Page 1: Table Of Contents
Inspect Wiring ......29 Economizer (if available) ..... . 4 Carrier Comfort Network (CCN) and Free-Standing/Factory-Mounted Starter or VFD . . . 4 Local Equipment Network (LEN) Interface .
Page 2: Safety Considerations
PUMPOUT AND REFRIGERANT SAFETY CONSIDERATIONS TRANSFER PROCEDURES ....41 Centrifugal liquid chillers are designed to provide safe and reliable Preparation ....... . . 41 service when operated within design specifications.
Page 3: Introduction
ANSI/ASHRAE 15 (latest control system for those involved in the start-up, operation, and edition). Contact Carrier for further information on use of this maintenance of the unit before performing start-up procedures. It chiller with other refrigerants.
Page 4: Abbreviations And Explanations
Control Panel manual, it may cause interference to radio communications. The control panel includes the Carrier PIC 6 HMI touchscreen. It The PIC 6 control boards have been tested and found to com- allows user interface for controlling the chiller. It regulates the ply with the limits for a Class A computing device pursuant to chiller’s capacity as required to maintain proper leaving chilled...
Page 5 51 3 19XR T* 64 – Description 19XR — High Efficiency Semi-Hermetic Special Order Indicator Centrifugal Liquid Chiller – — Standard 19XRV — High Efficiency Semi-Hermetic S — Special Order Centrifugal Liquid Chiller with Unit-Mounted VFD Motor Voltage Code Code Volts-Phase-Hertz 60 —...
Page 6 19XR – Description Special Order Indicator — High Efficiency Semi-Hermetic 19XR – — Standard Centrifugal Liquid Chiller S — Special Order Evaporator Size Code (Digits 6, 7, 8) Motor Voltage Code Code Volts-Phase-Hertz A40-A42 A45-A47 2 — 400-3-50 (19XR6 only) A4A-A4C* 4 —...
Page 7 Evaporator In/Out Temperature Thermistors — Evaporator Pressure Transducer — Refrigerant Storage Tank — Control Panel 10 — Carrier Controller HMI 11 — Oil Drain/Charger Valve 12 — Oil Level Sightglass 13 — Power Panel 14 — Refrigerant Oil Cooler (not shown) 15 —...
Page 8 FRONT VIEW LEGEND 1 — Suction Elbow 2 — Chiller Identification Nameplate 3 — Condenser Auto Reset Relief Valves 4 — Condenser In/Out Temperature Thermistors 5 — Evaporator In/Out Temperature Thermistors 6 — Refrigerant Storage Tank Connection Valve (barely visible) 7 —...
Page 9 FRONT VIEW LEGEND 1 — Guide Vane Actuator* 2 — Suction Elbow 3 — Chiller Identification Nameplate 4 — Auxiliary Power Panel 5 — Condenser Auto. Reset Relief Valves 6 — Condenser Return End Waterbox Cover 7 — Evaporator Return End Waterbox Cover 8 —...
Page 10: Refrigeration Cycle
valve forms a liquid seal to keep FLASC chamber vapor from en- REFRIGERATION CYCLE tering the cooler. When liquid refrigerant passes through the valve, The compressor continuously draws refrigerant vapor from the some of it flashes to vapor in the reduced pressure on the cooler cooler at a rate set by the amount of guide vane opening and motor side.
Page 11: Motor And Oil Cooling Cycle
Fig. 7 — Refrigeration Cycle — 19XR(V) Two-Stage Compressor Flow to the motor cooling system passes through an orifice and MOTOR AND OIL COOLING CYCLE into the motor. Once past the orifice, the refrigerant is directed The motor and the lubricating oil are cooled by liquid refrigerant over the motor by spray nozzles.
Page 12: Lubrication Cycle
The oil pump is a gerotor-style pump with external filters. A LUBRICATION CYCLE gerotor pump has two rotors, one inside the other; their center Summary points are offset with respect to each other. This type of pump provides a smooth continuous flow. It is also quieter than other The oil pump, oil filter, and oil cooler make up a package located designs.
Page 13 FWD MOTOR REAR MOTOR BEARING BEARING OIL SUPPLY TO FORWARD HIGH SPEED BEARING LABYRINTH GAS LINE REAR HIGH OIL PRESS SPD BRG MOTOR REGULATOR COOLING LINE OIL FILTER FLOW STRAINERS OIL PUMP TXV BULB AND MOTOR HEATER ISOLATION VALVES PRESSURE EDUCTORS TRANSDUCER OIL COOLER...
Page 14 LEGEND 1 — Gerotor Oil Pump 2 — Isolation Valve 3 — Oil Pressure Regulator Valve 4 — Oil Sump Pressure Transducer 5 — Oil Sump Drain 6 — Bearing Temperature Sensor Terminal Block 7 — Oil Heater Fig. 10 — 19XR2-E Gerotor Oil Pump LEGEND a19-2116 1 —...
