Carrier AquaEdge 19XR Start-Up, Operation And Maintenance Instructions Manual
  1. Manuals
  2. Brands
  3. Carrier Manuals
  4. Chiller
  5. AquaEdge 19XR
  6. Start-up, operation and maintenance instructions manual

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

Two-stage semi-hermetic centrifugal liquid chillers with pic 5 controls and hfc-134a 50/60 hz
Hide thumbs Also See for AquaEdge 19XR:
Table of Contents

Advertisement

Quick Links

Download this manual
Start-Up, Operation, and Maintenance
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . 2
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Chiller Information Nameplate . . . . . . . . . . . . . . . . 4
System Components . . . . . . . . . . . . . . . . . . . . . . . 4
Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Motor-Compressor . . . . . . . . . . . . . . . . . . . . . . . . . 4
Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Economizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Free-Standing Starter . . . . . . . . . . . . . . . . . . . . . . . 4
REFRIGERATION CYCLE . . . . . . . . . . . . . . . . . . . . 7
MOTOR AND OIL COOLING CYCLE . . . . . . . . . . . 8
LUBRICATION CYCLE . . . . . . . . . . . . . . . . . . . . . . 8
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Oil Reclaim System . . . . . . . . . . . . . . . . . . . . . . . . . 8
STARTING EQUIPMENT . . . . . . . . . . . . . . . . . . . . 10
Solid-State Starter (Optional) . . . . . . . . . . . . . . . . 10
CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
PIC 5 System Components . . . . . . . . . . . . . . . . . 11
RECYCLE SEQUENCE . . . . . . . . . . . . . . . . . . . 11
Local Start/Stop Control . . . . . . . . . . . . . . . . . . . . 11
Lubrication Control . . . . . . . . . . . . . . . . . . . . . . . . 12
Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
BEFORE INITIAL START-UP . . . . . . . . . . . . . . . . 13
Job Data Required . . . . . . . . . . . . . . . . . . . . . . . . 13
Equipment Required . . . . . . . . . . . . . . . . . . . . . . . 13
Remove Shipping Packaging . . . . . . . . . . . . . . . . 13
Open Oil Circuit Valves . . . . . . . . . . . . . . . . . . . . 13
Tighten All Gasketed Joints . . . . . . . . . . . . . . . . . 13
Check Chiller Tightness . . . . . . . . . . . . . . . . . . . . 13
Refrigerant Tracer . . . . . . . . . . . . . . . . . . . . . . . . . 16
Leak Test Chiller . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Standing Vacuum Test . . . . . . . . . . . . . . . . . . . . . 16
Chiller Dehydration . . . . . . . . . . . . . . . . . . . . . . . . 18
Inspect Water Piping . . . . . . . . . . . . . . . . . . . . . . . 18
Check Relief Valves . . . . . . . . . . . . . . . . . . . . . . . 18
Inspect Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Check Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Oil Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Catalog No. 04-53190054-01
Two-Stage Semi-Hermetic Centrifugal Liquid Chillers
Instructions
Printed in U.S.A.
Form 19XR-CLT-14SS
with PIC 5 Controls and HFC-134a
Software Configuration . . . . . . . . . . . . . . . . . . . . 19
Input the Design Set Points . . . . . . . . . . . . . . . . 20
Input the Local Occupied Schedule . . . . . . . . . . 20
Input Service Configurations . . . . . . . . . . . . . . . 20
Field Set Up and Verification . . . . . . . . . . . . . . . 22
Quick Calibration) . . . . . . . . . . . . . . . . . . . . . . 24
Charge Refrigerant into Chiller . . . . . . . . . . . . . . 24
INITIAL START-UP . . . . . . . . . . . . . . . . . . . . . . . . 30
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Check Motor Rotation . . . . . . . . . . . . . . . . . . . . . 30
To Prevent Accidental Start-Up . . . . . . . . . . . . . 30
Check Chiller Operating Condition . . . . . . . . . . 30
Instruct the Customer Operator . . . . . . . . . . . . . 30
OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . 31
Operator Duties . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Prepare the Chiller for Start-Up . . . . . . . . . . . . . 31
To Start the Chiller . . . . . . . . . . . . . . . . . . . . . . . . 31
Check the Running System . . . . . . . . . . . . . . . . 31
To Stop the Chiller . . . . . . . . . . . . . . . . . . . . . . . . 31
After Limited Shutdown . . . . . . . . . . . . . . . . . . . 31
After Extended Shutdown . . . . . . . . . . . . . . . . . . 32
Cold Weather Operation . . . . . . . . . . . . . . . . . . . 32
Manual Guide Vane Operation . . . . . . . . . . . . . . 32
Refrigeration Log . . . . . . . . . . . . . . . . . . . . . . . . . 32
TRANSFER PROCEDURES . . . . . . . . . . . . . . . 32
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
GENERAL MAINTENANCE . . . . . . . . . . . . . . . . . 37
Refrigerant Properties . . . . . . . . . . . . . . . . . . . . . 37
Adding Refrigerant . . . . . . . . . . . . . . . . . . . . . . . 37
Adjusting the Refrigerant Charge . . . . . . . . . . . 37
Refrigerant Leak Testing . . . . . . . . . . . . . . . . . . . 37
Leak Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Standing Vacuum Test . . . . . . . . . . . . . . . . . . 37
Checking Guide Vanes . . . . . . . . . . . . . . . . . . . . 37
Trim Refrigerant Charge . . . . . . . . . . . . . . . . . . . 39
WEEKLY MAINTENANCE . . . . . . . . . . . . . . . . . . 39
Check the Lubrication System . . . . . . . . . . . . . . 39
SCHEDULED MAINTENANCE . . . . . . . . . . . . . . . 39
Service Ontime . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Inspect the Control Panel . . . . . . . . . . . . . . . . . . 39
Pg 1
®
AquaEdge
19XR
50/60 Hz
3-19
Replaces: 19XR-CLT-13SS

