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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
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.
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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