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

Hermetic centrifugal liquid chillers 50/60 hz with hcfc-22 and hfc-134a

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Start-Up, Operation, and Maintenance Instructions

Centrifugal liquid chillers are designed to provide

safe and reliable service when operated within design

speciﬁcations. When operating this equipment, use good

judgment and safety precautions to avoid damage to

equipment and property or injury to personnel.

Be sure you understand and follow the procedures and

safety precautions contained in the chiller instructions

as well as those listed in this guide.

DO NOT VENT refrigerant relief valves within a building. Outlet

from rupture disc or relief valve must be vented outdoors in

accordance with the latest edition of ANSI/ASHRAE 15

(American National Standards Institute/American Society of Heat-

ing, Refrigeration, and Air Conditioning Engineers). The accumu-

lation of refrigerant in an enclosed space can displace oxygen and

cause asphyxiation.

PROVIDE adequate ventilation in accordance with ANSI/ASHRAE

15, especially for enclosed and low overhead spaces. Inhalation

of high concentrations of vapor is harmful and may cause heart

irregularities, unconsciousness, or death. Misuse can be fatal.

Vapor is heavier than air and reduces the amount of oxygen avail-

able for breathing. Product causes eye and skin irritation. Decom-

position products are hazardous.

DO NOT USE OXYGEN to purge lines or to pressurize a chiller

for any purpose. Oxygen gas reacts violently with oil, grease, and

other common substances.

NEVER EXCEED speciﬁed test pressures, VERIFY the allowable

test pressure by checking the instruction literature and the design

pressures on the equipment nameplate.

DO NOT USE air for leak testing. Use only refrigerant or dry

nitrogen.

DO NOT VALVE OFF any safety device.

BE SURE that all pressure relief devices are properly installed and

functioning before operating any chiller.

DO NOT WELD OR FLAMECUT any refrigerant line or vessel

until all refrigerant (liquid and vapor) has been removed from chiller.

Traces of vapor should be displaced with dry air or nitrogen and

the work area should be well ventilated. Refrigerant in contact with

an open ﬂame produces toxic gases.

DO NOT USE eyebolts or eyebolt holes to rig chiller sections or

the entire assembly.

DO NOT work on high-voltage equipment unless you are a quali-

ﬁed electrician.

DO NOT WORK ON electrical components, including control pan-

els, switches, starters, or oil heater until you are sure ALL POWER

IS OFF and no residual voltage can leak from capacitors or solid-

state components.

LOCK OPEN AND TAG electrical circuits during servicing. IF WORK

IS INTERRUPTED, conﬁrm that all circuits are deenergized be-

fore resuming work.

AVOID SPILLING liquid refrigerant on skin or getting it into the

eyes. USE SAFETY GOGGLES. Wash any spills from the skin

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.

Manufacturer reserves the right to discontinue, or change at any time, speciﬁcations or designs without notice and without incurring obligations.

Book 2

PC 211

Tab

SAFETY CONSIDERATIONS

Catalog No. 531-971

Printed in U.S.A.

Hermetic Centrifugal Liquid Chillers

With HCFC-22 and HFC-134a

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/ASHRAE-15 (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 EN-

GAGE 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.

