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

40AUXILIARY EQUIPMENTStarters and disconnects, separate electrical sources, pumps, andcooling tower.DESCRIBE CHILLER CYCLESRefrigerant, motor cooling, lubrication, and oil reclaim.REVIEW MAINTENANCEScheduled, routine, and extended shutdowns, importance of a logsheet, importance of water treatment and tube cleaning, and im-portance of maintaining a leak-free chiller.SAFETY DEVICES AND PROCEDURESElectrical disconnects, relief device inspection, and handling re-frigerant.CHECK OPERATOR KNOWLEDGEStart, stop, and shutdown procedures, safety and operating con-trols, refrigerant and oil charging, and job safety.REVIEW THE START-UP, OPERATION, AND MAINTE-NANCE MANUAL.NOTE: Manuals and notebooks should not be stored under theVFD power module as they will block airflow into the powermodule cooling fan. Remove the manuals if they were placedunder the power module during shipping.OPERATING INSTRUCTIONSOperator Duties1. Become familiar with the chiller and related equipmentbefore operating the chiller.2. Prepare the system for start-up, start and stop the chiller,and place the system in a shutdown condition.3. Maintain a log of operating conditions and document anyabnormal readings.4. Inspect the equipment, make routine adjustments, and per-form a Control Test. Maintain the proper oil and refriger-ant levels.5. Protect the system from damage during shutdown periods.6. Maintain the set point, time schedules, and other PICfunctions.Prepare the Chiller for Start-UpFollow the steps described in the Initial Start-Up section, page 39.To Start the Chiller1. Start the water pumps, if they are not automatic.2. Press the Start/Stop icon on the HMI home screen to startthe system. If the chiller is in the OCCUPIED mode andthe start timers have expired, the start sequence will start.Follow the procedure described in the Start-Up/Shutdown/Recycle Sequence section, page 21.Check the Running SystemAfter the compressor starts, the operator should monitor the dis-play and observe the parameters for normal operating conditions:1. The oil reservoir temperature should be above 120°F(49°C) during shutdown. Normal operating temperature is120 to 165°F (49 to 74°C).2. For 19XR2-E: The bearing oil temperature accessed onthe TEMP screen should be 120 to 165°F (49 to 74°C) forcompressors with rolling element bearings. If the bearingtemperature reads more than 180°F (83°C) with the oilpump running, stop the chiller and determine the cause ofthe high temperature. Do not restart the chiller until cor-rected.For 19XR6/7:.The bearing temperature accessed from theTemperatures menu should be 140 to 210°F (60 to 99°C) forcompressors with rolling element bearings. If the bearingtemperature is high or in Alarm/Alert state with the oil pumprunning, stop the chiller and determine the cause of the hightemperature. Do not restart the chiller until corrected.3. The oil level should be visible anywhere in one of the twosight glasses. Foaming oil is acceptable as long as the oilpressure and temperature are within limits.4. The oil pressure should be between 18 and 40 psid (124and 207 kPad) differential, as seen on the HMI Transmis-sion Status screen. Typically the reading will be 18 to35 psid (124 to 241 kPad) at initial start-up.5. The moisture indicator sight glass on the refrigerantmotor cooling line should indicate refrigerant flow and adry condition.6. The condenser pressure and temperature varies with thechiller design conditions. Typically the pressure will rangebetween 60 and 135 psig (390 and 950 kPa) with a corre-sponding temperature range of 60 to 105°F (15 to 41°C).The condenser entering water temperature should be con-trolled below the specified design entering water tempera-ture to save on compressor kilowatt requirements.7. Cooler pressure and temperature also will vary with thedesign conditions. Typical pressure range will be between29.5 and 40.1 psig (203.4 and 276.4 kPa), with tempera-ture ranging between 34 and 45°F (1.1 and 7.2°C).8. The compressor may operate at full capacity for a shorttime after the pulldown ramping has ended, even thoughthe building load is small. The active electrical demandsetting can be overridden to limit the compressor kW, orthe pulldown rate can be decreased to avoid a high demandcharge for the short period of high demand operation. Pull-down rate can be based on load rate or temperature rateand is accessed on the MAINTENANCE MENUCAPACITY CONTROLS RAMP_DEM (RampingDemand Limit Value).9. The economizer (if installed) has two sight glasses thatlook into the float chamber. When the chiller is operating,the top sight glass is empty and the bottom sight glass isfull.To Stop the ChillerThe occupancy schedule starts and stops the chiller automaticallyonce the time schedule is configured.The unit can be stopped manually using the HMI by pressing thegreen Start/Stop icon . The Unit Start/Stop screen is displayed.Press Confirm Stop. The compressor will then follow the normalshutdown sequence as described in the Start-Up/Shutdown/Recy-cle Sequence section on page 21. The chiller is now in the OFFcontrol mode.If the chiller is stopped by an alarm condition, do not restart thechiller until the problem is diagnosed and corrected.After Limited ShutdownNo special preparations should be necessary. Follow the regularpreliminary checks and starting procedures.Preparation for Extended ShutdownThe refrigerant should be transferred into the pumpout storagetank (if supplied; see Pumpout and Refrigerant Transfer Proce-dures on page 41) to reduce chiller pressure and the possibilityof leaks. Maintain a holding charge of 5 to 10 lb (2.27 to 4.5 kg)of refrigerant or nitrogen to prevent air from leaking into thechiller.For season chiller shutdown and lay-up, if the treated water isnot drained then provisions should be made to start the pumpsweekly to circulate the water and avoid corrosion. Consult thewater treatment company for details. Carrier is not responsiblefor waterside corrosion.IMPORTANT: Do not attempt to stop the chiller by opening anisolating knife switch. High intensity arcing may occur.