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

Hermetic centrifugal liquid chillers 50/60 hz with pic ii controls and hfc-134a

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User manual (140 pages)

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SAFETY CONSIDERATIONS

with soap and water. If liquid refrigerant enters the eyes, IMME-

DIATELY FLUSH EYES with water and consult a physician.

NEVER APPLY an open ﬂame or live steam to a refrigerant

cylinder. Dangerous over pressure can result. When it is necessary

to heat refrigerant, use only warm (110 F [43 C]) water.

DO NOT REUSE disposable (nonreturnable) cylinders or attempt

to reﬁll them. It is DANGEROUS AND ILLEGAL. When cylinder

is emptied, evacuate remaining gas pressure, loosen the collar and

unscrew and discard the valve stem. DO NOT INCINERATE.

CHECK THE REFRIGERANT TYPE before adding refrigerant to

the chiller. The introduction of the wrong refrigerant can cause dam-

age or malfunction to this chiller.

Operation of this equipment with refrigerants other than those

cited herein should comply with ANSI/ASHRAE15 (latest edi-

tion). 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. Be sure pressure is at

0 psig (0 kPa) before breaking any refrigerant connection.

CAREFULLY INSPECT all relief devices, rupture discs, and other

relief devices AT LEAST ONCE A YEAR. If chiller operates in a

corrosive atmosphere, inspect the devices at more frequent

intervals.

DO NOT ATTEMPT TO REPAIR OR RECONDITION any relief

device when corrosion or build-up of foreign material (rust, dirt,

scale, etc.) is found within the valve body or mechanism. Replace

the device.

DO NOT install relief devices in series or backwards.

USE CARE when working near or in line with a compressed spring.

Sudden release of the spring can cause it and objects in its path to

act as projectiles.

DO NOT STEP on refrigerant lines. Broken lines can whip about

and release refrigerant, causing personal injury.

DO NOT climb over a chiller. Use platform, catwalk, or staging.

Follow safe practices when using ladders.

USE MECHANICAL EQUIPMENT (crane, hoist, etc.) to lift or

move inspection covers or other heavy components. Even if com-

ponents are light, use mechanical equipment when there is a risk of

slipping or losing your balance.

BE AWARE that certain automatic start arrangements CAN

ENGAGE THE STARTER, TOWER FAN, OR PUMPS. Open the

disconnect ahead of the starter, tower fans, or pumps.

USE only repair or replacement parts that meet the code require-

ments of the original equipment.

DO NOT VENT OR DRAIN waterboxes containing industrial brines,

liquid, gases, or semisolids without the permission of your process

control group.

DO NOT LOOSEN waterbox cover bolts until the waterbox has

been completely drained.

DOUBLE-CHECK that coupling nut wrenches, dial indicators, or

other items have been removed before rotating any shafts.

DO NOT LOOSEN a packing gland nut before checking that the

nut has a positive thread engagement.

PERIODICALLY INSPECT all valves, ﬁttings, and piping for cor-

rosion, rust, leaks, or damage.

PROVIDE A DRAIN connection in the vent line near each pres-

sure relief device to prevent a build-up of condensate or rain water.

Printed in U.S.A.