Page 15: Starting Equipment
19XR6-7 it is typical that 3-phase power is field supplied to the LiquiFlo2 is an active front end drive while PowerFlex 755, Carrier control panel which powers oil-pump, heater and controls. LCX 9000, and PowerFlex 700L are 6-pulse passive rectifier Consult specific wiring diagrams for details.
Page 16 1, 2 1 — Fuse Block, 30A, 600V, Class CC 2 — Fuse, Class CC, 600V, 20A (3) 3 — AC Contactor (3) — Pre-Charge 4 — Input Conductor Assembly 5 — Pre-Charge Resistor Assembly 6 — Power Module Assembly 7 —...
Page 17 Fig. 13 — PowerFlex 755 VFD Frame 6 Drive Fig. 14 — PowerFlex 755 VFD Frame 7 Drive Components (Internal) Components (Internal) Table 1 — LCX 9000 VFD Frame Size and Application (19XRV, 380-480V) MAXIMUM EATON FRAME CARRIER CONTINUOUS SIZE PART NO. AMP RATING 19XVE0485 19XVE0550 CH72...
Page 18 a19-1933 460V TRANSFORMER 3KVA 120V Cutler-Hammer ready fault START bypass STOP enter LEGEND — Inverter (198 lb; 485, 550, 605, or 680 amp) — Shunt Trip — Breaker Lug Kit (Load Side) — Breaker Lug Kit (Line Side) — Breaker Rating Plug —...
Page 19 460V TRANSFORMER 3KVA 120V Cutler-Hammer ready fault START bypass STOP enter LEGEND — Inverter (617 lb; 1275 or 1530 amp,) — Line Choke (400 amp, 118 lb; 500 amp, 118 lb; 600 amp, 175 lb) a19-1935 — Shunt Trip — Breaker Lug Kit (Load Side) —...
Page 20: Unit-Mounted Starters
The 19XR2-E chiller offers unit-mounted wye-delta and solid to speed. Once the motor is up to speed, the starter automatically state starters. See Carrier Specification Z-415 for specific starter connects the phase windings into a delta configuration. When con- requirements.
Page 21: Start-Up/Shutdown/ Recycle Sequence
NOTE: Prior to start-up, the start-to-start timer and the stop-to- Table 2 — Major PIC 6 Components and start timer must have elapsed and all alarms must be cleared (see Panel Locations Troubleshooting Guide section on page 53). When start-up is initiated, the status screen displays start-up prog- PIC 6 COMPONENT PANEL LOCATION ress and the Start/Stop icon...
Page 22 Fig. 21 — Chiller Controls and Sensor Locations MOTOR TEMPERATURE SENSOR CABLE COMPRESSOR OIL DISCHARGE OIL RECLAIM PRESSURE CABLE SIGHT GLASS BEARING TEMPERATURE SENSOR CABLE COMPRESSOR OIL SUMP DIFFUSER PRESSURE PRESSURE CABLE AND DIFFUSER ACTUATOR CABLE (FRAME 4 & 5 COMPRESSOR ONLY) COMPRESSOR OIL SUMP TEMPERATURE CABLE...
Page 23: Lubrication Control
Lubrication Control As part of the pre-start checks executed by the controls, the oil sump temperature is compared to the evaporator saturated refrig- erant temperature. If the oil temperature is less than 140F (60C) and less than evaporator saturated refrigerant temperature plus 50°F (27.8°C), the start-up will be delayed until either of these conditions is no longer true.
Page 24: Tighten All Gasketed Joints
Tighten All Gasketed Joints Check Chiller Tightness Gaskets normally relax by the time the chiller arrives at the job- Figure 26 outlines the proper sequence and procedures for leak site. Tighten all gasketed joints to ensure a leak-tight chiller (does testing.
Page 25 a19-1151tf.eps...
Page 26: Refrigerant Tracer
Vacuum Test section, below. ant, Carrier recommends the following leak test procedure. Refer b. If the chiller fails the standing vacuum test, check for to Tables 6 and 7 for refrigerant pressure/temperature values.
Page 27 Table 6 — Pressure — Temperature (F) Table 7 — Pressure — Temperature (C) TEMPERATURE HFC-134a PRESSURE R-513A PRESSURE TEMPERATURE HFC-134a PRESSURE R-513A PRESSURE (PSIG) (PSIG) (kPa) (kPa) 6.50 9.22 –17.8 44.8 63.6 7.52 10.32 –16.7 51.9 71.1 8.60 11.45 –15.6 59.3 79.0...
Page 28: Chiller Dehydration
Carrier as- Dehydration can be done at room temperatures. Using a cold trap sumes no responsibility for chiller damage resulting from un- (Fig.