Form 19XL-4SS

19XL

50/60 Hz

Pg 1

7-96

Replaces: 19XL-3SS

Table of Contents

Summary of Contents for Carrier 19XL

Page 1: Safety Considerations
Operation of this equipment with refrigerants other than those cited herein should comply with ANSI/ASHRAE-15 (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.
Page 2: Table Of Contents
SAFETY CONSIDERATIONS ....1 INTRODUCTION ......4 ABBREVIATIONS AND EXPLANATIONS .
Page 3 Inspect Wiring ......47 Carrier Comfort Network Interface ... 48 Check Starter .
Page 4: Introduction
Control Test ....... . 67 INTRODUCTION Prior to initial start-up of the 19XL unit, those involved in the start-up, operation, and maintenance should be thor- oughly familiar with these instructions and other necessary job data.
Page 5: Chiller Familiarization
• records the total chiller operating hours • sequences chiller start, stop, and recycle under micro- processor control • provides access to other CCN (Carrier Comfort Network) devices Factory-Mounted Starter (Optional) — allows the proper start and disconnect of electrical energy for the compressor-motor, oil pump, oil heater, and control panels.
Page 6 19XL FRONT VIEW 19XL REAR VIEW Fig. 2A — Typical 19XL Components — Design I LEGEND 1 — Unit-Mounted Starter 2 — Refrigerant Filter Drier 3 — Rigging Guide Bolt 4 — Refrigerant Moisture Indicator 5 — Motor Sight Glass 6 —...
Page 7 19XL FRONT VIEW 19XL REAR VIEW Fig. 2B — Typical 19XL Components — Design II 36 35 LEGEND 1 — Unit-Mounted Starter 2 — Refrigerant Filter Drier 3 — Rigging Guide Bolt 4 — Motor Sight Glass 5 — Refrigerant Moisture Indicator 6 —...
Page 8: Cooling Cycle
Fig. 3 — Refrigerant Motor Cooling and Oil Cooling Cycles Refrigerant that ﬂows to the oil cooling system is reg- ulated by a thermostatic expansion valve. There is always a minimum ﬂow bypassing the TXV, which ﬂows through an oriﬁce. The TXV valve regulates ﬂow into the oil/ refrigerant plate and frame-type heat exchanger.
Page 9: Oil Reclaim System
journal bearings within the bearing housing. The oil then drains into the oil reservoir at the base of the compressor. The PIC (Product Integrated Control) measures the temperature of the oil in the sump and maintains the temperature during shut- down (see Oil Sump Temperature Control section, page 32).
Page 10: During Light Load Conditions Starting Equipment
STARTING EQUIPMENT The 19XL requires a motor starter to operate the centrif- ugal hermetic compressor motor, the oil pump, and various auxiliary equipment. The starter serves as the main ﬁeld wiring interface for the contractor. Three types of starters are available from Carrier Cor- poration: solid-state, wye-delta, and across-the-line starters.
Page 11: Unit Mounted Wye-Delta Starter
Troubleshooting Guide section, page 66. Unit-Mounted Wye-Delta Starter (Optional) — 19XL chiller may be equipped with a wye-delta starter mounted on the unit (Fig. 7). 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 12 Fig. 8 — 19XL Controls and Sensor Locations Fig. 9 — Control Sensors (Temperature) LEGEND 1 — LID 2 — PSIO 3 — 8-Input Module (One of 2 Available) Fig. 10 — Control Sensors 4 — 5-Volt Transducer Power Supply (Pressure Transducer, Typical) 5 —...
Page 13: 6-Pack Relay Board
PROCESSOR MODULE (PSIO) — The PSIO is the brain of the PIC (Fig. 11). This module contains all the operating software needed to control the chiller. The 19XL uses 3 pres- sure transducers and 8 thermistors to sense pressures and tem- peratures.
Page 14: Lid Operation And Menus
LID Operation and Menus (Fig. 13-19) GENERAL • The LID display will automatically revert to the default screen after 15 minutes if no softkey activity takes place and if the chiller is not in the Pumpdown mode (Fig. 13). • When not in the default screen, the upper right-hand cor- ner of the LID always displays the name of the screen that you have entered (Fig.
Page 15: To View Point Status