Form 19XR-3SS

19XR

50/60 Hz

Pg 1

6-98

Replaces: New

Table of Contents

Summary of Contents for Carrier 19XR

Page 1: Safety Considerations
ANSI/ASHRAE 15 (American cited herein should comply with ANSI/ASHRAE15 (latest edi- National Standards Institute/American Society of Heating, Refrig- tion). Contact Carrier for further information on use of this chiller eration, and Air Conditioning Engineers). The accumulation of with other refrigerants.
Page 2: Table Of Contents
Safety Controls ......33 Carrier Comfort Network Interface ..52 Shunt Trip (Option) .
Page 3 CONTENTS (cont) Page Page Power Up the Controls and After Extended Shutdown ....60 Check the Oil Heater ..... 53 Cold Weather Operation .
Page 4: Introduction
The chiller software part number of the 19XR unit is lo- his own expense, will be required to take whatever mea- sures may be required to correct the interference.
Page 5: Chiller Familiarization
• displays status of motor starter erant can remove heat from water ﬂowing through its inter- • provides access to other CCN (Carrier Comfort Network) nal tubes. devices Condenser — The condenser operates at a higher temperature/pressure than the cooler and has water ﬂowing...
Page 6: Front/Rear View
29 — Liquid Line Isolation Valve (Optional) 30 — Linear Float Valve Chamber 31 — Vessel Take-Apart Connector 32 — Discharge Isolation Valve (Optional) 33 — Pumpout Valve 34 — Condenser Pressure Transducer 29 28 27 REAR VIEW Fig. 2 — Typical 19XR Components...
Page 7: Factory-Mounted Starter (Optional)
[37 to 40 C]) when it is discharged from the compressor into Factory-Mounted Starter (Optional) — The starter the condenser. allows for the proper start and disconnect of electrical en- ergy for the compressor-motor, oil pump, oil heater, and con- Relatively cool (typically 65 to 90 F [18 to 32 C]) water trol panel.
Page 8: Lubrication Cycle
STARTING EQUIPMENT the CVC default screen. The oil pump discharges oil to the The 19XR requires a motor starter to operate the centrifu- oil ﬁlter assembly. This ﬁlter can be closed to permit gal hermetic compressor motor, the oil pump, and various removal of the ﬁlter without draining the entire oil system...
Page 9: Unit-Mounted Solid-State Starter
• power indication shock. This capability is summed up by the phrase ‘‘soft start- • proper phasing for rotation ing.’’ The solid-state starter is available as a 19XR option • start circuit energized (factory supplied and installed). The solid-state starters manu- •...
Page 10: Unit-Mounted Wye-Delta Starter
Unit-Mounted Wye-Delta Starter (Optional) — The 19XR chiller may be equipped with a wye-delta starter mounted on the unit. This starter is intended for use with low-voltage motors (under 600 v). It reduces the starting current inrush by connecting each phase of the motor windings into a wye conﬁguration.
Page 11 SENSOR CABLES COOLER PRESSURE CONNECTION CONDENSER CONDENSER CONDENSER COMPRESSOR MOTOR WINDING PRESSURE PRESSURE SCHRADER DISCHARGE TEMPERATURE CONNECTION CABLE FITTING (HIDDEN) ELBOW JOINTS CABLE TRANSDUCER TOP VIEW VIEW A — A (COMPRESSOR DETAIL) Fig. 7 — 19XR Controls and Sensor Locations...
Page 12: Chiller Visual Controller (Cvc)
The PIC II can interface with the Carrier Comfort Net- tower fan, spare alarm contacts, and the shunt trip. The ISM work (CCN) if desired. It can communicate with other monitors starter inputs such as line voltage, motor current, PIC I or PIC II equipped chillers and other CCN devices.
Page 13 Fig. 10 — Control Panel Fig. 11 — Power Panel...
Page 14: Cvc Operation And Menus
CVC Operation and Menus (Fig. 12-18) PRIMARY STATUS COMPRESSOR DATE TIME MESSAGE ONTIME SECONDARY GENERAL STATUS RUNNING TEMP CONTROL 01-01-95 11:48 • The CVC display automatically reverts to the default screen MESSAGE LEAVING CHILLED WATER 28.8 HOURS after 15 minutes if no softkey activity takes place and if CHW IN CHW OUT EVAP REF...
Page 15: To View Status
2. Press NEXT or PREVIOUS to highlight the desired • Press QUIT to leave the selected decision or ﬁeld with- out saving any changes. status table. The list of tables is: • MAINSTAT — Overall chiller status • STARTUP — Status required to perform startup of chiller •...
Page 16 CONTROL TEST CONTROL ALGORITHM STATUS EQUIPMENT CONFIGURATION ISM (STARTER) CONFIG DATA EQUIPMENT SERVICE TIME AND DATE ATTACH TO NETWORK DEVICE LOG OUT OF DEVICE CVC CONFIGURATION PREVIOUS SELECT EXIT NEXT SEE FIGURE 16 Fig. 15 — 19XR CVC Menu Structure...
Page 17: Alarms And Alerts
SELECT EXIT NEXT Select a Parameter SELECT NEXT PREVIOUS EXIT Modify a Parameter INCREASE ENTER (ANALOG VALUES) DECREASE QUIT DISABLE QUIT ENTER (DISCRETE VALUES) ENABLE ENTER (DISCRETE VALUES) QUIT CONTINUED ON NEXT PAGE Fig. 16 — 19XR Service Menu Structure...