Page 29: Mechanical Starter
(19XR6/7), power panel terminals is correct with no external power supplied to the (19XR2-E) and optional pumpout compressor. inputs of the Carrier/starter controls. Ensure that fused disconnects or circuit breakers have Verify that all of the VFD power module circuit board con- been supplied for all power leads to the chiller or associ- nectors are fully engaged and taped in place.
Page 30: Carrier Comfort Network (Ccn) And Local Equipment Network (Len) Interface
WARNING sight glass (Fig. 3-5). If oil is added, it must meet Carrier’s spec- Do not apply power unless a qualified Carrier technician is ification for centrifugal compressor use as described in the Oil present.
Page 31: Power Up Controls And Check Oil Heater
They should match the chiller labels and data sheets for the selection. If you have questions contact the Carrier Technical Service Manager or Service Engineering. See the 19XR with PIC 6 Controls Operation and Troubleshooting manual for instructions on using the PIC 6 interface to configure the 19XR unit.
Page 32 Passwords must be from 1 to 5 digits (range from 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. Fig. 33 — Unit Selection INPUT TIME AND DATE LOGIN/LOGOUT Set day and time and if applicable Holidays through Main Menu Press the lock icon on the home screen to enter the password.
Page 33 Table 9 — Typical Job Site Parameters (Main MenuConfiguration MenuOption Configuration [for all Starter/VFD options]) PARAMETER TABLE CONF_OPT — Disable/Enable AUTO RESTART OPTION CONF_OPT — Disable/Enable COMMON SENSOR OPTION CONF_OPT — 0=No EC valve, 1= Continuous (two contactor control - one to open, one to close with EC (HGBP) VALVE OPTION feedback of fully closed and open position), 2= on/off (1 contactor control - either on or off and no feedback), 3 = mA (control by 4-20 mA signal with feedback)
Page 34: Field Set Up And Verification
REFRIGERATION. THE COMPRESSOR MOTOR CONTROLLER AND OVERLOAD PROTECTION MUST BE side of the VFD (See Fig. 35). IN ACCORDANCE WITH CARRIER a19-1881 SPECIFICATION Z-415. - Internal Machine Electrical Nameplate — located on the inside of the left VFD enclosure door.
Page 35 CALC REF DELTA TSAT + ENVELOPE LINE OFFSET surge prevention will occur. If ACTUAL GUIDE VANE POSITION is less than 30%, then in- crease SURGE DELTA TSMIN in steps of 2ºF (1.2ºC) until one of the three conditions listed above no longer applies. Do not Tsmax=60 change SURGE DELTA TSMAX.
Page 36: Perform A Controls Test (Quick Test/Quick Calibration)
The Configuration Menu has other tables to select, view, or modi- accessed when the chiller is in STOP mode.) On the QUICK fy parameters. Carrier’s certified drawings have the configuration TEST table screen, select a test to be performed. values required for the jobsite. Modify these values only if re- quested.
Page 37: Check Optional Pumpout System Controls And Compressor
Quick Calibration, which is also located in the Main Menu, is used Slowly open the refrigerant charging valves. The chiller to calibrate inlet guide vanes and devices with 4-20mA feedback. cooler and condenser pressures will gradually equalize. Calibration is mandatory for chiller function and controls will not This process takes approximately 15 minutes.
Page 38 TRIMMING REFRIGERANT CHARGE the 19XR Installation Instructions manual for required chiller re- frigerant charge or consult chiller nameplates. The 19XR chiller is shipped with the correct charge for the design If low load oil loss is experienced, operate the chiller at low load duty of the chiller.
Page 39: Initial Start-Up
INITIAL START-UP IMPORTANT: Startup engineer is to be properly certified for the starter/VFD. Extended VFD warranty may be affected. 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.
Page 40: Operating Instructions
Consult the For 19XR6/7:.The bearing temperature accessed from the water treatment company for details. Carrier is not responsible Temperatures menu should be 140 to 210°F (60 to 99°C) for for waterside corrosion.
Page 41: After Extended Shutdown
This is a good time to brush the tubes and inspect the of data is possible by using CCN devices such as the Data Collec- Schrader fittings on the waterside flow devices for fouling, if nec- tion module and a Building Supervisor. Contact a Carrier repre- essary. sentative for more information.
Page 43: Operating The Optional Pumpout Unit (Fig. 44)
POSITIVE PRESSURE CHILLERS WITH STORAGE TANKS DANGER In the Valve/Condition tables that accompany these instructions, the letter “C” indicates a closed valve. Figures 40 and 41 show During transfer of refrigerant into and out of the optional stor- the locations of the valves. age tank, carefully monitor the storage tank level gage.
Page 44 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 storage VALVE tank, carefully monitor the storage tank level gage. Do not fill CONDITION the tank more than 90% of capacity to allow for refrigerant ex- b.
