Carrier 19XR - Page 49

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Fig. 28 — 19XR Leak Test Procedures

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Safety Considerations1
- Table of Contents2
- Reset Type2
Introduction4
Abbreviations and Explanations4
19XR Identification5
Cooler5
Chiller Familiarization5
Chiller Information Nameplate5
System Components5
Condenser5
Motor-Compressor5
Control Panel5
Front/Rear View6
Factory-Mounted Starter or Variable7
- Frequency Drive (Optional)7
Storage Vessel (Optional)7
Refrigeration Cycle7
Motor and Lubricating Oil7
- Cooling Cycle7
Vfd Cooling Cycle8
Lubrication Cycle8
Summary8
Details8
Oil Reclaim System8
- Primary Oil Recovery Mode8
- Secondary Oil Recovery Method8
Starting Equipment9
Unit-Mounted Solid-State Starter9
- (Optional)9
Unit-Mounted Wye-Delta Starter10
- (Optional)10
Unit-Mounted VFD (Optional)10
Controls10
Definitions10
- Analog Signal10
- Discrete Signal10
Integrated Starter Module (Ism11
- Optional11
- Optional12
- Chiller Visual Controller (CVC)13
- Components and Panel Locations13
- International Chiller Visual13
- Controller (ICVC)13
- Integrated Starter Module (Ism)13
- Chiller Control Module (CCM)13
- Oil Heater Contactor (1C)13
- Oil Pump Contactor (2C)13
- Hot Gas Bypass Contactor Relay (3C)13
- Control Transformers (T1, T2)13
General11
PIC II System Components11
CVC/ICVC Operation and Menus15
- General15
- Alarms and Alerts15
- CVC/ICVC Menu Items15
- BASIC CVC/ICVC OPERATIONS (Using the Softkeys)15
- To View Status16
- Override Operations16
- Alarms and Alerts18
- Time Schedule Operation20
- To View and Change Set Points21
- Service Operation21
  - Service Operation22
  - Alarms and Alerts22
PIC II System Functions33
- Capacity Control Fixed Speed33
- Capacity Control Vfd33
- Ecw Control Option33
- Control Point Deadband33
- Diffuser Control33
- Proportional Bands and Gain33
- Demand Limiting34
- Chiller Timers34
- Occupancy Schedule34
Safety Controls34
Shunt Trip (Option)35
Default Screen Freeze35
Ramp Loading36
Capacity Override36
High Discharge Temperature Control36
Oil Sump Temperature Control36
Oil Cooler36
Remote Start/Stop Controls36
Spare Safety Inputs36
Alarm (Trip) Output Contacts37
Refrigerant Leak Detector37
Kilowatt Output37
Remote Reset of Alarms37
Condenser Pump Control37
Condenser Freeze Prevention38
Evaporator Freeze Protection (ICVC Only)38
Tower Fan Relay Low and High38
Auto. Restart after Power Failure38
Water/Brine Reset38
Demand Limit Control Option39
Surge Prevention Algorithm39
- (Fixed Speed Chiller)39
Surge Prevention Algorithm with VFD40
Surge Protection VFD Units40
Surge Protection (Fixed Speed Chiller)40
- Head Pressure Reference Output40
Lead/Lag Control40
- Common Point Sensor Installation41
- Chiller Communication Wiring41
- Lead/Lag Operation41
- Load Balancing41
- Faulted Chiller Operation42
- Load Balancing42
- Auto. Restart after Power Failure42
Ice Build Control43
- Ice Build Initiation43
- Start-Up/Recycle Operation43
- Temperature Control During Ice Build43
- Termination of Ice Build43
- Return to Non-Ice Build Operations44
Attach to Network Device Control44
- Attaching to Other Ccn Modules44
- Controls45
Service Operation45
- To Access the Service Screens45
- To Log out of Network Device45
- Holiday Scheduling45
Start-Up/Shutdown/Recycle46
- Sequence46
Local Start-Up46
Shutdown Sequence47
Automatic Soft Stop Amps Threshold47
Chilled Water Recycle Mode47
Safety Shutdown47
Before Initial Start-Up48
Job Data Required48
Equipment Required48
Using the Optional Storage Tank48
- And Pumpout System48
Remove Shipping Packaging48
Open Oil Circuit Valves48
Tighten All Gasketed Joints and Guide Vane Shaft Packing48
Check Chiller Tightness48
Refrigerant Tracer48
Leak Test Chiller50
Standing Vacuum Test50