Page 18 (last 2 digits of part number — English or S.I. Metric Units indicate software version) — Password LEGEND — Carrier Comfort Network — Chiller Visual Control — Integrated Starter Module PIC II — Product Integrated Control II Fig. 16 — 19XR Service Menu Structure (cont)
Page 19: Time Schedule Operation
For Discrete Points — Press START or STOP to se- 2. Press NEXT or PREVIOUS to highlight the de- lect the desired state. sired schedule. OCCPC01S — LOCAL Time Schedule OCCPC02S — ICE BUILD Time Schedule OCCPC03 — CCN Time Schedule Analog Points —...
Page 20: To View And Change Set Points
2. There are 5 set points on this screen: BASE DEMAND b. Press ENABLE to select days in the day-of-week LIMIT, LCW SETPOINT (leaving chilled water set point), ﬁelds. Press DISABLE to eliminate days from the ECW SETPOINT (entering chilled water set point), ICE period.
Page 21: Alarms And Alerts
— Milliamps erence CCN/BS documentation or use CCN/BS programs. For more — Pressure information, see the 19XR CCN literature. — Solid State — Temperature — Variable Frequency Drive —...
Page 22 Table 2 — CVC Display Data (cont) EXAMPLE 2 — MAINTSTAT DISPLAY SCREEN To access this display from the CVC default screen: 1. Press MENU 2. Press STATUS ( MAINSTAT will be highlighted). 3. Press SELECT . DESCRIPTION STATUS UNITS POINT Control Mode NOTE 1...
Page 23 Table 2 — CVC Display Data (cont) EXAMPLE 4 — COMPRESS DISPLAY SCREEN To access this display from the CVC default screen: 1. Press MENU 2. Press STATUS . 3. Scroll down to highlight COMPRESS . 4. Press SELECT . DESCRIPTION STATUS UNITS...
Page 24 Table 2 — CVC Display Data (cont) EXAMPLE 6 — POWER DISPLAY SCREEN To access this display from the CVC default screen: 1. Press MENU 2. Press STATUS . 3. Scroll down to highlight POWER . 4. Press SELECT . DESCRIPTION STATUS UNITS...
Page 25 Table 2 — CVC Display Data (cont) EXAMPLE 8 — SET POINT DISPLAY SCREEN To access this display from the CVC default screen: 1. Press MENU 2. Press SETPOINT (Base Demand Limit will be highlighted). 3. Press SELECT . DESCRIPTION STATUS UNITS POINT...
Page 26 Table 2 — CVC Display Data (cont) EXAMPLE 10 — OVERRIDE DISPLAY SCREEN To access this display from the CVC default screen: 1. Press MENU 2. Press SERVICE . 3. Scroll down to highlight CONTROL ALGORITHM STATUS . 4. Press SELECT . 5.
Page 27 Table 2 — CVC Display Data (cont) EXAMPLE 12 — ISM HIST DISPLAY SCREEN To access this display from the CVC default screen: 1. Press MENU 2. Press SERVICE . 3. Scroll down to highlight CONTROL ALGORITHM STATUS . 4. Press SELECT . 5.
Page 28 Table 2 — CVC Display Data (cont) EXAMPLE 14 — NET OPT DISPLAY SCREEN To access this display from the CVC default screen: 1. Press MENU 2. Press SERVICE . 3. Scroll down to highlight EQUIPMENT CONFIGURATION . 4. Press SELECT . 5.
Page 29 Table 2 — CVC Display Data (cont) EXAMPLE 16 — OPTIONS DISPLAY SCREEN To access this display from the CVC default screen: 1. Press MENU 2. Press SERVICE . 3. Scroll down to highlight EQUIPMENT SERVICE . 4. Press SELECT . 5.
Page 30 Table 2 — CVC Display Data (cont) EXAMPLE 18 — SETUP2 DISPLAY SCREEN To access this display from the CVC default screen: 1. Press MENU 2. Press SERVICE . 3. Scroll down to highlight EQUIPMENT SERVICE . 4. Press SELECT . 5.
Page 31 Table 2 — CVC Display Data (cont) EXAMPLE 20 — RAMP_DEM DISPLAY SCREEN To access this display from the CVC default screen: 1. Press MENU 2. Press SERVICE . 3. Scroll down to highlight EQUIPMENT SERVICE . 4. Press SELECT . 5.
Page 32: Pic Ii System Functions
(0.6° C) is the default setting. OCCUPANCY SCHEDULE — The chiller schedule, de- DIFFUSER CONTROL — On 19XR compressors equipped scribed in the Time Schedule Operation section (page 19), with a variable discharge diffuser, the PIC II adjusts the dif- determines when the chiller can run.
Page 33: Occupancy Schedule
Figure 17 shows a schedule for a typical office building • voltage imbalance with a 3-hour, off-peak, cool-down period from midnight • current imbalance to 3 a.m., following a weekend shutdown. Holiday periods • excessive motor acceleration time are in an unoccupied state 24 hours per day. The building •...
Page 34 Table 3 — Protective Safety Limits and Control Settings MONITORED PARAMETER LIMIT APPLICABLE COMMENTS TEMPERATURE SENSORS OUT OF –40 to 245 F (–40 to 118.3 C) Must be outside range for 2 seconds RANGE PRESSURE TRANSDUCERS OUT OF 0.06 to 0.98 Voltage Ratio Must be outside range for 3 seconds.
Page 35: Shunt Trip (Option)
If kilowatts is selected for the DEMAND LIMIT SOURCE, Shunt Trip (Option) — The function of the shunt trip the MOTOR RATED KILOWATTS must be entered (infor- option on the PIC II is to act as a safety trip. The shunt trip mation found on the chiller Requisition form).