Page 45 h. Turn off the pumpout compressor. Return Refrigerant to Normal Operating Conditions Evacuate gas from chiller cooler vessel. Be sure that the chiller vessel that was opened has been a. Close liquid line service valves 2 and 5; open valves 3 evacuated.
Page 46: General Maintenance
Remove the set screw in the guide vane coupling. In addition, Carrier recommends that leaks totaling less than the Loosen the holddown bolts on the guide vane actuator. above rate but more than a rate of 0.1% of the total charge per year Pull the guide vane actuator away from the suction housing.
Page 47 SUCTION GUIDE VANE GUIDE VANE HOUSING ACTUATOR ACTUATOR SHAFT SCREWS GUIDE VANE ACTUATOR SPROCKET DRIVE CHAIN ACTUATOR BRACKET CHAIN GUARD HOLDDOWN BOLTS (3) GUIDE VANE SHAFT GUIDE VANE a19-1731 SPROCKET Fig. 46 — 19XR2,3,4,5,E Guide Vane Actuator Linkage GUIDE VANE ACTUATOR a19-2123 Fig.
Page 48: Trim Refrigerant Charge
GUIDE VANE ACTUATOR Fig. 48 — Guide Vane Actuator, Frame Size 7 GUIDE VANE ACTUATOR SET SCREW ACTUATOR BRACKET GUIDE VANE COUPLING a19-2128 HOLDDOWN NOTE: Rotate coupling clockwise to close guide vanes. BOLTS (4) Rotate coupling counterclockwise to open guide vanes. Fig.
Page 49: Scheduled Maintenance
The PIC 6 control system continues Oil Specification with start-up only after the temperature is within allowable limits. If oil is added, it must meet Carrier specifications. For units using R-134a/R-513A, use inhibited polyolester-based synthetic com- SCHEDULED MAINTENANCE pressor oil formatted for use with HFC, gear-driven, hermetic compressors, with ISO Viscosity Grade 68.
Page 50: Vfd Refrigerant Strainer (If Equipped)
ECONOMIZER FLOAT SYSTEM (IF EQUIPPED) VFD Refrigerant Strainer (if equipped) A refrigerant strainer is located in the in. line that supplies re- For two-stage compressors, the economizer has a low side ball frigerant to the VFD. The strainer should be replaced once a year type float system.
Page 51: Inspect Relief Valves And Piping
Contact damage to the equipment and possible injury to personnel, these your Carrier representative to obtain these brushes. Do not use devices must be kept in peak operating condition. wire brushes.
Page 52: Recalibrate Pressure Transducers
Fig. 53 — Pumpout Control Box (Interior) Service Instructions. Ordering Replacement Chiller Parts OPTIONAL PUMPOUT COMPRESSOR OIL CHARGE When ordering Carrier specified parts, the following information Use oil conforming to Carrier specifications for reciprocating must accompany an order: compressor usage. Oil requirements are as follows: •...
Page 53: Troubleshooting Guide
TROUBLESHOOTING GUIDE Checking Display Messages The first area to check when troubleshooting the 19XR is the HMI Overview display. Status messages are displayed at the bottom of the screen, The PIC 6 control system has many features to help the operator and the alarm icon indicates a fault.
Page 54 Table 12 — 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 55 Table 13 — 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 56 CHECK SENSOR ACCURACY sensor, apply a pipe sealant or thread sealant to the sensor threads. Place the sensor in a medium of known temperature and compare An additional thermistor, factory installed in the bottom of the that temperature to the measured reading. The thermometer used cooler barrel, is displayed as Evap Refrig Liquid Temp on the to determine the temperature of the medium should be of laborato- TEMPERATURES display screen.
Page 57: Checking Pressure Transducers
voltage ratio of the transducer. To obtain the voltage Checking Pressure Transducers ratio, divide the voltage (dc) input from the transducer by There are 4 typically factory-installed pressure transducers mea- the supply voltage signal or measure across the positive suring refrigerant and oil pressure and, if equipped, a fifth pressure (+ red) and negative (–...
Page 58 a19-2292 Fig. 57 — Inputs for Optional Waterside Delta P Transducers for IOB4 SCHRADER VALVE NPTF TEE, BRASS WATERBOX NOZZLE BALL VALVE TWO (2) 2” PIPE NIPPLES - 18 NPT Fig. 58 — Suggested Installation of Pressure Transducers into Water Nozzles Using Flushable Dirt Leg Trap...
Page 59 Table 14 — 19XR Heat Exchanger Weights ENGLISH Dry Rigging Weight (lb) * Machine Charge Dry Rigging Weight (kg) * Machine Charge CODE † Refrigerant Weight (lb) Water Weight (lb) Refrigerant Weight (kg) Water Weight (kg) Evaporator Condenser Evaporator Condenser Only Only Only...
