Carrier 19XR User Manual

Also see for AquaEdge 19XRV series: Start-up, operation and maintenance instructions Start-up and service instructions Installation instructions Start-up, operation and maintenance instructions Start-up and service instructions

Contents

73SCHEDULED MAINTENANCEEstablish a regular maintenance schedule based on your ac-tual chiller requirements such as chiller load, run hours, andwater quality. The time intervals listed in this section areoffered as guides to service only.Service Ontime — The CVC/ICVC will display a SER-VICE ONTIME value on the MAINSTAT screen. This valueshould be reset to zero by the service person or the operatoreach time major service work is completed so that the timebetween service can be viewed and tracked.Inspect the Control Panel — Maintenance consists ofgeneral cleaning and tightening of connections. Vacuum thecabinet to eliminate dust build-up. If the chiller control mal-functions, refer to the Troubleshooting Guide section for con-trol checks and adjustments.Check Safety and Operating Controls Monthly —To ensure chiller protection, the automated Control Testshould be performed at least once per month. See Table 3for safety control settings. See Table 9 for Control Testfunctions.Changing Oil Filter — Change the oil filter on ayearly basis or when the chiller is opened for repairs. The19XR has an isolatable oil filter so that the filter may bechanged with the refrigerant remaining in the chiller. Usethe following procedure:1. Ensure the compressor is off and the disconnect for thecompressor is open.2. Disconnect the power to the oil pump.3. Close the oil filter isolation valves located behind powerpanel on top of oil pump assembly.4. Connect an oil charging hose from the oil charging valve(Fig. 2) and place the other end in a clean container suit-able for used oil. The oil drained from the filter housingshould be used as an oil sample and sent to a laboratoryfor proper analysis. Do not contaminate this sample.5. Slowly open the charging valve to drain the oil from thehousing.6. Once all oil has been drained, place some rags or absor-bent material under the oil filter housing to catch anydrips once the filter is opened. Remove the 4 bolts fromthe end of the filter housing and remove the filter cover.7. Remove the filter retainer by unscrewing the retainer nut.The filter may now be removed and disposed of properly.8. Replace the old filter with a new filter. Install the filter re-tainer and tighten down the retainer nut. Install the filtercover and tighten the 4 bolts.9. Evacuate the filter housing by placing a vacuum pump onthe charging valve. Follow the normal evacuation proce-dures. Shut the charging valve when done and reconnectthe valve so that new oil can be pumped into the filterhousing. Fill with the same amount that was removed;then close the charging valve.10. Remove the hose from the charging valve, open the isola-tion valves to the filter housing, and turn on the power tothe pump and the motor.Oil Specification — If oil is added, it must meet the fol-lowing 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 oil af-ter the first year of operation and every five years thereafter asa minimum in addition to a yearly oil analysis. However, if acontinuous oil monitoring system is functioning and a yearlyoil analysis is performed, the time between oil changes can beextended.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 condi-tions, 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, re-move the excess oil. The oil level should now be equal tothe amount shown in Step 2.Refrigerant Filter — A refrigerant filter/drier, located onthe refrigerant cooling line to the motor, should be changedonce a year or more often if filter condition indicates a need formore frequent replacement. Change the filter by closing the fil-ter isolation valves (Fig. 4) and slowly opening the flare fittingswith a wrench and back-up wrench to relieve the pressure. Amoisture indicator sight glass is located beyond this filter to in-dicate the volume and moisture in the refrigerant. If the mois-ture indicator indicates moisture, locate the source of water im-mediately by performing a thorough leak check.Oil Reclaim Filter — The oil reclaim system has astrainer on the eductor suction line, a strainer on the dischargepressure line, and a filter on the cooler scavenging line.Replace the filter once per year or more often if filter conditionindicates a need for more frequent replacement. Change the fil-ter by closing the filter isolation valves and slowly opening theflare fitting with a wrench and back-up wrench to relieve thepressure. Change the strainers once every 5 years or wheneverrefrigerant is evacuated from the cooler.Ensure power to the control center is off when cleaning andtightening connections inside the control panel.The oil filter housing is at a high pressure. Relieve thispressure slowly.