Page 36: Oil Cooler
Table 4 — Capacity Overrides SECOND STAGE OVERRIDE FIRST STAGE SET POINT SET POINT TERMINATION OVERRIDE CAPACITY CONTROL View/Modify Default Conﬁgurable Value Value on CVC Screen Value Range Override HIGH CONDENSER 125 psig 90 to 165 psig Override SETUP1 Set Point PRESSURE (862 kPa) (620 to 1138 kPa)
Page 37: Condenser Freeze Prevention
energize to try to decrease the pressure. The pump will turn off when the condenser pressure is 3.5 psi (24.1 kPa) less than the pressure override or when the condenser re- The tower fan relay control is not a substitute for a frigerant temperature (CONDENSER REFRIG TEMP) is within condenser water temperature control.
Page 38: Demand Limit Control Option
The maximum T = (ECW) − (LCW) lift a particular impeller wheel can perform varies with the Fig. 19 — 19XR Hot Gas Bypass/Surge gas ﬂow across the impeller and the size of the wheel. Prevention with Default English Settings A surge condition occurs when the lift becomes so high the gas ﬂow across the impeller reverses.
Page 39: Surge Protection
CHILLER COMMUNICATION WIRING — Refer to the 2-chiller water system. A third chiller can be added to the chiller’s Installation Instructions, Carrier Comfort Network lead/lag system as a standby chiller to start up in case Interface section for information on chiller communication the lead or lag chiller in the system has shut down during wiring.
Page 40: Faulted Chiller Operation
running, the lead chiller monitors conditions and eval- start. If the lag chiller fails to start, the standby chiller, if uates whether the capacity has been reduced enough for the conﬁgured is started. lead chiller to sustain the system alone. If the capacity is Lag Chiller Shutdown Requirements —...
Page 41: Load Balancing
LOAD BALANCING — When the LOAD BALANCE • the chilled water temperature is less than the ice build set OPTION (see LEADLAG screen) is enabled, the lead chiller point and the remote contact inputs from an ice level in- sets the ACTIVE DEMAND LIMIT in the lag chiller to the dicator are open.
Page 42: Termination Of Ice Build
ATTACH softkey to upload the LOCAL device. • attach the CVC to any CCN device, if the chiller has been connected to a CCN network. This may include other PIC- The CVC for the 19XR will be uploaded and default screen controlled chillers. will display.
Page 43: Service Operation
HOLIDAY SCHEDULING (Fig. 22) — The time schedules Service Operation — An overview of the tables and may be conﬁgured for special operation during a holiday screens available for the SERVICE function is shown in period. When modifying a time period, the ‘‘H’’ at the end Fig.
Page 44: Start-Up/Shutdown/Recycle
WATER FLOW VERIFY TIME (operator-conﬁgured, default START-UP/SHUTDOWN/RECYCLE 5 minutes) expires to conﬁrm ﬂow. After ﬂow is veriﬁed, the SEQUENCE (Fig. 23) chilled water temperature is compared to CONTROL POINT Local Start-Up — Local start-up (or a manual start-up) plus 1/2 CHILLED WATER DEADBAND. If the temperature is less than or equal to this value, the PIC II turns off the is initiated by pressing the LOCAL menu softkey on the condenser pump relay and goes into a RECYCLE mode.
Page 45: Shutdown Sequence
Shutdown Sequence — Chilled Water Recycle Mode — Chiller shutdown begins if The chiller may cycle any of the following occurs: off and wait until the load increases to restart when the compressor is running in a lightly loaded condition. This •...
Page 46: Before Initial Start-Up
Figure 25 outlines the proper sequence and procedures for leak testing. 19XR chillers are shipped with the refrigerant contained in the condenser shell and the oil charge in the compressor. The cooler is shipped with a 15 psig (103 kPa) refrigerant charge.
Page 47 Fig. 25 — 19XR Leak Test Procedures...
Page 48: Leak Test Chiller
(see Transfer Refrig- rating contaminants from the refrigerant, Carrier recommends erant from Pumpout Storage Tank to Chiller section, the following leak test procedure. See Fig. 25 for an outline page 63).
Page 49 Fig. 26 — Typical Optional Pumpout System Piping Schematic with Storage Tank Fig. 27 — Typical Optional Pumpout System Piping Schematic without Storage Tank...
Page 50 Table 5A — HFC-134a Pressure — Table 5B — HFC-134a Pressure — Temperature (F) Temperature (C) TEMPERATURE, PRESSURE TEMPERATURE, PRESSURE GAGE (psig) (kPa) 6.50 -18.0 44.8 7.52 -16.7 51.9 8.60 -15.6 59.3 9.66 -14.4 66.6 10.79 -13.3 74.4 11.96 -12.2 82.5 13.17 -11.1...
Page 51: Chiller Dehydration
29.8 in. Hg vac, ref 30 in. bar. (0.1 psia)(–100.61 kPa) or The 19XR relief valves are set to relieve at the 185 psig a vacuum indicator reads 35 F (1.7 C). Operate the pump (1275 kPa) chiller design pressure.
