Carrier 19XL User manual

19XL

50/60 Hz

Hermetic Centrifugal Liquid Chillers

with HCFC–22 and HFC–134a

Start-Up, Operation, and Maintenance Instructions

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

without incurring obligations.

PC 211 Catalog No. 531-94512-94 Form 19XL-3SS Replaces: 19XL-2SS

Copyright

©

Carrier Corporation 1994

Safety Considerations

Centrifugal liquid chillers are designed to provide safe and reliable service when

operated within design specifications. When operating this equipment, use good

judgement 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 machine instructions as well as those listed in this guide.

®

DO NOT VENT refrigerant relief devices 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

Heating, Refrigeration, and Air Conditioning Engineers). The accumulation 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

available for breathing. Product causes eye and skin irritation. Decomposition

products are hazardous.

DO NOT USE OXYGEN to purge lines or to pressurize a machine 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 machine.

DANGER

!

DANGER

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 dis-

placed 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 machine sections or the entire

assembly.

DO NOT work on high-voltage equipment unless you are a qualified electrician.

DO NOT WORK ON electrical components, including control panels, switches,

starters, or oil heater until you are sure ALL POWER IS OFF and no residual volt-

age can leak from capacitors or solid-state components.

LOCK OPEN AND TAG electrical circuits during servicing. IF WORK IS INTER-

RUPTED, confirm that all circuits are deenergized before resuming work.

DO NOT siphon refrigerant.

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, IMMEDIATELY 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.

WARNING

!

WARNING

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 machine. The

introduction of the wrong refrigerant can cause machine damage or malfunction

to this machine. Operation of this equipment with refrigerants other than those

cited herein should comply with ANSI/ASHRAE-15 (latest edition). Contact Car-

rier for further information on use of this machine with other refrigerants.

DO NOT ATTEMPT TO REMOVE fittings, covers, etc., while machine is under

pressure or while machine 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 machine operates in a corrosive atmosphere,

inspect the devices at more frequent intervals.

DO NOT ATTEMPT TO REPAIR OR RECONDITION any relief device when corro-

sion 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.

WARNING

!

WARNING

CAUTION

!

DO NOT STEP on refrigerant lines. Broken lines can whip about and release

refrigerant, causing personal injury.

DO NOT climb over a machine. 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 components are light, use mechani-

cal equipment when there is a risk of slipping or losing your balance.

BE AWARE that certain automatic start arrangements CAN ENGAGE THE

STARTER, TOWER FAN, OR PUMPS. Open the disconnect

ahead of

the starter,

tower fan, and pumps.

USE only repair or replacement parts that meet the code requirements 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 posi-

tive thread engagement.

CAUTION

!

PERIODICALLY INSPECT all valves, fittings, and piping for corrosion, rust,

leaks, or damage.

PROVIDE A DRAIN connection in the vent line near each pressure relief device

to prevent a build-up of condensate or rain water.

Contents

List of Tables

List of Figures

Safety Considerations

Introduction

Abbreviations and Explanations

Machine Familiarization

Machine Information Plate

System Components

Cooler

Condenser

Motor-Compressor

Control Center

Factory-Mounted Starter (Optional)

Storage Vessel (Optional)

Contents

Refrigeration Cycle

Motor/Oil Refrigeration Cooling Cycle

Lubrication Cycle

Summary

Details

Oil Reclaim System

During Normal Machine Operation

During Light Load Conditions

Starting Equipment

Unit Mounted Solid-State Starter (Optional)

Unit Mounted Wye-Delta Starter (Optional)

Controls

Definitions

Analog Signal

Contents

Digital Signal

Volatile Memory

General

PIC System Components

Processor Module (PSIO)

Starter Management Module (SMM)

Local Interface Device (LID)

6-Pack Relay Board

8-Input Modules

Oil Heater Contactor (1C)

Oil Pump Contactor (2C)

Hot Gas Bypass Contactor Relay (3C) (Optional)

Control Transformers (T1-T4)

Control and Oil Heater Voltage Selector (S1)

LID Operation and Menus

General

Alarm and Alerts

Contents

Menu Structure

To View Point Status

Override Operations

Time Schedule Operation

To View and Change Set Points

Service Operation

PIC System Functions

Capacity Control

Entering Chilled Water Control

Deadband

Proportional Bands and Gain

Demand Limiting

Machine Timers

Occupancy Schedule

Safety Controls

Shunt Trip

Contents

Default Screen Freeze

Motor Cooling Control

Ramp Loading Control

Capacity Override

High Discharge Temperature Control

Oil Sump Temperature Control

PSIO Software Versions 08 and Lower

PSIO Software Versions 09 and Higher

Oil Cooler

Remote Start/Stop Controls

Spare Safety Inputs

Spare Alarm Contacts

Condenser Pump Control

Condenser Freeze Protection

Contents

Tower Fan Relay

Auto. Restart After Power Failure

Water/Brine Reset

Demand Limit Control, Option (Requires Optional 8-Input Module)