• Press EXIT to return to the previous screen level. • Press INCREASE or DECREASE to change the high- lighted point value. TO VIEW POINT STATUS (Fig. 15) — Point Status is the actual value of all of the temperatures, pressures, relays, and actuators sensed and controlled by the PIC.
Page 16: Time Schedule Operation
3. Press RELEASE to remove the override and return the point to the PIC’s automatic control. Override Indication— An override value is indicated by ‘‘SUPVSR,’’ ‘‘SERVC,’’ or ‘‘BEST’’ ﬂashing next to the point value on the Status table. TIME SCHEDULE OPERATION (Fig. 16) 1.
Page 20: To View And Change Set Points
TO VIEW AND CHANGE SET POINTS (Fig. 19) 1. To view the Set Point table, at the Menu screen press SETPOINT . 2. There are 4 set points on this screen: Base Demand Limit; LCW Set Point (leaving chilled water set point); ECW Set Point (entering chilled water set point);...
Page 21 NOTES: 1. Only 12 lines of information appear on the LID screen at any given time. Press NEXT or PREVIOUS to highlight a point or to view points below or above the current screen. 2. The LID may be conﬁgured in English or SI units, as required, through the LID conﬁguration screen. 3.
Page 22 To access this display from the LID default screen: 1. Press MENU 2. Press STATUS . 3. Scroll down to highlight STATUS02. 4. Press SELECT . DESCRIPTION Hot Gas Bypass Relay *Chilled Water Pump Chilled Water Flow *Condenser Water Pump Condenser Water Flow Compressor Start Relay Compressor Start Contact...
Page 23 EXAMPLE 5 — CONFIGURATION (CONFIG) DISPLAY SCREEN To access this display from the LID default screen: 1. Press MENU 2. Press SERVICE . 3. Scroll down to highlight EQUIPMENT CONFIGURATION. 4. Press SELECT . 5. Scroll down to highlight CONFIG. 6.
Page 24 To access this display from the LID default screen: 1. Press MENU 2. Press SERVICE . 3. Scroll down to highlight EQUIPMENT SERVICE. 4. Press SELECT . 5. Scroll down to highlight SERVICE1. 6. Press SELECT . DESCRIPTION CONFIGURABLE RANGE Motor Temp Override 150-200 (66-93) 150-245 (1034-1689)
Page 25 To access this display from the LID default screen: 1. Press MENU 2. Press SERVICE . 3. Scroll down to highlight EQUIPMENT SERVICE. 4. Press SELECT . 5. Scroll down to highlight SERVICE2. 6. Press SELECT . DESCRIPTION CONFIGURABLE RANGE OPTIONS BOARD 1 20 mA POWER CONFIGURATION External = 0, Internal = 1...
Page 26 EXAMPLE 10 — MAINTENANCE (MAINT01) DISPLAY SCREEN To access this display from the LID default screen: 1. Press MENU 2. Press SERVICE . 3. Scroll down to highlight ALGORITHM STATUS. 4. Press SELECT . 5. Scroll down to highlight MAINT01. DESCRIPTION CAPACITY CONTROL Control Point...
Page 27 EXAMPLE 12 — MAINTENANCE (MAINT03) DISPLAY SCREEN To access this display from the LID default screen: 1. Press MENU 2. Press SERVICE . 3. Scroll down to highlight CONTROL ALGORITHM STATUS. 4. Press SELECT . 5. Scroll down to highlight MAINT03. 6.
Page 28: Pic System Functions
PIC System Functions NOTE: Throughout this manual, words printed in capital let- ters and italics represent values that may be viewed on the LID. See Table 2 for examples of LID screens. Point names are listed in the Description column. An overview of LID operation and menus is given in Fig.
Page 29: Safety Controls
Safety Controls — The PIC monitors all safety control inputs, and if required, shuts down the chiller or limits the guide vanes to protect the chiller from possible damage from any of the following conditions: • high bearing temperature • high motor winding temperature •...
Page 30 Table 3 — Protective Safety Limits and Control Settings MONITORED PARAMETER TEMPERATURE SENSORS OUT OF RANGE PRESSURE TRANSDUCERS OUT OF RANGE COMPRESSOR DISCHARGE TEMPERATURE MOTOR WINDING TEMPERATURE BEARING TEMPERATURE EVAPORATOR REFRIGERANT TEMPERATURE TRANSDUCER VOLTAGE CONDENSER PRESSURE — SWITCH — CONTROL OIL PRESSURE —...
Page 31: Ramp Loading Control