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the AquaEdge 19XR and is the answer not in the manual?

Questions and answers

Gary Hall
February 28, 2025

how many teeth are on the Low Speed Bull Gear in a Carrier Model# 19XRV70714VFLHH64 Serial #23126. I have high vibration at 40 and 80 times run speed. could this be the bull gear or Thrust Bearings

User image 67c1db0b8b54a
0

Related Manuals for Carrier AquaEdge 19XR

Summary of Contents for Carrier AquaEdge 19XR

  • Page 1: Table Of Contents

    ® AquaEdge 19XR Two-Stage Semi-Hermetic Centrifugal Liquid Chillers with PIC 5 Controls and HFC-134a 50/60 Hz Start-Up, Operation, and Maintenance Instructions SAFETY CONSIDERATIONS ....2 Power Up Controls and Check Oil Heater .

  • Page 2: Safety Considerations

    Changing Oil Filter ......39 DANGER Oil Specification ......40 Failure to follow these procedures will result in severe per- Oil Changes .

  • Page 3: Introduction

    Operation of this equipment with refrigerants other than for corrosion, rust, leaks, or damage. those cited herein should comply with ANSI/ASHRAE 15 (latest edition). Contact Carrier for further information on PROVIDE A DRAIN connection in the vent line near each use of this chiller with other refrigerants.

  • Page 4: Abbreviations And Explanations

    CAUTION • displays status of motor starter • provides access to other CCN (Carrier Comfort Network ® WHEN FLUSHING THE WATER SYSTEMS isolate the devices and energy management systems chiller from the water circuits to prevent damage to the heat exchanger tubes.
  • Page 5 19XR – Description Special Order Indicator — High Efficiency Semi-Hermetic 19XR – — Standard Centrifugal Liquid Chiller S — Special Order Motor Voltage Code Cooler Size Code (Digits 6, 7, 8) Code Volts-Phase-Hertz A 4 0- A 4 2 — 400-3-50 A4 5 - A 4 7 4 —...
  • Page 6 FRONT VIEW LEGEND 1 — Guide Vane Actuator 2 — Suction Elbow 3 — Chiller Identification Nameplate 4 — Control Panel 5 — Condenser Auto. Reset Relief Valves 6 — Condenser Return End Waterbox Cover 7 — Cooler Return End Waterbox Cover 8 —...

  • Page 7: Refrigeration Cycle

    liquid. The FLASC vapor is recondensed on the tubes which are REFRIGERATION CYCLE cooled by entering condenser water. The liquid drains into a high The compressor continuously draws refrigerant vapor from the side float valve chamber between the FLASC chamber and the cooler at a rate set by the amount of guide vane opening.

  • Page 8: Motor And Oil Cooling Cycle

    the pump discharge. A range of 18 to 40 psid (124 to 172 kPad) MOTOR AND OIL COOLING CYCLE is normal. This differential pressure can be read directly from The motor and the lubricating oil are cooled by liquid refrigerant the default HMI screen.
  • Page 9 OIL LINE a19- VENT LINE LEGEND 1 — Motor Stator 6 — Oil Heater 2 — Impellers 7 — Oil Pump 3 — Variable Inlet Guide Vanes 8 — Oil Filters 4 — Transmission 9 — Motor Rotor 5 — High Speed Shaft Bearings 10 —...