Page 60 Table 14 — 19XR Heat Exchanger Weights (cont) ENGLISH Dry Rigging Weight (lb) * Machine Charge Dry Rigging Weight (kg) * Machine Charge CODE † Refrigerant Weight (lb) Water Weight (lb) Refrigerant Weight (kg) Water Weight (kg) Evaporator Condenser Evaporator Condenser Only Only...
Page 61 Table 14 — 19XR Heat Exchanger Weights (cont) ENGLISH Dry Rigging Weight (lb) * Machine Charge Dry Rigging Weight (kg) * Machine Charge CODE † Refrigerant Weight (lb) Water Weight (lb) Refrigerant Weight (kg) Water Weight (kg) Evaporator Condenser Evaporator Condenser Only Only...
Page 62 Table 14 — 19XR Heat Exchanger Weights (cont) ENGLISH Dry Rigging Weight (lb) * Machine Charge Dry Rigging Weight (kg) * Machine Charge CODE † Refrigerant Weight (lb) Water Weight (lb) Refrigerant Weight (kg) Water Weight (kg) Evaporator Condenser Evaporator Condenser Only Only...
Page 63 Table 15 — Economizer Weight DRY WEIGHT REFRIGERANT OPERATION DRY WEIGHT REFRIGERANT OPERATION FRAME SIZE (lb)* WEIGHT (lb) WEIGHT (lb) (kg)* WEIGHT (kg) WEIGHT (kg) XRC (fr 5 HX) 1019 1229 XRC (fr 6,7 HX) 1252 1502 1054 1337 1589 1949 2749 3395...
Page 64 Table 17 — 19XRV Additional Data for Marine Waterboxes (19XR6/7)* ENGLISH (lb) SI (kg) HEAT EXCHANGER COUPLING TYPE Rigging Weight Water Weight Rigging Weight Water Weight FRAME, PASS psig Cooler Condenser Cooler Condenser Cooler Condenser Cooler Condenser Victaulic 2794 2582 1267 1171 SIZE 6,...
Page 65 (compressor weight column), stator, rotor, and end bell included. Applicable to standard compressors only. For high lift com- cover weights. pressors, contact Carrier Chiller Marketing for weights. † See Model Number Nomenclature. †† Stator weight includes the stator and shell.
Page 66 (compressor weight column), stator, rotor, and end bell included. Applicable to standard compressors only. For high lift com- cover weights. pressors, contact Carrier Chiller Marketing for weights. † See Model Number Nomenclature. †† Stator weight includes the stator and shell.
Page 67 Table 20 — 19XR,XRV COMPRESSOR AND MOTOR WEIGHTS*— STANDARD AND HIGH-EFFICIENCY MOTORS COMPRESSOR FRAME SIZE 4† ENGLISH Compressor Compressor 60 Hz 50 Hz 60 Hz 50 Hz End Bell End Bell MOTOR Weight** Weight** Cover Cover CODE Stator Rotor Stator Rotor Stator Rotor...
Page 68 (compressor weight column), stator, rotor, and end bell included. Applicable to standard compressors only. For high lift com- cover weights. pressors, contact Carrier Chiller Marketing for weights. † See Model Number Nomenclature. †† Stator weight includes the stator and shell.
Page 69 Table 21 — 19XR,XRV COMPRESSOR AND MOTOR WEIGHTS*— STANDARD AND HIGH-EFFICIENCY MOTORS COMPRESSOR FRAME SIZE 5† ENGLISH 60 Hz 50 Hz 60 Hz 50 Hz End Bell End Bell MOTOR Compressor Compressor Cover Cover Stator Rotor Stator Rotor Stator Rotor Stator Rotor CODE...
Page 70 (compressor weight column), stator, rotor, and end bell included. Applicable to standard compressors only. For high lift com- cover weights. pressors, contact Carrier Chiller Marketing for weights. † See Model Number Nomenclature. †† Stator weight includes the stator and shell.
Page 71 Table 22 — 19XR,XRC COMPRESSOR AND MOTOR WEIGHTS*— HIGH-EFFICIENCY MOTORS COMPRESSOR FRAME SIZE C† ENGLISH 50Hz 60Hz 50Hz 60Hz Compres- Motor Compressor End Cover Stator Rotor Stator Rotor Stator Rotor Stator Rotor Code Cover Weight (lb) (lb) Weight Weight Weight Weight Weight Weight...
Page 72 Table 23 — 19XR,XRV COMPRESSOR AND MOTOR WEIGHTS*— STANDARD AND HIGH-EFFICIENCY MOTORS COMPRESSOR FRAME SIZE E† ENGLISH 60 Hz 50 Hz 60 Hz 50 Hz End Bell End Bell MOTOR Compressor Compressor Cover Cover Stator Rotor Stator Rotor Stator Rotor Stator Rotor CODE...