Ramp Loading Control — The ramp loading control slows down the rate at which the compressor loads up. This control can prevent the compressor from loading up during the short period of time when the chiller is started, and the chilled water loop has to be brought down to normal design conditions.
Page 32: High Discharge Temperature Control
High Discharge Temperature Control — discharge temperature increases above 160 F (71.1 C) (PSIO Software Version 09 and higher) or 180 F (82 C) (PSIO Software Version 08 or lower), the guide vanes are propor- tionally opened to increase gas ﬂow through the compressor. If the leaving chilled water temperature is then brought 5°...
Page 33: Tower Fan Relay
Tower Fan Relay — Low condenser water tempera- ture can cause the chiller to shut down on low refrigerant temperature. The tower fan relay, located in the starter, is controlled by the PIC to energize and deenergize as the pres- sure differential between cooler and condenser vessels changes in order to prevent low condenser water temperature and to maximize chiller efficiency.
Page 34: Surge Protection
— Leaving Chilled Water P = (Condenser kPa) — (Cooler kPa) T = (ECW) — (LCW) Fig. 21 — 19XL with Default Metric Settings Lead/Lag System Requirements: • all chillers must have PSIO software capable of perform- ing the lead/lag function •...
Page 35: Common Point Sensor Installation
CHILLER COMMUNICATION WIRING — Refer to the chiller’s Installation Instructions or to the Carrier Comfort Network Interface section on page 48 of this manual for information on chiller communication wiring.
Page 36: Faulted Chiller Operation
4. Lead chiller temperature pulldown rate of the CHILLED WATER temperature is less than 0.5° F (0.27° C) per minute. 5. The lag chiller status indicates it is in CCN mode and is not faulted. If the current lag chiller is in an alarm con- dition, then the standby chiller becomes the active lag chiller, if it is conﬁgured and available.
Page 37: Temperature Control During Ice Build
START-UP/RECYCLE OPERATION — If the chiller is not running when ice build activates, then the PIC checks the following parameters, based on the ICE BUILD TERMINA- TION value, to avoid starting the compressor unnecessarily: • if ICE BUILD TERMINATION is set to the temperature only option (zero) and the ENTERING CHILLED WATER temperature is less than or equal to the ICE BUILD SET POINT;...
Page 38: Attaching To Other Ccn Modules Service Operation
ATTACH TO NETWORK DEVICE table and press the ATTACH softkey to upload the LOCAL device. The PSIO for the 19XL will now be uploaded. NOTE: The LID will not automatically reattach to the PSIO module on the chiller. Press the ATTACH softkey to attach to LOCAL DEVICE and view the chiller PSIO.
Page 39: Start-Up/Shutdown/Recycle
6. Press NEXT to highlight the holiday table that you wish to view or change. Each table is one holiday pe- riod, starting on a speciﬁc date, and lasting up to 99 days. 7. Press SELECT to access the holiday table. The Con- ﬁguration Select table now shows the holiday start month and day, and how many days the holiday period will last.
Page 40: Shutdown Sequence
and go into a RECYCLE mode. If the water/brine tempera- ture is high enough, the start-up sequence continues on to check the guide vane position. If the guide vanes are more than 6% open, the start-up waits until the PIC closes the vanes. If the vanes are closed, and the oil pump pressure is less than 3 psid (21 kPad), the oil pump relay will then be en- ergized.
Page 41: Safety Shutdown
Check Chiller Tightness — proper sequence and procedures for leak testing. 19XL chillers are shipped with the refrigerant contained in the condenser shell and the oil charge shipped in the compressor. The cooler will have a 15 psig (103 kPa) refrigerant charge.
Page 43: Standing Vacuum Test
procedures in the Transfer Refrigerant from Storage Tank to Chiller section, Steps 1a-e, page 59. Never charge liquid refrigerant into the chiller if the pressure in the chiller is less than 68 psig (469 kPa) for HCFC-22 and 35 psig (241 kPa) for HFC-134a.