  • Page 10: Starting Equipment

    • power indication • proper phasing for rotation All starters must include a Carrier control module called the In- • start circuit energized tegrated Starter Module (ISM). This module controls and mon- • ground fault itors all aspects of the starter.

  • Page 11: Controls

    CONTROLS START-UP/SHUTDOWN/ RECYCLE SEQUENCE Definitions Local Start/Stop Control ANALOG SIGNAL Local start-up (or manual start-up) is initiated by pressing the An analog signal varies in proportion to the monitored source. It gray Start/Stop icon on the HMI interface. See Fig. 6. quantifies values between operating limits.

  • Page 12: Lubrication Control

    PIC 5 control system closes the vanes. If the vanes are closed and the oil pump pressure is less than 4 psi (27.6 kPa), the oil pump relay energizes. The PIC 5 control system then waits un- til the oil pressure (OIL PRESS VERIFY TIME, operator-con- figured, default of 40 seconds) reaches a maximum of 18 psi (124 kPa).

  • Page 13: Before Initial Start-Up

    BEFORE INITIAL START-UP Check Chiller Tightness Figure 11 outlines the proper sequence and procedures for leak Job Data Required testing. • list of applicable design temperatures and pressures (prod- The 19XR chillers are shipped with the refrigerant contained in uct data submittal) the condenser shell and the oil charge in the compressor.
  • Page 14 Table 3 — Bolt Torque Requirements, Foot Pounds SAE 8 SAE 2, A307 GR A SAE 5 HEX HEAD HEX HEAD SOCKET HEAD OR HEX WITH 6 RADIAL LINES OR BOLT SIZE NO MARKS WITH 3 RADIAL LINES, OR SA499 SA354 GR BD (in.) LOW CARBON STEEL...
  • Page 15 a19-1151tf.eps...

  • Page 16: Refrigerant Tracer

    Refrigerant Tracer greater than 0.1% of the total charge per year must be Carrier recommends the use of an environmentally acceptable repaired. Note the total chiller leak rate on the start-up report. refrigerant tracer for leak testing with an electronic detector.
  • Page 17 Table 5 — HFC-134a Pressure — Temperature (F) Table 6 — HFC-134a Pressure — Temperature (C) TEMPERATURE PRESSURE TEMPERATURE PRESSURE (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 90.8...

  • Page 18: Chiller Dehydration

    Chiller Dehydration Dehydration is recommended if the chiller has been open for a considerable period of time, if the chiller is known to contain moisture, or if there has been a complete loss of chiller holding charge or refrigerant pressure. CAUTION Do not start or megohm-test the compressor motor or oil pump motor, even for a rotation check, if the chiller is un-...

  • Page 19: Check Starter

    (Fig. 2). If oil is added, it must meet Carrier’s specifi- cation for centrifugal compressor use as described in the Oil at the motor with the power leads disconnected.

  • Page 20: Input The Design Set Points

    1 to 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 21 User Login Screen Fig. 16 — Lock Icon Fig. 17 — User Login Screen The User Login Screen is displayed. Enter the password on this screen. See Fig 17. The language and system of measurement can MODIFY CONTROLLER IDENTIFICATION IF NECESSARY also be changed on this screen.

  • Page 22: Field Set Up And Verification

    REFRIGERATION. THE COMPRESSOR MOTOR CONTROLLER increase SURGE DELTA TSMIN in steps of 2ºF (1.2ºC) until AND OVERLOAD PROTECTION MUST BE IN ACCORDANCE WITH CARRIER a19-1881 SPECIFICATION Z-415. one of the three conditions listed above no longer applies. Do not change SURGE DELTA TSMAX.
  • Page 23 Speed Factor =1.60 Tsmin=30 Speed Factor =1.85 Tsmin=40 Speed Factor =2.00 Tsmin=50 GV_POS a19-1962 a19-1959 Fig. 22 — Effect of SURGE LINE SPEED FACTOR GV_POS on Surge Prevention Fig. 19 — Effect of SURGE DELTA TSMIN on If ACTUAL GUIDE VANE POSITION is less than 30%, go to Surge Prevention Step 1.