Surge Prevention Algorithm

Surge Protection

Lead/Lag Control

Common Point Sensor Installation

Machine Communication Wiring

Lead/Lag Operation

Faulted Chiller Operation

Load Balancing

Auto Restart After Power Failure

Ice Build Control

Ice Build Initiation

Contents

Start-Up/Recycle Operation

Temperature Control During Ice Build

Termination of Ice Build

Return to Non-ice Build Operations

Attach to Network Device Control

Changing Refrigerant Types

Attaching to Other CCN Modules

Service Operation

To Log On

To Log Off

Holiday Scheduling

Start-Up/Shutdown/Recycle Sequence

Local Start-Up

Shutdown Sequence

Automatic Soft-Stop Amps Threshold (PSIO Software Version 09 and

Higher)

Contents

Chilled Water Recycle Mode

Safety Shutdown

Before Initial Start-Up

Job Data Required

Equipment Required

Using the Optional Storage Tank and Pumpout System

Remove Shipping Packaging

Open Oil Circuit Valves

Torque All Gasketed Joints

Check Machine Tightness

Refrigerant Tracer

Leak Test Machine

Standing Vacuum Test

Contents

Machine Dehydration

Inspect Water Piping

Check Optional Pumpout Compressor Water Piping

Check Relief Devices

Inspect Wiring

Carrier Comfort Network Interface

Check Starter

Mechanical-Type Starters

Benshaw, Inc. Solid-State Starter

Cutler-Hammer® Solid-State Starters

Oil Charge

Power Up the Controls and Check the Oil Heater

Software Version

Set Up Machine Control Configuration

Input the Design Set Points

Contents

Input the Local Occupied Schedule (OCCPC01S)

Selecting Refrigerant Type

To Confirm Refrigerant Type

To Change Refrigerant Type

Input Service Configurations

Password

Input Time and Date

Change LID Configuration If Necessary

Modify Controller Identification If Necessary

Input Equipment Service Parameters If Necessary

Modify Equipment Configuration If Necessary

Check Voltage Supply

Perform an Automated Control Test

Check Optional Pumpout System Controls and Compressor

High Altitude Locations

Contents

Charge Refrigerant into Machine

19XL Machine Equalization without Pumpout Unit

19XL Machine Equalization with Pumpout Unit

Trimming Refrigerant Charge

Initial Start-Up

Preparation

Manual Operation of the Guide Vanes

Dry Run to Test Start-Up Sequence

Check Rotation

If Rotation Is Proper

If the Motor Rotation Is Not Clockwise

Notes on Solid-State Starters (Benshaw, Inc.)

Check Oil Pressure and Compressor Stop

Calibrate Motor Current Demand Setting

To Prevent Accidental Start-Up

Contents

Check Machine Operating Condition

Instruct the Customer Operator

Cooler-Condenser

Optional Storage Tank and Pumpout System

Motor Compressor Assembly

Motor Compressor Lubrication System

Control System

Auxiliary Equipment

Describe Machine Cycles

Review Maintenance

Safety Devices and Procedures

Check Operator Knowledge

Review the Start-Up, Operation, and Maintenance Manual

Operating Instructions

Operator Duties

Contents

Prepare the Machine for Start-Up

To Start the Machine

Check the Running System

To Stop the Machine

After Limited Shutdown

Extended Shutdown

After Extended Shutdown

Cold Weather Operation

Manual Guide Vane Operation

Refrigeration Log

Pumpout and Refrigerant Transfer Procedures

Preparation

Operating the Optional Pumpout Compressor

To Read Refrigerant Pressures

Contents

Machines with Storage Tanks

Transfer Refrigerant from Storage Tank to Machine

Transfer the Refrigerant from Machine to Storage Tank

Machines with Isolation Valves

Transfer All Refrigerant to Condenser Vessel

Transfer All Refrigerant to Cooler/Compressor Vessel

Return Refrigerant to Normal Operating Conditions

General Maintenance

Refrigerant Properties

Adding Refrigerant

Removing Refrigerant

Adjusting the Refrigerant Charge

Refrigerant Leak Testing

Leak Rate

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