Page 52: Carrier Comfort Network Interface
The overload trip inspect the contactors if this has occurred. amps must be 108% to 120% of the rated load amps. Carrier Comfort Network Interface — The Carrier 4. The starter for a centrifugal compressor motor must con-...
Page 53: Mechanical Starter
STARTER been conﬁrmed. As the 19XR unit is conﬁgured, all conﬁguration settings This equipment is at line voltage when AC power is should be written down. A log, such as the one shown on connected.
Page 54: Password
SERVICE menu will not be possible unless Refrigerant design refrigerant temperature. the CVC_PSWD menu on the STATUS screen is Trippoint accessed by a Carrier representative. Evaporator Flow SETUP1 — Enter 50% of design Delta P Cutout pressure drop to 0.5 psi (3.4 kPa).* Condenser Flow SETUP1 —...
Page 55: If Necessary
See Fig. 10. To peratures at this difference. Use the proper saturated pres- obtain proper settings for diffuser control, contact a Carrier sure and temperature for the particular refrigerant used. Engineering representative.
Page 56: Perform A Control Test
Table 6 — Control Test Menu Functions Perform a Control Test — Check the safety controls status by performing an automated control test. Access the TESTS TO BE CONTROL TEST table and select a test to be performed DEVICES TESTED PERFORMED function (Table 6).
Page 57: Chiller Equalization Without A
The standard 19XR chiller is shipped with the refrigerant already charged in the vessels. However, the 19XR may be ordered with a nitrogen holding charge of 15 psig (103 kPa). Whenever turning the discharge isolation valve, be Evacuate the nitrogen from the entire chiller, and charge the sure to reattach the valve locking device.
Page 58: Initial Start-Up
3. When the starter is energized and the motor begins to turn, Table 7 lists the 19XR chiller refrigerant charges for each check for clockwise motor rotation (Fig. 29). cooler and condenser code. Total refrigerant charge is the IF THE MOTOR ROTATION IS CLOCKWISE, allow the sum of the cooler and condenser charge.
Page 59: Initial Start-Up
REVIEW MAINTENANCE — Scheduled, routine, and Check Oil Pressure and Compressor Stop extended shutdowns, importance of a log sheet, importance 1. When the motor is at full speed, note the differential oil of water treatment and tube cleaning, and importance of main- pressure reading on the CVC default screen.
Page 60: To Stop The Chiller
Leave the oil charge in the chiller with the oil heater devices such as the Data Collection module and a Build- and controls energized to maintain the minimum oil reser- ing Supervisor. Contact a Carrier representative for more voir temperature. information.
Page 61 Date REFRIGERATION LOG CARRIER 19XR HERMETIC CENTRIFUGAL REFRIGERATION MACHINE Plant MACHINE MODEL NO. MACHINE SERIAL NO. REFRIGERANT TYPE DATE COOLER CONDENSER COMPRESSOR Refrigerant Water Refrigerant Water Motor OPER- Pressure Temp Pressure Temp ATOR REMARKS BEARING Temp TIME Press. Amperage INITIALS TEMP Press.
Page 62: Procedures
Pumpout Unit Terminal *Bimetal thermal protector imbedded in motor winding. Operating the Optional Pumpout Unit Fig. 31 — 19XR Pumpout Unit Wiring Schematic 1. Be sure that the suction and the discharge service valves on the optional pumpout compressor are open (back- seated) during operation.
Page 63: Procedures
TRANSFER REFRIGERANT FROM CHILLER TO Chillers with Storage Tanks — If the chiller has iso- PUMPOUT STORAGE TANK lation valves, leave them open for the following procedures. The letter ‘‘C’’ describes a closed valve. See Fig. 15, 16, 26, 1. Equalize refrigerant pressure. and 27.
Page 64: Transfer All Refrigerant To
2. Evacuate the refrigerant gas from the chiller condenser Chillers with Isolation Valves vessel. TRANSFER ALL REFRIGERANT TO CHILLER CON- a. Access the PUMPDOWN LOCKOUT function ac- DENSER VESSEL — For chillers with isolation valves, cessed from the CVC CONTROL TEST table to turn refrigerant can be stored in one chiller vessel or the other on the chiller water pumps.
Page 65: General Maintenance
Removing Refrigerant — If the optional pumpout sys- Vacuum Test — tem is used, the 19XR refrigerant charge may be transferred After pressurizing the chiller, test for to a pumpout storage tank or to the chiller condenser or cooler leaks with an electronic halide leak detector, soap bubble vessels.
Page 66: Weekly Maintenance
Changing Oil Filter — Change the oil ﬁlter on a yearly basis or when the chiller is opened for repairs. The 19XR Fig. 33 — Guide Vane Actuator Linkage has an isolatable oil ﬁlter so that the ﬁlter may be changed with the refrigerant remaining in the chiller.
Page 67: Oil Speciﬁcation