  • Page 24: Perform A Controls Test (Quick Test/Quick Calibration)

    MODIFY EQUIPMENT CONFIGURATION IF NECESSARY CHILLER EQUALIZATION WITHOUT A PUMPOUT UNIT The EQUIPMENT SERVICE table has screens to select, view, or modify parameters. Carrier’s certified drawings have the CAUTION configuration values required for the jobsite. Modify these val- ues only if requested. Modifications can include:...
  • Page 25 If the chiller has been shipped with a holding charge, the refrig- erant is added through the pumpout charging connection (Fig. 23 WARNING and 24, valve 1b). First evacuate the nitrogen holding charge Whenever turning the discharge isolation valve, be sure to from the chiller vessels.
  • Page 26 REFRIGERANT CHARGING VALVE CHILLER CONDENSER VESSEL CHILLER COOLER VESSEL COOLER REFRIGERANT REFRIGERANT CHARGING PRESSURE ISOLATION LIQUID LINE VALVE RELIEF SAFETY VALVE SERVICE VALVE VALVE SEPARATOR PUMPOUT CONDENSER PUMPOUT SERVICE VALVE ON SERVICE VALVE ON COMPRESSOR CHILLER PUMPOUT UNIT PUMPOUT CONDENSER WATER SUPPLY a19-1722 AND RETURN...
  • Page 27 Table 8 — 19XR Two-Stage Compressor Frame Size 6 Heat Exchanger Refrigerant Charge ENGLISH MACHINE CHARGE MACHINE CHARGE CODE* REFRIGERANT WEIGHT (lb) REFRIGERANT WEIGHT (kg) COOLER ONLY CONDENSER ONLY ECONOMIZER ONLY COOLER ONLY CONDENSER ONLY ECONOMIZER ONLY 1647 1773 1887 1599 1714 1837...
  • Page 28 Table 9 — 19XR Two-Stage Compressor Frame Size 7 Heat Exchanger Refrigerant Charge ENGLISH MACHINE CHARGE MACHINE CHARGE CODE* REFRIGERANT WEIGHT (lb) REFRIGERANT WEIGHT (kg) COOLER ONLY CONDENSER ONLY ECONOMIZER ONLY COOLER ONLY CONDENSER ONLY ECONOMIZER ONLY 2273 — 1031 —...
  • Page 29 Table 9 — 19XR Two-Stage Compressor Frame Size 7 Heat Exchanger Refrigerant Charge (cont) ENGLISH MACHINE CHARGE MACHINE CHARGE CODE* REFRIGERANT WEIGHT (lb) REFRIGERANT WEIGHT (kg) COOLER ONLY CONDENSER ONLY ECONOMIZER ONLY COOLER ONLY CONDENSER ONLY ECONOMIZER ONLY — — 2190 —...

  • Page 30: Initial Start-Up

    INITIAL START-UP Preparation Before starting the chiller, verify: Power is on to the main starter, oil pump relay, tower fan starter, oil heater relay, and the chiller control panel. Cooling tower water is at proper level and at-or-below design entering temperature. Chiller is charged with refrigerant and all refrigerant and oil valves are in their proper operating positions.

  • Page 31: Operating Instructions

    CONTROL SYSTEM The oil level should be visible anywhere in one of the two sight glasses. Foaming oil is acceptable as long as the oil CCN and LOCAL start, reset, menu, softkey functions, HMI pressure and temperature are within limits. operation, occupancy schedule, set points, safety controls, and The oil pressure should be between 18 and 40 psid (124 auxiliary and optional controls.

  • Page 32: After Extended Shutdown

    See Check Chiller Data Collection module and a Building Supervisor. Contact a Tightness section, page 13. Carrier representative for more information. Recharge the chiller by transferring refrigerant from the pumpout storage tank (if supplied). Follow the Pumpout and Refrigerant PUMPOUT AND REFRIGERANT Transfer Procedures section.

  • Page 34: Operating The Optional Pumpout Unit (Fig. 27)

    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 23 and 24 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 35 Transfer Refrigerant from Pumpout Storage Tank to Chiller 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 36: General Maintenance

    h. Turn off the pumpout compressor. Turn on chiller water pumps. Open valves 1a, 1b, and 3. Evacuate gas from chiller cooler vessel. a. Close liquid line service valves 2 and 5; open valves 3 VALVE and 4. CONDITION Crack open valve 5, gradually increasing pressure in the VALVE evacuated chiller vessel to 35 psig (241 kPa).

  • Page 37: Adding Refrigerant

    In addition, Carrier recommends that leaks totaling less than screws on the guide vane actuator shaft need to be re- the above rate but more than a rate of 0.1% of the total charge seated.
  • Page 38 GUIDE VANE ACTUATOR a19-2123 Fig. 29 — Guide Vane Actuator, Frame Size 6 GUIDE VANE ACTUATOR Fig. 30 — Guide Vane Actuator, Frame Size 7...