Page 44 Table 5A — HCFC-22 Pressure — Temperature (F) PRESSURE (psi) TEMPERATURE Absolute Gage −50 11.67 6.154* −48 12.34 4.829* −46 13.00 3.445* −44 13.71 2.002* −42 14.45 0.498* −40 15.22 0.526 −38 16.02 1.328 −36 16.86 2.163 −34 17.73 3.032 −32 18.63 3.937...
Page 45 Table 5C — HFC-134a Pressure — Temperature (F) TEMPERATURE PRESSURE (psig) 6.50 7.52 8.60 9.66 10.79 11.96 13.17 14.42 15.72 17.06 18.45 19.88 21.37 22.90 24.48 26.11 27.80 29.53 31.32 33.17 35.08 37.04 39.06 41.14 43.28 45.48 47.74 50.07 52.47 54.93 Table 5D —...
Page 46 Fig. 27 — Typical Optional Pumpout System Piping Schematic with Storage Tank Fig. 28 — Typical Optional Pumpout System Piping Schematic without Storage Tank...
Page 47: Chiller Dehydration
Piping connections must allow for access to the valve mechanism for periodic inspection and leak testing. 19XL relief valves are set to relieve at the 300 psig (2068 kPa) chiller design pressure. Inspect Wiring Do not check voltage supply without proper equipment and precautions.
Page 48: Carrier Comfort Network Interface
Clean and inspect the contactors if this has occurred. Carrier Comfort Network Interface — Comfort Network (CCN) communication bus wiring is sup- plied and installed by the electrical contractor. It consists of shielded, 3-conductor cable with drain wire.
Page 49: Benshaw, Inc. Solid-State Starter
3. Some dashpot-type magnetic overload relays must be filled with oil on the jobsite. If the starter is equipped with de- vices of this type, remove the ﬂuid cups from these mag- netic overload relays. Add dashpot oil to cups per instructions supplied with the starter.
Page 50: Oil Charge
(Fig. 2A or 2B). If oil is added, it must meet Carrier’s speci- ﬁcation for centrifugal compressor usage as described in the Oil Speciﬁcation section on page 63.
Page 51: Modify Controller Identification
MODIFY CONTROLLER IDENTIFICATION IF NECES- SARY — The controller identiﬁcation screen is used to change the PSIO module address. Change this address for each chiller if there is more than one chiller at the jobsite. Write the new address on the PSIO module for future reference. Change the LID address if there is more than one chiller on the jobsite.
Page 52: Modify Equipment Configuration
3300/50 MODIFY EQUIPMENT CONFIGURATION IF NECES- SARY — The Equipment Conﬁguration table has tables to select and view or modify. Carrier’s certiﬁed drawings will have the conﬁguration values required for the jobsite. Modify these tables only if requested. Conﬁg Table Modiﬁcations — Change the values in this table per job data.
Page 53: High Altitude Locations
The standard 19XL chiller will have the refrigerant already charged in the vessels. The 19XL may be ordered with a nitrogen holding charge of 15 psig (103 kPa). Evacu- ate the entire chiller, and charge chiller from refrigerant cylinders.
Page 54: 19Xl Chiller Equalization With
19XL CHILLER EQUALIZATION WITH PUMPOUT UNIT — The following procedure describes how to equal- ize refrigerant pressure on an isolated 19XL chiller using the pumpout unit. 1. Access the TERMINATE LOCKOUT mode in the Con- trol Test. 2. Turn on the chilled water and condenser water pumps to prevent possible freezing.
Page 55: Initial Start-Up
INITIAL START-UP Preparation — Before starting the chiller, check that the: 1. Power is on to the main starter, oil pump relay, tower fan starter, oil heater relay, and the chiller control center. 2. Cooling tower water is at proper level, and at or below design entering temperature.
Page 56: Check Oil Pressure And Compressor Stop
2. Observe that all 6-gate LEDs are lit on the starter SCR control board. 3. The factory setting should bring the motor to full voltage in 15 to 30 seconds. If the setting is not correct, adjust the ramp potentiometer counterclockwise for a shorter time, clockwise for a longer time.
Page 57: To Stop The Chiller
Automatic recording of PIC data is possible through the use of CCN devices such as the Data Collection module and a Building Supervisor. Contact your Carrier representative for more information. Be sure that the water...
