Weekly Maintenance - Carrier 23xl Start-Up, Operation And Maintenance Instructions Manual

WEEKLY MAINTENANCE

Check the Lubrication System —
el on the sight glasses and observe the level each week while
the chiller is shut down.
If the level goes below the sight glass, the oil reclaim sys-
tem will need to be checked for proper operation. If additional
oil is required, add it through the oil charging valve (Fig. 2A
and 2B). A hand pump is required for adding oil against refrig-
erant pressure. The oil charge is approximately 4.2 gal (15.9 L)
for TC frame 1 and 2 chillers and 10 gal (38 L) for TD frame 4
chillers. The oil must meet Carrier's specifications for the
23XL chillers. Refer to Changing Oil and Oil Filter section.
Any oil that is added should be logged by noting the amount
and date in Fig. 37 on page 68. Any oil that is added due to oil
loss not related to service will eventually return to the sump. It
must be removed when the level is above the sight glass.
NOTE: TD frame 4 chillers do not use an oil heater.
On TC frame 1 and 2 chillers, a 500-watt oil heater is con-
trolled by the PIC II to maintain oil temperature above 140 F
(60 C) [120 F (48.9 C)] or refrigerant temperature plus 35 F
(19 C) when the compressor is off (see the Controls section on
page 13). The CVC Status-COMPRESS table displays whether
the heater is energized or not. If the PIC II shows that the heater
is energized, but the sump is not heating up, the power to the oil
heater may be off or the oil level may be too low. Check the oil
level, the oil heater contactor voltage, and oil heater resistance.
The PIC II will not permit compressor start-up if the oil
temperature is too low (TC fame 1 and 2 chillers). The control
will continue with start-up only after the temperature is within
limits.
SCHEDULED MAINTENANCE
Establish a regular maintenance schedule based on the actu-
al chiller requirements such as chiller load, run hours, and wa-
ter quality. The time intervals listed in this section are offered
as guides to service only.
Service Ontime —
The CVC will display a SERVICE
ONTIME value on the MAINSTAT table. This value should be
reset to zero by the service person or the operator each time
major service work is completed so that time between service
can be seen.
Inspect the Control Panel —
ly limited to general cleaning and tightening of connections.
Vacuum the cabinet to eliminate dust build-up. In the event of
chiller control malfunctions, refer to the Troubleshooting
Guide section for control checks and adjustments.
Be sure power to the control panel is off when cleaning and
tightening connections inside the control panel.
Check Safety and
Monthly —
To ensure chiller protection, the Automated
Control Test in the service menu should be done at least once
per month. See Table 4 for safety control settings.
Changing Oil and Oil Filter —
across the filter has approached the OIL FILTER PRESS
ALERT value on the Equipment Service, Service1 table,
change oil filter as needed. Otherwise, change the oil filter on a
yearly basis.
Change the oil after the first year of operation. Then,
change the oil at least every three years, or as needed. Howev-
er, if a continuous oil monitoring system is present and/or a
Mark the oil lev-
Maintenance is general-
Operating Controls
If the pressure drop
yearly oil analysis is performed, the time between oil changes
may be extended. The 23XL TC frame 1 and 2 chillers use
approximately 4.2 gal (15.9 L) of oil. The 23XL TD frame 4
chillers use approximately 10 gal (38 L) of oil. See Oil Specifi-
cation section on page 74 for additional information.
This product is hygroscopic. Containers should remain
tightly sealed in a clean and dry environment to prevent
moisture absorption from the air.
TC FRAME 1 AND 2 CHILLERS — The 23XL oil sump
can be isolated to change the oil filter and oil while the refriger-
ant remains inside the chiller. Use the following procedure to
change the oil and oil filter (if required):
IMPORTANT: Remove oil from TC frame 1 and 2 chill-
ers before changing the oil filter. Refer to Fig. 2A and 3.
1. Make sure the compressor is off and the disconnect for
the compressor is open.
2. Open the control and oil heater circuit breaker in order
to turn off the power to the oil heater.
3. Close the 3 oil sump isolation valves. One isolation
valve is upstream and one isolation valve is down-
stream of the oil sump. The third isolation valve is in
the oil sump vent line.
Be sure the power to the oil heater is off when the oil sump
is isolated and full. If the oil heater remains energized,
over-pressurization of the oil sump could result in the fail-
ure of the oil solenoid valve, discharge of hot oil, and per-
sonal injury.
4. Connect an oil charging hose to the oil drain valve. See
Fig. 3. Place the other end of the oil charging hose in a
clean container suitable for used oil. A portion of the
oil drained from the sump should be used as an oil
sample and should be sent to a laboratory for proper
analysis. Do not contaminate this sample.
5. Slowly open the drain valve in order to drain the oil
from the sump.
The oil sump is at high pressure. Relieve pressure slowly.
6. Once the oil has been drained, place absorbent mate-
rial under the oil sump to catch any oil that may leak
out once the oil sump cover is opened. Continue with
Steps 7, 8, and 9 if a new oil filter is required. Proceed
to Step 10 if no oil filter change is required.
7. Remove the 6 bolts from the end of the oil sump and
remove the oil sump cover.
8. Remove the oil filter retaining spring. Remove and
properly discard the oil filter.
9. Insert a new oil filter. Seat the filter retaining spring
against the flange stop. Install the oil sump cover with
a new O-ring. Insert and tighten the 6 bolts that secure
the oil sump cover.
10. Evacuate the oil sump by placing a vacuum pump on
the drain valve. Follow normal evacuation procedures.
Shut off the drain valve when the oil sump has been
evacuated. Charge new oil through the drain valve.
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