⁄ full in the upper sight glass, remove the excess oil. The oil level should now be equal Fig. 34 — 19XR Float Valve Design to the amount shown in Step 2. Inspect Relief Valves and Piping — The relief valves Refrigerant Filter —...
Page 68: And Flow Devices
See Chiller Dehydration section, page 51. Carrier Part Number ....PP23BZ103 The total oil charge, 4.5 pints (2.6 L), consists of Water Treatment —...
Page 69: Troubleshooting Guide
Checking Display Messages — The ﬁrst area to check when troubleshooting the 19XR is the CVC display. If the alarm light is ﬂashing, check the primary and secondary mes- sage lines on the CVC default screen (Fig. 12). These mes- sages will indicate where the fault is occurring.
Page 70: Check Sensor Accuracy
CCM PRESSURE TRANSDUCERS screen) There are or measure across the positive (+ red) and negative 8 pressure transducers on 19XR chillers. They determine (− black) leads of the transducer. For example, the con- cooler, condenser, oil pressure, and cooler and condenser flow.
Page 71: Control Test
These maintenance screens are very useful in helping to Control Test — The Control Test feature can check all determine how the control temperature is calculated and guide the thermistor temperature sensors, pressure transducers, pumps vane positioned and for observing the reactions from load and their associated ﬂow devices, the guide vane actuator, changes, control point overrides, hot gas bypass, surge pre- and other control outputs such as hot gas bypass.
Page 72 Table 8 — CVC Primary and Secondary Messages and Custom Alarm/Alert Messages with Troubleshooting Guides (cont) C. IN RECYCLE SHUTDOWN PRIMARY MESSAGE SECONDARY MESSAGE PROBABLE CAUSE/REMEDY RECYCLE RESTART PENDING OCCUPIED MODE Unit in recycle mode, chilled water temperature is not sufficiently above set point to start.
Page 73 Table 8 — CVC Primary and Secondary Messages and Custom Alarm/Alert Messages with Troubleshooting Guides (cont) F. NORMAL RUN PRIMARY MESSAGE SECONDARY MESSAGE CAUSE/REMEDY RUNNING — RESET ACTIVE 4-20 mA SIGNAL Auto chilled water reset active based on external input. RUNNING —...
Page 74 Table 8 — CVC Primary and Secondary Messages and Custom Alarm/Alert Messages with Troubleshooting Guides (cont) I. CHILLER PROTECT LIMIT FAULTS PRIMARY SECONDARY ALARM MESSAGE ADDITIONAL STATE MESSAGE MESSAGE PRIMARY CAUSE CAUSE/REMEDY PROTECTIVE 1M CONTACT 200->1M Aux Contact Fault; LIMIT FAULT Check 1M Contactor and PROTECTIVE...
Page 75 Table 8 — CVC Primary and Secondary Messages and Custom Alarm/Alert Messages with Troubleshooting Guides (cont) I. CHILLER PROTECT LIMIT FAULTS (cont) PRIMARY SECONDARY ALARM MESSAGE ADDITIONAL STATE MESSAGE MESSAGE PRIMARY CAUSE CAUSE/REMEDY PROTECTIVE OIL PRESS 227->Oil Pump Delta P Check transducer wiring and accuracy.
Page 76 Table 8 — CVC Primary and Secondary Messages and Custom Alarm/Alert Messages with Troubleshooting Guides (cont) I. CHILLER PROTECT LIMIT FAULTS (cont) PRIMARY SECONDARY ALARM MESSAGE ADDITIONAL STATE MESSAGE MESSAGE PRIMARY CAUSE CAUSE/REMEDY PROTECTIVE INVALID DIFFUSER 246->Diffuser Control Invalid Check diffuser/inlet guide vane schedule. LIMIT CONFIG Conﬁguration:...
Page 77 Table 8 — CVC Primary and Secondary Messages and Custom Alarm/Alert Messages with Troubleshooting Guides (cont) J. CHILLER ALERTS (cont) PRIMARY SECONDARY ALARM MESSAGE ADDITIONAL STATE MESSAGE MESSAGE PRIMARY CAUSE CAUSE/REMEDY CONDENSER PRESSURE PUMP RELAY 151->High Condenser Check sensor wiring and accuracy. ALERT ENERGIZED Pressure [VALUE]: Pump...
Page 78 Table 9A — Thermistor Temperature (F) vs Resistance/Voltage Drop TEMPERATURE VOLTAGE RESISTANCE TEMPERATURE VOLTAGE RESISTANCE TEMPERATURE VOLTAGE RESISTANCE DROP (V) (Ohms) DROP (V) (Ohms) DROP (V) (Ohms) −25 4.821 98,010 3.409 7,665 1.211 1,141 −24 4.818 94,707 3.382 7,468 1.192 1,118 −23 4.814...
Page 79 Table 9B — Thermistor Temperature (C) vs Resistance/Voltage Drop TEMPERATURE VOLTAGE RESISTANCE TEMPERATURE VOLTAGE RESISTANCE DROP (V) (Ohms) DROP (V) (Ohms) −40 4.896 168 230 1.898 2 184 −39 4.889 157 440 1.852 2 101 −38 4.882 147 410 1.807 2 021 −37 4.874...
Page 80: Control Modules
Control Modules Notes on Module Operation 1. The chiller operator monitors and modiﬁes conﬁgura- tions in the microprocessor by using the 4 softkeys and the CVC. Communications between the CVC and the CCM Turn controller power off before servicing controls. This is accomplished through the SIO (Sensor Input/Output) ensures safety and prevents damage to the controller.
Page 81: Chiller Control Module (Ccm)
Replacing Defective Processor Modules — pertaining to the Benshaw, Inc., solid-state starter may be found in the following paragraphs and in the Carrier RE- module replacement part number is printed on a small label DISTART MICRO Instruction Manual supplied by the starter on the rear of the CVC module.