Page 59: Pumpout And Refrigerant Transfer Procedures
PUMPOUT AND REFRIGERANT TRANSFER PROCEDURES Preparation — The 19XL may come equipped with an optional storage tank or pumpout system, or a pump- out compressor. The refrigerant can be pumped for service work to either the cooler/compressor vessel or the condenser vessel by using the optional pumpout system.
Page 60: Transfer The Refrigerant From
2. Transfer remaining refrigerant. a. Close valve 5 and open valve 4. VALVE 1a 1b 2 3 4 5 6 7 8 10 11 12 13 14 CONDITION b. Turn off the chiller water pumps through the LID. c. Turn off the pumpout condenser water, and turn on the pumpout compressor to push liquid out of the storage tank.
Page 61: Transfer All Refrigerant To Chiller Cooler/Compressor Vessel
65 psig (448 kPa) [30 psig (207 kPa)]. Removing Refrigerant — is used, the 19XL refrigerant charge may be transferred to a pumpout storage tank or to the chiller condenser or cooler vessels. Follow procedures in the Pumpout and Refrigerant Transfer Procedures section when removing refrigerant from the pumpout storage tank to the chiller vessel.
Page 62: Repair The Leak, Retest, And Apply
The oil charge is approximately 8 gallons (30 L). The added oil must meet Carrier speciﬁcations for the 19XL. Refer to Changing Oil Filter and Oil Changes sections on page 63. Any additional oil that is added should be logged by noting the amount and date.
Page 63: Scheduled Maintenance
Changing Oil Filter — Change the oil ﬁlter on a yearly basis or when the chiller is opened for repairs. The 19XL has an isolatable oil ﬁlter so that the ﬁlter may be changed with the refrigerant remaining in the chiller. Use the follow- ing procedure: 1.
Page 64: Inspect Refrigerant Float System
During the tube cleaning process, use brushes especially designed to avoid scraping and scratching the tube wall. Con- tact your Carrier representative to obtain these brushes. Do not use wire brushes. The relief valves Hard scale may require chemical treatment for its pre- vention or removal.
Page 65: Water Treatment
Water must be within design ﬂow limits, clean, and treated to ensure proper chiller performance and reduce the potential of tubing damage due to corrosion, scaling, ero- sion, and algae. Carrier assumes no responsibility for chiller damage resulting from untreated or improperly treated water.
Page 66: Troubleshooting Guide
Alarm History table. Checking the Display Messages — to check when troubleshooting the 19XL is the LID display. If the alarm light is ﬂashing, check the primary and second- ary message lines on the LID default screen (Fig. 13). These messages will indicate where the fault is occurring.
Page 67: Control Algorithms Checkout Procedure
If the transducer value is not within the calibration range, the transducer will return to the original reading. If the LID pressure value is within the allowed range (noted above), check the voltage ratio of the transducer. To ob- tain the voltage ratio, divide the voltage (dc) input from the transducer by the supply voltage signal, measured at the PSIO terminals J7-J34 and J7-J35.
Page 68 READY TO START IN XX MIN READY TO START READY TO START STARTUP INHIBITED READY TO START IN XX MIN — Compressor Start Contact — Compressor Current — Carrier Comfort Network CDFL — Condenser Water Flow CHIL S — Chiller Start/Stop — Chilled Water CHWS —...
Page 69 Table 9 — LID Primary and Secondary Messages and Custom Alarm/Alert Messages C. IN RECYCLE SHUTDOWN PRIMARY MESSAGE RECYCLE RESTART PENDING RECYCLE RESTART PENDING RECYCLE RESTART PENDING RECYCLE RESTART PENDING D. PRE-START ALERTS: These alerts only delay start-up. When alert is corrected, the start-up will continue. No reset is necessary. PRIMARY MESSAGE SECONDARY MESSAGE PRESTART ALERT...
