINGS Low Speed Journal - Gear End 0.0055/0.0043 0.0069/0.0059 Low Speed Journal - Motor End 0.0053/0.0043 0.0065/0.0055 Low Speed Labyrinth to Thrust Disk...
Page 86 –0.0007-0.0007 [0/017-0.017] THRUST 0.003-0.0011 [0.008-0.027] Interference fit VIEW A2 VIEW D LOW SPEED SHAFT THRUST DISK REAR, HIGH SPEED SHAFT BEARING 0.02 - 0.024 [0.50 - 0.60] 0.00079 - 0.0007 [0.020 - 0.018] –0.0014 - 0.0000 [-0.035 - 0.000] 0.012 - 0.016 [0.31 - 0.40] –0.0014 - 0.000 [–0.035 - 0.000]...
Page 87 Table 45 — 19XR Two-stage Compressor Frames 6 and 7 Fits and Clearances COMPRESSOR ITEM FRAME 6 (in.) FRAME 6 (mm) FRAME 7 (in.) FRAME 7 (mm) DESCRIPTION Low Speed Journal — Compressor End 0.006/0.007 0.15/0.18 0.006/0.008 0.15/0.19 Low Speed Journal —Motor End 0.004/0.005 0.10/0.11 0.004/0.006...
Page 88 ITEM N ITEM O SECTION B-B SEE DETAIL E ITEM M ITEM F ITEM E LEGEND — 1st Stage Eye Labyrinth — 1st Stage Impeller Shim a19-2277 — Intake Wall ITEM K — 2nd Stage Eye Labyrinth — Diaphragm ITEM L —...
Page 89 ITEM H ITEM G a19-2220 DETAIL C HIGH SPEED BEARING DETAIL D ITEM B MOTOR END LOW SPEED BEARING MOTOR END a19-2279 ITEM J a19-2280 DETAIL E HIGH SPEED BEARING COMPRESSOR END (XR6 SHOWN) Fig. 55 — Compressor Fits and Clearances — Two-Stage Compressor, Frame Sizes 6 and 7 (cont)
Page 90 CAUTION CAUTION USE COPPER CONDUCTORS ONLY USE COPPER CONDUCTORS ONLY UTILISEZ DES CONDUCTEURS EN CUIVRE SEULMENT UTILISEZ DES CONDUCTEURS EN CUIVRE SEULMENT ALWAYS USE 2 WRENCHES TO TIGHTEN ALWAYS USE 2 WRENCHES TO TIGHTEN • TERM INSULATOR TO MOTOR – 15-35 ft. lb. •...
Page 91 CAUTION USE COPPER CONDUCTORS ONLY UTILISEZ DES CONDUCTEURS EN CUIVRE SEULMENT ALWAYS USE 2 WRENCHES TO TIGHTEN • TERM INSULATOR TO MOTOR – 15-35 ft. lb. • BRASS NUT TO TERM INSULATOR – 3 ft. lb. max • ADAPTOR TO TERM STUD – 20-35 ft. lb. •...
Page 92 Fig. 58 — 19XR2-E Control Panel 2IOB AND 2TB 1IOB AND 1TB OPTIONAL MODEM OPTIONAL ROUTER OPTIONAL 4IOB AND 4TB CONTROLS 3IOB AND 3TB CIRCUIT BREAKER Fig. 59 — 19XR2-E Control Panel, IOB Layer...
Page 93 OPTION FOR 19XRC 230V T1 AND T2 OUTPUT ARE 24 VAC GUIDE VANE CONTROL TRANSFORMERS ACTUATOR OPTIONAL EC/HGBP LOW VOLTAGE CONTROL CONTROL WIRING OIL HEATER (1C) CONTACTOR OIL PUMP (2C) CONTACTOR Fig. 60 — 19XR2-E Power Panel 7TB IN HMI PANEL FOR CUSTOMER COMMUNICATION CCN CONNECTION...
Page 94 Fig. 62 — 19XR6-7 Control Panel, IOB Layer Fig. 63 — 19XR6-7 Control Panel, Bottom Layer...
Page 95 — Oil Heater Contactor Mechanically Connected — Oil Pump Contactor — EC Valve Solenoid Open Relay 1-4IOB — Carrier Input Output Board 1-4 1-4TB — Terminal Block 1-4 Power Panel Terminal Block — Chiller Alert Relay — Chiller Alarm Relay...
Page 96 TO 2IOB 24 VAC FROM DRAWING 19XR05044701 REV H Fig. 64 — 19XR2-E Chiller Control Schematic...
Page 97 TO EC VALVE TO COMP’R FROM 1IOB FROM DRAWING 19XR05044701 REV H (OPTION) OIL HEATER Fig. 64 — 19XR2-E Chiller Control Schematic (cont)
Page 98 TO 4IOB 24 VAC TO 4IOB 24 VAC TO 4TB FROM DRAWING 19XR05044701 REV H Fig. 64 — 19XR2-E Chiller Control Schematic (cont)
Page 99 FROM 3IOB FROM 3IOB FROM 3IOB FROM 3IOB FROM DRAWING 19XR05044701 REV H Fig. 64 — 19XR2-E Chiller Control Schematic (cont)
Page 100 To GV L1, L2 (XRC only) To GV L1, L2 (XRC only) To 2IOB J12-10 To 2IOB J12-7 To 2IOB J12-2 * Wiring shown from HMI J10 to A, C, B in power panel is for Benshaw Unit Mount Starters only. For units with ISM, the A, C, B in the power panel is connected to LEN bus (+, -, G).
