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

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Carrier 19XRV Start-up, Operation And Maintenance Instructions Manual Manual pdf 76 page image

Inspect the Control Panel -- Maintenance consists ofgeneral cleaning and tightening of connections. Vacuum thecabinet to eliminate dust build-up. If the chiller controlmalfunctions, refer to the Troubleshooting Guide section forcontrol checks and adjustments.Ensure power to the control center is off when cleaning andtightening connections inside the control p_mel. Failure todisconnect power could result in electrocution.Check Safety and Operating ControlsMonthly -- Check values of monitored parameters (seeTable 6 for safety control settings). To ensure chiller protec-tion, the Automated Control Test should be performed atleast once per month (with machine in OFF mode). SeeTable 12 for Control Test functions.Changing Oil Filter--Change the oil filter on ayearly basis or when the chiller is opened for repairs. The19XRV chiller has an isolatable oil filter so that the filtermay be changed with the refrigerant remaining in thechiller. Early 19XRV compressors were designed with theoil filter housing attached to the oil pump. The followingprocedure applies to later 19XRV compressors which havethe oil filter separate flom the oil pump.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. Close the isolation valves located on both ends of the oilfiltel: Have rags and a catch basin available to collect oilspillage.5. Equfdize the filter's higher internal pressure to ambientby connecting an oil charging hose to the Schmder valveon the oil filter housing. Collect the oil-refrigerant mix-ture which is dischm'gedi6. Remove the oil filter assembly by loosening the hex nutson both ends of the filter assembly.7. Insert the replacement tilter assembly with the rerow onthe housing pointing away from the oil pump.8. Rotate the assembly so that the schraeder drain vfflve isoriented fit the bottom, and tighten the connection nut oneach end to a torque of approximately 30 ft-lb (41 N-m)The oil filter housing is at a high pressure. Relieve thispressure slowly. Failure to do so could result in serious per-sonal injury.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 stone amount that was removed;then close file charging valve.10. Remove the hose from the chmging valve, open the isola-tion valves to the filter housing, and turn on the power tothe pump and the motol: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: PP23BZI03) may beordered from a local Carrier representative.Oil Changes--Cmrier recommends changing the oilafter the first year of operation and every three to five yearsthereafter as a minimum in addition to a yedy oil amdysis.Howevel: if a continuous oil monitoring system is functioningand a yearly oil analysis is performed, file 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 file control and oil heater circuit breakel:4. When the chiller pressure is 5 psig (34 kPa) or less, drainthe oil reservoir by opening the oil charging vfdve(Fig. 2). Slowly open the valve against refrigerantpressure.5. Change the oil filter fit this time. See Changing Oil Filtersection.6. Change the refrigerant filter fit this time, see the nextsection, Refrigerant Filtec7. Charge the chiller with oil. Chmge until the oil level isequal to the oil level marked in Step 2. Turn on the powerto the oil heater and let file PIC [II warm it up to fit 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,remove the excess oil. The oil level should now be equalto the amount shown in Step 2.Refrigerant Filter -- A refrigerant filter/driel, located onthe refrigerant cooling line to the motol; should be changedonce a ye;u or more often if filter condition indicates a need formore frequent replacement. Change the filter by closing thefilter isolation valves (Fig. 4) and slowly opening the flarefittings with a wrench and back-up wrench to relieve the pres-sure. A moisture indicator sight glass is located beyond thisfilter to indicate the volume and moisture in the refrigerant. Ifthe moisture indicator indicates moisture, locate the source ofwater immediately by performing a thorough leak check.Oil Reclaim Filter--The oil reclaim system has astrainer on file eductor suction line, a strainer on the dischargepressure line, and a filter on the cooler scavenging line.Replace file filter once per year or more often if tilter conditionindicates a need for more frequent replacement. Change thefilter by closing the filter isolation valves and slowly openingthe flare fitting with a wrench and back-up wrench to relievethe pressure. Change the stminel_ once every 5 yeal_ or when-ever refrigerant is evacuated from the coolel:76