Page 70 Table 9 — LID Primary and Secondary Messages and Custom Alarm/Alert Messages F. START-UP FAILURES: This is an alarm condition. A manual reset is required to clear. PRIMARY MESSAGE SECONDARY MESSAGE FAILURE TO START LOW OIL PRESSURE FAILURE TO START OIL PRESS SENSOR FAULT LOW CHILLED WATER FAILURE TO START...
Page 71 Table 9 — LID Primary and Secondary Messages and Custom Alarm/Alert Messages G. COMPRESSOR JUMPSTART AND REFRIGERANT PROTECTION PRIMARY MESSAGE SECONDARY MESSAGE UNAUTHORIZED UNIT SHOULD BE OPERATION STOPPED EVAP PRESS/TEMP POTENTIAL FREEZE-UP TOO LOW FAILURE TO STOP DISCONNECT POWER LOSS OF WITH STARTER COMMUNCIATION STARTER CONTACT...
Page 72 Table 9 — LID Primary and Secondary Messages and Custom Alarm/Alert Messages I. NORMAL RUN OVERRIDES ACTIVE (ALERTS) PRIMARY MESSAGE SECONDARY MESSAGE RUN CAPACITY HIGH CONDENSER PRESSURE LIMITED RUN CAPACITY HIGH MOTOR TEMPERATURE LIMITED RUN CAPACITY LOW EVAP REFRIG TEMP LIMITED RUN CAPACITY HIGH COMPRESSOR LIFT...
Page 73 Table 9 — LID Primary and Secondary Messages and Custom Alarm/Alert Messages K. CHILLER PROTECT LIMIT FAULTS Excessive numbers of the same fault can lead to severe chiller damage. Seek service expertise. PRIMARY MESSAGE SECONDARY MESSAGE HIGH DISCHARGE PROTECTIVE LIMIT TEMP LOW REFRIGERANT PROTECTIVE LIMIT...
Page 74 Table 9 — LID Primary and Secondary Messages and Custom Alarm/Alert Messages L. CHILLER ALERTS PRIMARY MESSAGE SECONDARY MESSAGE HIGH AMPS AT SHUTDOWN High Amps at Recycle: Check guide vane RECYCLE ALERT LEAVING COND WATER SENSOR FAULT ALERT TEMP ENTERING COND WATER SENSOR FAULT ALERT TEMP LOW OIL PRESSURE...
Page 75 Table 9 — LID Primary and Secondary Messages and Custom Alarm/Alert Messages N. OTHER PROBLEMS/MALFUNCTIONS DESCRIPTION/MALFUNCTION Chilled Water/Brine Temperature Too High (Machine Running) Chilled Water/Brine Temperature Too Low (Machine Running) Chilled Water Temperature Fluctuates. Vanes Hunt Low Oil Sump Temperature While Running (Less than 100 F [38 C]) At Power Up, Default Screen Does Not Appear, ‘‘Tables Loading’’...
Page 76 Table 10A — Thermistor Temperature (F) vs Resistance/Voltage Drop TEMPERATURE VOLTAGE RESISTANCE DROP (V) (Ohms) −25 4.821 98,010 −24 4.818 94,707 −23 4.814 91,522 −22 4.806 88,449 −21 4.800 85,486 −20 4.793 82,627 −19 4.786 79,871 −18 4.779 77,212 −17 4.772 74,648 −16...
Page 77 Table 10B — Thermistor Temperature (C) vs Resistance/Voltage Drop TEMPERATURE VOLTAGE RESISTANCE DROP (V) (Ohms) −40 4.896 168 230 −39 4.889 157 440 −38 4.882 147 410 −37 4.874 138 090 −36 4.866 129 410 −35 4.857 121 330 −34 4.848 113 810 −33...
Page 78: Control Modules
Control Modules Turn controller power off before servicing controls. This ensures safety and prevents damage to controller. The Processor module (PSIO), 8-input (Options) mod- ules, Starter Management Module (SMM), and the Local Interface Device (LID) module perform continuous di- agnostic evaluations of the hardware to determine its con- dition.
Page 79: Processor Module (Psio)
NOTE: Address switches on this module can be at any position. Addresses are only changed through the LID screen or CCN. Fig. 40 — LID Module (Rear View) and LED Locations Processor Module (PSIO) (Fig. 41) INPUTS — Each input channel has 3 terminals; only 2 of the terminals are used.
Page 80: Replacing Defective Processor Modules
PSIO module. The model and serial numbers are printed on the unit nameplate located on an exterior corner post. The proper software is factory-installed by Carrier in the replacement module. When ordering a replacement proces- sor module (PSIO), specify complete replacement part number, full unit model number, and serial number.
Page 81: Solid-State Starters
Solid-State Starters — Troubleshooting guides and in- formation pertaining to the operation of the solid-state starter may be found in Fig. 44-46 and Table 11. Attempt to solve the problem by using the following preliminary checks before consulting the troubleshooting table.
Page 82 LEGEND SCR — Silicon Control Rectiﬁer *See test procedure described in Testing SCRs in Solid-State Starters section on page 81. Fig. 45 — Solid-State Starter, General Operation Troubleshooting Guide (Typical)