Page 101 To GV L1, L2 (XRC only) To GV L1, L2 (XRC only) To 2IOB J12-10 To 2IOB J12-7 To 2IOB J12-2 FROM DRAWING 19XR05044701 REV H Fig. 66 — 19XR2-E Chiller Control Schematic for Unit Mount VFD Chiller...
Page 102 Fig. 67 — 19XR6-7 Controls Diagram...
Page 103 Fig. 68 — 19XR6-7 Chiller Control Schematic...
Page 104 Fig. 68 — 19XR6-7 Chiller Control Schematic (cont)
Page 105 Fig. 68 — 19XR6-7 Chiller Control Schematic (cont)
Page 106 Fig. 68 — 19XR6-7 Chiller Control Schematic (cont)
Page 107 Fig. 69 — 19XR6-7 Starter Wiring...
Page 108 LEGEND FOR Fig. 67-69 Control Abbreviations — Fig. 67-69 Wiring Codes — Fig. 67-69 — Oil Heater Contactor — Chiller Alert — Oil Pump Contactor — Chiller Alarm — Micro Circuit Breaker, Control Box AUTO_DEM — Demand Limit Input — Micro Circuit Breaker, HMI AUTO_RES —...
Page 109: Appendix A - Pic 6 Screen And Table Structure
APPENDIX A — PIC 6 SCREEN AND TABLE STRUCTURE Home Synoptic Main Menu Login / Logout Screen Confirm Stop Choose operating mode Alarm Menu Main Menu Alarm Menu General Parameters Temperatures Pressures Reset Alarms Inputs Status Run Times Modes Current Alarms Hydraulic Status Outputs Status Configuration Menu...
Page 110 APPENDIX A — PIC 6 SCREEN AND TABLE STRUCTURE (cont) Main Menu Description ICON DISPLAYED TEXT* ACCESS ASSOCIATED TABLE General Parameters GENUNIT Temperatures TEMP Pressures PRESSURE Inputs Status INPUTS Outputs Status OUTPUTS Hydraulic Status HYDRLIC Run Times RUNTIME Modes MODES Trending TRENDING Setpoint...
Page 111: Appendix B - Ccn Communication Wiring For Multiple Chillers (Typical)
APPENDIX B — CCN COMMUNICATION WIRING FOR MULTIPLE CHILLERS (TYPICAL) DRAIN WIRE BLACK (G) WHITE (–) RED (+) NOTE: Field-supplied terminal strip must be located in control panel. a19-2133 19XR6-7 shown (HMI control box) - for 19XR2-E the CCN connection is located in the control panel (see below —...
Page 112: Appendix C - Maintenance Summary
APPENDIX C — MAINTENANCE SUMMARY AND LOG SHEETS 19XR Maintenance Interval Requirements WEEKLY COMPRESSOR Check Oil Level. CONTROLS Review PIC 6 Alarm/Alert History. COOLER None. STARTER None. CONDENSER None. OIL RECLAIM None. MONTHLY COMPRESSOR None. CONTROLS Perform an Automated Controls test. COOLER STARTER None.
Page 113 APPENDIX C — MAINTENANCE SUMMARY AND LOG SHEETS (cont) 19XR Monthly Maintenance Log MONTH DATE OPERATOR UNIT SECTION ACTION UNIT ENTRY Change Oil Charge yes/no Change Oil Filter yes/no Send Oil Sample Out for Analysis yes/no COMPRESSOR Leak Test Inspect Compressor Rotors yes/no Bearing Inspection yes/no...
Page 114 APPENDIX C — MAINTENANCE SUMMARY AND LOG SHEETS (cont) 19XR Seasonal Shutdown Log MONTH DATE OPERATOR UNIT SECTION ACTION ENTRY Isolate and Drain Waterbox COOLER Remove Waterbox Cover from One End Use Compressed Air to Clean Tubes Isolate and Drain Waterbox CONDENSER Remove Waterbox Cover from One End Use Compressed Air to Clean Tubes...
Page 115: Index
INDEX Abbreviations and explanations, Motor and oil cooling cycle, Starter Bearing and gear maintenance, Motor rotation, checking, Free-standing, description, Bearings, Oil changes, Mechanical, checking, Bolt torque requirements, Oil charge, Starting equipment, 16, 50 Chiller Oil circuit valves, opening, Start-Up Components, Oil filter, changing, Accidental, preventing, 8-10...
Page 116 © 2021 Carrier Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. Catalog No. 04-53190076-01 Printed in U.S.A. Form 19XR-CLT-18SS Rev. A Pg 116 12-21 Replaces: 19XR-CLT-17SS...