Page 73 (compressor weight column), stator, rotor, and end bell included. Applicable to standard compressors only. For high lift com- cover weights. pressors, contact Carrier Chiller Marketing for weights. † See Model Number Nomenclature. †† Stator weight includes the stator and shell.
Page 74 Table 24 — 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 75 Table 24 — 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 76 Table 25 — 19XR Compressor and Motor Weights* — High-Efficiency Motors Two-Stage Compressor Frame Size 6, 50 Hz ENGLISH STATOR AND ROTOR END BELL STATOR AND ROTOR END BELL MOTOR COMPRESSOR COMPRESSOR HOUSING AND SHAFT COVER HOUSING AND SHAFT COVER CODE WEIGHT†...
Page 77 Table 26 — 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 78 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 79 Table 28 — 19XR Waterbox Cover Weights Cooler Frames 2, 3 ENGLISH (LB) METRIC (KG) COOLER COOLER WATERBOX DESCRIPTION FRAME 2 FRAME 3 FRAME 2 FRAME 3 NOZZLES FLANGED NOZZLES FLANGED NOZZLES FLANGED NOZZLES FLANGED NIH, 1 Pass Cover, 150 psig (1034 kPa) NIH, 2 Pass Cover, 150 psig (1034 kPa) NIH, 3 Pass Cover, 150 psig (1034 kPa) MWB End Cover, 150 psig (1034 kPa)
Page 80 Table 30 — 19XR Waterbox Cover Weights Cooler Frames 4, 5 ENGLISH (LB) METRIC (KG) COOLER COOLER WATERBOX DESCRIPTION FRAME 4 FRAME 5 FRAME 4 FRAME 5 FLANGED FLANGED FLANGED FLANGED NOZZLES NOZZLES NOZZLES NOZZLES NIH, 1 Pass Cover, 150 psig (1034 kPa) NIH, 2 Pass Cover, 150 psig (1034 kPa) NIH, 3 Pass Cover, 150 psig (1034 kPa) MWB End Cover, 150 psig (1034 kPa)
Page 81 Table 32 — 19XR Waterbox Cover Weights Cooler Frames 6, 7 ENGLISH (LB) METRIC (KG) COOLER COOLER WATERBOX DESCRIPTION FRAME 6 FRAME 7 FRAME 6 FRAME 7 FLANGED FLANGED FLANGED FLANGED NOZZLES NOZZLES NOZZLES NOZZLES NIH, 1 Pass Cover, 150 psig (1034 kPa) NIH, 2 Pass Cover, 150 psig (1034 kPa) NIH, 3 Pass Cover, 150 psig (1034 kPa) 1250...
Page 82 Table 34 — 19XR Waterbox Cover Weights Cooler Frames 8 ENGLISH (LB) METRIC (KG) COOLER COOLER WATERBOX DESCRIPTION FRAME 8 FRAME 8 FLANGED FLANGED NOZZLES NOZZLES NIH, 1 Pass Cover, 150 psig (1034 kPa) NIH, 2 Pass Cover, 150 psig (1034 kPa) NIH, 3 Pass Cover, 150 psig (1034 kPa) 1629 1687...
Page 83 Table 36 — 19XR Waterbox Cover Weights, Two-Stage Compressor Frame 6 Two-Stage Compressor Frame 6; Cooler Frame A ENGLISH (LB) METRIC (KG) COOLER COOLER WATERBOX DESCRIPTION PASSES FRAME A FRAME A STANDARD STANDARD FLANGED FLANGED NOZZLES NOZZLES Dished Head, 150 psig 1006 1171 MWB End Cover, 150 psig...
Page 84 Table 38 — 19XR Waterbox Cover Weights, Two-Stage Compressor Frame 7 Two-Stage Compressor Frame 7; Cooler Frames B, C ENGLISH (LB) METRIC (KG) COOLER COOLER WATERBOX DESCRIPTION PASSES FRAME B FRAME C FRAME B FRAME C FLANGED FLANGED FLANGED FLANGED NOZZLES NOZZLES NOZZLES...
Page 85 Table 40 — 19XR2-E Component Weights FRAME 2 FRAME 3 FRAME 4 FRAME 5 FRAME E COMPRESSOR* COMPRESSOR* COMPRESSOR* COMPRESSOR* COMPRESSOR* COMPONENT SUCTION ELBOW DISCHARGE ELBOW CONTROL PANEL† OPTIONAL COOLER INLET ISOLATION VALVE OPTIONAL DISCHARGE ISOLATION VALVE STD TIER VFD — 380, 400, AND 460-V —...
Page 86 High Speed Journal-Gear End .0050/.0040 .0048/.0038 .0062/.0052 Depends on impeller size, contact your Carrier Service Representa- removed) and the bearing temperature sensor must be removed from tive for more information. the high speed shaft and bearing assembly before the high speed shaft and bearing assembly can be separated from the transmission.