- Chiller Dehydration53
Inspect Water Piping53
Check Relief Valves53
Inspect Wiring53
- Carrier Comfort Network Interface54
- Solid-State Starter54
- Check the Oil Heater55
- Oil Charge55
- Software Configuration55
Check Starter54
- Input Time and Date55
- Password55
- Change CVC/ICVC Configuration56
- Change Language56
- To Change Display to Metric Units56
- To Change the Password56
- If Necessary57
- If Necessary58
- Parameters if Necessary58
- Password58
- Verify Vfd Configuration and Change58
- Vfd Chiller Field Set up and Verification58
- If Necessary59
  - Necessary59
  - Password59
- Password60
- VFD CONTROL VERIFICATION (Running60
- If Necessary61
- Modify Equipment Configuration61
- Password61
- And Waterside Flow Device Calibration62
- Cooler Condenser Pressure Transducer62
- Perform a Control Test62
- Charge Refrigerant into Chiller63
- Chiller Equalization Without a63
- Controls and Compressor63
- High Altitude Locations63
- Pumpout Unit63
- Initial Start-Up64
- Dry Run to Test Start-Up Sequence65
Input the Design Set Points55
Input Service Configurations55
Check Motor Rotation65
Check Oil Pressure and Compressor Stop65
To Prevent Accidental Start-Up65
Check Chiller Operating Condition65
- Instruct the Customer Operator65
- Cooler-Condenser65
- Operating Instructions66
- Initial Start-Up66
- Operator Duties66
- Prepare the Chiller for Start-Up66
To Start the Chiller66
Check the Running System66
To Stop the Chiller66
- After Limited Shutdown66
Preparation for Extended Shutdown66
- After Extended Shutdown67
- Cold Weather Operation67
- Manual Guide Vane Operation67
- Operating the Optional Pumpout Unit67
- Procedures67
- Pumpout and Refrigerant Transfer Procedures67
- Refrigeration Log67
- To Read Refrigerant Pressures67
- Chillers with Storage Tanks69
- Transfer Refrigerant from69
- Chiller Condenser Vessel70
- Chiller Cooler Vessel70
- Chillers with Isolation Valves70
- Transfer All Refrigerant to70
- Adding Refrigerant71
- General Maintenance71
- Procedures71
Removing Refrigerant71
- Adjusting the Refrigerant Charge71
- Refrigerant Leak Testing71
- Leak Rate71
Test after Service, Repair, or Major Leak71
Standing Vacuum Test72
Checking Guide Vane Linkage72
Trim Refrigerant Charge72
Weekly Maintenance72
Check the Lubrication System72
- Scheduled Maintenance73
- Service Ontime73
- Inspect the Control Panel73
- Monthly73
- Changing Oil Filter73
- Oil Specification73
- Oil Changes73
- Refrigerant Filter73
- Oil Reclaim Filter73
Inspect Relief Valves and Piping74
Compressor Bearing and Gear Maintenance74
Inspect the Heat Exchanger Tubes74
- And Flow Devices74
- Cooler and Flow Devices74
- Condenser and Flow Devices74
Water Leaks74
Inspect Refrigerant Float System74
Water Treatment75
Inspect the Starting Equipment75
Check Pressure Transducers75
Optional Pumpout System Maintenance75
- Optional Pumpout Compressor Oil Charge75
- Optional Pumpout Safety Control Settings75
Ordering Replacement Chiller Parts75
Troubleshooting Guide76
Overview76
Checking Display Messages76
Checking Temperature Sensors76
- Resistance Check76
- Voltage Drop76
- Check Sensor Accuracy76
- Dual Temperature Sensors76
Checking Pressure Transducers76
- Units Equipped with CVC76
- Transducer Replacement77
Control Algorithms Checkout Procedure77
Control Test77
- Troubleshooting78
- Chiller Protect Limit Faults81
Control Modules87
- RED LED (Labeled as STAT)87
Notes on Module Operation87
Chiller Control Module (CCM)88
Integrated Starter Module88
Replacing Defective Processor Modules88
- Installation88
Solid-State Starters88
- Testing Silicon Control Rectifiers in88
- Benshaw, Inc. Solid-State Starters88
- Scr Removal/Installation90
Physical Data90
Index123

Carrier 19XR - Page 49

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