  • Page 39: Trim Refrigerant Charge

    Failure to do so could result in serious personal injury. frame size 7 the oil charge is 44.5 gal (168 L). The added oil must meet Carrier specifications for the 19XR chiller. Refer to Changing Oil Filter and Oil Changes sections.

  • Page 40: Oil Specification

    • The liquid line downstream of the float valve feels warm. If oil is added, it must meet Carrier specifications. For units us- This indicates condenser gas flowing past the float. An in- ing R-134a, use inhibited polyolester-based synthetic compres- crease in kW/Ton will also occur.

  • Page 41: Inspect Relief Valves And Piping

    Contact cannot be field inspected; excessive vibration is the primary sign your Carrier representative to obtain these brushes. Do not use of wear or damage. If either symptom appears, contact an expe- wire brushes.

  • Page 42: Water Leaks

    The refrigerant moisture indicator on the refrigerant motor cool- OPTIONAL PUMPOUT COMPRESSOR OIL CHARGE ing line (Fig. 2) indicates whether there is water leakage during Use oil conforming to Carrier specifications for reciprocating chiller operation. Water leaks should be repaired immediately. compressor usage. Oil requirements are as follows:...

  • Page 43: 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 5 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 44 Table 10 — 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 45 Table 11 — 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 46 CHECK SENSOR ACCURACY See Fig. 2 for sensor locations. The sensors are immersed direct- ly in the refrigerant or water circuits. When installing a new sen- Place the sensor in a medium of known temperature and com- sor, apply a pipe sealant or thread sealant to the sensor threads. pare that temperature to the measured reading.

