Check Starter; Oil Charge; Power Up Controls And Check Oil Heater; Software Configuration - Carrier AquaEdge 19XR Start-Up, Operation And Maintenance Instructions Manual

6. Ensure all electrical equipment and controls are properly
grounded in accordance with job drawings, certified draw-
ings, and all applicable electrical codes.
7. Ensure the customer's contractor has verified proper oper-
ation of the pumps, cooling tower fans, and associated
auxiliary equipment. This includes ensuring motors are
properly lubricated and have proper electrical supply and
proper rotation.
8. Test the chiller compressor motor and its power lead insu-
lation resistance with an insulation tester such as a meg-
ohmmeter. (Use a tester rated for motor voltage.)
a. Open the starter main disconnect switch and follow
lockout/tagout rules.
CAUTION
If the motor starter is a solid-state starter, the motor leads
must be disconnected from the starter before an insulation
test is performed. The voltage generated from the tester can
damage the starter solid-state components.
b. With the tester connected to the motor leads, take 10-
second and 60-second megohm readings as follows:
3-Lead Motor — Tie terminals 1, 2, and 3 together
and test between the group and ground.
c. Divide the 60-second resistance reading by the 10-
second reading. The ratio, or polarization index, must
be one or higher. Both the 10 and 60-second readings
must be at least 50 megohms. If the readings on a
field-installed starter are unsatisfactory, repeat the test
at the motor with the power leads disconnected. Satis-
factory readings in this second test indicate the fault is
in the power leads.

Check Starter

WARNING
BE AWARE that certain automatic start arrangements can
engage the starter. Open the disconnect ahead of the starter
in addition to shutting off the chiller or pump. Failure to
follow this procedure may result in personal injury by elec-
tric shock.
Use the instruction and service manual supplied by the starter
manufacturer to verify the starter has been installed correctly,
to set up and calibrate the starter, and for complete trouble-
shooting information.
WARNING
The main disconnect on the starter front panel may not de-
energize all internal circuits. Open all internal and remote
disconnects before servicing the starter. Failure to follow
this procedure may result in personal injury by electric
shock.
MECHANICAL STARTER
1. Check all field wiring connections for tightness, clearance
from moving parts, and correct connection.
2. Check the contactor(s) to ensure they move freely. Check
all other electro-mechanical devices, such as relays, for
free movement. If the devices do not move freely, contact
the starter manufacturer for replacement components.
3. Reapply starter control power (not main chiller power) to
check the electrical functions.
Ensure the starter (with relay 1CR closed) goes through a
complete and proper start cycle.
SOLID-STATE STARTER
This equipment is at line voltage when AC power is connect-
ed. Pressing the STOP button does not remove voltage.
An isolation switch or circuit breaker must be open ahead
of any solid-state starter when the chiller is in a vacuum. If
not, damage to the machine may result.
1. Ensure all wiring connections are properly terminated to
the starter.
2. Verify the ground wire to the starter is installed properly
and is sufficient size.
3. Verify the motors are properly grounded to the starter.
4. Verify the proper ac input voltage is brought into the
starter according to the certified drawings.
5. Apply power to the starter.

Oil Charge

The oil charge for the 19XR two-stage compressor frame size 6
is 29 gal (110 L); for frame size 7 the oil charge is 44.5 gal
(168 L).
The chiller is shipped with oil in the compressor. When the sump
is full, the oil level should be no higher than the middle of the
upper sight glass, and minimum level is the bottom of the lower
sight glass (Fig. 2). If oil is added, it must meet Carrier's specifi-
cation for centrifugal compressor use as described in the Oil
Specification section on page 40. Charge the oil through the oil
charging valve located near the bottom of the transmission hous-
ing. The oil must be pumped from the oil container through the
charging valve due to higher refrigerant pressure. The pumping
device must be able to lift from 0 to 200 psig (0 to 1380 kPa) or
above unit pressure. Oil should only be charged or removed
when the chiller is shut down.

Power Up Controls and Check Oil Heater

Ensure that an oil level is visible in the compressor and the
chiller is not in a vacuum before energizing the controls. Typi-
cally a circuit breaker in the starter energizes the oil heater and
the control circuit.
The oil heater is energized by powering the control circuit.
This should be done several hours before start-up to minimize
oil-refrigerant migration. The oil heater is controlled by the
PIC 5 and is powered through a contactor in the control panel.
A separate circuit breaker powers the heater, oil pump, and the
control circuit. This arrangement allows the heater to energize
when the main motor circuit breaker is off for service work or
extended shutdowns.

Software Configuration

Do not operate the chiller before the control configurations
have been checked and a Control Test has been satisfactori-
ly completed. Protection by safety controls cannot be as-
sumed until all control configurations have been confirmed.
See the 19XR with PIC 5 Controls Operation and Trouble-
shooting manual for instructions on using the PIC 5 interface to
configure the 19XR unit. As the unit is configured, all configu-
ration settings should be written down. A log, such as the one
shown on pages CL-1 to CL-11, provides a list for configura-
tion values.
19
WARNING
CAUTION
WARNING