Page 83 Fig. 46 — Solid-State Starter, Starter Fault (Motor Will Not Start) Troubleshooting Guide (Typical)
Page 84 Table 11 — Benshaw, Inc. Solid-State Starter Troubleshooting Guide PROBLEM AK board phase correct not 1. L1 and L3 switch phases reversed. 2. Missing phase voltage. 3. Improper line voltage. AK board relay not on. Ribbon cable not properly seated. AK board power 1.
Page 85: Physical Data
Physical Data — Tables 12-17 and Fig. 47-51 pro- vide additional information regarding compressor ﬁts and HEAT NUMBER VESSEL EXCHANGER OF TUBES CODE COOLER HEAT NUMBER VESSEL EXCHANGER OF TUBES CODE CONDENSER NOTES: 1. Design I chillers are equipped with a ﬂoat box, and chiller weight is based on a 150 psi (1034 kPa) waterbox with 2 pass arrangement.
Page 86 HEAT WATERBOX EXCHANGER DESCRIPTION NIH, 1 PASS COVER NIH, 2 PASS COVER NIH, 3 PASS COVER COOLERS NIH, PLAIN END COVER MWB COVER PLAIN END COVER NIH, 1 PASS COVER NIH, 2 PASS COVER NIH, 3 PASS COVER CONDENSERS NIH, PLAIN END COVER MWB COVER PLAIN END COVER HEAT...
Page 87 ENGLISH MOTOR Stator Weight Compressor SIZE (lb) Weight (lb) 60 Hz 50 Hz 2660 1135 1147 2660 1143 1150 2660 1153 1213 2660 1162 1227 2660 1202 1283 2660 1225 1308 2660 1276 1341 2660 1289 1356 2660 1306 1363 2660 1335 1384...
Page 88 NOTES: 1. Dimensions are in inches with rotor in the thrust position. 2. All clearances listed are new chiller tolerances. 3. All radial clearances are diametrical. NOTE: Radial clearances shown are diametrical. Fig. 47 — Compressor Fits and Clearances...
Page 89 ITEM LEGEND N•m — Newton Meters *Not shown. *‘‘Z’’ clearance is determined by a combination of impeller diameter and shroud size. The table lists ‘‘Z’’ clearances for each compressor code. Figure 1 shows the location (on the chiller information plate) of the compressor code for each chiller. COMPRESSOR ‘‘Z’’...
Page 90 — Relay Designation — Local Interface Device — Milliampere — Normally Closed Fig. 48 — Electronic PIC Controls Wiring Schematic (For 19XL with No Backlight or with Fluorescent Backlight) — Normally Open PSIO — Processor Sensor Input/ Output Module RBPL — Relay Board Plug —...
Page 91 Fig. 48 — Electronic PIC Controls Wiring Schematic (For 19XL with No Backlight or with Fluorescent Backlight) (cont)
Page 92 — Relay Designation — Local Interface Device — Milliampere — Normally Closed Fig. 49 — Electronic PIC Controls Wiring Schematic (For 19XL with Halogen Backlight) — Normally Open PSIO — Processor Sensor Input/ Output Module RBPL — Relay Board Plug —...
Page 93 Fig. 49 — Electronic PIC Controls Wiring Schematic (For 19XL with Halogen Backlight) (cont)
Page 94 Fig. 50 — Chiller Power Panel, Starter Assembly, and Motor Wiring Schematic LEGEND — Pilot Relay PWR — Power RLA — Rated Load Amps SMM — Starter Management Module — Terminal Board — Variable Number Starter Cabinet Wiring Field Wiring Carrier Factory Wiring...
Page 95 Fig. 50 — Chiller Power Panel, Starter Assembly, and Motor Wiring Schematic (cont)
Page 98: Index
Automatic Soft-Stop Amps Threshold, 40 Auto. Restart After Power Failure, 33 Before Initial Start-Up, 41 Calibrate Motor Current, 56 Capacity Override, 31 Carrier Comfort Network Interface, 48 Changing Oil Filter, 63 Charge Refrigerant Into Chiller, 53 Chilled Water Recycle Mode, 40 Chiller Dehydration, 47...
Page 99 Storage Vessel, 5 Summary (Lubrication Cycle), 8 Surge Prevention Algorithm, 33 Surge Protection, 34 System Components, 5 Temperature Sensors (Check), 66 Test After Service, Repair, or Major Leak, 61 Tighten All Gasketed Joints and Guide Vane Shaft Packing, 41 Tower Fan Relay, 33 Trim Refrigerant Charge, 62 INDEX (cont) Troubleshooting Guide, 66...
Page 100 Copyright 1996 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. 531-971 Printed in U.S.A. Form 19XL-4SS Pg 100 7-96 Replaces: 19XL-3SS...

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

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