  • Page 47: Checking Pressure Transducers

    voltage ratio of the transducer. To obtain the voltage ratio, Checking Pressure Transducers divide the voltage (dc) input from the transducer by the There are 4 factory-installed pressure transducers measuring supply voltage signal or measure across the positive refrigerant and oil pressure, and a fifth pressure transducer (+ red) and negative (–...
  • Page 48 a19-2292 Fig. 36 — Inputs for Optional Waterside Delta P Transducers for IOB4 WATERBOX NOZZLE TWO (2) 2” PIPE NIPPLES - 18 NPT SCHRADER VALVE BALL VALVE NPTF TEE, BRASS Fig. 37 — Suggested Installation of Pressure Transducers into Water Nozzles Using Flushable Dirt Leg Trap...
  • Page 49 Table 12 — 19XR Two-Stage Compressor Frame Size 6 Heat Exchanger Weights (English) DRY RIGGING WEIGHT (lb)* REFRIGERANT WEIGHT (lb) WATER WEIGHT (lb) CODE† COOLER CONDENSER COOLER CONDENSER COOLER CONDENSER ONLY ONLY ONLY ONLY ONLY ONLY 16,877 18,542 1647 4328 4553 17,270 19,062...
  • Page 50 Table 13 — 19XR Two-Stage Compressor Frame Size 6 Heat Exchanger Weights (SI) DRY RIGGING WEIGHT (kg)* REFRIGERANT WEIGHT (kg) WATER WEIGHT (kg) CODE† COOLER CONDENSER COOLER CONDENSER COOLER CONDENSER ONLY ONLY ONLY ONLY ONLY ONLY 7655 8410 1963 2065 7833 8646 2067...
  • Page 51 Table 14 — 19XR Two-Stage Compressor Frame Size 7 Heat Exchanger Weights (English) DRY RIGGING WEIGHT (lb)* REFRIGERANT WEIGHT (lb) WATER WEIGHT (lb) CODE† COOLER ONLY CONDENSER ONLY COOLER ONLY CONDENSER ONLY COOLER ONLY CONDENSER ONLY 24,704 — 2273 — 6,340 —...
  • Page 52 Table 14 — 19XR Two-Stage Compressor Frame Size 7 Heat Exchanger Weights (English) (cont) DRY RIGGING WEIGHT (lb)* REFRIGERANT WEIGHT (lb) WATER WEIGHT (lb) CODE† COOLER ONLY CONDENSER ONLY COOLER ONLY CONDENSER ONLY COOLER ONLY CONDENSER ONLY — 35,286 — 1947 —...
  • Page 53 Table 15 — 19XR Two-Stage Compressor Frame Size 7 Heat Exchanger Weights (SI) DRY RIGGING WEIGHT (kg)* REFRIGERANT WEIGHT (kg) WATER WEIGHT (kg) CODE† COOLER ONLY CONDENSER ONLY COOLER ONLY CONDENSER ONLY COOLER ONLY CONDENSER ONLY 11 206 — 1031 —...
  • Page 54 Table 15 — 19XR Two-Stage Compressor Frame Size 7 Heat Exchanger Weights (SI) (cont) DRY RIGGING WEIGHT (kg)* REFRIGERANT WEIGHT (kg) WATER WEIGHT (kg) CODE† COOLER ONLY CONDENSER ONLY COOLER ONLY CONDENSER ONLY COOLER ONLY CONDENSER ONLY — 16 005 —...
  • Page 55 Table 19 — Additional Weights for 19XR 300 psig (2068 kPa) Marine Waterboxes* ASME Two-Stage Compressors, Frame Size 6 — English (lb) NUMBER COOLER CONDENSER Rigging Wgt Rigging Wgt FRAME PASSES Water Wgt Water Wgt Victaulic Flange Victaulic Flange 6379 6709 5058 5573...
  • Page 56 Table 22 — Additional Weights for 19XR 150 psig (1034 kPa) Marine Waterboxes* Two-Stage Compressors, Frame Size 7† — SI (kg) NUMBER COOLER CONDENSER Rigging Wgt Rigging Wgt FRAME PASSES Water Wgt Water Wgt Victaulic Flange Victaulic Flange 1835 1984 3675 —...
  • Page 57 Table 25 — 19XR Compressor and Motor Weights* — High-Efficiency Motors Two-Stage Compressor Frame Size 6, 50 Hz ENGLISH ROTOR ROTOR STATOR AND END BELL STATOR AND END BELL MOTOR COMPRESSOR COMPRESSOR HOUSING COVER HOUSING COVER CODE WEIGHT† SHAFT WEIGHT† SHAFT WEIGHT WEIGHT...
  • Page 58 Table 26 — 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 59 Table 26 — 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 60 Table 27 — 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 61 Table 28 — 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 62 Table 29 — 19XR Waterbox Cover Weights, Two-Stage Compressor Frame 6 — English (lb) Two-Stage Compressor Frame 6; Cooler Frame A COOLER FRAME A WATERBOX DESCRIPTION PASSES STANDARD NOZZLES FLANGED Dished Head, 150 psig 1006 1171 MWB End Cover, 150 psig MWB End Cover (ASME), 300 psig 2460 2460...
  • Page 63 Table 31 — 19XR Waterbox Cover Weights, Two-Stage Compressor Frame 6 — SI (kg) Two-Stage Compressor Frame 6; Cooler Frame A COOLER FRAME A WATERBOX DESCRIPTION PASSES STANDARD NOZZLES FLANGED Dished Head, 1034 kPa MWB End Cover, 1034 kPa MWB End Cover (ASME), 2068 kPa 1116 1116 Dished Head, 1034 kPa...
  • Page 64 Table 33 — 19XR Waterbox Cover Weights, Two-Stage Compressor Frame 7 — English (lb) Two-Stage Compressor Frame 7; Cooler Frames B, C COOLER FRAME B FRAME C WATERBOX DESCRIPTION PASSES STANDARD NOZZLES FLANGED STANDARD NOZZLES FLANGED Dished Head, 150 psig 1380 1545 1849...
  • Page 65 Table 35 — 19XR Waterbox Cover Weights, Two-Stage Compressor Frame 7 — SI (kg) Two-Stage Compressor Frame 7; Cooler Frames B, C COOLER FRAME B FRAME C WATERBOX DESCRIPTION PASSES STANDARD NOZZLES FLANGED STANDARD NOZZLES FLANGED Dished Head, 1034 kPa MWB End Cover, 1034 kPa MWB End Cover (ASME), 2068 kPa 1554...
  • Page 66 Table 37 — Compressor Component Weights FRAME 6 FRAME 7 COMPRESSOR COMPRESSOR COMPONENT TRANSMISSION ASSEMBLY (INCLUDING BULL GEAR, HIGH SPEED SHAFT, 11,243 5100 13,481 6115 STATOR, ROTOR, MOTOR END COVER) BULL GEAR HIGH SPEED SHAFT ASSEMBLY SUCTION ASSEMBLY (INCLUDING BLADE RING) 1520 2125 BLADE RING ASSEMBLY...
  • Page 67 ITEM N ITEM O SECTION B-B SEE DETAIL E ITEM M ITEM F ITEM E a19-2277 ITEM K ITEM L DETAIL A AERO LEGEND — 1st Stage Eye Labyrinth — High Speed Shelf Labyrinth Sleeve — 1st Stage Impeller Shim —...
  • Page 68 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. 38 —Compressor Fits and Clearances — Two-Stage Compressor, Frame Sizes 6 and 7 (cont)
  • Page 69 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 70 Fig. 41 — Control Panel, IOB Layer 1TB — CUSTOMER 3-PHASE POWER CONNECTION FOR CONTROL PANEL 2TB — FIELD WIRING CONNECTION FROM STARTER Fig. 42 — Control Panel, Bottom Layer...
  • Page 71 (devices not supplied b) 3/4" stud - 35-40 ft-lb by Carrier) must have 24 VAC rating. MAX current is 60 mA, nom- - For low voltage terminal box busbar connection clamp bus- inal current is 10 mA. Switches with gold-plated bifurcated con- bar between 1-1/2"...