Page 82: V/I Inputs
DISCRETE DISCRETE 24 VAC OUTPUTS OUTPUTS ANALOG OUT V/I INPUTS STAT COMM THERMISTORS DIFF PRESSURE PRESSURE Fig. 37 — Chiller Control Module (CCM) COM STAT INTEGRATED STARTER MODULE FUSE J3-1 J3-2 J3-3 Fig. 38 — Integrated Starter Module (ISM)
Page 83: Scr Removal/Installation
5. Using an ohmmeter, perform the following resistance measurements and record the results: Care must be taken to prevent nut rotation while tight- SCR PAIRS MEASURE RECORDED ening the bolts. If the nut rotates while tighting the BEING BETWEEN VALUE bolt, SCR replacement must be started over.
Page 84: Scr Removal/Installation Physical Data
and wiring schematics for the operator’s convenience during Physical Data — Tables 10A-17 and Fig. 40-47 pro- troubleshooting. vide additional information on component weights, com- pressor ﬁts and clearances, physical and electrical data, Table 10A — Heat Exchanger Data (English) ENGLISH NUMBER OF Dry (Rigging) Weight...
Page 85 Table 10B — Heat Exchanger Data (SI) NUMBER OF Dry (Rigging) Weight TUBES Chiller Charge (kg) CODE Refrigerant Water Volume Cooler Condenser Weight Cooler Condenser Only Only Cooler Condenser Cooler Condenser 1244 1226 1275 1257 1307 1296 1362 1353 1401 1391 1440 1439...
Page 86 Table 11 — 19XR Additional Data for Marine Waterboxes* ENGLISH HEAT EXCHANGER Rigging Weight Water Volume Rigging Weight Water Volume FRAME, PASS Psig (lb) (gal) (kg) FRAME 2, 1 AND 2 PASS 1034 FRAME 2, 2 PASS 1034 FRAME 3, 1 AND 2 PASS...
Page 87 Table 13 — 19XR Motor Weights Standard and High Efficiency Motors ENGLISH MOTOR Stator Weight* Rotor Weight† Stator Weight* Rotor Weight† End Bell End Bell SIZE (lb) (lb) (kg) (kg) Cover Cover (lb) (kg) 60 Hz 50 Hz 60 Hz...
Page 88 Table 14A — 19XR Waterbox Cover Weights — English (lb) FRAME 1 FRAME 2 FRAME 3 HEAT WATERBOX Standard Standard Standard EXCHANGER DESCRIPTION Flanged Flanged Flanged Nozzles Nozzles Nozzles NIH, 1 Pass Cover, 150 psig NIH, 2 Pass Cover, 150 psig...
Page 89 Table 14B — 19XR Waterbox Cover Weights — SI (kg) FRAME 1 FRAME 2 FRAME 3 HEAT WATERBOX Standard Standard Standard EXCHANGER DESCRIPTION Flanged Flanged Flanged Nozzles Nozzles Nozzles NIH, 1 Pass Cover, 1034 kPa NIH, 2 Pass Cover, 1034 kPa...
Page 90 Table 15 — Optional Pumpout System Table 17 — Motor Voltage Code Electrical Data MOTOR VOLTAGE CODE Code Volts Frequency MOTOR CONDENSER VOLTS-PH-Hz CODE UNIT 19EA47-748 575-3-60 23.0 19EA42-748 200/208-3-60 10.9 63.5 19EA44-748 230-3-60 57.5 19EA46-748 400/460-3-50/60 28.8 LEGEND 2400 LRA —...
Page 91 2. Dimensions are with rotor in thrust position. 3. Dimensions shown are in inches. 4. Impeller spacing should be performed in accordance with most recent Carrier Service Bulletin on impeller spacing. VIEW A LOW SPEED SHAFT THRUST DISK Fig. 40 — Compressor Fits and Clearances...
Page 92 VIEW B − HIGH SPEED SHAFT 19XR COMPRESSOR CLEARANCES COMPRESSOR CODE ITEM 221-299 321-389 421-489 521-599 .0050 .0050 .0055 .0069 .0040 .0040 .0043 .0059 .0050 .0050 .0053 .0065 .0040 .0040 .0043 .0055 .0115 .0115 .0100 .0010 .0055 .0080 .0050 .0060 .0190...
Page 93 — Bearing Denotes Oil Pump Terminal — Contactor — Circuit Breaker Denotes Power Panel Terminal — Chiller Control Module — Carrier Comfort Network Denotes Motor Starter Panel Conn COMP’R — Compressor COND — Condenser Denotes Component Terminal — Chiller Visual Controller...
Page 94 Denotes Oil Pump Terminal — Bearing — Contactor — Circuit Breaker Denotes Power Panel Terminal — Chiller Control Module Denotes Motor Starter Panel Conn — Carrier Comfort Network COMP’R — Compressor Denotes Component Terminal COND — Condenser — Chiller Visual Controller Wire Splice DISCH —...
Page 95 LEGEND — Auxiliary — Transformer — Contactor — Terminal Board — Circuit Breaker — Chiller Control Module Denotes Oil Pump Terminal COMM — Communication COMPR — Compressor Denotes Power Panel Terminal DISCH — Discharge — Frame Denotes Mach. Control Panel Conn. —...
Page 96 NOTE: Power factor correction capacitors (when required) are connected ahead of all current transformers for proper calibration and sensing by the ISM and IQDP4130. LEGEND AUX — Auxiliary HPR — Horsepower — Contactor — Integrated Starter Module — Circuit Breaker —...
Page 97 LEGEND NOTES: — Auxiliary — Ground LED status with power applied and prior to run command. Wire Node Symbol ‘‘ON’’ PC Board Terminals — Bridge Rectiﬁer — Main Supply Power may have terminal block — Circuit Breaker — Control Power Supply COMM —...
Page 98 LEGEND — Auxiliary — Contactor — Circuit Breaker COMM — Communication COND — Condenser — Control Power Transformer — Control Relay — Current Transformer — Disconnect Switch EVAP — Evaporator — Fuse — Ground GFCT — Ground Fault Current Transformer —...
