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

Also see for AquaEdge 19XR: Controls operation and troubleshooting Start-up, operation and maintenance instructions Start-up, operation and maintenance instructions

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

196. Ensure all electrical equipment and controls are properlygrounded in accordance with job drawings, certified draw-ings, and all applicable electrical codes.7. Ensure the customer’s contractor has verified proper oper-ation of the pumps, cooling tower fans, and associatedauxiliary equipment. This includes ensuring motors areproperly lubricated and have proper electrical supply andproper rotation.8. Test the chiller compressor motor and its power lead insu-lation resistance with an insulation tester such as a meg-ohmmeter. (Use a tester rated for motor voltage.)a. Open the starter main disconnect switch and followlockout/tagout rules.b. With the tester connected to the motor leads, take 10-second and 60-second megohm readings as follows:3-Lead Motor — Tie terminals 1, 2, and 3 togetherand test between the group and ground.c. Divide the 60-second resistance reading by the 10-second reading. The ratio, or polarization index, mustbe one or higher. Both the 10 and 60-second readingsmust be at least 50 megohms. If the readings on afield-installed starter are unsatisfactory, repeat the testat the motor with the power leads disconnected. Satis-factory readings in this second test indicate the fault isin the power leads.Check StarterUse the instruction and service manual supplied by the startermanufacturer to verify the starter has been installed correctly,to set up and calibrate the starter, and for complete trouble-shooting information.MECHANICAL STARTER1. Check all field wiring connections for tightness, clearancefrom moving parts, and correct connection.2. Check the contactor(s) to ensure they move freely. Checkall other electro-mechanical devices, such as relays, forfree movement. If the devices do not move freely, contactthe starter manufacturer for replacement components.3. Reapply starter control power (not main chiller power) tocheck the electrical functions.Ensure the starter (with relay 1CR closed) goes through acomplete and proper start cycle.SOLID-STATE STARTER1. Ensure all wiring connections are properly terminated tothe starter.2. Verify the ground wire to the starter is installed properlyand is sufficient size.3. Verify the motors are properly grounded to the starter.4. Verify the proper ac input voltage is brought into thestarter according to the certified drawings.5. Apply power to the starter.Oil ChargeThe oil charge for the 19XR two-stage compressor frame size 6is 29 gal (110 L); for frame size 7 the oil charge is 44.5 gal(168 L).The chiller is shipped with oil in the compressor. When the sumpis full, the oil level should be no higher than the middle of theupper sight glass, and minimum level is the bottom of the lowersight glass (Fig. 2). If oil is added, it must meet Carrier’s specifi-cation for centrifugal compressor use as described in the OilSpecification section on page 40. Charge the oil through the oilcharging valve located near the bottom of the transmission hous-ing. The oil must be pumped from the oil container through thecharging valve due to higher refrigerant pressure. The pumpingdevice must be able to lift from 0 to 200 psig (0 to 1380 kPa) orabove unit pressure. Oil should only be charged or removedwhen the chiller is shut down.Power Up Controls and Check Oil HeaterEnsure that an oil level is visible in the compressor and thechiller is not in a vacuum before energizing the controls. Typi-cally a circuit breaker in the starter energizes the oil heater andthe control circuit.The oil heater is energized by powering the control circuit.This should be done several hours before start-up to minimizeoil-refrigerant migration. The oil heater is controlled by thePIC 5 and is powered through a contactor in the control panel.A separate circuit breaker powers the heater, oil pump, and thecontrol circuit. This arrangement allows the heater to energizewhen the main motor circuit breaker is off for service work orextended shutdowns.Software ConfigurationSee the 19XR with PIC 5 Controls Operation and Trouble-shooting manual for instructions on using the PIC 5 interface toconfigure the 19XR unit. As the unit is configured, all configu-ration settings should be written down. A log, such as the oneshown on pages CL-1 to CL-11, provides a list for configura-tion values.CAUTIONIf the motor starter is a solid-state starter, the motor leadsmust be disconnected from the starter before an insulationtest is performed. The voltage generated from the tester candamage the starter solid-state components.WARNINGBE AWARE that certain automatic start arrangements canengage the starter. Open the disconnect ahead of the starterin addition to shutting off the chiller or pump. Failure tofollow this procedure may result in personal injury by elec-tric shock.WARNINGThe main disconnect on the starter front panel may not de-energize all internal circuits. Open all internal and remotedisconnects before servicing the starter. Failure to followthis procedure may result in personal injury by electricshock.WARNINGThis equipment is at line voltage when AC power is connect-ed. Pressing the STOP button does not remove voltage.CAUTIONAn isolation switch or circuit breaker must be open aheadof any solid-state starter when the chiller is in a vacuum. Ifnot, damage to the machine may result.WARNINGDo not operate the chiller before the control configurationshave been checked and a Control Test has been satisfactori-ly completed. Protection by safety controls cannot be as-sumed until all control configurations have been confirmed.