Scheduled Maintenance; Service Ontime; Oil Changes - Carrier 19XRV Start-Up, Operation And Maintenance Instructions Manual

SCHEDULED MAINTENANCE

Establish a regular maintenance schedule based on 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.
The ICVC will display a SERVICE
Service Ontime —
ONTIME value on the MAINSTAT 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
service can be viewed and tracked.
Inspect the Control Panel —
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 for
control checks and adjustments.
Ensure power to the VFD is off when cleaning and
tightening connections inside the VFD enclosure. Failure
to disconnect power could result in electrocution.
Check Safety and
Check values of monitored parameters (see
Monthly —
Table 6 for safety control settings). To ensure chiller protec-
tion, the Automated Control Test should be performed at
least once per month (with machine in OFF mode). See
Table 13 for Control Test functions.
Changing Oil Filter —
yearly basis or when the chiller is opened for repairs. The
19XRV chiller has an isolatable oil filter so that the filter
may be changed with the refrigerant remaining in the
chiller. Early 19XRV compressors were designed with the
oil filter housing attached to the oil pump. The following
procedure applies to later 19XRV compressors which have
the oil filter separate from the oil pump.
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 located behind power
panel on top of oil pump assembly.
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 mix-
ture 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 schraeder drain valve is
oriented 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
pressure slowly. Failure to do so could result in serious per-
sonal 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
Maintenance consists of
Operating Controls
Change the oil filter on a
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 —
lowing Carrier specifications:
Oil Type for units using R-134a . . . . . . . . . . . . . . . . . . Inhibited
ISO Viscosity Grade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
The polyolester-based oil (P/N: PP23BZ103) may be
ordered from a local Carrier representative.
Carrier recommends changing the oil
Oil Changes —
after the first year of operation and every three to five 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, the time between oil
changes can be extended.
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. 2). 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
section, 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 III 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 previous oil level's mark (Step 2).
Refrigerant Filter —
the refrigerant cooling line to the motor, should be changed
once a year or more often if filter condition indicates a need for
more frequent replacement. Change the filter by closing the
filter isolation valves (see Fig. 4) and slowly opening the flare
fittings with a wrench and back-up wrench to relieve the pres-
sure. A moisture indicator sight glass is located beyond this
filter to indicate the volume and moisture in the refrigerant. If
the moisture indicator indicates moisture, locate the source of
water immediately by performing a thorough leak check.
Oil Reclaim Filter —
strainer on the eductor suction line, a strainer on the discharge
pressure line, and a filter on the cooler scavenging line.
Replace the filter once per year or more often if filter condition
indicates a need for more frequent replacement. Change the
filter by closing the filter isolation valves and slowly opening
the flare fitting with a wrench and back-up wrench to relieve
the pressure. Change the strainers once every 5 years or when-
ever refrigerant is evacuated from the cooler.
79
If oil is added, it must meet the fol-
polyolester-based synthetic
compressor oil formatted for
use with HFC, gear-driven,
hermetic compressors.
1 / full in the upper sight glass,
2
A refrigerant filter/drier, located on
The oil reclaim system has a