Page 99 LEGEND — Auxiliary — Contactor — Circuit Breaker COMM — Communication COND — Condenser — Control Power Transformer — Control Relay — Current Transformer — Disconnect Switch EVAP — Evaporator — Fuse — Ground GFCT — Ground Fault Current Transformer —...
Page 100: Index
Safety Considerations, 1 Ice Build Control, 41 Safety Controls, 33 Initial Start-Up, 58 Safety Shutdown, 45 Initial Start-Up Checklist for 19XR Hermetic Scheduled Maintenance, 66 Centrifugal Liquid Chiller, CL-1 Service Conﬁgurations (Input), 53 Inspect the Control Panel, 66 Service Ontime, 66...
Page 101 INDEX (cont) Storage Vessel, 7 Unit Mounted Solid-State Starter, 9 Summary (Lubrication Cycle), 8 Unit Mounted Wye-Delta Starter, 10 Surge Prevention Algorithm, 38 Using the Optional Storage Tank and Pumpout Surge Protection, 39 System, 46 System Components, 5 Water/Brine Reset, 37 Temperature Sensors (Check), 69 Water Leaks, 68 Test After Service, Repair, or Major Leak, 65...
Page 104 Copyright 1998 Carrier Corporation Manufacturer reserves the right to discontinue, or change at any time, speciﬁcations or designs without notice and without incurring obligations. Book 2 PC 211 Catalog No. 531-974 Printed in U.S.A. Form 19XR-3SS Pg 104 6-98 Replaces: New...
Page 105: Initial Start-Up Checklist For 19Xr Hermetic Centrifugal Liquid Chiller
INITIAL START-UP CHECKLIST FOR 19XR HERMETIC CENTRIFUGAL LIQUID CHILLER (Remove and use for job ﬁle.) MACHINE INFORMATION: NAME JOB NO. ADDRESS MODEL CITY STATE DESIGN CONDITIONS: FLOW TEMPERATURE TEMPERATURE PRESSURE SUCTION CONDENSER TONS BRINE PASS RATE DROP TEMPERATURE TEMPERATURE COOLER...
Page 106 E: After Machine Has Been Successfully Run and Set Up, Shut Down and Mark Shutdown Oil and Refrigerant Levels. F: Give Operating Instructions to Owner’s Operating Personnel. Hours Given: Hours G: Call your Carrier factory representative to report chiller start-up. SIGNATURES: CARRIER CUSTOMER...
Page 107 19XR PIC II SETPOINT TABLE CONFIGURATION SHEET DESCRIPTION RANGE UNITS DEFAULT VALUE Base Demand Limit 40 to 100 LCW Setpoint 10 to 120 DEG F 50.0 ECW Setpoint 15 to 120 DEG F 60.0 Ice Build Setpoint 15 to 60 DEG F 40.0...
Page 108 Period 4: Period 5: Period 6: Period 7: Period 8: NOTE: Default setting is OCCUPIED 24 hours/day. ICE BUILD 19XR PIC II TIME SCHEDULE CONFIGURATION SHEET OCCPC02S Day Flag Occupied Unoccupied M T W T F S S H Time...
Page 109 19XR PIC II ISM_CONF TABLE CONFIGURATION SHEET DESCRIPTION RANGE UNITS DEFAULT VALUE Starter Type 0 to 2 (0=Full, 1=Red, 2=SS/VFD) Motor Rated Line Voltage 200 to 13200 VOLTS Volt Transformer Ratio: 1 1 to 33 Overvoltage Threshold 105 to 115...
Page 110 19XR PIC II OPTIONS TABLE CONFIGURATION SHEET DESCRIPTION RANGE UNITS DEFAULT VALUE Auto Restart Option DSABLE/ENABLE DSABLE Remote Contacts Option DSABLE/ENABLE DSABLE Soft Stop Amps Threshold 40 to 100 Surge/Hot Gas Bypass Surge Limit/HGBP Option Select: Surge=0, HGBP=1 Min. Load Point (T1/P1) Surge/HGBP Delta T1 0.5 to 15...
Page 111 19XR PIC II SETUP1 TABLE CONFIGURATION SHEET DESCRIPTION RANGE UNITS DEFAULT VALUE Comp Motor Temp Override 150 to 200 DEG F Cond Press Override 90 to 165 Comp Discharge Alert 125 to 200 DEG F Comp Thrust Brg Alert 165 to 185...
Page 112 19XR PIC II SETUP2 TABLE CONFIGURATION SHEET DESCRIPTION STATUS UNITS DEFAULT VALUE Capacity Control Proportional Inc Band 2 to 10 Proportional Dec Band 2 to 10 Proportional ECW Gain 1 to 3 Guide Vane Travel Limit 30 to 100 Diffuser Control...
Page 113 19XR PIC II LEADLAG TABLE CONFIGURATION SHEET DESDRIPTION RANGE UNITS DEFAULT VALUE Lead Lag Control LEAD/LAG Conﬁguration 0 to 3 DSABLE=0, LEAD=1, LAG=2, STANDBY=3 Load Balance Option DSABLE/ENABLE DSABLE Common Sensor Option DSABLE/ENABLE DSABLE LAG Percent Capacity 25 to 75...
Page 114 19XR PIC II RAMP_DEM TABLE CONFIGURATION SHEET DESCRIPTION RANGE UNITS DEFAULT VALUE Pulldown Ramp Type: Select: Temp=0, Load=1 Demand Limit + kW Ramp Demand Limit Source Select: Amps=0, kW=1 Motor Load Ramp % Min 5 to 20 Demand Limit Prop Band...
Page 115 BROADCAST (BRODEF) CONFIGURATION SHEET DESCRIPTION RANGE UNITS DEFAULT VALUE Time Broadcast Enable DISABLE/ENABLE DSABLE Daylight Savings Start Month 1 to 12 Start Day of Week 1 to 7 Start Week 1 to 5 Start Time 00:00 to 24:00 HH:MM 02:00 Start Advance 0 to 360 Stop Month...
Page 116 Copyright 1998 Carrier Corporation Manufacturer reserves the right to discontinue, or change at any time, speciﬁcations or designs without notice and without incurring obligations. Book 2 PC 211 Catalog No. 531-974 Printed in U.S.A. Form 19XR-3SS Pg CL-12 6-98 Replaces: New...

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

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