  • Page 72: Appendix A: Pic

    COMPRESSOR MOTOR STARTER NOTE CHILLER SYSTEM INPUT CONTACTS: SPARE SAFETY ICE BUILD REMOTE START PIC5 CONTROL PANEL 4TB (INPUTS) NOTE THAT IF IOB4 OPTION IS ACTIVATED, THEN OUTPUTS EVAP PUMP, COND PUMP, LOW FAN, HI FAN ARE CONTROLLED FROM IOB4, NOT THE ISM CARD. SEE NOTE 3.1 FOR ALL INPUTS HEAD PRESSURE REFERENCE OUTPUT IS FROM IOB-3 J14-1,4...
  • Page 73 CONTROL PANEL L1 L2 L3 HMI CONTROL PANEL – GROUNDING FOR HMI Fig. 43 —19XR Typical Field Wiring with Free-Standing Starter (Medium Voltage) (cont)
  • Page 74 SEE TABLE FOR CABLE MINIMUM INSULATION REQUIREMENTS* 3 Ø LV and 1 Ø 115 POWER SUPPLY IS REQUIRED AND MUST BE FIELD SUPPLIED WITH BRANCH CIRCUIT PROTECTION (8 kVA MINIMUM REQUIRED) CARRIER ISM MODULE CONTROL POWER DISCONNECT TRANSFORMER ISOLATED GATE...
  • Page 77 a19-2062...
  • Page 78 a19-2063...
  • Page 80 CONTINUED ON NEXT PAGE a19-2064 Fig. 44 —Typical Field Wiring with Free-Standing Variable Frequency Drive (VFD) (Medium Voltage) (cont)
  • Page 81 CONTINUED FROM PREVIOUS PAGE a19-2066 Fig. 44 —Typical Field Wiring with Free-Standing Variable Frequency Drive (VFD) (Medium-Voltage) (cont)
  • Page 82 — Warning Relay XIOx — External Inputs/Outputs Contact Location Description — Start Relay Carrier ISM to be programmed by Carrier before start-up. Relay contacts shown without signal power applied. Relay Location Description Calibrate for 4-20 mA; 0-5 vdc (Default 0-10 vdc).
  • Page 83 VFD and motor terminals without consulting Carrier for If primary pump, tower fan, and flow control is by other means, also special requirements. provide parallel means for control by Carrier. Failure to do so could result in machine freeze-up or overpressure. CABLE INSULATION REQUIREMENTS...
  • Page 84 Fig. 45 — Controls Diagram...
  • Page 85 Fig. 46 — IOB 1...
  • Page 86 Fig. 47 — IOB 2...
  • Page 87 Fig. 48 — IOB 3...
  • Page 88 Fig. 49 — IOB 4...
  • Page 89 USE 8TB-9, 10 (IOB3) Fig. 50 — Starter Wiring...
  • Page 90 LEGEND FOR FIG. 45-50 Control Abbreviations — Fig. 45-50 Wiring Codes — Fig. 45-50 — 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 91: Screen And Menu Structure

