Carrier 19XL User Manual

Start-up, operation, and maintenance instructions, Safety considerations

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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

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.

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Table of contents

Document Outline

Contents
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)
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
  - 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
  - Alarms and Alerts
  - 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
- Default Screen Freeze
- Motor Cooling Control
- Ramp Loading Control
- Capacity Override
- High Discharge Temperature Control
- Oil Sump Temperature Control
  - PSIO Software Version 08 and Lower
  - PSIO Software Version 09 and Higher
- Oil Cooler
- Remote Start/Stop Controls
- Spare Safety Inputs
  - Spare Alarm Contacts
- Condenser Pump Control
- Condenser Freeze Prevention
- 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
  - 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)
- 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
- 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
- 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 Controltest
- Check Optional Pumpout System Controls and Compressor
- High Altitude Locations
- 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
- Check Oil Pressure and Compressor Stop
- Calibrate Motor Current Demand Setting
- Check Machine Operating Condition
- To Prevent Accidental Start-Up
- Instruct the Customer Operator
Operating Instructions
- Operator Duties
- 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
- 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
- Test After Service, Repair, or Major Leak
  - Refrigerant Tracer
  - To Pressurize With Dry Nitrogen
- Repair the Leak, Retest, and Apply Standing Vacuum Test
- Checking Guide Vane Linkage
  - Checking the Auxiliary Switch on Guide Vane Actuator
- Trim Refrigerant Charge
Weekly Maintenance
- Check the Lubrication System
Scheduled Maintenance
- Service Ontime
- Inspect the Control Center
- Check Safety and Operating Controls Monthly
- Changing Oil Filter
- Oil Specification
- Oil Changes
  - To Change the Oil
- Refrigerant Filter
- Oil Reclaim Filters
- Inspect Refrigerant Float System
- Inspect Relief Valves and Piping
- Compressor Bearing and Gear Maintenance
- Inspect the Heat Exchanger Tubes
  - Cooler
  - Condenser
- Water Leaks
- Water Treatment
- Inspect the Starting Equipment
- Check Pressure Transducers
- Optional Pumpout System Maintenance
  - Optional Pumpout Compressor Oil Charge
  - Optional Pumpout Safety Control Settings
- Ordering Replacement Chiller Parts
Troubleshooting Guide
- Overview
- Checking the Display Messages
- Checking Temperature Sensors
- Checking Pressure Transducers
  - Transducer Replacement
- Control Algorithms Checkout Procedure
- Control Test
- Control Modules
  - Red Led
  - Green LEDs
- Notes on Module Operation
- Processor Module (PSIO)
  - Inputs
  - Outputs
- Starter Management Module (SMM)
  - Inputs
  - Outputs
- Options Modules (8-Input)
- Replacing Defective Processor Modules
  - Installation
- Solid-State Starters
- Physical Data
Initial Start-Up Checklist for 19XL Hermetic Centrifugal Liquid Chiller
List of Tables
List of Figures