Carrier AquaEdge 19XRV series Operation, Maintenance And Installation 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

88Adding Refrigerant — Follow the procedures de-scribed in Trim Refrigerant Charge section, page 88.Removing Refrigerant — If the optional pumpout sys-tem is used, the 19XRV refrigerant charge may be transferredto a pumpout storage tank or to the chiller condenser or coolervessels. Follow the procedures in the Pumpout and RefrigerantTransfer Procedures section when transferring refrigerant fromone vessel to another.Adjusting the Refrigerant Charge — If the addi-tion or removal of refrigerant is required to improve chillerperformance, follow the procedures given under the TrimRefrigerant Charge section, page 88.Refrigerant Leak Testing — Because HFC-134a re-frigerant is above atmospheric pressure at room temperature,leak testing can be performed with refrigerant in the chiller.Use an electronic halide leak detector, soap bubble solution, orultrasonic leak detector. Ensure that the room is well ventilatedand free from concentration of refrigerant to keep false read-ings to a minimum. Before making any necessary repairs to aleak, transfer all refrigerant from the leaking vessel.Leak Rate — It is recommended by ASHRAE that chillersbe taken off line immediately and repaired if the refrigerantleak rate for the entire chiller is more than 10% of the operatingrefrigerant charge per year.In addition, Carrier recommends that leaks totaling less thanthe above rate, but more than a rate of 0.1% of the total chargeper year, should be repaired during annual maintenance orwhenever the refrigerant is transferred for other service work.Test After Service, Repair, or Major Leak — If allthe refrigerant has been lost or if the chiller has been opened forservice, the chiller or the affected vessels must be pressure test-ed and leak tested. Refer to the Leak Test Chiller section to per-form a leak test.TESTING WITH REFRIGERANT TRACER — Use an en-vironmentally acceptable refrigerant as a tracer for leak testprocedures. Use dry nitrogen to raise the machine pressure toleak testing levels.TESTING WITHOUT REFRIGERANT TRACER — An-other method of leak testing is to pressurize with nitrogen onlyand to use a soap bubble solution or an ultrasonic leak detectorto determine if leaks are present.TO PRESSURIZE WITH DRY NITROGENNOTE: Pressurizing with dry nitrogen for leak testing shouldnot be done if the full refrigerant charge is in the vesselbecause purging the nitrogen is very difficult.1. Connect a copper tube from the pressure regulator on thecylinder to the refrigerant charging valve. Never applyfull cylinder pressure to the pressurizing line. Follow thelisted sequence.2. Open the charging valve fully.3. Slowly open the cylinder regulating valve.4. Observe the pressure gage on the chiller and close theregulating valve when the pressure reaches test level. Donot exceed 140 psig (965 kPa).5. Close the charging valve on the chiller. Remove thecopper tube if it is no longer required.Repair the Leak, Retest, and Apply StandingVacuum Test — After pressurizing the chiller, test forleaks with an electronic halide leak detector, soap bubblesolution, or an ultrasonic leak detector. Bring the chiller back toatmospheric pressure, repair any leaks found, and retest.After retesting and finding no leaks, apply a standingvacuum test. Then dehydrate the chiller. Refer to the StandingVacuum Test and Chiller Dehydration section (pages 67 and70) in the Before Initial Start-Up section.Checking Guide Vane Linkage — When the chilleris off, the guide vanes are closed and the actuator mechanism isin the position shown in Fig. 50. Slack in the guide vane actua-tor’s drive chain can only be removed with the guide vaneactuator fully closed and the chiller shut down. Complete thefollowing steps to adjust chain tension and position:1. Remove the two set screws in the guide vane actuatorsprocket.2. Loosen the guide vane actuator’s holddown bolts.3. Pull the guide vane actuator away from the suction hous-ing along the slotted holes in the actuator bracket.4. Rotate the guide vane sprocket fully clockwise andspot-drill the guide vane actuator shaft. Spot-drilling isnecessary when the guide vane actuator sprocket setscrews on the guide vane actuator shaft need to bere-seated. (Remember: Spot-drill and tighten the first setscrew before spot-drilling for the second set screw.)Trim Refrigerant Charge — To remove any excess re-frigerant, follow the procedure in Transfer Refrigerant fromChiller to Pumpout Storage Tank Vessel section, page 85.Refer to the Trimming Refrigerant Charge section onpage 80.WEEKLY MAINTENANCECheck the Lubrication System — Mark the oil levelon the reservoir sight glass, and observe the level each weekwhile the chiller is shut down.If the level goes below the lower sight glass, check the oilreclaim system for proper operation. If additional oil isrequired, add it through the oil drain charging valve (Fig. 2 and3). A pump is required when adding oil against refrigerantpressure. The oil charge for the 19XRV compressor depends onthe compressor Frame size:• Frame 2 compressor — 8 gal (30 L)• Frame 3 compressor — 8 gal (30 L)• Frame 4 compressor — 10 gal (37.8 L)• Frame 4 compressor with split ring diffuser — 12 gal(45 L)• Frame 5 compressor — 18 gal (67.8 L)• Frame E compressor — 18 gal (67.8 L)CAUTIONAlways use the compressor pumpdown function in theControl Test table to turn on the cooler pump and lock outthe compressor when transferring refrigerant. Liquid refrig-erant may flash into a gas and cause water in the heaterexchanger tubes to freeze when the chiller pressure isbelow 35 psig (241 kPa) for HFC-134a, resulting in equip-ment damage.WARNINGRefrigerant HFC-134a should not be mixed with air oroxygen and pressurized for leak testing. In general, thisrefrigerant should not be present with high concentrationsof air or oxygen above atmospheric pressures, because themixture can undergo combustion, which could result inserious personal injury or death.