Page 87 THRUST THRUST a19-1637 a19-1636 VIEW A1 VIEW A2 LOW SPEED SHAFT THRUST DISK LOW SPEED SHAFT THRUST DISK FRAME 2 COMPRESSORS FRAME 3, 4, AND 5 COMPRESSORS NOTE 5 THRUST IMPELLER SHIMMING TO BE DETERMINED AT ASSEMBLY SEE VIEW C a19-1639 VIEW B —...
Page 88 +0.0007 -0.0007 0.0050 0.025 0.0020 0.005 +0.0007 -0.0007 THRUST 0.0011 0.0013 INTERFERENCE 0.0011 a19-1640 0.0013 INTERFERENCE 0.0012 0.0004 VIEW B — HIGH SPEED SHAFT WITH ROLLING ELEMENT BEARINGS a19-1641 VIEW C — HIGH SPEED SHAFT RING SEAL Fig. 59 — Compressor Fits and Clearances — Single-Stage Compressors (cont)
Page 89 Table 43 — 19XR Compressor Frame C, E Fits and Clearances COMPRESSOR FRAME C FRAME E ITEM CODE C21-C09 E21-E69 DESCRIPTION ROLLING ELEMENT BEARINGS ROLLING ELEMENT BEARINGS Low Speed Journal - Gear End 0.0055/0.0043 0.0069/0.0059 Low Speed Journal - Motor End 0.0053/0.0043 0.0065/0.0055 Low Speed Labyrinth to Thrust Disk...
Page 90 –0.0007-0.0007 [0/017-0.017] THRUST 0.003-0.0011 [0.008-0.027] Interference fit VIEW A2 VIEW D LOW SPEED SHAFT THRUST DISK REAR, HIGH SPEED SHAFT BEARING 0.02 - 0.024 [0.50 - 0.60] 0.00079 - 0.0007 [0.020 - 0.018] –0.0014 - 0.0000 [-0.035 - 0.000] 0.012 - 0.016 [0.31 - 0.40] –0.0014 - 0.000 [–0.035 - 0.000]...
Page 91 Table 44 — 19XR Two-stage Compressor Frames 6 and 7 Fits and Clearances COMPRESSOR ITEM FRAME 6 (in.) FRAME 6 (mm) FRAME 7 (in.) FRAME 7 (mm) DESCRIPTION Low Speed Journal — Compressor End 0.006/0.007 0.15/0.18 0.006/0.008 0.15/0.19 Low Speed Journal —Motor End 0.004/0.005 0.10/0.11 0.004/0.006...
Page 92 ITEM N ITEM O SECTION B-B SEE DETAIL E ITEM M ITEM F ITEM E LEGEND — 1st Stage Eye Labyrinth a19-2277 — 1st Stage Impeller Shim — Intake Wall ITEM K — 2nd Stage Eye Labyrinth — Diaphragm ITEM L —...
Page 93 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. 61 — Compressor Fits and Clearances — Two-Stage Compressor, Frame Sizes 6 and 7 (cont)
Page 94 Mandatory for medium/high voltage. CAUTION CAUTION USE COPPER CONDUCTORS ONLY USE COPPER CONDUCTORS ONLY UTILISEZ DES CONDUCTEURS EN CUIVRE SEULMENT UTILISEZ DES CONDUCTEURS EN CUIVRE SEULMENT ALWAYS USE 2 WRENCHES TO TIGHTEN ALWAYS USE 2 WRENCHES TO TIGHTEN • TERM INSULATOR TO MOTOR – 15-35 ft. lb. •...
Page 95 Mandatory for medium/high voltage. 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 •...
Page 96 Fig. 64 — 19XR2-E Control Panel Fig. 65 — 19XR2-E Control Panel, IOB Layer...
Page 97 OPTION FOR 19XRC 230V T1 AND T2 OUTPUT ARE 24 VAC GUIDE VANE CONTROL TRANSFORMERS ACTUATOR OPTIONAL EC/HGBP LOW VOLTAGE CONTROL CONTROL WIRING OIL HEATER (1C) CONTACTOR OIL PUMP (2C) CONTACTOR Fig. 66 — 19XR2-E Power Panel 7TB IN HMI PANEL FOR CUSTOMER COMMUNICATION CCN CONNECTION...
Page 98 Fig. 68 — 19XR6-7 Control Panel, IOB Layer 1TB — CUSTOMER 3-PHASE POWER CONNECTION FOR CONTROL PANEL 2TB — FIELD WIRING CONNECTION FROM STARTER Fig. 69 — 19XR6-7 Control Panel, Bottom Layer...
Page 99 TO 2IOB TO MODEM TO HMI FROM DRAWING 19XR05044701 REV C Fig. 70 — 19XR2-E Chiller Control Schematic...
