Introduction - Carrier AquaEdge 19XRV series Operation, Maintenance And Installation Manual

• AUXILIARY EQUIPMENT
• DESCRIBE CHILLER CYCLES
• REVIEW MAINTENANCE
• SAFETY DEVICES AND PROCEDURES
• CHECK OPERATOR KNOWLEDGE
• REVIEW THE START-UP, OPERATION, AND
MAINTENANCE MANUAL
OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . 81-83
Operator Duties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Prepare the Chiller for Start-Up. . . . . . . . . . . . . . . . . . 81
To Start the Chiller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Check the Running System . . . . . . . . . . . . . . . . . . . . . 81
To Stop the Chiller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
After Limited Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . 82
Preparation for Extended Shutdown. . . . . . . . . . . . . 82
After Extended Shutdown . . . . . . . . . . . . . . . . . . . . . . . 82
Cold Weather Operation . . . . . . . . . . . . . . . . . . . . . . . . . 82
Manual Guide Vane Operation . . . . . . . . . . . . . . . . . . . 82
Refrigeration Log. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
PUMPOUT AND REFRIGERANT TRANSFER
PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84-87
Preparation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Operating the Optional Pumpout Unit . . . . . . . . . . . 84
• POSITIVE PRESSURE CHILLERS WITH
STORAGE TANKS
• CHILLERS WITH ISOLATION VALVES
• DISTILLING THE REFRIGERANT
GENERAL MAINTENANCE . . . . . . . . . . . . . . . . . . . 87-88
Refrigerant Properties. . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Adding Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Removing Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Adjusting the Refrigerant Charge . . . . . . . . . . . . . . . 88
Refrigerant Leak Testing . . . . . . . . . . . . . . . . . . . . . . . . 88
Leak Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Test After Service, Repair, or Major Leak . . . . . . . . 88
• TESTING WITH REFRIGERANT TRACER
• TESTING WITHOUT REFRIGERANT TRACER
• TO PRESSURIZE WITH DRY NITROGEN
Repair the Leak, Retest, and Apply
Standing Vacuum Test . . . . . . . . . . . . . . . . . . . . . . . . 88
Checking Guide Vane Linkage . . . . . . . . . . . . . . . . . . 88
Trim Refrigerant Charge. . . . . . . . . . . . . . . . . . . . . . . . . 88
WEEKLY MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . 88
Check the Lubrication System . . . . . . . . . . . . . . . . . . 88
SCHEDULED MAINTENANCE . . . . . . . . . . . . . . . . 89-93
Service Ontime . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Inspect the Control Panel . . . . . . . . . . . . . . . . . . . . . . . 89
Check Safety and Operating Controls
Monthly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Changing Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Oil Specification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Oil Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
• TO CHANGE THE OIL
Refrigerant Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Oil Reclaim Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
VFD Refrigerant Strainer . . . . . . . . . . . . . . . . . . . . . . . . 90
Inspect Refrigerant Float System . . . . . . . . . . . . . . . . 90
Inspect Relief Valves and Piping . . . . . . . . . . . . . . . . 91
Compressor Bearing and Gear
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Inspect the Heat Exchanger Tubes
and Flow Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
• COOLER AND OPTIONAL FLOW DEVICES
• CONDENSER AND OPTIONAL FLOW DEVICES
Water Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Water Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Inspect the VFD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Recalibrate Pressure Transducers . . . . . . . . . . . . . . 92
CONTENTS (cont)
Page
Optional Pumpout System Maintenance. . . . . . . . . 92
• OPTIONAL PUMPOUT COMPRESSOR OIL
CHARGE
• OPTIONAL PUMPOUT SAFETY CONTROL
SETTINGS
Ordering Replacement Chiller Parts . . . . . . . . . . . . . 92
TROUBLESHOOTING GUIDE . . . . . . . . . . . . . . . . 93-166
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Checking Display Messages . . . . . . . . . . . . . . . . . . . . 93
Checking Temperature Sensors . . . . . . . . . . . . . . . . . 93
• RESISTANCE CHECK
• VOLTAGE DROP
• CHECK SENSOR ACCURACY
• DUAL TEMPERATURE SENSORS
Checking Pressure Transducers . . . . . . . . . . . . . . . . 93
• COOLER CONDENSER PRESSURE TRANSDUCER
AND OPTIONAL WATERSIDE FLOW DEVICE
CALIBRATION
• TRANSDUCER REPLACEMENT
Control Algorithms Checkout Procedure . . . . . . . . 94
Control Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Control Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
• RED LED (Labeled as STAT)
• GREEN LED (Labeled as COM)
Notes on Module Operation . . . . . . . . . . . . . . . . . . . . 113
Chiller Control Module (CCM) . . . . . . . . . . . . . . . . . . 113
• INPUTS
• OUTPUTS
Replacing Defective Processor Modules . . . . . . . 114
• INSTALLATION
Gateway Status LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . 115
• DRIVE STATUS INDICATOR
• MS STATUS INDICATOR
• NET A STATUS INDICATOR
• NET B STATUS INDICATOR
End of Life and Equipment Disposal . . . . . . . . . . . 116
Physical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
APPENDIX A - LIQUIFLO™ 2 ICVC
PARAMETER INDEX . . . . . . . . . . . . . . . . . . . . . 167-174
APPENDIX B - LEAD/LAG WIRING . . . . . . . . 175,176
APPENDIX C - MAINTENANCE SUMMARY
AND LOG SHEETS . . . . . . . . . . . . . . . . . . . . . . . 177-180
APPENDIX D - BACNET
COMMUNICATION OPTION. . . . . . . . . . . . . . . 181-187
INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
INITIAL START-UP CHECKLIST FOR
19XRV HERMETIC CENTRIFUGAL
LIQUID CHILLER . . . . . . . . . . . . . . . . . . . .CL-1 to CL-12
Prior to initial start-up of the 19XRV unit, those involved in
the start-up, operation, and maintenance should be thoroughly
familiar with these instructions and other necessary job data.
This book is outlined to familiarize those involved in the
start-up, operation, and maintenance of the unit with the con-
trol system before performing start-up procedures. Procedures
in this manual are arranged in the sequence required for proper
chiller start-up and operation.
4

INTRODUCTION

Page