Scheduled Maintenance; Service Ontime; Inspect The Control Center; Check Safety And Operating Controls - Carrier 19XL Start-Up, Operation And Maintenance Instructions Manual

SCHEDULED MAINTENANCE

Establish a regular maintenance schedule based on the
actual chiller requirements such as chiller load, run hours,
and water quality. The time intervals listed in this section are
offered as guides to service only.
Service Ontime —
The LID will display a SERVICE
ONTIME value on the Status01 table. This value should be
reset to zero by the service person or the operator each time
major service work is completed so that time between serv-
ice can be viewed.
Inspect the Control Center —
ited to general cleaning and tightening of connections. Vacuum
the cabinet to eliminate dust build-up. In the event of chiller
control malfunctions, refer to the Troubleshooting Guide sec-
tion for control checks and adjustments.
Be sure power to the control center is off when
cleaning and tightening connections inside the control
center.
Check Safety and Operating Controls Monthly
—
To ensure chiller protection, the Control Test Automated
Test should be done at least once per month. See
Table 3 for safety control settings. See Table 7 for Control
Test functions.
Changing Oil Filter —
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. Make sure that the compressor is off, and the disconnect
for the compressor is open.
2. Disconnect the power to the oil pump.
3. Close the oil filter isolation valves (Fig. 4).
4. Connect an oil charging hose from the oil charging valve
(Fig. 4), and place the other end in a clean container
suitable for used oil. The oil drained from the filter hous-
ing should be used as an oil sample to be sent to a labo-
ratory for proper analysis. Do not contaminate this sample.
5. Slowly open the charging valve to drain the oil from the
housing.
The oil filter housing is at a high pressure. Relieve
this pressure slowly.
6. Once all oil has been drained, place some rags or ab-
sorbent material under the oil filter housing to catch any
drips once the filter is opened. Remove the 4 bolts from
the end of the filter housing and remove the filter cover.
7. Remove the filter retainer by unscrewing the retainer nut.
The filter may now be removed and disposed of
properly.
8. Replace the old filter with a new filter. Install the filter
retainer and tighten down the retainer nut. Install the fil-
ter cover and tighten the 4 bolts.
9. Evacuate the filter housing by placing a vacuum pump
on the charging valve. Follow the normal evacuation pro-
cedures. Shut the charging valve when done, and recon-
nect the valve so that new oil can be pumped into the
filter housing. Fill with the same amount that was
removed, then close the charging valve.
Maintenance is lim-
Change the oil filter on a yearly
10. Remove the hose from the charging valve, open the iso-
lation valves to the filter housing, and turn on the power
to the pump and the motor.
Oil Specification —
proximately 11.7 gal. (44.3 L) of oil. If oil is added, it must
meet the following Carrier specifications:
• Oil type for HCFC-22 Chillers only . . . . . . . . . . . Alkyl-
benzene-based synthetic compressor oil
ISO Viscosity Grade . . . . . . . . . . . . . . . . . . . . . . . . . . 86
• Oil Type for units using R-134a . . . . . . . . . . . . Inhibited
polyolester-based synthetic compressor
ISO Viscosity Grade . . . . . . . . . . . . . . . . . . . . . . . . . . 68
The alkyl-benzene type oil (part number PP23BZ101) or
the polyolester-based oil (part number PP23BZ103) may be
ordered from your local Carrier representative.
Oil Changes —
Carrier recommends changing the oil
after the first year of operation and every 3 years thereafter
as a minimum in addition to a yearly oil analysis. However,
if a continuous oil monitoring system is functioning and a
yearly oil analysis is performed, time between oil changes
can be extended.

TO CHANGE THE OIL

1. Transfer the refrigerant into the condenser (for isolatable
vessels) or a storage tank.
2. Mark the existing oil level.
3. Open the control and oil heater circuit breaker.
4. When the chiller pressure is 5 psi (34 kPa) or less, drain
the oil reservoir by opening the oil charging valve
(Fig. 2A or Fig. 2B). Slowly open the valve against
refrigerant pressure.
5. Change the oil filter at this time. See Changing Oil Filter
section.
6. Change the refrigerant filter at this time; see the next sec-
tion, Refrigerant Filter.
7. Charge the chiller with oil. Charge until the oil level is
equal to the oil level marked in Step 2. Turn on the
power to the oil heater and let the PIC warm it up to at
least 140 F (60 C). Operate the oil pump manually, through
the Control Test, for 2 minutes. The oil level should be
full in the lower sight glass for shutdown conditions. If
the oil level is above
remove the excess oil. The oil level should now be equal
to the amount shown in Step 2.
Refrigerant Filter —
on the refrigerant cooling line to the motor (Fig. 2A or 2B),
should be changed once a year, or more often if filter
condition indicates a need for more frequent replacement.
Change the filter with the chiller pressure at 0 psig (0 kPa)
by transferring the refrigerant to the condenser vessel, (if iso-
lation valves are present), or a storage tank. A moisture
indicator sight glass is located beyond this filter to indicate
the volume and moisture in the refrigerant. If the moisture
indicator (dry-eye) indicates moisture, locate the source of
water immediately by performing a thorough leak check.
Oil Reclaim Filters —
strainer on the eductor suction line and a filter on the cooler
scavaging line. Replace these filters once per year, or more
often if filter condition indicates a need for more frequent
replacement. Change these filters by transferring the refrig-
erant charge to a storage vessel or the condenser.
63
The 19XL compressor holds ap-
specifically formatted for use in
HCFC-22 gear-driven machines
oil formatted for use with HFC, gear-
driven, hermetic compressors.
1 ⁄ full in the upper sight glass,
2
A refrigerant filter drier, located
The oil reclaim system has a