Page 100 HP_SW FROM 1IOB FROM DRAWING 19XR05044701 REV C Fig. 70 — 19XR2-E Chiller Control Schematic (cont)
Page 101 TO 4IOB TO 4IOB FROM DRAWING 19XR05044701 REV C Fig. 70 — 19XR2-E Chiller Control Schematic (cont)
Page 102 FROM 3IOB FROM 3IOB FROM DRAWING 19XR05044701 REV C Fig. 70 — 19XR2-E Chiller Control Schematic (cont)
Page 103 Fig. 71 — 19XR6-7 Controls Diagram...
Page 104 Fig. 72 — 19XR6-7 IOB 1...
Page 105 Fig. 73 — 19XR6-7 IOB 2...
Page 106 Fig. 74 — 19XR6-7 IOB 3...
Page 107 Fig. 75 — 19XR6-7 IOB 4...
Page 108 GROUND NEUTRAL LEG OF THE THREE CURRENT TRANSFORMERS. USE 8TB-9, 10 (IOB3) Fig. 76 — 19XR6-7 Starter Wiring...
Page 109 LEGEND FOR Fig. 71-76 Control Abbreviations — Fig. 71-76 Wiring Codes — Fig. 71-76 — 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 110: Structure
APPENDIX A — PIC 6 SCREEN AND TABLE STRUCTURE Home Synoptic Main Menu Login/ Log out screen Confirm Stop Choose operating mode Alarm Menu Main Menu Alarm Menu Reset Alarms General Parameters Temperatures Pressures Input Status Outputs Status Hydraulic Status Current Alarms History Alarms Run Times...
Page 111: Appendix A - Pic 6 Screen And Table
APPENDIX A — PIC 6 SCREEN AND TABLE STRUCTURE (cont) Main Menu Description ICON DISPLAYED TEXT* ACCESS ASSOCIATED TABLE General Parameters GENUNIT Temperatures TEMP Pressures PRESSURE Inputs Status INPUTS Outputs Status OUTPUTS Hydraulic Status HYDRLIC Run Times RUNTIME Modes MODES Setpoint User SETPOINT...
Page 112: Appendix B - Ccn Communication Wiring For Multiple Chillers (Typical)
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 19XR6-7 shown (HMI control box) - for 19XR2-E the CCN connection is located in the control panel (see below —...
Page 113: Appendix C - Maintenance Summary And Log Sheets
APPENDIX C — MAINTENANCE SUMMARY AND LOG SHEETS 19XR Maintenance Interval Requirements WEEKLY COMPRESSOR Check Oil Level. CONTROLS Review PIC 6 Alarm/Alert History. COOLER None. STARTER None. CONDENSER None. OIL RECLAIM None. MONTHLY COMPRESSOR None. CONTROLS Perform an Automated Controls test. COOLER None.
Page 116: Index
Control test (quick test), Oil charge, Equipment required, Oil circuit valves, opening, © 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. 04-53190059-01 Printed in U.S.A.
Page 117: Initial Start-Up Checklist
REFRIGERANT: Type: Charge   CARRIER OBLIGATIONS: Assemble....  Leak Test ....Yes ...
Page 118 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 119 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 120 19XR PIC 6 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 121 19XR PIC 6 ISM CONFIGURATION TABLE (CONF_ISM) CONFIGURATION SHEET (Must be configured for all fixed speed machines with ISM, Benshaw MX3, freestanding VFD) 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...
Page 122 19XR PIC 6 OPTION CONFIGURATION TABLE (CONF_OPT) CONFIGURATION SHEET DESCRIPTION RANGE UNITS DEFAULT VALUE Auto Restart Option DSABLE/ENABLE DSABLE Common Sensor Option DSABLE/ENABLE DSABLE EC Valve Option 0 = No, 1= Cont 0 to 3 2 = On/Off, 3 = 4-20 mA EC Valve Selection 0 = Disable, 1 = Surge 0 to 3...
Page 123 19XR PIC 6 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 124 19XR PIC 6 SERVICE PARAMETERS TABLE CONFIGURATION SHEET DESCRIPTION STATUS UNITS DEFAULT VALUE 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 Proportional Dec Band 2.0 to 10.0...
Page 125 19XR PIC 6 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 126 19XR PIC 6 CFGSURGE SURGE CORRECTION CONFIG TABLE CONFIGURATION SHEET DESCRIPTION RANGE UNITS DEFAULT VALUE Surge Line Configuration 0 to 1 0=PR, 1=Delta T IGV1 Pos Configuration 0 to 1 0-Degree, 1=Percentage Surge Delta Tsmax 0.0 to 150.0 °F 70.0 Surge Delta Tsmin 0.0 to 150.0 °F...
Page 127 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 128 © 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. 04-53190059-01 Printed in U.S.A. Form 19XR-CLT-15SS Pg CL-12 9-19 Replaces: NEW...

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

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