Carrier 19XR Start-up, Operation And Maintenance Instructions Manual

Also see for HERMETIC CENTRIFUGAL LIQUID CHILLERS 19XR: User manual Start-up and service instructions Installation instructions Product data Installation instructions

Contents

Carrier 19XR Start-up, Operation And Maintenance Instructions Manual Manual pdf 67 page image

Oil Specification — If oil is added, it must meet thefollowing Carrier specifications:Oil Type for units using R-134a . . . . . . . . . . . . . . Inhibitedpolyolester-based syntheticcompressor oil formatted foruse with HFC, gear-driven,hermetic compressors.ISO Viscosity Grade . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68The polyolester-based oil (P/N: PP23BZ103) may beordered from your local Carrier representative.Oil Changes — Carrier recommends changing the oilafter the first year of operation and every five years there-after as a minimum in addition to a yearly oil analysis. How-ever, if a continuous oil monitoring system is functioningand a yearly oil analysis is performed, the time between oilchanges can be extended.TO CHANGE THE OIL1. 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, drainthe oil reservoir by opening the oil charging valve(Fig. 2). Slowly open the valve against refrigerantpressure.5. Change the oil filter at this time. See Changing Oil Filtersection.6. Change the refrigerant filter at this time, see the next sec-tion, Refrigerant Filter.7. Charge the chiller with oil. Charge until the oil level isequal to the oil level marked in Step 2. Turn on the powerto the oil heater and let the PIC II warm it up to at least140 F (60 C). Operate the oil pump manually, using theControl Test function, for 2 minutes. For shutdown con-ditions, the oil level should be full in the lower sight glass.If the oil level is above 1 ⁄2 full in the upper sight glass,remove the excess oil. The oil level should now be equalto the amount shown in Step 2.Refrigerant Filter — A refrigerant filter/drier, locatedon the refrigerant cooling line to the motor, should be changedonce a year or more often if filter condition indicates a needfor more frequent replacement. Change the filter by closingthe filter isolation valves (Fig. 4) and slowly opening theflare fittings with a wrench and back-up wrench to relievethe pressure. A moisture indicator sight glass is located be-yond this filter to indicate the volume and moisture in therefrigerant. If the moisture indicator indicates moisture,locate the source of water immediately by performing athorough leak check.Oil Reclaim Filter — The oil reclaim system has a straineron the eductor suction line, a strainer on the discharge pres-sure line, and a filter on the cooler scavenging line. Replacethe filter once per year or more often if filter condition in-dicates a need for more frequent replacement. Change thefilter by closing the filter isolation valves and slowly open-ing the flare fitting with a wrench and back-up wrench torelieve the pressure. Change the strainers once every 5 yearsor whenever refrigerant is evacuated from the cooler.Inspect Refrigerant Float System — Perform thisinspection every 5 years or when the condenser is openedfor service.1. Transfer the refrigerant into the cooler vessel or into apumpout storage tank.2. Remove the float access cover.3. Clean the chamber and valve assembly thoroughly. Besure the valve moves freely. Ensure that all openings arefree of obstructions.4. Examine the cover gasket and replace if necessary.See Fig. 34 for a view of the float valve design. For linearfloat valve designs, inspect the orientation of the float slidepin. It must be pointed toward the bubbler tube for properoperation.Inspect Relief Valves and Piping — The relief valveson this chiller protect the system against the potentially dan-gerous effects of overpressure. To ensure against damage tothe equipment and possible injury to personnel, these de-vices must be kept in peak operating condition.As a minimum, the following maintenance is required.1. At least once a year, disconnect the vent piping at thevalve outlet and carefully inspect the valve body and mecha-nism for any evidence of internal corrosion or rust, dirt,scale, leakage, etc.2. If corrosion or foreign material is found, do not attemptto repair or recondition. Replace the valve.3. If the chiller is installed in a corrosive atmosphere or therelief valves are vented into a corrosive atmosphere, in-spect the relief valves at more frequent intervals.Compressor Bearing and Gear Maintenance —The key to good bearing and gear maintenance is properlubrication. Use the proper grade of oil, maintained at rec-ommended level, temperature, and pressure. Inspect thelubrication system regularly and thoroughly.To inspect the bearings, a complete compressor teardownis required. Only a trained service technician should removeand examine the bearings. The cover plate on older com-pressor bases was used for factory-test purposes and is notusable for bearing or gear inspection. The bearings and gearsshould be examined on a scheduled basis for signs of wear.The frequency of examination is determined by the hours ofLEGEND1 — Refrigerant Inlet from FLASC Chamber2 — Linear Float Assembly3 — Float Screen4 — Bubble Line5 — Float Cover6 — Bubble Line Connection7 — Refrigerant Outlet to Cooler8 — GasketFig. 34 — 19XR Float Valve Design67