Page 117: Initial Start-Up Checklist
Voltage __________ Hertz ________ REFRIGERANT: Type: Charge CARRIER OBLIGATIONS: Assemble....  Leak Test ....Yes ...
Page 118 CHECK OIL LEVEL AND RECORD: ADD OIL: Yes   Amount: 1/2 Top sight glass 1/2 Bottom sight glass RECORD PRESSURE DROPS: Cooler Condenser CHARGE REFRIGERANT: Initial Charge Final Charge After Trim INSPECT WIRING AND RECORD ELECTRICAL DATA: RATINGS: Motor Voltage Motor RLA Chiller LRA Rating Actual Line Voltages: Starter/VFD...
Page 119 Yes  No  NOTE: This can be accomplished through BMS interlock with Carrier controls (typically via BACnet or Modbus) or hardwire connections to pumps. Chiller MUST maintain pump control for freeze protection purposes. If answer to above is "No" the customer must sign off that this is not installed and a copy must be kept with the startup paperwork since this can result in loss of warranty coverage.
Page 120 19XR PIC 6 SET POINT TABLE CONFIGURATION SHEET DESCRIPTION RANGE UNITS VALUE Cooling ECW set point 15.0 to 120.0 °F Cooling LCW set point 10.0 to 120.0 °F Heating ECDW set point 63.0 to 150.0 °F Heating LCDW set point 63.0 to 150.0 °F Ice Build set point...
Page 121 19XR PIC 6 ISM CONFIGURATION TABLE (CONF_ISM) CONFIGURATION SHEET (Must be configured for all fixed speed machines with ISM, Benshaw MX3, freestanding VFD) DESCRIPTION RANGE UNITS DEFAULT VALUE Communication Timeout 0 to 255 Starter Type 0 = Full Volt 1 = Reduced Volt 0 to 3 2 = Solid State 3 = FS VFD Single Cycle Dropout...
Page 122 19XR PIC 6 OPTION CONFIGURATION TABLE (CONF_OPT) CONFIGURATION SHEET DESCRIPTION RANGE UNITS DEFAULT VALUE CONF_OPT DSABLE/ENABLE ENABLE Auto Restart DSABLE/ENABLE DSABLE Swift Restart Option DSABLE/ENABLE ENABLE Gas Torque Factor 0.25 to 3 1.00 Guide Vane/SRD Factor 0.7 to 1.2 0.95 Power Recovery Timeout 0 to 60 15.0...
Page 123 19XR PIC 6 SRD TABLE CONFIGURATION SHEET DESCRIPTION RANGE UNITS DEFAULT VALUE Diffuser Option DSABLE/ENABLE DSABLE SRD IGV Offset Select 1 to 5 Low Lift Profile Select 1 to 5 Diffuser Full Span mA 15.0 to 22.0 18.0 GV 1 Pos @ 25% Load 0.0 to 83.0 GV 1 Pos @ 50% Load 0.0 to 83.0...
Page 124 19XR PIC 6 SERVICE PARAMETERS TABLE CONFIGURATION SHEET DESCRIPTION RANGE UNITS DEFAULT VALUE Atmospheric Pressure 8 to 15 14.5 GV1 Travel Limit 30 to 100 GV1 Closure at Startup 0 to 40 Controlled Fluid DB 0.5 to 2.0 Derivative EWT Gain 1.0 to 3.0 Proportional Dec Band 2.0 to 10.0...
Page 125 19XR PIC 6 CONF_MS MASTER SLAVE TABLE CONFIGURATION SHEET DESCRIPTION RANGE UNITS DEFAULT VALUE Slave Address 1 to 236 Master/Slave Select 0 = Disable 0 to 2 1 = Master 2 = Slave Chiller Connection Type 0 = Parallel 0 to 1 1 = Series Middle Sensor Option YES/NO...
Page 126 19XR PIC 6 CFGSURGE SURGE CORRECTION CONFIG TABLE CONFIGURATION SHEET DESCRIPTION RANGE UNITS DEFAULT VALUE Surge Line Configuration 0 to 1 0=PR, 1=Delta T IGV1 Pos Configuration 0 to 1 0-Degree, 1=Percentage Surge Delta Tsmax 0.0 to 150.0 °F 70.0 Surge Delta Tsmin 0.0 to 150.0 °F...
Page 127 DISPLAY AND ALARM SHUTDOWN STATE RECORD SHEET PRIMARY MESSAGE: DATE: TIME: SECONDARY MESSAGE: COMPRESSOR ONTIME: CHW OUT CHW IN EVAP REF CDW IN COND REF CDW OUT AMPS % OILPRESS OIL TEMP COMMUNICATION MESSAGE DISPLAY AND ALARM SHUTDOWN STATE RECORD SHEET PRIMARY MESSAGE: DATE: TIME:...
Page 128 © 2021 Carrier Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. Catalog No. 04-53190076-01 Printed in U.S.A. Form 19XR-CLT-18SS Rev. A Pg CL-12 12-21 Replaces: 19XR-CLT-17SS...

Carrier AquaEdge 19XR Start-Up, Operation And Maintenance Instructions Manual

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