Weekly Maintenance; Check The Lubrication System; Scheduled Maintenance; Service Ontime - Carrier AquaEdge 19XR Start-Up, Operation And Maintenance Instructions Manual

WEEKLY MAINTENANCE

Check the Lubrication System

Mark the oil level on the reservoir sight glass, and observe the
level each week while the chiller is shut down.
If the level goes below the lower sight glass, check the oil reclaim
system for proper operation. If additional oil is required, add it
through the oil drain charging valve (Fig. 3-5). A pump is re-
quired when adding oil against refrigerant pressure. See "Oil
Charge" on page 28 for 19XR compressor family oil charge.
The added oil must meet Carrier specifications for the 19XR
chiller. Refer to Changing Oil Filter and Oil Changes sections.
Any additional oil that is added should be logged by noting the
amount and date. Any oil that is added due to oil loss that is not
related to service will eventually return to the sump. It must be
removed when the level is high.
An oil heater is controlled by the PIC 6 control system to main-
tain oil temperature (see the 19XR with PIC 6 Controls Opera-
tion and Troubleshooting manual) when the compressor is off.
If the PIC 6 control system shows that the heater is energized
and if the sump is still not heating up, the power to the oil heat-
er may be off or the oil level may be too low. Check the oil lev-
el, the oil heater contactor voltage, and oil heater resistance.
The PIC 6 control system does not permit compressor start-up
if the oil temperature is too low. The PIC 6 control system con-
tinues with start-up only after the temperature is within allow-
able limits.

SCHEDULED MAINTENANCE

Establish a regular maintenance schedule based on your 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 HMI will display a SERVICE ONTIME value on the
MAIN MENU  RUN TIMES screen. This value should be
reset to zero by the service person or the operator each time
major service work is completed so that the time between ser-
vice events can be viewed and tracked.

Inspect the Control Panel

Maintenance consists of general cleaning and tightening of
connections. Vacuum the cabinet to eliminate dust build-up. If
the chiller control malfunctions, refer to the Troubleshooting
Guide section on page 51 for control checks and adjustments.
WARNING
Ensure power to the starter is isolated when cleaning and tight-
ening connections inside the starter enclosure. Failure to dis-
connect power could result in electrocution. The oil filter
housing is at a high pressure. Relieve this pressure slowly.
Failure to do so could result in serious personal injury.

Changing Oil Filter

Change the oil filter on a yearly basis or when the chiller is
opened for repairs. The 19XR chiller has an isolatable oil filter
so that the filter may be changed with the refrigerant remaining
in the chiller. Use the following procedure:
1. Ensure 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.
4. Close the isolation valves located on both ends of the oil
filter. Have rags and a catch basin available to collect oil
spillage.
5. Equalize the filter's higher internal pressure to ambient by
connecting an oil charging hose to the Schrader valve on
the oil filter housing. Collect the oil-refrigerant mixture
which is discharged.
6. Remove the oil filter assembly by loosening the hex nuts
on both ends of the filter assembly.
7. Insert the replacement filter assembly with the arrow on
the housing pointing away from the oil pump.
8. Rotate the assembly so that the Schrader drain valve is ori-
ented at the bottom, and tighten the connection nut on each
end to a torque of approximately 30 ft-lb (41 N-m).
The oil filter housing is at a high pressure. Relieve this pres-
sure slowly. Failure to do so could result in serious personal
injury.
9. Evacuate the filter housing by placing a vacuum pump on
the charging valve. Follow the normal evacuation proce-
dures. Shut the charging valve when done and reconnect
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.
10. Remove the hose from the charging valve, open the isola-
tion valves to the filter housing, and turn on the power to
the pump and the motor.

Oil Specification

If oil is added, it must meet Carrier specifications. For units us-
ing R-134a/R-513A, use inhibited polyolester-based synthetic
compressor oil formatted for use with HFC, gear-driven, her-
metic compressors, with ISO Viscosity Grade 68. The polyo-
lester-based oil (P/N: PP23BZ103) may be ordered from your
local Carrier representative.

Oil Changes

Carrier recommends that a yearly oil analysis be performed to
determine when to change oil and when to perform a compressor
inspection. However, if yearly analysis is not performed or avail-
able, the time between oil changes should be no longer than 5
years. Additionally Carrier recommends vibration measurement
done at regular intervals to obtain a signature of the moving
compressor parts as part of a total preventive maintenance
(TPM) program.
TO CHANGE THE OIL
1. Transfer the refrigerant into the chiller condenser vessel
(for isolatable vessels) or to a pumpout storage tank.
2. Mark the existing oil level.
3. Open the control and oil heater circuit breaker.
4. When the chiller pressure is 5 psig (34 kPa) or less, drain the
oil reservoir by opening the oil charging valve (Fig. 3-5).
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 6 warm it up to at least
140°F (60°C). Operate the oil pump manually, using the
Control Test function, for 2 minutes. For shutdown condi-
tions, the oil level should be full in the lower sight glass. 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

A refrigerant filter/drier, located on the refrigerant cooling line to
the motor, should be changed once a year or more often if filter
47
WARNING
/ full in the upper sight glass,
1
2