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

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

Contents

2PUMPOUT AND REFRIGERANTTRANSFER PROCEDURES . . . . . . . . . . . . . . . . . 41Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41Operating the Optional Pumpout Unit (Fig. 44) . . . 43GENERAL MAINTENANCE . . . . . . . . . . . . . . . . . . . . 46Refrigerant Properties . . . . . . . . . . . . . . . . . . . . . . . . 46Adding Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . 46Adjusting the Refrigerant Charge . . . . . . . . . . . . . . 46Refrigerant Leak Testing . . . . . . . . . . . . . . . . . . . . . 46Leak Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46Test After Service, Repair, or Major Leak . . . . . . . . 46Repair the Leak, Retest, and ApplyStanding Vacuum Test . . . . . . . . . . . . . . . . . . . . . 46Checking Guide Vanes . . . . . . . . . . . . . . . . . . . . . . . 46Trim Refrigerant Charge . . . . . . . . . . . . . . . . . . . . . . 48WEEKLY MAINTENANCE . . . . . . . . . . . . . . . . . . . . . 48Check the Lubrication System . . . . . . . . . . . . . . . . . 48SCHEDULED MAINTENANCE . . . . . . . . . . . . . . . . . . 49Service Ontime . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49Inspect the Control Panel . . . . . . . . . . . . . . . . . . . . . 49Changing Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . 49Oil Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49Oil Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49Refrigerant Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49VFD Refrigerant Strainer (if equipped) . . . . . . . . . . 50Oil Reclaim Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50Inspect Refrigerant Float System . . . . . . . . . . . . . . 50Inspect Relief Valves and Piping . . . . . . . . . . . . . . . 51Compressor Bearing and Gear Maintenance . . . . . 51Inspect the Heat Exchanger Tubes andFlow Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51Water Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51Water Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51Inspect the Starting Equipment or VFD . . . . . . . . . . 51Recalibrate Pressure Transducers . . . . . . . . . . . . . 52Optional Pumpout System Maintenance . . . . . . . . . 52Ordering Replacement Chiller Parts . . . . . . . . . . . . 52TROUBLESHOOTING GUIDE . . . . . . . . . . . . . . . . . . 53Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53Checking Display Messages . . . . . . . . . . . . . . . . . . 53Checking Temperature Sensors . . . . . . . . . . . . . . . 53Checking Pressure Transducers . . . . . . . . . . . . . . . 57High Altitude Locations . . . . . . . . . . . . . . . . . . . . . . 57Quick Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57Pumpdown/Lockout . . . . . . . . . . . . . . . . . . . . . . . . . 57Physical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57APPENDIX A — PIC 6 SCREEN AND TABLESTRUCTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110APPENDIX B — CCN COMMUNICATION WIRINGFOR MULTIPLE CHILLERS (TYPICAL) . . . . . . . 112APPENDIX C — MAINTENANCE SUMMARYAND LOG SHEETS . . . . . . . . . . . . . . . . . . . . . . . 113INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116INITIAL START-UP CHECKLISTFOR 19XR SEMI-HERMETIC TWO-STAGECENTRIFUGAL LIQUID CHILLER . . . . . . . . . . . CL-1SAFETY CONSIDERATIONSCentrifugal liquid chillers are designed to provide safe and reliableservice when operated within design specifications. When operat-ing this equipment, use good judgment and safety precautions toavoid damage to equipment and property or injury to personnel.Be sure you understand and follow the procedures and safety pre-cautions contained in the chiller instructions as well as those listedin this guide.DANGERFailure to follow these procedures will result in severe person-al injury or death.DO NOT VENT refrigerant relief valves within a building.Outlet from rupture disc or relief valve must be vented out-doors in accordance with the latest edition of ANSI/ASHRAE15 (American National Standards Institute/American Societyof Heating, Refrigerating, and Air-Conditioning Engineers).The accumulation of refrigerant in an enclosed space can dis-place oxygen and cause asphyxiation.PROVIDE adequate ventilation in accordance with ANSI/ASHRAE 15, especially for enclosed and low overhead spac-es. Inhalation of high concentrations of vapor is harmful andmay cause heart irregularities, unconsciousness, or death. Mis-use can be fatal. Vapor is heavier than air and reduces theamount of oxygen available for breathing. Product causes eyeand skin irritation. Decomposition products are hazardous.DO NOT USE OXYGEN to purge lines or to pressurize achiller for any purpose. Oxygen gas reacts violently with oil,grease, and other common substances.NEVER EXCEED specified test pressures; VERIFY the al-lowable test pressure by checking the instruction literatureand the design pressures on the equipment nameplate.DO NOT USE air for leak testing. Use only refrigerant or drynitrogen.DO NOT VALVE OFF any safety device.BE SURE that all pressure relief devices are properly installedand functioning before operating any chiller.RISK OF INJURY OR DEATH by electrocution. High volt-age is present on motor leads even though the motor is not run-ning when a solid-state or wye-delta mechanical starter isused. Open the power supply disconnect before touching mo-tor leads or terminals.WARNINGFailure to follow these procedures may result in personal inju-ry or death.DO NOT USE TORCH to remove any component. Systemcontains oil and refrigerant under pressure.To remove a component, wear protective gloves and gogglesand proceed as follows:1. Shut off electrical power to unit.2. Recover refrigerant to relieve all pressure from systemusing both high-pressure and low pressure ports.3. Traces of vapor should be displaced with nitrogen andthe work area should be well ventilated. Refrigerant incontact with an open flame produces toxic gases.4. Cut component connection tubing with tubing cutterand remove component from unit. Use a pan to catchany oil that may come out of the lines and as a gage forhow much oil to add to the system.5. Carefully unsweat remaining tubing stubs when neces-sary. Oil can ignite when exposed to torch flame.(Warnings continued on next page.)