    APPENDIX A — PIC 5 SCREEN AND MENU STRUCTURE HOME MAIN MENU LOG IN/LOG OUT CONFIRM STOP CHOOSE OPERATING MODE ALARM MENU Main Menu General Parameters Temperatures Pressures Inputs Status Outputs Status Hydraulic Status Trending Modes Run Times a19-2238 Fig. A — Screen Structure, Basic Level (All) Access (No Password Required)
  • Page 92 APPENDIX A — PIC 5 SCREEN AND MENU STRUCTURE (cont) HOME MAIN MENU LOG IN/LOG OUT CONFIRM STOP CHOOSE OPERATING MODE ALARM MENU Main Menu General Parameters Temperatures Pressures Inputs Status Outputs Status Hydraulic Status Run Times Modes Setpoint Main Menu Main Menu a19-2281 a19-2239...
  • Page 93 APPENDIX A — PIC 5 SCREEN AND MENU STRUCTURE (cont) HOME MAIN MENU LOG IN/LOG OUT CONFIRM STOP CHOOSE OPERATING MODE ALARM MENU Main Menu General Parameters Temperatures Pressures Inputs Status Outputs Status Hydraulic Status Run Times Modes Setpoint Main Menu Configuration Menu Quick Test Maintenance Menu...
  • Page 94 APPENDIX A — PIC 5 SCREEN AND MENU STRUCTURE (cont) Main Menu Description ICON DISPLAYED TEXT* ACCESS ASSOCIATED TABLE† General Parameters Basic, User, Factory GENUINT Temperatures Basic, User, Factory TEMP Pressures Basic, User, Factory PRESSURE Inputs Status Basic, User, Factory INPUTS Outputs Status Basic, User, Factory...
  • Page 95 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...
  • Page 96 APPENDIX C — MAINTENANCE SUMMARY AND LOG SHEETS 19XR Maintenance Interval Requirements WEEKLY COMPRESSOR Check Oil Level. CONTROLS Review PIC 5 Alarm/Alert History. COOLER None. STARTER None. CONDENSER None. OIL RECLAIM None. MONTHLY COMPRESSOR None. CONTROLS Perform an Automated Controls test. COOLER None.
  • Page 99 INDEX Abbreviations and explanations, Oil changes, Start-Up Bearing and gear maintenance, Oil charge, Accidental, preventing, Bearings, Oil circuit valves, opening, Before initial, Bolt torque requirements, Oil filter, changing, Chiller dehydration, Chiller Oil heater, checking, Controls, powering up, Components, Oil pressure and compressor Control test (quick test), Dehydration, stop, checking,...
  • Page 100 Copyright 2019 Carrier Corporation Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. Catalog No. 04-53190054-01 Printed in U.S.A. Form 19XR-CLT-14SS Pg 100 3-19 Replaces: 19XR-CLT-13SS...
  • Page 101 REFRIGERANT: Type: Charge   CARRIER OBLIGATIONS: Assemble....  Leak Test ....Yes ...
  • Page 102 COMPRESSOR MOTOR AND CONTROL PANEL MUST BE PROPERLY AND INDIVIDUALLY CONNECTED BACK TO THE EARTH GROUND IN THE STARTER (IN ACCORDANCE WITH CERTIFIED DRAWINGS). WATER/BRINE PUMP CONTROL: Can the Carrier controls independently start the pumps? Yes  No  Condenser Water Pump Yes ...
  • Page 103 C: After machine has been successfully run and set up, shut down and mark shutdown oil and refrigerant levels. D: Give operating instructions to owner’s operating personnel. Hours Given: Hours E: Call your Carrier factory representative to report chiller start-up. SIGNATURES: CARRIER TECHNICIAN...
  • Page 104 19XR PIC 5 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 105 19XR PIC 5 ISM CONFIGURATION TABLE (CONF_ISM) CONFIGURATION SHEET 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 DSABLE/ENABLE DSABLE...
  • Page 106 19XR PIC 5 OPTION CONFIGURATION TABLE (CONF_OPT) CONFIGURATION SHEET DESCRIPTION RANGE UNITS DEFAULT VALUE Auto Restart Option DSABLE/ENABLE DSABLE Common Sensor Option DSABLE/ENABLE DSABLE Water Pressure Option DSABLE/ENABLE DSABLE EC Valve Option 0 = No, 1 = Cont 0 to 3 2 = On/Off, 3 = 4-20 mA EC Selection 0 = Disable, 1 = Surge...
  • Page 107 19XR PIC 5 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 108 19XR PIC 5 SERVICE PARAMETERS TABLE CONFIGURATION SHEET DESCRIPTION STATUS UNITS DEFAULT VALUE Service Password 0 to 65535 2222 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...
  • Page 109 19XR PIC 5 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 110 19XR PIC 5 CFGSURGE SURGE CORRECTION CONFIG TABLE CONFIGURATION SHEET DESCRIPTION RANGE UNITS DEFAULT VALUE Surge Line Configuration 0 = PR 0 to 1 1 = Delta T IGV1 Pos Configuration 0 = Degree 0 to 1 1 = Percentage Surge Delta Tsmax 0 to 150 Surge Delta Tsmin...
  • Page 111 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 112 Copyright 2019 Carrier Corporation Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. Catalog No. 04-53190054-01 Printed in U.S.A. Form 19XR-CLT-14SS Pg CL-12 3-19 Replaces: 19XR-CLT-13SS...

Table of Contents

Save PDF